Motor simulator leakage control method, device, equipment, medium and product

Abstract

The application relates to the technical field of motor simulator leakage monitoring, in particular to a motor simulator liquid leakage control method, device, equipment, medium and product, the method comprising the following steps: acquiring the running duration of a cooling system and humidity information of a motor simulator; positioning the liquid leakage position of the motor simulator according to the running duration and the humidity information; and executing a liquid leakage control action of the motor simulator according to the liquid leakage position. Therefore, the problems that the liquid leakage of the motor simulator cannot be positioned in time in the prior art are solved.

Description

Technical Field

[0001] This application relates to the field of motor simulator leakage monitoring technology, and in particular to a method, device, equipment, medium and product for controlling leakage in a motor simulator. Background Technology

[0002] In the field of electric drive system testing for new energy vehicles, motor simulators are crucial equipment for ensuring the performance and reliability of inverters. As equipment power and operating time continue to increase, internal cooling circuits are prone to leakage, leading to unexpected test bench shutdowns. Related technologies often identify leaks through pre-filling sealing checks or in-operation liquid accumulation detection, which struggles to pinpoint the leak location after it occurs, significantly impacting the testing process. Summary of the Invention

[0003] This application provides a method, device, equipment, medium, and product for controlling leakage in a motor simulator, in order to solve the problem that leakage in a motor simulator cannot be located in a timely manner in related technologies.

[0004] The first aspect of this application provides a method for controlling liquid leakage in a motor simulator, comprising the following steps: acquiring the running time of the cooling system and the humidity information of the motor simulator; locating the leakage location of the motor simulator based on the running time and humidity information; and executing a liquid leakage control action of the motor simulator based on the leakage location.

[0005] Based on the above technical means, this application embodiment can detect leakage abnormalities in a timely manner during equipment operation by acquiring the running time of the cooling system and the humidity information of the motor simulator in real time. Then, based on this information, the location of the leakage can be accurately determined, and the corresponding leakage control action can be automatically executed according to the location result. This effectively solves the problem that leakage of the motor simulator cannot be detected and located in a timely manner in related technologies, and improves the safety of equipment operation and the stability of the testing system.

[0006] Optionally, the motor simulator includes a power unit, which includes multiple power modules and a circuit board. Multiple power modules are disposed on the circuit board. The humidity information of the motor simulator includes first humidity information of the power modules and second humidity information of the circuit board.

[0007] Based on the above technical means, this application embodiment collects the first humidity information of the power module and the second humidity information of the circuit board respectively, which can more detailed and comprehensively reflect the humidity status of different key components inside the motor simulator, effectively improve the accuracy and reliability of leakage identification, and provide reliable data support for subsequent accurate location of leakage.

[0008] Optionally, the first humidity information of the power module includes at least one of the humidity information of the heat exchanger cooling inlet and the humidity information of the heat exchanger cooling outlet.

[0009] Based on the above technical means, this application embodiment can monitor humidity changes in real time from the entry and exit path of the cooling medium by collecting at least one of the humidity information of the cooling inlet and the humidity information of the cooling outlet of the heat exchanger, thereby further improving the sensitivity and coverage of leakage detection and providing a more comprehensive basis for accurately determining whether a leak has occurred in the cooling circuit.

[0010] Optionally, locating the leakage location of the motor simulator based on runtime and humidity information includes: extracting a first humidity value from the first humidity information and a second humidity value from the second humidity information; and locating the leakage location of the motor simulator based on the runtime, the first humidity value, and the second humidity value.

[0011] Based on the above technical means, this application embodiment extracts the first humidity value of the power module and the second humidity value of the circuit board respectively, and makes a comprehensive judgment in combination with the running time of the cooling system. This can more accurately identify leakage characteristics, distinguish the location and extent of leakage, thereby achieving reliable positioning of the leakage location of the motor simulator and further improving the accuracy and response speed of leakage detection.

[0012] Optionally, the location of the leak in the motor simulator is determined based on the runtime, a first humidity value, and a second humidity value, including: if the runtime is greater than a duration threshold, the first humidity value is greater than the first threshold, and the second humidity value is greater than the second threshold, then the cooling circuit of the motor simulator is determined to be leaking; if the runtime is less than or equal to the duration threshold, then the power module of the motor simulator is determined to be leaking when the first humidity value is greater than the first threshold and the second humidity value is greater than the second threshold; if the runtime is less than or equal to the duration threshold, then the power module circuit board of the motor simulator is determined to be cooling abnormally when the first humidity value is greater than the first threshold and the second humidity value is less than or equal to the second threshold; if the runtime is less than or equal to the duration threshold, then the heat exchanger cooling interface of the motor simulator is determined to be leaking when the first humidity value is less than or equal to the first threshold and the second humidity value is greater than the second threshold.

