A monitoring method and system for a wheel corner joggle module

Abstract

The present application relates to the technical field of intelligent chassis corner module testing of automobiles, and specifically relates to a monitoring method and system for a wheel corner module, which synchronizes in time temperature data, motor operating state parameters, torque distribution instructions and actual output torque, calculates the temperature difference inside the motor, the temperature difference between left and right wheel edge driving motors and the temperature rise rate, and identifies non-uniform temperature states or abnormal temperature rise states based on preset threshold values; at the same time, the standard output torque is obtained from a standard performance parameter library according to the motor speed, average temperature and working mode, the performance decay coefficient of the actual output torque relative to the standard output torque is calculated, and a performance decay state is identified when the performance decay coefficient meets the decay determination condition. The system generates a state identifier and a fault code according to the identification result, and displays, stores or alarms. The present application can correlate and analyze temperature characteristics with working states and torque performance, and improve the integrity and traceability of abnormal state identification of the wheel corner module.

Description

Technical Field

[0001] This invention generally relates to the field of automotive intelligent chassis corner module testing technology, and specifically to a monitoring method and system for wheel-side corner modules. Background Technology

[0002] With the development of distributed drive and intelligent chassis technology in electric vehicles, wheel-side corner modules are gradually integrating functions such as drive, braking, steering, and suspension. As the power execution component in the wheel-side corner module, the wheel-side drive motor is subjected to frequent start-stop, continuous high torque output, road impact, and electromagnetic interference. Its winding temperature distribution, temperature rise process, and torque output capability directly affect the reliability of the corner module.

[0003] Existing monitoring solutions typically collect motor temperature, controller fault codes, or torque commands separately. Temperature monitoring often uses a single temperature measurement point method, which makes it difficult to reflect the temperature differences between different winding positions within the same motor. At the same time, there is a lack of a unified time reference between temperature data and speed, torque commands, and actual output torque, making it difficult to accurately identify the correlation between temperature anomalies and output performance degradation.

[0004] Furthermore, after frequent start-stop or continuous high-load operation, the wheel-side drive motor may exhibit an actual output torque lower than the calibrated value under the same speed, temperature, and operating mode. Relying solely on a single temperature threshold or controller fault code makes it difficult to distinguish between different states such as localized non-uniform temperature, rapid temperature rise, and performance degradation, and is also not conducive to recording the complete operating conditions when the abnormality occurs.

[0005] Therefore, a monitoring method and system for wheel edge corner modules is needed to simultaneously process temperature data, operating status parameters, and torque performance from multiple temperature measurement points and form a monitoring scheme with quantifiable judgment results. Summary of the Invention

[0006] The purpose of this invention is to provide a monitoring method and system for wheel edge corner modules, which aims to synchronously process temperature data, operating status parameters and torque performance from multiple temperature measurement points and form a monitoring scheme with quantifiable judgment results.

[0007] In a first aspect, the present invention provides a monitoring method for a wheel-side corner module, comprising: collecting temperature data from at least two temperature measuring points of a left wheel-side drive motor and a right wheel-side drive motor, and collecting operating status parameters, torque distribution commands, and actual output torque data; and synchronizing the temperature data, operating status parameters, torque distribution commands, and actual output torque data in time. Calculate the internal temperature difference of the same wheel-side drive motor, the inter-motor temperature difference between the left and right wheel-side drive motors, and the temperature rise rate of each wheel-side drive motor, and identify non-uniform temperature states based on the corresponding thresholds. Based on the current speed and average temperature, the standard output torque is obtained from the preset standard performance parameter library. The ratio of the difference between the standard output torque and the actual output torque to the standard output torque is calculated to obtain the performance degradation coefficient. The performance degradation status is identified according to the preset degradation threshold. Based on the identification results, status identifiers and fault codes are generated and displayed, stored, or alarmed.

