An automated comprehensive test tool for electric vehicle all-in-one controller

Abstract

The application belongs to the technical field of new energy automobile electric control equipment, and particularly relates to an automatic comprehensive test tool for a multi-in-one controller of an electric automobile, which comprises a cabinet, a partition plate fixedly installed in the cabinet, a test mechanism arranged at a middle position in a test chamber, and a control unit, a power supply unit, a high-voltage relay and a pre-charging test unit, an auxiliary drive and a DCDC test unit, a main drive / auxiliary drive load test unit, a temperature sensor simulation unit, an insulation detection simulation unit and a HALL current test unit installed in the installation chamber; the automatic comprehensive test tool integrates high-voltage power supply, low-voltage power supply, communication control, relay detection, pre-charging detection, load switching, voltage acquisition, current acquisition, temperature sensor simulation, insulation state simulation, HALL current detection and test report output functions in the same test system, so as to improve the whole machine test efficiency, test consistency and product shipment quality tracing capability of the multi-in-one controller.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle electronic control equipment technology, specifically to an automated integrated testing fixture for an all-in-one controller for electric vehicles. Background Technology

[0002] As the electrification level of new energy commercial vehicles continues to increase, the vehicle's electronic control system is gradually developing towards higher integration. Multi-function controllers typically integrate multiple functional units such as PDU, DC-DC converter, OBC, oil pump, air pump, main drive MCU, auxiliary drive MCU, insulation detection module, and current detection module into a single controller. These controllers are characterized by a large number of high-voltage interfaces, complex low-voltage signals, multiple communication networks, numerous relay branches, many detection items, and significant differences in product configuration.

[0003] Before a product leaves the factory, an all-in-one controller typically needs to complete multiple tests, including low-voltage power supply testing, constant power supply testing, ON position wake-up testing, charging wake-up testing, CAN communication testing, relay on / off testing, pre-charge circuit testing, high-voltage sampling testing, DC-DC output testing, oil pump and air pump operation testing, main drive and auxiliary drive load testing, temperature sampling testing, insulation testing, HALL current testing, and overall machine fault status testing.

[0004] Existing testing methods typically rely on manual wiring, manual load switching, manual control command sending, manual reading of instrument readings, and manual recording of test results. This approach suffers from problems such as complex testing procedures, long testing cycles, poor test consistency, high risk of manual wiring errors, high risk of missed tests and misjudgments, and difficulty in data traceability. This is especially true for multi-function controllers, which internally include high-voltage buses, multiple high-voltage outputs, low-voltage wake-up signals, multiple CAN communication interfaces, motor temperature sampling interfaces, insulation detection interfaces, and Hall current detection interfaces. If traditional distributed testing methods are still used, not only will testing efficiency be low, but it will also be difficult to meet the consistency and traceability requirements of mass production processes. Therefore, we propose an automated integrated testing fixture for multi-function controllers in electric vehicles to solve the above problems. Summary of the Invention

[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides an automated integrated testing fixture for all-in-one controllers of electric vehicles, solving the problems mentioned in the background section.

[0006] (II) Technical Solution To achieve the above objectives, the present invention specifically adopts the following technical solution: An automated integrated testing fixture for an all-in-one controller for electric vehicles includes a cabinet. A partition is fixedly installed inside the cabinet, dividing it from left to right into a testing chamber and an installation chamber. A testing mechanism is located in the center of the testing chamber. The installation chamber houses a control unit, a power supply unit, a high-voltage relay and pre-charge testing unit, an auxiliary drive and DC-DC testing unit, a main drive / auxiliary drive load testing unit, a temperature sensor simulation unit, an insulation detection simulation unit, and a HAL current testing unit. The control unit is electrically connected to the testing mechanism via the power supply unit, the high-voltage relay and pre-charge testing unit, the auxiliary drive and DC-DC testing unit, the main drive / auxiliary drive load testing unit, the temperature sensor simulation unit, the insulation detection simulation unit, and the HAL current testing unit.

[0007] Furthermore, the testing mechanism includes a fixture, a first electric telescopic rod, a pressure plate, an industrial camera, a second electric telescopic rod, and an adapter. The fixture is installed between the left and right inner walls of the testing chamber. The first electric telescopic rod is installed on the upper inner wall of the corresponding cabinet on the upper side of the fixture. A pressure plate is installed on the lower surface of the output shaft of the first electric telescopic rod. An industrial camera is embedded on the pressure plate. There are two second electric telescopic rods arranged on the left and right sides. The second electric telescopic rods are installed on the left and right inner walls of the testing chamber, and an adapter is installed on the output shaft of each second electric telescopic rod.