[0013] Based on the above technical means, this application embodiment compares the cooling system running time, power module humidity value, and circuit board humidity value with corresponding thresholds. It can clearly distinguish different fault types such as cooling circuit leakage, power module leakage, power module circuit board cooling abnormality, and heat exchanger cooling interface leakage according to different combinations of conditions. This enables accurate determination of leakage location and fault type, making fault identification more detailed and reliable, and facilitating subsequent targeted control measures.

[0014] Optionally, the leakage control action of the motor simulator is executed according to the leakage location, including: generating leakage warning information and leakage control instructions according to the leakage location; and simultaneously executing leakage warning based on the leakage warning information and controlling the motor simulator to execute a shutdown action based on the leakage control instructions.

[0015] Based on the above technical means, this application embodiment combines the accurately located leakage location to simultaneously generate corresponding leakage warning information and control commands. On the one hand, the intuitive warning information quickly provides feedback on the fault location, facilitating maintenance personnel to quickly troubleshoot the problem. On the other hand, it simultaneously controls the motor simulator to perform a shutdown action, which can both prevent the leakage from further damaging the components and prevent the test bench from suddenly and unexpectedly shutting down, thus taking into account both the timeliness of fault warning and the effectiveness of equipment protection.

[0016] A second aspect of this application provides a motor simulator leakage control device, comprising: an acquisition module for acquiring the running time of the cooling system and the humidity information of the motor simulator; a positioning module for locating the leakage position of the motor simulator based on the running time and humidity information; and a control module for executing leakage control actions of the motor simulator based on the leakage position.

[0017] Optionally, the motor simulator includes a power unit, which includes multiple power modules and a circuit board. Multiple power modules are disposed on the circuit board. The humidity information of the motor simulator includes first humidity information of the power modules and second humidity information of the circuit board.

[0018] Optionally, the first humidity information of the power module includes at least one of the humidity information of the heat exchanger cooling inlet and the humidity information of the heat exchanger cooling outlet.

[0019] Optionally, the positioning module is further configured to: extract the first humidity value from the first humidity information and the second humidity value from the second humidity information; and locate the leakage location of the motor simulator based on the running time, the first humidity value, and the second humidity value.

[0020] Optionally, the positioning module is further configured to: determine that the cooling circuit of the motor simulator is leaking if the running time is greater than the duration threshold, the first humidity value is greater than the first threshold, and the second humidity value is greater than the second threshold; determine that the power module of the motor simulator is leaking if the running time is less than or equal to the duration threshold, and the first humidity value is greater than the first threshold and the second humidity value is greater than the second threshold; determine that the power module circuit board of the motor simulator is cooling abnormally if the running time is less than or equal to the duration threshold, and the heat exchanger cooling interface of the motor simulator is leaking if the running time is less than or equal to the duration threshold, and the first humidity value is less than or equal to the first threshold and the second humidity value is greater than the second threshold; and determine that the heat exchanger cooling interface of the motor simulator is leaking if the running time is less than or equal to the duration threshold, and the first humidity value is less than or equal to the first threshold and the second humidity value is greater than the second threshold.

[0021] Optionally, the control module is further configured to: generate leakage warning information and leakage control commands based on the leakage location; and simultaneously execute leakage warning based on the leakage warning information and control the motor simulator to perform a shutdown action based on the leakage control commands.

[0022] A third aspect of this application provides an electronic device, including: a memory, a processor, and a computer program stored in the memory and capable of running on the processor, wherein the processor executes the program to implement the motor simulator leakage control method as described above.

[0023] A fourth aspect of this application provides a computer-readable storage medium having a computer program stored thereon, which is executed by a processor to implement the motor simulator leakage control method as described above.

[0024] A fifth aspect of this application provides a computer program that, when executed, is used to implement the motor simulator leakage control method as described in the above embodiments.

[0025] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0026] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a flowchart of a method for controlling leakage in a motor simulator according to an embodiment of this application; Figure 2 This is a hardware layout diagram provided according to an embodiment of this application; Figure 3 This is a system architecture diagram provided according to an embodiment of this application; Figure 4 This is a flowchart of a motor simulator leakage control method according to an embodiment of this application; Figure 5 This is a block diagram illustrating a leakage control device for a motor simulator according to an embodiment of this application. Figure 6 This is a schematic diagram of the structure of an electronic device provided according to an embodiment of this application. Detailed Implementation

[0027] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0028] Currently, the new energy vehicle industry is developing rapidly, and the upgrading and iteration of new energy test and verification benches are accelerating. The performance and power of test benches are continuously improving. As a comprehensive testing equipment, the new energy inverter assembly test bench undertakes tasks such as inverter performance, reliability, functional safety testing, and extreme condition assessment. The motor simulator, as the core component of the test bench, is responsible for simulating motor power consumption online. Its power simulation module consists of 16 power units, each containing 3 power modules with integrated high-speed IGBT (Insulated Gate Bipolar Transistor) elements. It relies on multiple series cooling loops to achieve high heat flux density heat dissipation and has a large number of internal interconnecting connectors.