[0008] According to the technical solution provided by the present invention, the internal temperature difference of the motor is the difference between the highest and lowest temperatures of multiple temperature sensors of the same wheel-side drive motor at the same calculation time; the inter-motor temperature difference is the absolute value of the difference between the average temperatures of the left and right wheel-side drive motors at the same calculation time; and the temperature rise rate is the difference between the average temperature at the current calculation time and the average temperature at the previous calculation time divided by the corresponding time interval.

[0009] According to the technical solution provided by the present invention, the preset standard performance parameter library is obtained by calibrating the wheel-side drive motor under different speed ranges, temperature ranges, and target torque ranges, and outputs a standard output torque that matches the current speed, average temperature, and target torque using a multi-dimensional index or interpolation method.

[0010] According to the technical solution provided by the present invention, when the performance degradation coefficient is greater than or equal to a preset degradation threshold for at least two consecutive calculation times, the performance degradation state is identified.

[0011] According to the technical solution provided by the present invention, the operating state parameters include at least motor speed, stator current, and rotor position; the torque distribution command includes the target torque of each wheel, torque distribution ratio, and adjustment coefficient.

[0012] Secondly, the present invention provides a monitoring system for a wheel edge corner module, capable of employing the wheel edge corner module monitoring method described above, comprising: The motor temperature monitoring module includes temperature sensors embedded in each wheel-side drive motor, the temperature sensors being used to collect the winding temperature data of the wheel-side drive motor in real time; An angle module status monitoring device is communicatively connected to the motor temperature monitoring module, the angle module controller, and the drive motor actuator, respectively. The angle module status monitoring device includes a signal processing module and a fault diagnosis module. The data interaction unit is communicatively connected to the motor temperature monitoring module, the corner module status monitoring device, and the test terminal, respectively, for data transmission between the modules. The test terminal is communicatively connected to the data interaction unit and is used for data display, storage, and parameter configuration. The corner module status monitoring device receives temperature data uploaded by the motor temperature monitoring module through the data interaction unit, reads the motor operating status parameters and torque distribution strategy instructions output by the corner module controller, and collects the actual output torque data of the drive motor actuator. The signal processing module calculates the temperature difference at different monitoring points of each motor winding, the temperature difference between the left and right wheel-side motor windings, and the temperature rise rate based on the winding temperature data. It also compares the actual output torque with the corresponding parameters in the preset standard performance parameter library to calculate the performance attenuation coefficient. The fault diagnosis module determines a non-uniform temperature state and generates a corresponding fault code when any one of the temperature difference, temperature difference value, or temperature rise rate exceeds a preset threshold. It also determines a performance degradation state and generates a corresponding fault code when the performance degradation coefficient exceeds a preset degradation threshold.

[0013] According to the technical solution provided by the present invention, the temperature sensor is connected to the end of the stator winding and / or the iron core slot of the wheel-side drive motor, and the sampling frequency is not less than 100Hz.

[0014] According to the technical solution provided by the present invention, the fault diagnosis module can match the corresponding fault code according to the fault type and classify the fault level into minor fault, general fault and serious fault, and link the audible and visual alarm module for different levels to realize graded reminders; the corner module status monitoring device integrates a display module and an audible and visual alarm module, the display module is used to display the fault code and monitoring parameters in real time, and the audible and visual alarm module triggers different alarm signals according to the fault level.

[0015] According to the technical solution provided by the present invention, the data interaction unit adopts a dual communication link design, including a CAN / CAN FD bus link and an Ethernet link; the CAN / CAN FD bus link is used to connect the motor temperature monitoring module, the corner module status monitoring device and the corner module controller, with a transmission rate of not less than 500kbps; the Ethernet link is used to connect the corner module status monitoring device and the test terminal. The data interaction unit has a built-in data caching module for temporarily storing data to avoid data loss due to communication interruption; The data interaction unit also integrates an anti-interference module, which resists electromagnetic interference and vibration through shielding and signal filtering.

