A bench test apparatus and method for the cooling capacity of a DHT oil cooler under real vehicle operating conditions.

Abstract

A bench test apparatus and method for the cooling capacity of a DHT oil cooler under real-vehicle operating conditions belongs to the technical field of hybrid transmission component performance testing. The bench body includes: a transfer fixture for fixing the DHT oil cooler under test; a DHT real-vehicle operating condition simulation system for simulating the dynamic heat generation conditions of a DHT in a real vehicle; an oil circulation supply system for providing circulating oil to the DHT oil cooler under test; a coolant circulation system for providing circulating water to the DHT oil cooler under test; an environmental simulation system for simulating the actual vehicle environment conditions of the DHT oil cooler under test; a high-precision data acquisition system for synchronously collecting heat transfer performance parameters of the oil cooler; and a safety protection control system for overall system operation monitoring and safety protection control. This invention improves the accuracy of oil cooler cooling performance testing and provides reliable experimental support for DHT thermal management system optimization, oil cooler selection and calibration, and component performance verification.

Description

Technical Field

[0001] This invention relates to a bench test apparatus and method for the cooling capacity of a DHT oil cooler under actual vehicle conditions, belonging to the technical field of hybrid transmission component performance testing. Background Technology

[0002] DHT (Dual-mode transmission) is the core power transmission component of hybrid vehicles. During its operation, the motor rotor, clutch, and gear pairs continuously generate a large amount of heat. The oil cooler that comes with the transmission is a key heat dissipation component to ensure that the DHT operates at a constant temperature, avoid high-temperature failure, and improve transmission efficiency and service life. The cooling capacity of the oil cooler directly determines the thermal stability of the DHT under full speed and full load conditions.

[0003] Currently, most bench testing equipment for oil cooler cooling performance adopts a steady-state single-condition testing mode, which can only conduct steady-state heat transfer performance tests at fixed oil temperature, fixed flow rate, and fixed ambient temperature. It cannot simulate the dynamic heat generation, transient temperature rise, and load alternation characteristics of DHT during the switching process between pure electric, hybrid, and direct drive modes. This results in problems such as distortion between the simulated operating conditions and the actual vehicle operating conditions, incomplete parameter acquisition dimensions, and poor adaptability to hybrid-specific operating conditions. Consequently, the test results cannot accurately reflect the cooling efficiency, heat dissipation limit, and operating condition adaptability of the oil cooler under all operating conditions in the actual vehicle, making it difficult to meet the testing requirements for DHT thermal management system optimization, oil cooler selection and calibration, and component performance verification. Summary of the Invention

[0004] To address the problems existing in the background art, the present invention provides a bench test device and method for the cooling capacity of a DHT oil cooler under actual vehicle operating conditions.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a bench test device for the cooling capacity of a DHT oil cooler under actual vehicle conditions, comprising a bench body, wherein the bench body is provided with a transfer fixture for fixing the DHT oil cooler to be tested, the bench body also integrating a DHT actual vehicle condition simulation system for simulating the dynamic heat generation conditions of DHT actual vehicle operation, an oil circulation supply system for providing circulating oil to the DHT oil cooler to be tested, a coolant circulation system for providing circulating water to the DHT oil cooler to be tested, an environmental simulation system for simulating the actual vehicle environment conditions in which the DHT oil cooler to be tested is located, a high-precision data acquisition system for synchronously acquiring the heat exchange performance parameters of the oil cooler, and a safety protection control system for monitoring and controlling the operation of the entire machine.

[0006] Furthermore, the oil circuit output end of the oil circulation supply system is connected to the oil circuit inlet of the DHT oil cooler under test, and the oil circuit input end of the oil circulation supply system is connected to the oil circuit outlet of the DHT oil cooler under test, forming a circulating oil circuit.

[0007] Furthermore, the DHT real-vehicle operating condition simulation system is signal-connected to the oil circulation supply system to output dynamic heat source control signals and simulate the heat generation state of the DHT transmission under different operating conditions.

[0008] Furthermore, the coolant circulation system's water circuit output end is connected to the water circuit inlet of the DHT oil cooler under test, and the coolant circulation system's water circuit input end is connected to the water circuit outlet of the DHT oil cooler under test, forming a circulating water loop.

[0009] Furthermore, the environmental simulation system is enclosed on the outside of the DHT oil cooler under test to adjust and simulate the actual vehicle environment temperature where the DHT oil cooler under test is located.

[0010] Furthermore, the high-precision data acquisition system includes temperature sensors and pressure sensors respectively installed at the oil inlet, oil outlet, water inlet, and water outlet of the DHT oil cooler under test, as well as flow sensors respectively installed in the circulating oil circuit and circulating water circuit, for real-time synchronous acquisition of oil parameters and coolant parameters of the DHT oil cooler under test before and after heat exchange.