[0029] The relevant technologies for addressing the leakage problem in motor simulators have the following drawbacks: First, leakage detection is lagging. The motor simulator power module has a fully enclosed structure and lacks specific internal leakage monitoring methods, so it cannot be detected in time during operation if the cooling medium leaks. Secondly, the fault location is vague, lacking the ability to accurately locate single power modules and internal points. The bench control interface lacks detailed alarm prompts, making it impossible to quickly determine the leaking module and the specific leak location. Third, the fault handling is passive. Leaked media can easily accumulate on the circuit board and corrode the components, or even cause IGBT short circuit and burnout. A single module failure can trigger the shutdown of the entire test bench. Fourth, the operation and maintenance costs are high, troubleshooting takes a long time and repairs are difficult, large-scale burnout of power components can cause huge losses, and the test bench recovery cycle is long.

[0030] In summary, the relevant technologies lack online monitoring, precise location and proactive prevention mechanisms for leakage in motor simulators, making it difficult to achieve early warning of potential leakage hazards, rapid location of faults, and to prevent the expansion of the fault range, reduce downtime losses and maintenance costs, which seriously restricts the stable operation of the test bench and testing efficiency.

[0031] The following description, with reference to the accompanying drawings, describes a method, apparatus, device, medium, and product for controlling leakage in a motor simulator according to embodiments of this application. Addressing the issues of timely leakage location in motor simulators mentioned in the background section, this application provides an intelligent predictive control method for motor simulator leakage. This method involves distributing humidity sensors at the cooling medium outlet of the power module radiator inside the power unit, at the interfaces of the main cooling pipes, and on the surface of the circuit board. A multi-channel hygrometer centrally collects humidity data from these locations, communicates with the controller based on the MODBUS (Modicon Bus) protocol, synchronously records humidity change trends, and establishes a database. The humidity data from each channel is then combined with real-time operating data from the test bench for analysis and calculation to accurately pinpoint the leakage fault unit and specific leak point. Finally, alarm information is pushed through text prompts and fault displays. Simultaneously, it is interlocked with the test bench and shares alarm data. This method can monitor micro-leakage and potential seepage in the cooling circuit in real time, protecting components in the early stages of leakage and preventing short circuits, burnout, and further damage. It also boasts advantages such as high versatility, low cost, convenient installation and operation, and high positioning accuracy, making it suitable for various liquid-cooled power electronic circuits and achieving comprehensive safety early warning protection.

[0032] Specifically, Figure 1 This is a flowchart of a method for controlling leakage in a motor simulator, provided as an embodiment of this application.

[0033] like Figure 1 As shown, the leakage control method for the motor simulator includes the following steps: In step S101, the running time of the cooling system and the humidity information of the motor simulator are obtained.

[0034] It is understood that by acquiring the running time of the cooling system and the humidity information of the motor simulator, the embodiments of this application can establish basic monitoring data from both time and state dimensions, providing a reliable basis for subsequent judgment of whether leakage has occurred, identification of fault type and location of leakage, thereby realizing real-time perception and early identification of leakage status of motor simulator, effectively improving the timeliness and accuracy of leakage detection.

[0035] Specifically, such as Figure 2 As shown, the motor simulator 9 consists of the first power unit 6, the second power unit 7, ..., the sixteenth power unit 8, as follows. Figure 3 As shown, each power unit consists of a power unit circuit base plate 1, a high-speed IGBT 2, and a heat exchanger 3; the cooling medium is 25% propylene glycol at a constant temperature of 20°C, which enters the heat exchanger 3 through the cooling inlet 4 and flows along... Figure 1The flow direction shown indicates that the water flows through the heat exchanger and exits from the other end, carrying away the heat generated by the high-speed IGBT 2. Humidity data is collected by the inlet humidity sensor 50 (lower end of the heat exchanger outlet), the outlet humidity sensor 51 (lower end of the heat exchanger inlet), and the circuit board humidity sensor 52 (surface of the power unit circuit board 1). The data is then connected to the multi-channel humidity acquisition module 11 via the humidity sensor connection line 10. At the same time, the runtime information in the real-time data 13 of the motor simulator cooling system is acquired. The data is transmitted to the controller 14 based on the TCP (Transmission Control Protocol) protocol, providing basic data for subsequent leakage detection.

[0036] In this embodiment, the motor simulator includes a power unit, which includes multiple power modules and a circuit board. Multiple power modules are disposed on the circuit board. The humidity information of the motor simulator includes first humidity information of the power modules and second humidity information of the circuit board.