[0016] The beneficial effects of this invention are as follows: The monitoring method calculates the internal temperature difference of the motor through multiple temperature measurement points of the same motor, and combines the temperature difference between the left and right motors and the temperature rise rate to distinguish between local thermal unevenness, inconsistent thermal states between the left and right sides, and rapid temperature rise; simultaneously, by synchronizing temperature, speed, operating mode, and actual output torque over time, and calling standard performance values ​​according to the current operating conditions, performance degradation can be quantitatively identified, avoiding misjudgments caused by monitoring a single parameter; and based on the fault coding and hierarchical alarm design, the fault type and fault condition can be quickly located, providing accurate support for fault diagnosis and improving the reliability and timeliness of the system's fault diagnosis. The detection system adopts a dual communication link design, combined with anti-interference processing and data caching mechanisms, to ensure distortion-free and delay-free transmission of temperature data, status parameters, and fault information, and can adapt to harsh on-board environments such as wheel-side vibration, electromagnetic interference, and high and low temperatures, meeting the dual needs of bench testing and on-board monitoring. Attached Figure Description

[0017] Other features, objects, and advantages of the invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings.

[0018] Figure 1 This is a schematic diagram of the monitoring method for the wheel edge corner module provided in an embodiment of this application.

[0019] Figure 2 This is a schematic diagram of a wheel edge corner module monitoring system provided in an embodiment of this application. Detailed Implementation

[0020] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0021] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0022] Example 1 Please refer to Figure 1 The monitoring method for the wheel-side corner module provided by the present invention includes collecting temperature data from at least two temperature measuring points of each of at least two wheel-side drive motors, and collecting operating status parameters, torque distribution commands, and actual output torque data; and adding timing sequences to the temperature data, operating status parameters, torque distribution commands, and actual output torque data. The operating status parameters include at least motor speed, stator current, rotor position, and operating mode; the torque distribution commands include the target torque for each wheel-side, the torque distribution ratio, and the adjustment coefficient.

[0023] The internal temperature difference of the same wheel-side drive motor, the inter-motor temperature difference between the left and right wheel-side drive motors, and the temperature rise rate of each wheel-side drive motor are calculated. Non-uniform temperature conditions or abnormal temperature rise conditions are then identified based on corresponding thresholds. In this embodiment, the temperature difference threshold between the left and right motors is set to 5℃, and the temperature rise rate threshold is set to 2℃ / min.

[0024] The internal temperature difference of the motor is the difference between the highest and lowest temperatures of multiple temperature sensors on the same wheel-side drive motor at the same calculation time. This parameter is used to reflect the temperature distribution differences between different winding positions of the same motor.

[0025] The temperature difference between motors is the absolute value of the difference between the average temperatures of the left and right wheel-side drive motors at the same calculation time, and is used to characterize the thermal consistency of the left and right wheel-side drive motors.

[0026] The temperature rise rate is calculated by dividing the difference between the average temperature at the current calculation moment and the average temperature at the previous calculation moment by the corresponding time interval. To prevent the judgment result from frequently switching around the threshold, a non-uniform temperature state or an abnormal temperature rise state is identified when the condition is met for N consecutive calculation moments. In this embodiment, N=3.

[0027] It should be noted that before calculating the internal temperature difference of the motor, the temperature difference between motors, and the temperature rise rate, the temperature data is subjected to range verification, mutation rate verification, and multi-temperature point consistency verification. When the data of any temperature sensor is determined to be invalid, the corresponding temperature data is discarded, and the remaining valid temperature data of the same wheel-side drive motor are used for status identification.

[0028] Based on the current speed, average temperature, and operating mode, the standard output torque is obtained from the preset standard performance parameter library. The ratio of the difference between the standard output torque and the actual output torque to the standard output torque is calculated to obtain the performance degradation coefficient. The performance degradation status is identified based on the degradation threshold. Status identifiers and fault codes are generated based on the identification results and displayed, stored, or alarmed.