[0008] Furthermore, the control unit includes a microcontroller, an operation display screen, a communication control module, and a software module. The microcontroller is installed in the upper part of the installation room, and the operation display screen is embedded in the front side of the corresponding cabinet. The communication control module integrates multiple CAN communication cards (such as CANA, CANB, CANC, CAND, etc.) and connects to the control unit through a high-speed backplane bus. This unit connects to the controller under test through the CAN interface on the test interface adapter, and is responsible for sending various control commands (such as relay activation, module enable, start / stop commands), and reading the operating status, voltage / current / temperature sampling values, fault codes, software version number, and number of error frames reported by the controller in real time. The software module automatically summarizes the physical data collected from each functional unit and the controller-reported data read through the communication control module according to the preset test process, pass threshold, and judgment logic, and performs real-time comparison and judgment. After all tests are completed, the unit automatically generates a structured whole-machine test report, including the product barcode, test time, measured values, reported values, errors, judgment results, and abnormal information of all test items, and binds the report to the product barcode and automatically stores it in the database or a specified path.

[0009] Furthermore, the power supply unit includes a high-voltage power supply module and a low-voltage power supply module. The high-voltage power supply module is used to provide a controllable high-voltage bus voltage to the multi-in-one controller under test. Its core is a high-voltage programmable DC power supply, which can be precisely set and output the high voltage required for testing through the control unit. A 618V test platform is preferred. The output end of this unit is connected to the high-voltage bus interface of the test interface adapter to provide high-voltage power supply to the controller's PDU, DC-DC, main drive and auxiliary drive modules. The low-voltage power supply module is used to provide various low-voltage signals to the controller under test. This unit includes: 24V constant power supply: supplies power to the constant power terminals of the controller; ON position wake-up signal source: simulates the vehicle's ON position signal; Charging wake-up signal source: Simulates the wake-up signal from the charging gun connection; Multi-channel programmable DC power supply: provides the necessary drive power for main and negative relay drivers, HALL sensors, etc.; all low-voltage signal outputs are switched and distributed through the low-voltage signal matrix relay board and connected to the corresponding low-voltage interface of the test interface adapter.

[0010] Furthermore, the high-voltage relay and pre-charge test unit are used to automatically detect the on / off status of each high-voltage relay inside the controller and the function of the pre-charge circuit. This unit includes: Relay status detection board: Contains multiple high-precision voltage / resistance measurement channels, which are connected to the front and rear test points on the test interface adapter of each high-voltage branch (such as main positive, main negative, three-in-one, air conditioner, large and small upper structure, etc.) through analog / digital switch matrix; Precharge detection circuit: Includes a high-precision resistance meter and a programmable load, used to measure the precharge resistance value and voltage change during the precharge process; The control unit sends a command to close a designated relay through the communication control module. Then, the unit automatically switches the measurement channel to collect the voltage or resistance at the front and rear ends of the relay to determine whether the on / off state is normal and whether the pre-charge function meets the standard.

[0011] Furthermore, the auxiliary drive and DC-DC testing unit includes a function for automating tests on auxiliary drive modules such as oil pumps, air pumps, and DC-DC converters. This unit includes: Programmable electronic loads: simulating oil pump, air pump motor, and DC-DC output loads; High-precision voltage / current acquisition card: Acquires the input voltage, output voltage, and output current of each module; Temperature sampling circuit: Acquires the operating temperature of the module; During testing, the communication control module sends an enable command, and the unit automatically connects to the corresponding load and collects physical signals. At the same time, the communication control module reads the data reported by the controller, which is then compared and judged by the control unit.

[0012] Furthermore, the main drive / auxiliary drive load test unit is used to perform load performance tests on the main drive MCU and the auxiliary drive MCU. The core of this unit is: Three-phase programmable load module: can simulate the characteristics of inductive loads or motor loads; High-precision three-phase current sensor and data acquisition card: used for accurate measurement of U / V / W three-phase output current; Bus voltage sampling circuit: measures the DC bus voltage at the MCU input terminal; Motor feedback signal simulator: simulates resolver or encoder signals; During testing, the unit is connected to the motor three-phase output terminals of the test interface adapter via a heavy-duty connector to simulate real working conditions and simultaneously collect physical quantities for comparison with the values ​​reported by the controller.

[0013] Furthermore, the temperature sensor simulation unit is used to verify the accuracy of the controller's temperature sampling function. This unit is a high-precision multi-channel resistor matrix box, which has a series of high-precision, low-temperature-drift precision resistors built in. Through the relay matrix controlled by the control unit, the resistor values ​​representing different temperatures can be automatically switched to the corresponding temperature sampling interface of the controller.