[0037] It is understood that by collecting the first humidity information of the power module and the second humidity information of the circuit board respectively, the embodiments of this application can more detailed and comprehensively reflect the humidity status of different key components inside the motor simulator, effectively improving the accuracy and reliability of leakage identification, and providing reliable data support for subsequent accurate location of leakage.

[0038] It should be noted that, in this embodiment, the first humidity information refers to the humidity data collected by humidity sensors arranged at the cooling inlet and outlet of the power module heat exchanger. This data reflects the humidity status of the cooling medium flow path and the power module itself, and serves as a monitoring indicator to determine whether leakage or seepage has occurred in the cooling circuit. The second humidity information refers to the humidity data collected by humidity sensors arranged on the surface of the power unit circuit board. This data reflects humidity changes in the circuit board area and serves as a monitoring indicator to determine whether the leaked medium has diffused to the electronic component area, thus preventing short circuits and burnout. These two types of information correspond to different monitoring locations and fault scenarios, together constituting complete data for leak detection in the motor simulator.

[0039] Specifically, such as Figure 2 and Figure 3As shown, the inlet humidity sensor 50 (resistive type, fixed to the lower end of the heat exchanger outlet with insulating glue) and the outlet humidity sensor 51 (resistive type, fixed to the lower end of the heat exchanger inlet with insulating glue) of the heat exchanger 3 collect the first humidity information of the power module, and the circuit board humidity sensor 52 (capacitive type, fixed with insulating glue) fixed on the surface of the power unit circuit board 1 collects the second humidity information of the circuit board; each power module corresponds to 3 humidity sensor connection lines 10, which centrally transmit the humidity data to the multi-channel humidity acquisition module 11, and then the controller 14 generates trend curves and databases based on the LABVIEW (Laboratory Virtual Instrument Engineering Workbench) host computer software to realize independent monitoring of the humidity status of different components.

[0040] In this embodiment, the first humidity information of the power module includes at least one of the humidity information of the heat exchanger cooling inlet and the humidity information of the heat exchanger cooling outlet.

[0041] It is understood that by collecting at least one of the humidity information at the cooling inlet and the humidity information at the cooling outlet of the heat exchanger, the embodiments of this application can monitor humidity changes in real time from the entry and exit path of the cooling medium, further improving the sensitivity and coverage of leak detection, and providing a more comprehensive basis for accurately determining whether a leak has occurred in the cooling circuit.

[0042] It should be noted that the heat exchanger in this embodiment is the core heat dissipation component of the motor simulator power module. It is closely fitted with power control components such as high-speed IGBTs and is used to promptly remove the high heat flux generated by the components during operation. It has a cooling medium flow channel inside, and the cooling medium (e.g., 25% propylene glycol at a constant temperature of 20°C) flows in from the cooling inlet, flows through the flow channel, and flows out from the cooling outlet. Through continuous circulation, it removes heat to ensure that the power components operate stably within a safe temperature range. At the same time, the cooling inlet, outlet, and pipe interface of the heat exchanger are high-risk areas for leakage. Therefore, humidity sensors are arranged at the lower end of the inlet and outlet to accurately monitor humidity changes caused by cooling medium leakage, providing direct evidence for early leakage warning.

[0043] Specifically, such as Figure 3 As shown, the outlet humidity sensor 51 is a resistive humidity sensor, which is fixed to the lower end of the inlet of the heat exchanger 3 with insulating glue and is used to collect humidity information at the cooling inlet of the heat exchanger; the inlet humidity sensor 50 is a resistive humidity sensor, which is fixed to the lower end of the outlet of the heat exchanger 3 with insulating glue and is used to collect humidity information at the cooling outlet of the heat exchanger; the two types of humidity data are aggregated by the multi-channel humidity acquisition module 11 and transmitted to the controller 14 for analysis to realize the monitoring of humidity changes in the cooling medium inlet and outlet paths.

[0044] In step S102, the location of the leak in the motor simulator is located based on the runtime and humidity information.

[0045] It is understood that the embodiments of this application make a comprehensive judgment based on the running time of the cooling system and the humidity information of the motor simulator, which can accurately distinguish different parts and different degrees of leakage, and achieve precise location of the leakage location. This solves the problems of not being able to quickly locate the fault point and low troubleshooting efficiency in related technologies, and provides a reliable basis for subsequent execution of targeted control actions.

[0046] Specifically, such as Figure 2 As shown, after the controller 14 obtains the cooling system running time, the first humidity value of the power module (inlet / outlet humidity), and the second humidity value of the circuit board, it performs logical judgment based on the preset threshold and trigger time TN1, TN2, and TN3. Combining the combination relationship between the running time and humidity data, it locates the leakage location and fault type. At the same time, it can query the specific leakage amount through the parameters recorded by the controller 14.