[0011] Furthermore, the safety protection and control system is electrically connected to the DHT real vehicle operating condition simulation system, oil circulation supply system, coolant circulation system, environmental simulation system, and high-precision data acquisition system, respectively, for monitoring the overall machine operating status and safety protection control.

[0012] The present invention discloses a test method for a bench test apparatus for the cooling capacity of a DHT oil cooler under real vehicle operating conditions, the method comprising the following steps:

[0013] S1: Fix the DHT oil cooler to be tested on the adapter fixture, and install temperature sensors, pressure sensors and flow sensors at the corresponding measuring points on the oil circuit inlet and outlet and the oil circulation supply system pipeline, and the water circuit inlet and outlet and the coolant circulation system pipeline of the DHT oil cooler to be tested.

[0014] S2: Enter all the operating parameters required for this test into the safety protection and control system;

[0015] S3: Start the oil circulation supply system, coolant circulation system and environmental simulation system to adjust the oil temperature, water temperature and ambient temperature to the set initial values, and maintain the system in constant temperature, constant flow and stable pressure operation;

[0016] S4: Activate the DHT real vehicle operating condition simulation system, output the oil heat source temperature and oil circuit flow control signal under dynamic operating conditions, and simulate the real-time heat generation state of DHT.

[0017] In S4, the dynamic operating condition simulation covers the switching process of three modes: DHT pure electric drive, hybrid drive, and engine direct drive.

[0018] S5: All test parameters are acquired synchronously at high frequency through a high-precision data acquisition system;

[0019] S6: Execute all working conditions to be verified in sequence to fully cover all working scenarios of DHT;

[0020] In S6, the operating conditions to be verified include high and low temperature environment conditions, steady-state load conditions, transient alternating conditions, and extreme load conditions.

[0021] S7: After all operating conditions are tested, stop the heat source simulation, wait for the system to cool down, shut down all circulation systems, and export and process the collected test data.

[0022] Compared with the prior art, the beneficial effects of the present invention are:

[0023] This invention can accurately simulate the dynamic operating conditions of DHT oil coolers in real vehicles, effectively solving the problems of traditional bench testing, such as single operating conditions, distortion with real vehicle operating conditions, and poor adaptability to hybrid operating conditions. It significantly improves the accuracy of oil cooler cooling performance testing. Through the coordinated operation of multiple systems including oil circuit, water circuit, environment, and operating condition simulation, it can cover all scenarios of testing conditions, such as high and low temperatures, steady state, transient alternation, and extreme load. It comprehensively evaluates the cooling efficiency, heat dissipation limit, and operating condition adaptability of oil coolers. Moreover, the device operates stably and safely with a high degree of automation, providing reliable test support for the optimization of DHT thermal management systems, oil cooler selection and calibration, and component performance verification. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the testing device of the present invention. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0026] A bench test device for the cooling capacity of a DHT oil cooler under actual vehicle conditions includes a bench body. The bench body is provided with an adapter 3 for fixing the DHT oil cooler 5 to be tested. The adapter 3 is designed according to the actual vehicle installation posture so that the installation angle and pipeline connection method of the DHT oil cooler 5 to be tested are consistent with the actual vehicle installation state, ensuring the matching degree between the test conditions and the actual vehicle state. The test bench also integrates a DHT vehicle operating condition simulation system 7 for simulating the dynamic heat generation conditions of a real DHT vehicle, an oil circulation supply system 1 for providing circulating oil to the DHT oil cooler 5 under test, a coolant circulation system 2 for providing circulating water to the DHT oil cooler 5 under test, an environmental simulation system 8 for simulating the real vehicle environment conditions of the DHT oil cooler 5 under test, a high-precision data acquisition system 6 for synchronously collecting heat exchange performance parameters of the oil cooler, and a safety protection control system 9 for monitoring the operation of the entire machine and ensuring safety. All systems work together to achieve bench testing of the cooling capacity of the oil cooler under real vehicle operating conditions.

[0027] Furthermore, the oil circulation supply system 1 forms a circulating oil circuit. Its oil circuit output end is connected to the oil circuit inlet of the DHT oil cooler 5 under test through a pipeline, and its oil circuit input end is connected to the oil circuit outlet of the DHT oil cooler 5 under test through a pipeline, forming a circulating oil circuit to provide circulating transmission oil to the DHT oil cooler 5 under test, simulating the oil circuit circulation inside the DHT transmission.

[0028] Furthermore, the DHT real vehicle operating condition simulation system 7 is signal-connected to the oil circulation supply system 1, and is used to output dynamic heat source control signals to adjust the temperature and flow of the oil, simulate the real-time heat generation state of the motor, gears and clutch of the DHT transmission under different operating conditions of pure electric, hybrid and direct drive, and reproduce the transient temperature rise and load alternation characteristics.