[0029] The preset standard performance parameter library is obtained by calibrating the wheel-side drive motor in different speed ranges, temperature ranges, target torque ranges and working modes, and uses multi-dimensional indexing or interpolation to output standard output torque that matches the current speed, average temperature, target torque and working mode.

[0030] The performance degradation state is identified when the performance degradation coefficient is greater than or equal to a preset degradation threshold for at least two consecutive calculation times. In this embodiment, the performance degradation threshold is set to 10%.

[0031] Example 2 This invention provides a monitoring system for wheel edge corner modules, capable of employing the wheel edge corner module monitoring method described above, including: The motor temperature monitoring module includes temperature sensors embedded in each wheel-side drive motor. The temperature sensors are used to collect the winding temperature data of the wheel-side drive motor in real time. The corner module status monitoring device is communicatively connected to the motor temperature monitoring module, the corner module controller, and the drive motor actuator, and includes a signal processing module and a fault diagnosis module. The data interaction unit is connected to the motor temperature monitoring module, the corner module status monitoring device and the test terminal respectively, and is used for data transmission between the modules. The test terminal communicates with the data interaction unit and is used for data display, storage, and parameter configuration.

[0032] Specifically, the temperature sensor is connected to the end of the stator winding and / or inside the core slot of the wheel-side drive motor, closely fitting the winding to ensure the accuracy and timeliness of temperature acquisition. The temperature sensor uses automotive-grade high-precision temperature sensing elements, covering a temperature range of -40℃ to 200℃. It is suitable for the full range of temperature changes of the wheel-side drive motor, from low-temperature start-up to high-temperature full-load operation, with a temperature measurement accuracy of no less than ±1℃, meeting the high-precision requirements for motor temperature uniformity judgment and overheat warning.

[0033] Its working principle is as follows: Based on the characteristic of the resistance of the thermistor changing with temperature (or the thermoelectric effect of the thermocouple), the physical quantity of the temperature of the motor winding is converted into an acquireable electrical signal (voltage signal or current signal). After being processed by the internal signal conditioning circuit (filtering, amplification, calibration) of the sensor, a standardized digital temperature signal is output. Each temperature sensor is connected to the data interaction unit through shielded wires. It adopts an anti-interference design to avoid the influence of wheel vibration and electromagnetic interference on the temperature data, ensuring that the original temperature data is transmitted directly to the corner module status monitoring device and the test terminal without distortion or delay. The data transmission frequency is synchronized with the subsequent status monitoring device and is not lower than 100Hz.

[0034] The corner module status monitoring device is the core processing and diagnostic unit of the entire system. It adopts an embedded controller design and integrates a signal processing module, a fault diagnosis module, a display module, and a communication module. It communicates bidirectionally with the motor temperature monitoring module, the corner module controller, the drive motor actuator, and the data interaction unit to achieve collaborative acquisition, in-depth processing, and accurate diagnosis of multiple parameters.

[0035] The corner module status monitoring device receives temperature data uploaded by the motor temperature monitoring module through the data interaction unit, reads the motor operating status parameters and torque distribution strategy instructions output by the corner module controller, and collects the actual output torque data of the drive motor actuator. The signal processing module calculates the temperature difference at different monitoring points of each motor winding, the temperature difference between the left and right wheel-side motor windings, and the rate of temperature rise based on the winding temperature data. It then compares the actual output torque with the corresponding parameters in a preset standard performance parameter library to calculate the performance degradation coefficient. When the performance degradation coefficient exceeds a preset degradation threshold, it is determined that the motor has experienced performance degradation. Simultaneously, the degree of performance degradation, its duration, and the corresponding temperature and torque conditions are recorded to provide data support for subsequent maintenance. The core principle is that after high-frequency motor operation, the increased winding temperature leads to increased winding resistance and changes in magnetic field strength, resulting in a decrease in torque output and a slower response. Through the linkage analysis of temperature and performance parameters, the performance degradation state can be accurately identified, avoiding misjudgments caused by monitoring only a single parameter.