[0047] In this embodiment of the application, locating the leakage location of the motor simulator based on runtime and humidity information includes: extracting a first humidity value from the first humidity information and a second humidity value from the second humidity information; and locating the leakage location of the motor simulator based on the runtime, the first humidity value, and the second humidity value.

[0048] It is understood that by extracting the first humidity value of the power module and the second humidity value of the circuit board respectively, and combining them with the running time of the cooling system for comprehensive judgment, the leakage characteristics can be identified more accurately, the location and extent of leakage can be distinguished, and the leakage location of the motor simulator can be reliably located, thereby further improving the accuracy and response speed of leakage detection.

[0049] It should be noted that, in this embodiment, the first humidity value refers to the quantified value extracted from the first humidity information collected by the humidity sensors at the cooling inlet and cooling outlet of the power module heat exchanger. It is used to characterize the real-time humidity level of the cooling medium flow path and the power module body, and is the data for determining whether there is leakage or seepage in the cooling circuit. The second humidity value refers to the quantified value extracted from the second humidity information collected by the humidity sensor on the surface of the power unit circuit board. It is used to characterize the real-time humidity level of the circuit board area, and is the key data for determining whether the leaking medium has spread to the electronic component area and avoiding short circuit burnout. The running time refers to the continuous running time of the cooling system from this start-up to the current moment. It is used to help distinguish the development stage of the leakage (such as early micro-leakage, late large-scale leakage) and the type of fault. By combining the threshold comparison of the first humidity value and the second humidity value, the precise location of the leakage and the degree of fault can be achieved.

[0050] Specifically, such as Figure 2 As shown, the controller 14 extracts the first humidity value of the power module (data collected by the inlet humidity sensor 50 and the outlet humidity sensor 51) and the second humidity value of the circuit board (data collected by the circuit board humidity sensor 52) from the multi-channel humidity acquisition module 11. At the same time, it extracts the running time from the real-time data 13 of the motor simulator cooling system. The controller performs correlation analysis on the three types of data and combines the states of the trigger times TN1, TN2, and TN3 to accurately determine the location of leakage and the type of fault.

[0051] In this embodiment, locating the leakage location of the motor simulator based on the runtime, a first humidity value, and a second humidity value includes: if the runtime is greater than a duration threshold, the first humidity value is greater than a first threshold, and the second humidity value is greater than a second threshold, then the cooling circuit of the motor simulator is determined to be leaking; if the runtime is less than or equal to the duration threshold, then the power module of the motor simulator is determined to be leaking when the first humidity value is greater than the first threshold and the second humidity value is greater than the second threshold; if the runtime is less than or equal to the duration threshold, then the power module circuit board of the motor simulator is determined to be cooling abnormally when the first humidity value is greater than the first threshold and the second humidity value is less than or equal to the second threshold; if the runtime is less than or equal to the duration threshold, then the heat exchanger cooling interface of the motor simulator is determined to be leaking when the first humidity value is less than or equal to the first threshold and the second humidity value is greater than the second threshold.

[0052] It is understood that by comparing the cooling system running time, power module humidity value, and circuit board humidity value with corresponding thresholds, this embodiment of the application can clearly distinguish different fault types such as cooling circuit leakage, power module leakage, power module circuit board cooling abnormality, and heat exchanger cooling interface leakage according to different combinations of conditions. This enables accurate determination of the leakage location and fault type, making fault identification more detailed and reliable, and facilitating subsequent targeted control measures.

[0053] It should be noted that the duration threshold in this embodiment is a time judgment threshold set in advance based on the operating characteristics, aging law, and leakage development law of the motor simulator cooling system. It is used to distinguish whether the cooling system is in a long-term or short-term operating state, thereby assisting in determining whether the leakage is a systemic loop leakage or a local module / interface leakage. The first threshold is a judgment threshold set for the humidity at the cooling inlet and outlet of the power module heat exchanger, used to determine whether there is abnormal humidity in the power module body and cooling channel area. The second threshold is a judgment threshold set for the humidity of the circuit board surface area, used to determine whether the circuit board and electronic component area are affected by the leaking medium.

[0054] Among them, abnormal cooling of the power module circuit board refers to insufficient heat dissipation of the power module, low flow rate of the cooling medium or abnormal temperature, which leads to poor heat dissipation of the power components and local high temperature, and indirectly causes abnormal fluctuations in humidity in the monitoring area, but has not yet formed an obvious leakage state. This state can provide early warning of abnormal operation of the cooling system and avoid further failures such as leakage and overheating due to heat dissipation problems.