[0029] Furthermore, the coolant circulation system 2 forms a circulating water circuit. Its water output end is connected to the water inlet of the DHT oil cooler 5 under test through a pipeline, and its water input end is connected to the water outlet of the DHT oil cooler 5 under test through a pipeline, forming a circulating water circuit to provide circulating coolant to the DHT oil cooler 5 under test, accurately reproducing the water temperature and water flow conditions of the whole vehicle cooling circuit.

[0030] Furthermore, the environmental simulation system 8 is enclosed on the outside of the DHT oil cooler 5 under test, and is used to adjust and simulate the actual vehicle environment temperature where the DHT oil cooler 5 is located, adjust the temperature of the internal space, simulate the high and low temperature external environment during vehicle operation, and match the environmental conditions of the actual vehicle operation.

[0031] Furthermore, the high-precision data acquisition system 6 includes temperature sensors and pressure sensors respectively installed at the oil inlet, oil outlet, water inlet, and water outlet of the DHT oil cooler 5 under test, as well as flow sensors respectively installed in the circulating oil circuit and circulating water circuit. All sensors adopt a high-frequency synchronous acquisition mode to collect oil and coolant parameters such as oil temperature, oil pressure, water temperature, water pressure, oil flow rate, coolant flow rate, and ambient temperature of the DHT oil cooler 5 under test before and after heat exchange in real time, ensuring the time consistency and acquisition accuracy of the data.

[0032] Furthermore, the safety protection and control system 9 is electrically connected to the DHT real-vehicle operating condition simulation system 7, the oil circulation supply system 1, the coolant circulation system 2, the environmental simulation system 8, and the high-precision data acquisition system 6, respectively, for monitoring the overall machine's operating status and providing safety protection control. On one hand, it is used for setting the overall machine's operating parameters and controlling operating condition switching; on the other hand, it is used for real-time monitoring of the operating status of each system, and has alarm and automatic shutdown protection functions for abnormal operating conditions such as over-temperature, over-pressure, and pipeline leakage, ensuring the equipment's long-term stable operation.

[0033] The present invention discloses a test method for a bench test apparatus for the cooling capacity of a DHT oil cooler under real vehicle operating conditions, the method comprising the following steps:

[0034] S1: Fix the DHT oil cooler 5 to be tested on the adapter 3. According to the actual vehicle pipeline route, connect the oil inlet and outlet of the DHT oil cooler 5 to the corresponding pipelines of the oil circulation supply system 1, and the water inlet and outlet to the corresponding pipelines of the coolant circulation system 2. Install temperature sensors and pressure sensors at the corresponding measuring points of the oil inlet and outlet and water inlet and outlet of the oil cooler, and install flow sensors in the circuit. After the installation is completed, perform pipeline sealing test to confirm that there is no leakage in the pipeline and that the sensor data acquisition is normal.

[0035] S2: Input all the operating parameters required for this test into the safety protection control system 9, including initial oil temperature, oil pressure, oil flow range, initial water temperature, coolant flow range, ambient temperature range, as well as the dynamic change curve of the hybrid operating condition and the operating condition switching logic.

[0036] S3: Start the oil circulation supply system 1, coolant circulation system 2 and environmental simulation system 8, and gradually raise or lower the oil temperature, water temperature and ambient temperature to the set initial value according to the set rate. After the fluctuation of each parameter stabilizes within the allowable error range, the system maintains constant temperature, constant flow and stable pressure operation.

[0037] S4: Activate the DHT real vehicle operating condition simulation system 7, output the oil heat source temperature and oil flow control signal of the dynamic operating condition according to the preset operating condition curve, dynamically simulate the real-time heat generation state of the DHT motor, gear and clutch in different working modes, and reproduce the transient temperature rise and load alternation characteristics during the switching process of pure electric, hybrid and direct drive modes.

[0038] In S4, the dynamic operating condition simulation covers the switching process of three modes: DHT pure electric drive, hybrid drive, and engine direct drive, and reproduces the transient temperature rise and load alternation state.

[0039] S5: The high-precision data acquisition system 6 acquires all test parameters of the oil cooler, including inlet and outlet oil temperature, inlet and outlet water temperature, oil flow rate, coolant flow rate, oil pressure, water pressure, and ambient temperature, at a set acquisition frequency. All acquired data is accompanied by a unified timestamp to ensure data synchronization.

[0040] S6: According to the preset test condition sequence, all test conditions to be verified are executed in sequence, fully covering the entire working scenario of DHT. During the test, the test condition switching and data recording are automatically completed.

[0041] In S6, the operating conditions to be verified include high and low temperature environment conditions, steady-state load conditions, transient alternating conditions, and extreme load conditions.

[0042] S7: After all operating conditions are tested, stop the heat source simulation, wait for the system to cool down, shut down all circulation systems, and export and process the collected test data.