[0036] The fault diagnosis module determines a non-uniform temperature state and generates a corresponding fault code when any of the temperature difference, temperature difference value, or temperature rise rate exceeds a preset threshold. It also determines a performance degradation state and generates a corresponding fault code when the performance degradation coefficient exceeds a preset degradation threshold.

[0037] The fault diagnosis module can match corresponding fault codes based on fault type and classify fault levels into minor, general, and severe faults. It then triggers tiered alerts via audible and visual alarm modules for different levels. The corner module status monitoring device integrates a display module and an audible and visual alarm module. The display module shows fault codes and monitoring parameters in real time, while the audible and visual alarm module triggers different alarm signals based on the fault level. For example, an abnormal temperature difference inside the motor might correspond to fault code E001, and a normal temperature difference between the left and right motors might correspond to fault code E002. Fault codes are stored in association with the operating parameters at the time of the abnormality, and alerts, general alarms, or severe alarms are triggered based on the duration or severity.

[0038] The data interaction unit adopts a dual communication link design, including a CAN / CAN FD bus link and an Ethernet link; the CAN / CAN FD bus link is used to connect the motor temperature monitoring module, the corner module status monitoring device and the corner module controller, with a transmission rate of not less than 500kbps; the Ethernet link is used to connect the corner module status monitoring device and the test terminal. The data interaction unit has a built-in data caching module for temporary data storage to avoid data loss due to communication interruption. It also integrates an anti-interference module to resist electromagnetic interference and vibration through shielding and signal filtering.

[0039] The testing terminal uses an industrial-grade computer or a dedicated measurement and control terminal with built-in monitoring software to receive all data transmitted by the wheel corner module status monitoring device. This enables real-time data display, curve plotting, historical data querying, report generation, and parameter configuration. The testing terminal can display the temperature curves, torque distribution curves, performance degradation trend curves, and fault code lists of each wheel motor in real time. It also supports exporting historical data, providing data support for performance optimization, fault tracing, and lifespan assessment of the wheel corner module. Furthermore, the testing terminal can remotely modify various preset thresholds of the wheel corner module status monitoring device to adapt to the monitoring needs of different wheel corner module models.

[0040] In this application, unless otherwise expressly defined, the terms "installation," "connection," "linking," and "fixed connection" should be interpreted broadly. For example, they can refer to mechanical connections, interference fits, key connections, or welding; they can refer to direct connections or indirect connections through intermediate media (such as bearings or couplings). Those skilled in the art can understand the specific meaning of these terms in this application in conjunction with specific mechanical structures.

[0041] The terms “first”, “second”, etc. (e.g., first drive shaft, second drive shaft) used in this application are only used to distinguish objects that are spatially symmetrical or functionally similar, and are not necessarily used to describe a specific order or degree of importance.

[0042] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for monitoring wheel edge corner modules, characterized in that, include: Temperature data from at least two temperature measurement points of the left wheel drive motor and the right wheel drive motor are collected, along with operating status parameters, torque distribution commands, and actual output torque data; the temperature data, operating status parameters, torque distribution commands, and actual output torque data are synchronized in time. Calculate the internal temperature difference of the same wheel-side drive motor, the inter-motor temperature difference between the left and right wheel-side drive motors, and the temperature rise rate of each wheel-side drive motor, and identify non-uniform temperature states based on the corresponding thresholds. Based on the current speed and average temperature, the standard output torque is obtained from the preset standard performance parameter library. The ratio of the difference between the standard output torque and the actual output torque to the standard output torque is calculated to obtain the performance degradation coefficient. The performance degradation status is identified according to the preset degradation threshold. Based on the identification results, status identifiers and fault codes are generated and displayed, stored, or alarmed.

2. The monitoring method for the wheel edge corner module according to claim 1, characterized in that, The internal temperature difference of the motor is the difference between the highest and lowest temperatures of multiple temperature sensors on the same wheel-side drive motor at the same calculation time; the temperature difference between motors is the absolute value of the difference between the average temperatures of the left and right wheel-side drive motors at the same calculation time; the temperature rise rate is the difference between the average temperature at the current calculation time and the average temperature at the previous calculation time divided by the corresponding time interval.