[0014] Furthermore, the insulation detection simulation unit is used to verify the function of the controller's insulation detection module. This unit consists of two sets of high-precision programmable resistor networks (megohm level) and high-voltage relays, which are used to simulate the insulation resistance (R_p) of the battery positive terminal to ground and the insulation resistance (R_n) of the battery negative terminal to ground, respectively. By controlling the on and off combinations of the relays through the control unit, various insulation fault states can be accurately simulated. At the same time, the communication control module reads the insulation resistance value and fault level reported by the controller for comparison.

[0015] Furthermore, the HALL current test unit is used to test the sampling and communication functions of the controller's HALL current sensor. This unit includes: High-precision programmable DC constant current source: can generate preset test current (e.g., 50A±2.5A, 0A±1A) in each battery branch under test. High-precision standard current sensor: connected in series in the circuit, used to calibrate and verify the actual current value; During testing, a constant current source injects current into a designated branch. The standard sensor in this unit measures the actual current value, while the communication control module reads the HALL current value of that branch reported by the controller via CAN. The control unit then calculates the error.

[0016] (III) Beneficial Effects Compared with the prior art, the present invention provides an automated integrated testing fixture for an all-in-one controller for electric vehicles, which has the following advantages: This invention integrates numerous scattered test items of an all-in-one controller into a single automated process, avoiding repetitive manual wiring, switching, and recording. This significantly shortens the test cycle time per unit and reduces the risk of manual operation. Through fixed interfaces and automatic switching, it completely eliminates human errors such as high-voltage misconnection, signal reversal, and incorrect interface connection, improving test safety and reliability. Program-controlled execution of standardized test steps and judgment criteria eliminates differences in results caused by different operators, ensuring consistent test quality for batch products. By comparing the measured physical values ​​of the tooling with the values ​​reported by the controller software, it can quickly distinguish between hardware faults, sampling circuit faults, communication faults, and software logic faults, facilitating rapid repair on the production line. Test data is automatically bound to product barcodes and generates structured reports, providing a complete data foundation for subsequent quality analysis, after-sales traceability, and production management. By changing the integrated test interface adapter and loading different test configuration files, this tooling can quickly adapt to different models and configurations of all-in-one controllers, reducing the development cost and cycle time of new product testing systems. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is a schematic diagram of the main cross-sectional structure of the present invention; Figure 3 This is a schematic diagram of the system framework structure of the present invention; Figure 4 This is a schematic diagram of the process structure of the present invention; Figure 5 This is a schematic diagram of the circuit framework structure of the present invention.

[0018] In the diagram: 1. Cabinet; 2. Partition; 3. Test Chamber; 4. Installation Chamber; 5. Test Mechanism; 501. Fixture; 502. First Electric Telescopic Rod; 503. Pressure Plate; 504. Industrial Camera; 505. Second Electric Telescopic Rod; 506. Adapter; 6. Control Unit; 601. Microcontroller; 602. Operation Display Screen; 603. Communication Control Module; 604. Software Module; 7. Power Supply Unit; 8. High Voltage Relay and Pre-charge Test Unit; 9. Auxiliary Drive and DC-DC Test Unit; 10. Main Drive / Auxiliary Drive Load Test Unit; 11. Temperature Sensor Simulation Unit; 12. Insulation Detection Simulation Unit; 13. Hall Current Test Unit. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Example like Figures 1-5 As shown in the figure, an automated integrated testing fixture for an all-in-one controller for electric vehicles, proposed in one embodiment of the present invention, includes a cabinet 1. A partition 2 is fixedly installed inside the cabinet 1, dividing the cabinet 1 from left to right into a test chamber 3 and an installation chamber 4. A test mechanism 5 is arranged in the middle of the test chamber 3. A control unit 6, a power supply unit 7, a high-voltage relay and pre-charge test unit 8, an auxiliary drive and DC-DC test unit 9, a main drive / auxiliary drive load test unit 10, a temperature sensor simulation unit 11, an insulation detection simulation unit 12, and a Hall current test unit 13 are installed in the installation chamber 4. The control unit 6 is connected to the power supply unit 7, the high-voltage relay and pre-charge test unit 8, the auxiliary drive and DC-DC test unit 9, and the main drive / auxiliary drive load test unit 10. Test unit 9, main drive / auxiliary drive load test unit 10, temperature sensor simulation unit 11, insulation detection simulation unit 12, and HALL current test unit 13 are electrically connected to test mechanism 5. The main frame of the fixture adopts a standard industrial cabinet with strong and weak current partitions inside. Control unit 6 is located at the top of cabinet 1. The high-power power supply module of the high-voltage power supply module is placed at the bottom of cabinet 1 and equipped with independent air duct for heat dissipation. The low-voltage power supply module, wake-up unit, and communication control module 603 are installed in a backplane box. The high-voltage relay, pre-charge test unit 8, insulation detection simulation unit 12, and other parts involving high-voltage switching and measurement are installed in an independent module box with safety interlocking and protection.