[0055] Specifically, this application uses humidity data threshold trigger times TN1, TN2, and TN3 for monitoring and calculation: When TN3 > 0, if TN1 > 0 and TN2 > 0, it is determined that the cooling circuit is leaking; if N = 1, it indicates that the Nth cooling circuit is leaking; if N > 1, it indicates that multiple modules may be leaking, and the cooling system pressure needs to be checked. When TN3=0, if TN1>0 and TN2>0, it is determined that the Nth power module is leaking; When TN3=0, if TN1>0 and TN2=0, it is determined that the cooling temperature of the power module is too low and the cooling temperature needs to be adjusted. When TN3=0, if TN1=0 and TN2>0, it is determined that the input / output interface of the Nth power module unit is micro-permeable; When TN3=0, if TN1=0 and TN2=0, the system is considered to be operating normally.

[0056] In step S103, the leakage control action of the motor simulator is executed according to the leakage location.

[0057] It is understood that, based on the accurately located leakage location, the embodiments of this application automatically execute the corresponding leakage control actions, which can provide timely safety protection and early warning for the faulty parts, effectively prevent the leakage from further expanding and causing serious consequences such as short circuits and burnout of components, while reducing the losses caused by unexpected shutdown of the test bench and improving the operational safety and stability of the entire test system.

[0058] Specifically, such as Figure 2 As shown, the controller 14 generates corresponding control commands and alarm information based on the leakage location results: if it is determined to be a serious leak (such as a leak in the cooling circuit or a leak in the power module), the cooling system will be stopped immediately, and the safety emergency stop module of the high-voltage power supply 16 will be triggered through the I / O signal to control the test bench to stop and disconnect the power; if it is determined to be a minor abnormality (such as a low cooling temperature or minor seepage at the interface), a prompt message can be generated, allowing the test bench to continue testing while reminding maintenance personnel to perform maintenance and inspection as soon as possible.

[0059] In this embodiment, the leakage control action of the motor simulator is executed according to the leakage location, including: generating leakage warning information and leakage control command according to the leakage location; and simultaneously executing leakage warning based on the leakage warning information and controlling the motor simulator to execute a shutdown action based on the leakage control command.

[0060] It is understood that, in combination with the accurately located leakage position, the embodiments of this application simultaneously generate corresponding leakage warning information and control commands. On the one hand, the intuitive warning information quickly provides feedback on the fault location, making it convenient for maintenance personnel to quickly troubleshoot the problem. On the other hand, the motor simulator is simultaneously controlled to perform a shutdown action, which can not only prevent the leakage from further damaging the components, but also prevent the test bench from suddenly and unexpectedly shutting down, thus taking into account both the timeliness of fault warning and the effectiveness of equipment protection.

[0061] Specifically, such as Figure 2 As shown, the controller 14 uses the host computer software developed based on LabVIEW to generate alarm information prompts 15 from the leakage analysis results and display them to the operator and maintenance personnel in the form of text information. At the same time, it is connected to the safety emergency stop module of the high-voltage power supply 16 through I / O (Input / Output) signals, so as to control the test bench to stop and cut off the power immediately when needed, so as to realize the synchronous execution of leakage prompt and equipment protection, and avoid the problems of short circuit and burnout of components and long-term shutdown of the test bench caused by leakage.

[0062] According to the motor simulator leakage control method proposed in this application, by acquiring the running time of the cooling system and the humidity information of the motor simulator in real time, leakage abnormalities can be detected in a timely manner during equipment operation. Based on this information, the location of leakage can be accurately determined, and the corresponding leakage control action can be automatically executed according to the location result. This effectively solves the problem that leakage of motor simulator cannot be detected and located in a timely manner in related technologies, and improves the safety of equipment operation and the stability of the testing system.

[0063] The following will elaborate on the leakage control method for the motor simulator proposed in this application through a specific embodiment, such as... Figure 4 As shown, the specific steps are as follows: In step one, the system starts up and performs self-testing. After the equipment starts up, the motor simulator cooling system completes parameter initialization, resets the time record values ​​TN1, TN2, and TN3, and each power unit enters standby mode and resets the alarm. Subsequently, the multi-channel humidity acquisition module converts the humidity data into 485 communication data using the MODBUS protocol. The controller performs self-testing on the humidity data of each channel to determine whether the data transmission is within reasonable limits. If the data transmission is abnormal, the system immediately alarms and triggers the cooling system to stop, the test bench to stop, disconnects the high-voltage power supply, and ends monitoring. If the data is normal, real-time data recording is started and the next step is initiated.

[0064] In step two, humidity threshold triggering and operating status recording are performed. The humidity of the module circuit board is monitored in real time. When the real-time humidity exceeds the set threshold, the threshold trigger time is recorded as TN1. At the same time, the operating status of the cooling system is determined. If the cooling system is not running, it is started and the continuous running time is recorded as TN3. The cooling medium enters the motor simulator to start heat dissipation. Subsequently, the humidity of the power component cooling circuit interface is monitored. When the interface humidity exceeds the set threshold, the threshold trigger time is recorded as TN2.