[0043] Specifically, first stop the heat source output of the DHT real vehicle operating condition simulation system 7, and continue to run the oil circulation supply system 1 and the coolant circulation system 2 until the system cools down to a safe temperature. Then, shut down each circulation system and the environmental simulation system 8 in sequence. Finally, export all the collected data and perform subsequent calculations and analyses of performance parameters such as cooling efficiency, heat dissipation limit, and pressure loss.

[0044] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0045] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle conditions, comprising a bench body, wherein the bench body is provided with a transition fixture (3) for fixing the DHT oil cooler (5) to be tested, characterized in that: The test bench also integrates a DHT vehicle operating condition simulation system (7) for simulating the dynamic heat generation conditions of the DHT real vehicle operation, an oil circulation supply system (1) for providing circulating oil to the DHT oil cooler (5) under test, a coolant circulation system (2) for providing circulating water to the DHT oil cooler (5) under test, an environmental simulation system (8) for simulating the real vehicle environment conditions of the DHT oil cooler (5) under test, a high-precision data acquisition system (6) for synchronously acquiring the heat exchange performance parameters of the oil cooler, and a safety protection control system (9) for monitoring the operation and safety protection control of the whole machine.

2. The bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle conditions according to claim 1, characterized in that: The oil circulation supply system (1) has its oil circuit output end connected to the oil circuit inlet of the DHT oil cooler (5) under test, and its oil circuit input end connected to the oil circuit outlet of the DHT oil cooler (5) under test, thus forming a circulating oil circuit.

3. The bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle conditions according to claim 1, characterized in that: The DHT vehicle operating condition simulation system (7) is connected to the oil circulation supply system (1) by signal and is used to output dynamic heat source control signals to simulate the heat generation state of the DHT transmission under different operating conditions.

4. The bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle conditions according to claim 1, characterized in that: The coolant circulation system (2) has its water outlet connected to the water inlet of the DHT oil cooler (5) under test, and its water inlet connected to the water outlet of the DHT oil cooler (5) under test, thus forming a circulating water circuit.

5. The bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle conditions according to claim 1, characterized in that: The environmental simulation system (8) is placed outside the DHT oil cooler (5) under test to adjust and simulate the actual vehicle environment temperature where the DHT oil cooler (5) is located.

6. The bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle conditions according to claim 1, characterized in that: The high-precision data acquisition system (6) includes temperature sensors and pressure sensors respectively installed at the oil inlet, oil outlet, water inlet and water outlet of the DHT oil cooler (5) under test, as well as flow sensors respectively installed in the circulating oil circuit and circulating water circuit, for real-time synchronous acquisition of oil parameters and coolant parameters of the DHT oil cooler (5) before and after heat exchange.

7. The bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle conditions according to claim 1, characterized in that: The safety protection and control system (9) is electrically connected to the DHT real vehicle working condition simulation system (7), oil circulation supply system (1), coolant circulation system (2), environmental simulation system (8), and high-precision data acquisition system (6) respectively, and is used for monitoring the overall machine operation status and safety protection control.

8. A test method for a bench test apparatus for the cooling capacity of a DHT oil cooler under actual vehicle operating conditions according to any one of claims 1-7, characterized in that: The method includes the following steps: S1: Fix the DHT oil cooler (5) to be tested on the adapter (3), and install temperature sensor, pressure sensor and flow sensor at the corresponding measuring points on the oil inlet and outlet of the DHT oil cooler (5) to be tested and the oil circulation supply system (1) pipeline, the water inlet and outlet of the DHT oil cooler (5) to be tested and the coolant circulation system (2) pipeline. S2: Enter all the operating parameters required for this test into the safety protection control system (9); S3: Start the oil circulation supply system (1), coolant circulation system (2) and environmental simulation system (8) to adjust the oil temperature, water temperature and ambient temperature to the set initial values, and keep the system running in a constant temperature, constant flow and stable pressure. S4: Turn on the DHT real vehicle working condition simulation system (7), output the oil heat source temperature and oil circuit flow control signal of dynamic working condition, and simulate the real-time heat generation state of DHT. S5: All test parameters are collected synchronously at high frequency through a high-precision data acquisition system (6); S6: Execute all working conditions to be verified in sequence to fully cover all working scenarios of DHT; S7: After all operating conditions are tested, stop the heat source simulation, wait for the system to cool down, shut down all circulation systems, and export and process the collected test data.

9. The method according to claim 8, characterized in that: In S4, the dynamic operating condition simulation covers the switching process of three modes: DHT pure electric drive, hybrid drive, and engine direct drive.

10. The method according to claim 8, characterized in that: In S6, the operating conditions to be verified include high and low temperature environment conditions, steady-state load conditions, transient alternating conditions, and extreme load conditions.

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