[0021] like Figure 2 As shown, in some embodiments, the testing mechanism 5 includes a fixture 501, a first electric telescopic rod 502, a pressure plate 503, an industrial camera 504, a second electric telescopic rod 505, and an adapter 506. The fixture 501 is installed between the left and right inner walls of the testing chamber 3. The first electric telescopic rod 502 is installed on the upper inner wall of the cabinet 1 corresponding to the upper side of the fixture 501. The pressure plate 503 is installed on the lower surface of the output shaft of the first electric telescopic rod 502. The industrial camera 504 is embedded in the pressure plate 503. There are two second electric telescopic rods 505 arranged on the left and right sides. The second electric telescopic rods 505 are installed on the left and right inner walls of the testing chamber 3, and each of the second electric telescopic rods 505 is provided with an adapter 506 on its output shaft.

[0022] In this embodiment, the multi-function controller to be tested is placed in fixture 501. The first electric telescopic rod 502 drives the pressure plate 503 and industrial camera 504 to move downwards, so that the industrial camera 504 scans the barcode of the multi-function controller and sends the feedback to the control unit 6. At the same time, the pressure plate 503 presses the multi-function controller firmly in fixture 501. The output shafts of the left and right second electric telescopic rods 505 drive the left and right adapters 506 to be inserted into the sockets of the multi-function controller. The adapter 506 is a physical interface integration component. On one side, it gathers the test lines of all functional units through customized, mis-insertion-proof connectors (such as high-voltage connectors, low-voltage multi-core connectors, CAN ports, temperature sensor interfaces, etc.). On the other side, it provides a unified docking port (or wiring harness) that is fully matched with the interface of the multi-function controller under test. It ensures that all high and low voltage signals, communication signals and sensor signals can be docked in one connection, fundamentally eliminating manual wiring errors.

[0023] like Figure 4 As shown, in some embodiments, the control unit 6 includes a microcontroller 601, an operation display screen 602, a communication control module 603, and a software module 604. The microcontroller 601 is installed in the mounting chamber 4 near the upper side. The operation display screen 602 is embedded on the front side of the cabinet 1 corresponding to the microcontroller 601. The communication control module 603 integrates multiple CAN communication cards (such as CANA, CANB, CANC, CAND, etc.) and is connected to the control unit 6 through a high-speed backplane bus. This unit is connected to the controller under test through the CAN interface on the test interface adapter 506 and is responsible for sending various control commands (such as relay activation, module enable). The software module 604 automatically summarizes the physical data collected from each functional unit and the controller-reported data read through the communication control module 603 according to the preset test process, pass threshold and judgment logic, and performs real-time comparison and judgment. After all tests are completed, the unit automatically generates a structured whole machine test report, which includes product barcode, test time, measured value, reported value, error, judgment result and abnormal information of all test items, and binds the report with product barcode and automatically stores it in the database or a specified path.

[0024] In this embodiment, the microcontroller 601 is the "brain" of the entire test fixture. It runs the test main control software, which is responsible for scheduling all the above-mentioned functional units, parsing the test process, sending control commands, receiving and processing all collected data and communication data, and performing the final automatic judgment and report generation tasks. The communication control module 603 integrates communication interfaces such as CANA, CANB, CANC, and CAND, which are used to send relay closing commands, module enable commands, start / stop commands, and read information such as voltage, current, temperature, working status, fault status, software version number, and number of error frames reported by the controller.

[0025] like Figure 4 As shown, in some embodiments, the power supply unit 7 includes a high-voltage power supply module and a low-voltage power supply module. The high-voltage power supply module is used to provide a controllable high-voltage bus voltage to the multi-in-one controller under test. Its core is a high-voltage programmable DC power supply, which can be precisely set and output the high voltage required for testing through the control unit 6. A 618V test platform is preferred. The output end of this unit is connected to the high-voltage bus interface of the test interface adapter 506 to provide high-voltage power supply to the controller's PDU, DC-DC, main drive and auxiliary drive modules. The low-voltage power supply module is used to provide various low-voltage signals to the controller under test. This unit includes: 24V constant power supply: supplies power to the constant power terminals of the controller; ON position wake-up signal source: simulates the vehicle's ON position signal; Charging wake-up signal source: Simulates the wake-up signal from the charging gun connection; Multi-channel programmable DC power supply: provides the necessary drive power for main and negative relay drivers, HALL sensors, etc. All low-voltage signal outputs are switched and distributed via the low-voltage signal matrix relay board and connected to the corresponding low-voltage interface of the test interface adapter 506.