[0065] In step three, data synchronization and fault analysis are performed. Humidity data of TN1, TN2, TN3 and each channel are collected synchronously at the software level. Combined with the cooling system running time, the first humidity value (interface humidity), and the second humidity value (circuit board humidity), logical calculations are performed to generate leakage status judgment results for each power module and lock the fault unit location number N.

[0066] In step four, status assessment and fault handling are performed. Based on the analysis results, the operating status of each module is determined: if the status is normal, the test bench enters normal test conditions, continuously monitors in real time and performs cyclic monitoring; if the status is abnormal, a precise leak alarm message is generated, and a trigger signal is output to control the cooling system to stop, the test bench to stop urgently, disconnect the 800V high-voltage power supply of the motor simulator, and enter a safe shutdown state.

[0067] In step five, the monitoring cycle ends. Under normal test conditions, the system continuously collects data and cyclically executes the self-test, humidity monitoring, and analysis process; if an alarm is triggered and the system shuts down, the monitoring ends, and the system can be restarted after troubleshooting and repair.

[0068] In summary, the embodiments of this application have at least the following beneficial effects: (1) Low cost, simple operation, easy to debug and maintain.

[0069] (2) It can predict potential leakage faults in the power module in advance, ensuring safe operation of the equipment.

[0070] (3) It can directly locate the faulty unit and module of the power module, realize rapid repair, and effectively reduce the workload of maintenance personnel.

[0071] Next, the leakage control device for a motor simulator according to an embodiment of this application is described with reference to the accompanying drawings.

[0072] Figure 5 This is a block diagram of a motor simulator leakage control device according to an embodiment of this application.

[0073] like Figure 5 As shown, the motor simulator leakage control device 50 includes: an acquisition module 501, a positioning module 502, and a control module 503.

[0074] The acquisition module 501 is used to acquire the running time of the cooling system and the humidity information of the motor simulator; the positioning module 502 is used to locate the leakage position of the motor simulator based on the running time and humidity information; and the control module 503 is used to execute leakage control actions of the motor simulator based on the leakage position.

[0075] In this embodiment, the motor simulator includes a power unit, which includes multiple power modules and a circuit board. Multiple power modules are disposed on the circuit board. The humidity information of the motor simulator includes first humidity information of the power modules and second humidity information of the circuit board.

[0076] In this embodiment, the first humidity information of the power module includes at least one of the humidity information of the heat exchanger cooling inlet and the humidity information of the heat exchanger cooling outlet.

[0077] In this embodiment, the positioning module 502 is further configured to: extract the first humidity value from the first humidity information and the second humidity value from the second humidity information; and locate the leakage location of the motor simulator based on the running time, the first humidity value, and the second humidity value.

[0078] In this embodiment, the positioning module 502 is further configured to: determine that the cooling circuit of the motor simulator is leaking if the running time is greater than the duration threshold, the first humidity value is greater than the first threshold, and the second humidity value is greater than the second threshold; determine that the power module of the motor simulator is leaking if the running time is less than or equal to the duration threshold, and the first humidity value is greater than the first threshold and the second humidity value is greater than the second threshold; determine that the power module circuit board of the motor simulator is cooling abnormally if the running time is less than or equal to the duration threshold, and the heat exchanger cooling interface of the motor simulator is leaking if the running time is less than or equal to the duration threshold, and the first humidity value is less than or equal to the first threshold and the second humidity value is greater than the second threshold; and determine that the heat exchanger cooling interface of the motor simulator is leaking if the running time is less than or equal to the duration threshold, and the first humidity value is less than or equal to the first threshold and the second humidity value is greater than the second threshold.

[0079] In this embodiment, the control module 503 is further configured to: generate leakage warning information and leakage control command based on the leakage location; and simultaneously execute the leakage warning based on the leakage warning information and control the motor simulator to perform a shutdown action based on the leakage control command.

[0080] It should be noted that the foregoing explanation of the embodiment of the motor simulator leakage control method also applies to the motor simulator leakage control device of this embodiment, and will not be repeated here.

[0081] According to the motor simulator leakage control device proposed in this application embodiment, by acquiring the running time of the cooling system and the humidity information of the motor simulator in real time, leakage abnormalities can be detected in a timely manner during equipment operation. Based on this information, the location of leakage can be accurately determined, and the corresponding leakage control action can be automatically executed according to the location result. This effectively solves the problem that leakage of motor simulator cannot be detected and located in a timely manner in related technologies, and improves the safety of equipment operation and the stability of the testing system.

[0082] Figure 6 A schematic diagram of the structure of an electronic device provided in an embodiment of this application. The electronic device may include: The memory 601, the processor 602, and the computer program stored on the memory 601 and capable of running on the processor 602.

[0083] When the processor 602 executes the program, it implements the motor simulator leakage control method provided in the above embodiments.

[0084] Furthermore, electronic devices also include: Communication interface 603 is used for communication between memory 601 and processor 602.