3. The monitoring method for the wheel edge corner module according to claim 1, characterized in that, The preset standard performance parameter library is obtained by calibrating the wheel-side drive motor under different speed ranges, temperature ranges, and target torque ranges, and outputs a standard output torque that matches the current speed, average temperature, and target torque using multi-dimensional indexing or interpolation.

4. The monitoring method for the wheel edge corner module according to claim 1, characterized in that, The performance degradation state is identified when the performance degradation coefficient is greater than or equal to the preset degradation threshold for at least two consecutive calculation times.

5. The monitoring method for the wheel edge corner module according to claim 1, characterized in that, The operating status parameters include at least the motor speed, stator current, and rotor position; the torque distribution command includes the target torque for each wheel, the torque distribution ratio, and the adjustment coefficient.

6. A monitoring system for wheel edge corner modules, capable of employing the monitoring method for wheel edge corner modules as described in any one of claims 1-5, characterized in that, include: The motor temperature monitoring module includes temperature sensors embedded in each wheel-side drive motor, the temperature sensors being used to collect the winding temperature data of the wheel-side drive motor in real time; An angle module status monitoring device is communicatively connected to the motor temperature monitoring module, the angle module controller, and the drive motor actuator, respectively. The angle module status monitoring device includes a signal processing module and a fault diagnosis module. The data interaction unit is communicatively connected to the motor temperature monitoring module, the corner module status monitoring device, and the test terminal, respectively, for data transmission between the modules. The test terminal is communicatively connected to the data interaction unit and is used for data display, storage, and parameter configuration. The corner module status monitoring device receives temperature data uploaded by the motor temperature monitoring module through the data interaction unit, reads the motor operating status parameters and torque distribution strategy instructions output by the corner module controller, and collects the actual output torque data of the drive motor actuator. The signal processing module calculates the temperature difference at different monitoring points of each motor winding, the temperature difference between the left and right wheel-side motor windings, and the temperature rise rate based on the winding temperature data. It also compares the actual output torque with the corresponding parameters in the preset standard performance parameter library to calculate the performance attenuation coefficient. The fault diagnosis module determines a non-uniform temperature state and generates a corresponding fault code when any one of the temperature difference, temperature difference value, or temperature rise rate exceeds a preset threshold. It also determines a performance degradation state and generates a corresponding fault code when the performance degradation coefficient exceeds a preset degradation threshold.

7. The monitoring system for the wheel edge corner module according to claim 6, characterized in that, The temperature sensor is connected to the end of the stator winding and / or the iron core slot of the wheel-side drive motor, and the sampling frequency is not less than 100Hz.

8. The monitoring system for the wheel edge corner module according to claim 6, characterized in that, The fault diagnosis module can match the corresponding fault code according to the fault type and classify the fault level into minor fault, general fault and serious fault, and link the audible and visual alarm module for different levels to realize graded reminders; the corner module status monitoring device integrates a display module and an audible and visual alarm module. The display module is used to display the fault code and monitoring parameters in real time, and the audible and visual alarm module triggers different alarm signals according to the fault level.

9. The monitoring system for the wheel edge corner module according to claim 6, characterized in that, The data interaction unit adopts a dual communication link design, including a CAN / CAN FD bus link and an Ethernet link; the CAN / CAN FD bus link is used to connect the motor temperature monitoring module, the corner module status monitoring device and the corner module controller, with a transmission rate of not less than 500kbps; the Ethernet link is used to connect the corner module status monitoring device and the test terminal. The data interaction unit has a built-in data caching module for temporarily storing data to avoid data loss due to communication interruption; The data interaction unit also integrates an anti-interference module, which resists electromagnetic interference and vibration through shielding and signal filtering.

Images