[0026] In this embodiment, the high-voltage power supply module and the low-voltage power supply module are used to supply power to the specification unit to meet the power requirements during the testing process.

[0027] like Figure 4 As shown, in some embodiments, the high-voltage relay and pre-charge test unit 8 are used to automatically detect the on / off state of each high-voltage relay inside the controller and the function of the pre-charge circuit. This unit includes: Relay status detection board: Contains multiple high-precision voltage / resistance measurement channels, which are connected to the front and rear test points on the test interface adapter 506 of each high-voltage branch (such as main positive, main negative, three-in-one, air conditioner, large and small upper structure, etc.) through analog / digital switch matrix; Precharge detection circuit: Includes a high-precision resistance meter and a programmable load, used to measure the precharge resistance value and voltage change during the precharge process; The control unit 6 sends a command to close the designated relay through the communication control module 603. Then, the unit automatically switches the measurement channel to collect the voltage or resistance at the front and rear ends of the relay and determine whether the on / off state is normal and whether the pre-charge function meets the standard.

[0028] In this embodiment, the on / off status of each high-voltage relay inside the controller and the function of the pre-charge circuit are automatically detected, and the information is fed back to the control unit 6.

[0029] like Figure 4 As shown, in some embodiments, the auxiliary drive and DC-DC testing unit 9 includes a unit for automatically testing auxiliary drive modules such as oil pumps, air pumps, and DC-DC converters. This unit includes: Programmable electronic loads: simulating oil pump, air pump motor, and DC-DC output loads; High-precision voltage / current acquisition card: Acquires the input voltage, output voltage, and output current of each module; Temperature sampling circuit: Acquires the operating temperature of the module; During testing, the communication control module 603 sends an enable command, and the unit automatically connects to the corresponding load and collects physical signals. At the same time, the communication control module 603 reads the data reported by the controller, which is then compared and judged by the control unit 6.

[0030] In this embodiment, auxiliary drive modules such as oil pump, air pump, and DC-DC converter in the all-in-one controller are tested.

[0031] like Figure 4 As shown, in some embodiments, the main drive / auxiliary drive load test unit 10 is used to perform load performance tests on the main drive MCU and the auxiliary drive MCU. The core of this unit is: Three-phase programmable load module: can simulate the characteristics of inductive loads or motor loads; High-precision three-phase current sensor and data acquisition card: used for accurate measurement of U / V / W three-phase output current; Bus voltage sampling circuit: measures the DC bus voltage at the MCU input terminal; Motor feedback signal simulator: simulates resolver or encoder signals; During testing, the unit is connected to the motor three-phase output terminal of the test interface adapter 506 via a heavy-duty connector to simulate real working conditions and simultaneously collect physical quantities for comparison with the values ​​reported by the controller.

[0032] In this embodiment, the main drive MCU and auxiliary drive MCU of the all-in-one controller are used to perform load performance testing.

[0033] like Figure 4 As shown, in some embodiments, the temperature sensor simulation unit 11 is used to verify the accuracy of the controller's temperature sampling function. This unit is a high-precision multi-channel resistor matrix box, which has a series of high-precision, low-temperature-drift precision resistors built in. Through the relay matrix controlled by the control unit 6, the resistor values ​​representing different temperatures can be automatically switched to the corresponding temperature sampling interface of the controller.

[0034] In this embodiment, the unit used to verify the accuracy of the controller's temperature sampling function is a high-precision multi-channel resistor matrix box, which has a series of high-precision, low-temperature-drift precision resistors built in.

[0035] like Figure 4 As shown, in some embodiments, the insulation detection simulation unit 12 is used to verify the function of the controller insulation detection module. The unit consists of two sets of high-precision programmable resistor networks at the megohm level and high-voltage relays, which are used to simulate the insulation resistance (R_p) of the battery positive terminal to ground and the insulation resistance (R_n) of the battery negative terminal to ground, respectively. By controlling the on and off combinations of the relays through the control unit 6, various insulation fault states can be accurately simulated. At the same time, the communication control module 603 reads the insulation resistance value and fault level reported by the controller for comparison.