[0085] The memory 601 is used to store computer programs that can run on the processor 602.

[0086] The memory 601 may include high-speed RAM (Random Access Memory) memory, and may also include non-volatile memory, such as at least one disk storage.

[0087] If the memory 601, processor 602, and communication interface 603 are implemented independently, then the communication interface 603, memory 601, and processor 602 can be interconnected via a bus to complete communication between them. The bus can be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus, or an EISA (Extended Industry Standard Architecture) bus, etc. The bus can be divided into address bus, data bus, control bus, etc. For ease of representation, Figure 6 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0088] Optionally, in a specific implementation, if the memory 601, processor 602, and communication interface 603 are integrated on a single chip, then the memory 601, processor 602, and communication interface 603 can communicate with each other through an internal interface.

[0089] The processor 602 may be a CPU (Central Processing Unit), an ASIC (Application Specific Integrated Circuit), or one or more integrated circuits configured to implement the embodiments of this application.

[0090] This application also provides a computer-readable storage medium storing a computer program thereon, which, when executed by a processor, implements the above-described motor simulator leakage control method.

[0091] This application also provides a computer program product, including a computer program or instructions, which, when executed by a processor, implements the above-described motor simulator leakage control method.

[0092] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0093] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0094] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0095] It should be understood that various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any of the following techniques known in the art, or a combination thereof: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (FPGAs), field-programmable gate arrays (FPGAs), etc.

[0096] Those skilled in the art will understand that all or part of the steps of the methods implementing the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0097] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A method for controlling leakage in a motor simulator, characterized in that, Includes the following steps: Obtain the runtime of the cooling system and the humidity information of the motor simulator; The location of the leak in the motor simulator is determined based on the runtime and humidity information. The leakage control action of the motor simulator is executed according to the leakage location.

2. The method for controlling leakage in a motor simulator according to claim 1, characterized in that, The motor simulator includes a power unit, which includes multiple power modules and a circuit board. Multiple power modules are disposed on the circuit board. The humidity information of the motor simulator includes first humidity information of the power modules and second humidity information of the circuit board.

3. The method for controlling leakage in a motor simulator according to claim 2, characterized in that, The first humidity information of the power module includes at least one of the humidity information of the heat exchanger cooling inlet and the humidity information of the heat exchanger cooling outlet.

4. The method for controlling leakage in a motor simulator according to claim 2, characterized in that, The step of locating the leakage location of the motor simulator based on the runtime and the humidity information includes: Extract the first humidity value from the first humidity information and the second humidity value from the second humidity information; The location of the leak in the motor simulator is determined based on the runtime, the first humidity value, and the second humidity value.

5. The method for controlling leakage in a motor simulator according to claim 4, characterized in that, The step of locating the leakage location of the motor simulator based on the running time, the first humidity value, and the second humidity value includes: If the runtime is greater than the duration threshold, the first humidity value is greater than the first threshold, and the second humidity value is greater than the second threshold, then it is determined that the cooling circuit of the motor simulator is leaking. If the running time is less than or equal to the duration threshold, then when the first humidity value is greater than the first threshold and the second humidity value is greater than the second threshold, it is determined that the power module of the motor simulator is leaking. If the running time is less than or equal to the duration threshold, then when the first humidity value is greater than the first threshold and the second humidity value is less than or equal to the second threshold, it is determined that the power module circuit board of the motor simulator is abnormally cooled. If the running time is less than or equal to the duration threshold, then when the first humidity value is less than or equal to the first threshold and the second humidity value is greater than the second threshold, it is determined that the heat exchanger cooling interface of the motor simulator is leaking.

6. The method for controlling leakage in a motor simulator according to claim 1, characterized in that, The step of executing the leakage control action of the motor simulator according to the leakage location includes: Generate leakage warning information and leakage control commands based on the leakage location; While issuing a leak warning based on the leak warning information, the motor simulator is also controlled to perform a shutdown action based on the leak control command.

7. A leakage control device for a motor simulator, characterized in that, include: The acquisition module is used to acquire the runtime of the cooling system and the humidity information of the motor simulator; The positioning module is used to locate the leakage location of the motor simulator based on the running time and the humidity information; The control module is used to execute the leakage control action of the motor simulator according to the leakage location.

8. An electronic device, characterized in that, include: A memory, a processor, and a computer program stored in the memory and executable on the processor, the processor executing the program to implement the motor simulator leakage control method according to any one of claims 1-6.

9. A computer-readable storage medium having a computer program or instructions stored thereon, characterized in that, When the computer program or instructions are executed, they implement the motor simulator leakage control method according to any one of claims 1-6.

10. A computer program product, comprising a computer program or instructions, characterized in that, When the computer program or instructions are executed, they implement the motor simulator leakage control method according to any one of claims 1-6.

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