[0036] In this embodiment, the function of the controller insulation detection module is verified.

[0037] like Figure 5 As shown, in some embodiments, the HALL current test unit 13 is used to test the sampling and communication functions of the controller's HALL current sensor. This unit includes: High-precision programmable DC constant current source: can generate preset test current (e.g., 50A±2.5A, 0A±1A) in each battery branch under test. High-precision standard current sensor: connected in series in the circuit, used to calibrate and verify the actual current value; During testing, a constant current source injects current into a designated branch. The standard sensor in this unit measures the actual current value, while the communication control module 603 reads the HALL current value of that branch reported by the controller via CAN. The control unit 6 then calculates the error.

[0038] In this embodiment, the sampling and communication functions of the controller HALL current sensor are tested.

[0039] In use, the all-in-one controller under test is placed in fixture 501 within the testing mechanism 5. The first electric telescopic rod 502 moves the pressure plate 503 and industrial camera 504 downwards, simultaneously pressing the all-in-one controller firmly into fixture 501. The output shafts of the left and right second electric telescopic rods 505 drive the left and right adapters 506 to be inserted into the sockets of the all-in-one controller. The fixture connects to the high-voltage interface, low-voltage interface, CAN communication interface, temperature sampling interface, HALL current interface, and insulation detection interface of the controller under test via fixed interfaces. The industrial camera 504 first identifies the barcode of the product under test and feeds the information back to the microcontroller 601 in the control unit 6. The microcontroller 601 selects the corresponding test program based on the product barcode or product configuration. Following the sequence and test items, after the test begins, the fixture first performs a low-voltage power-on pre-check. The microcontroller 601 detects the communication interface terminal resistance, low-voltage power supply interface status, relay drive interface status, and connection status of key high and low voltage interfaces through data acquisition to determine whether the controller under test meets the power-on conditions. After the pre-power-on check is passed, the low-voltage power supply module provides low-voltage constant power to the controller under test and sequentially outputs the ON position wake-up signal and charging wake-up signal. It collects the low-voltage input current, wake-up level, sleep current, and low-voltage power supply status. The microcontroller 601 determines whether the low-voltage power supply and wake-up logic are normal according to preset thresholds. Subsequently, the fixture enters the high-voltage relay and pre-charge circuit test stage. The communication control module 603 sends the corresponding relay closing signal to the controller under test. Upon receiving a closing or opening command, the high-voltage relay and pre-charge test unit 8 determine whether the on / off status of the main positive relay, main negative relay, and each high-voltage branch relay is normal by measuring the voltage and resistance at the front and rear ends of the relay or reading the status reported by the controller. For branches with pre-charge circuits, the fixture determines whether the pre-charge relay and pre-charge resistor are normal by detecting the pre-charge resistance value, the voltage change at the front and rear ends of the pre-charge circuit, or the corresponding sampling data. During the high-voltage sampling test phase, the high-voltage power supply module provides a preset high-voltage bus voltage to the controller under test, and the communication control module 603 acquires the actual high-voltage voltage. At the same time, the communication control module 603 reads the bus voltage and voltage of each high-voltage branch reported by the controller under test. The microcontroller 601 compares the measured values ​​with the values ​​reported by the controller to determine... To check if the high-voltage sampling accuracy meets the preset requirements, during the DC-DC test phase, the microcontroller 601 controls the auxiliary drive and DC-DC test unit 9 to connect to a low-voltage load, and sends a DC-DC start command through the communication control module 603. The communication control module 603 measures the actual output voltage and output current of the DC-DC, and reads the output voltage, output current, temperature, operating status, and fault status reported by the controller under test. The control unit 6 judges the DC-DC output capability and sampling accuracy based on the measured values, reported values, and preset error range. During the oil pump, air pump, or other auxiliary drive module test phase, the communication control module 603 sends module enable and stop commands, and the main drive / auxiliary drive load test unit 10 connects to the corresponding test load.The communication control module 603 collects parameters such as input voltage, output current, output frequency, and temperature. The microcontroller 601 uses this information to determine if the auxiliary drive module is functioning correctly, based on the module's operating status, software version, and number of error frames. During the main / auxiliary drive MCU testing phase, the temperature sensor simulation unit 11 switches to the corresponding resistance value according to the test program to simulate sensor signals under different temperature conditions. The communication control module 603 reads the temperature value reported by the controller under test, and the microcontroller 601 compares it with the corresponding simulated temperature value to determine if the temperature sampling function is normal. Then, the load switching unit connects a motor load, inductive load, or simulated load according to the test items. The communication control module 603 collects the U / V / W three-phase output current, bus voltage, and feedback signal. The communication control module 603 reads the current, frequency, temperature, and fault status reported by the controller, thereby achieving automatic detection of the main and auxiliary drive output capabilities and sampling accuracy. During the insulation detection phase, the insulation detection simulation unit 12 uses the preset... An insulation simulation resistor of varying resistance value is connected to either the positive terminal to ground circuit or the negative terminal to ground circuit of the battery. The communication control module 603 reads the positive terminal to ground insulation resistance value, the negative terminal to ground insulation resistance value, and the insulation fault level reported by the controller under test. The microcontroller 601 compares the reported results with the preset resistance value and preset fault level to determine whether the insulation detection function is normal. During the HALL current test phase, the HALL current test unit 13 controls a DC source or constant current source to apply a preset test current in a designated branch. The communication control module 603 collects the actual current value and reads the current reported value of the corresponding HALL branch. The microcontroller 601 compares the actual current with the reported current to determine whether the HALL current sampling function and the corresponding communication function are normal. After all test items are completed, the microcontroller 601 summarizes the measured data of each test item, the controller reported data, the judgment results, and the abnormal information. The software module 604 generates an automatic test report for the entire machine based on the product barcode and binds the test records to the product barcode for archiving.

[0040] In summary, this automated integrated testing fixture for electric vehicle all-in-one controllers integrates functions such as high-voltage power supply, low-voltage power supply, communication control, relay detection, pre-charge detection, load switching, voltage acquisition, current acquisition, temperature sensor simulation, insulation status simulation, Hall current detection, and test report output into a single testing system. This improves the overall testing efficiency, test consistency, and product quality traceability of the all-in-one controller.

[0041] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automated integrated testing fixture for an all-in-one controller for electric vehicles, comprising a cabinet (1), characterized in that: The cabinet (1) is fixedly installed with a partition (2), which divides the cabinet (1) from left to right into a test chamber (3) and an installation chamber (4). A test mechanism (5) is set in the middle of the test chamber (3). The installation chamber (4) is equipped with a control unit (6), a power supply unit (7), a high-voltage relay and pre-charge test unit (8), an auxiliary drive and DC-DC test unit (9), a main drive / auxiliary drive load test unit (10), a temperature sensor simulation unit (11), an insulation detection simulation unit (12), and a Hall current test unit (13). The control unit (6) is electrically connected to the test mechanism (5) through the power supply unit (7), the high-voltage relay and pre-charge test unit (8), the auxiliary drive and DC-DC test unit (9), the main drive / auxiliary drive load test unit (10), the temperature sensor simulation unit (11), the insulation detection simulation unit (12), and the Hall current test unit (13).

2. The automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The testing mechanism (5) includes a fixture (501), a first electric telescopic rod (502), a pressure plate (503), an industrial camera (504), a second electric telescopic rod (505), and an adapter (506). The fixture (501) is installed between the left and right inner walls of the testing chamber (3). The first electric telescopic rod (502) is installed on the upper inner wall of the cabinet (1) corresponding to the upper side of the fixture (501). The pressure plate (503) is installed on the lower surface of the output shaft of the first electric telescopic rod (502). The industrial camera (504) is embedded in the pressure plate (503). There are two second electric telescopic rods (505) on the left and right sides. The second electric telescopic rods (505) are installed on the left and right inner walls of the testing chamber (3), and each of the output shafts of the second electric telescopic rods (505) is equipped with an adapter (506).

3. The automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The control unit (6) includes a microcontroller (601), an operation display screen (602), a communication control module (603), and a software module (604). The microcontroller (601) is installed in the installation chamber (4) near the upper side. The operation display screen (602) is embedded on the front side of the cabinet (1) corresponding to the microcontroller (601). The communication control module (603) integrates a multi-channel CAN communication card and connects to the control unit (6) through a high-speed backplane bus. This unit connects to the controller under test through the CAN interface on the test interface adapter (506), and is responsible for sending various control commands and reading the controller in real time. The software module (604) automatically summarizes the physical data collected from each functional unit and the controller-reported data read through the communication control module (603) according to the preset test process, pass threshold and judgment logic, and performs real-time comparison and judgment. After all tests are completed, the unit automatically generates a structured whole machine test report, which includes product barcode, test time, measured value of all test items, reported value, error, judgment result and abnormal information, and binds the report with product barcode and automatically stores it in the database or a specified path.

4. The automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The power supply unit (7) includes a high-voltage power supply module and a low-voltage power supply module. The high-voltage power supply module is used to provide a controllable high-voltage bus voltage to the multi-in-one controller under test. Its core is a high-voltage programmable DC power supply, which can be precisely set and output the high voltage required for testing through the control unit (6). The 618V test platform is preferred. The output end of the unit is connected to the high-voltage bus interface of the test interface adapter (506) to provide high-voltage power supply for the controller's PDU, DC-DC, main drive and auxiliary drive modules. The low-voltage power supply module is used to provide various low-voltage signals to the controller under test. This unit includes: 24V constant power supply: supplies power to the controller's constant power terminals; ON position wake-up signal source: simulates the vehicle's ON position signal; Charging wake-up signal source: Simulates the wake-up signal from the charging gun connection; Multi-channel programmable DC power supply: provides the necessary drive power for main and negative relay drivers, HALL sensors, etc. All low-voltage signal outputs are switched and distributed via the low-voltage signal matrix relay board and connected to the corresponding low-voltage interface of the test interface adapter (506).

5. An automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The high-voltage relay and pre-charge test unit (8) are used to automatically detect the on / off status of each high-voltage relay inside the controller and the function of the pre-charge circuit. This unit includes: Relay status detection board: contains multiple high-precision voltage / resistance measurement channels, which are connected to the front and rear test points of each high-voltage branch on the test interface adapter (506) through an analog / digital switch matrix; Precharge detection circuit: Includes a high-precision resistance meter and a programmable load, used to measure the precharge resistance value and voltage change during the precharge process; The control unit (6) sends a command to close the designated relay through the communication control module (603), and then the unit automatically switches the measurement channel to collect the voltage or resistance of the front and rear ends of the relay, and judges whether the on / off is normal and whether the pre-charge function meets the standard.

6. The automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The auxiliary drive and DC-DC test unit (9) includes a unit for automating tests on auxiliary drive modules such as oil pumps, air pumps, and DC-DC converters. This unit includes: Programmable electronic loads: simulating oil pump, air pump motor, and DC-DC output loads; High-precision voltage / current acquisition card: Acquires the input voltage, output voltage, and output current of each module; Temperature sampling circuit: Acquires the operating temperature of the module; During testing, the communication control module (603) sends an enable command, and the unit automatically connects to the corresponding load and collects physical signals. At the same time, the communication control module (603) reads the data reported by the controller, and the control unit (6) performs comparison and judgment.

7. An automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The main drive / auxiliary drive load test unit (10) is used to perform load performance tests on the main drive MCU and the auxiliary drive MCU. The core of this unit is: Three-phase programmable load module: can simulate the characteristics of inductive loads or motor loads; High-precision three-phase current sensor and data acquisition card: used for accurate measurement of U / V / W three-phase output current; Bus voltage sampling circuit: measures the DC bus voltage at the MCU input terminal; Motor feedback signal simulator: simulates resolver or encoder signals; During testing, the unit is connected to the motor three-phase output terminal of the test interface adapter (506) via a heavy-duty connector to simulate real working conditions and simultaneously collect physical quantities for comparison with the values ​​reported by the controller.

8. An automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The temperature sensor simulation unit (11) is used to verify the accuracy of the controller's temperature sampling function. This unit is a high-precision multi-channel resistor matrix box with a series of high-precision, low-temperature-drift precision resistors built in. Through the relay matrix controlled by the control unit (6), the resistor values ​​representing different temperatures can be automatically switched to the corresponding temperature sampling interface of the controller.

9. An automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The insulation detection simulation unit (12) is used to verify the function of the controller insulation detection module. The unit consists of two sets of high-precision programmable resistor networks and high-voltage relays, which are used to simulate the insulation resistance of the positive terminal of the battery to ground and the insulation resistance of the negative terminal of the battery to ground, respectively. By controlling the on and off combination of the relays through the control unit (6), various insulation fault states can be accurately simulated. At the same time, the communication control module (603) reads the insulation resistance value and fault level reported by the controller for comparison.

10. An automated integrated testing fixture for an all-in-one controller for electric vehicles according to claim 1, characterized in that: The HALL current test unit (13) is used to test the sampling and communication functions of the controller's HALL current sensor. This unit includes: High-precision programmable DC constant current source: can generate preset test current in each battery branch under test; High-precision standard current sensor: connected in series in the circuit, used to calibrate and verify the actual current value; During testing, a constant current source injects current into a designated branch. The standard sensor of the unit measures the actual current value, while the communication control module (603) reads the HALL current value of the branch reported by the controller via CAN. The control unit (6) calculates the error.

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