A fault emergency stop device for electrically driven bench test

Abstract

The application discloses a kind of electric drive rack test's fault emergency stop device, comprising: water chiller, flowmeter, control relay, emergency stop device, battery simulator, frequency conversion cabinet, dynamometer, router and host computer, pass through hardware contact interconnection link and double-layer network communication architecture, build the multi-level fault protection system of software and hardware cooperation.The application builds the three-level independent and complementary protection mechanism of field manual emergency stop, host computer automatic program emergency stop, hardware bottom-up automatic emergency stop, can comprehensively cover the manned operation, unmanned program normal, unmanned program failure three kinds of application scenarios under the condition of water chiller fault, effectively solve the technical defects of single protection mode of traditional electric drive test system, software protection failure without hardware bottom-up, fault response lag, poor fault tolerance of test, with the advantages of condition adaptation comprehensive, protection reliability is high, response speed is fast, the advantage of low transformation cost.

Description

Technical Field

[0001] This invention relates to the technical field of testing equipment for electric drive products, and in particular to an emergency stop device for testing electric drive benches. Background Technology

[0002] When electric drive products operate on laboratory test benches, cooling water needs to be supplied to keep their temperature within a safe range. Generally, the laboratory uses a chiller to supply cooling water to the electric drive products. The chiller communicates with a host computer via network cable or other means. The host computer can control the chiller and receive real-time status data from the chiller, including fault information. At the same time, the host computer establishes communication with each module in the test bench system, thereby controlling the operation of the entire test bench system.

[0003] During testing, the chiller may malfunction, causing parameters such as flow rate, temperature, or pressure to fall short of requirements, or even shut down. A chiller malfunction will cause the temperature of the electric drive components to exceed safe limits, resulting in damage or even burnout. Therefore, when the host computer receives a chiller malfunction signal, it will execute an emergency stop command, halting the test bench system and stopping the electric drive assembly. Alternatively, testing personnel can manually stop the test bench system by pressing the emergency stop button on the test bench control system after observing the chiller malfunction signal received by the host computer.

[0004] 2. Deficiencies and shortcomings of existing technologies:

[0005] When the chiller malfunctions, the host computer will fail to execute the emergency stop operation if any of the following three situations occur:

[0006] ① The host computer experienced a communication error when receiving a fault signal from the chiller;

[0007] ② A communication error occurred when the host computer sent an emergency stop command to the test bench;

[0008] ③ The host computer itself experiences a system crash or other malfunction.

[0009] If the emergency stop operation of the host computer fails and the test personnel do not operate the manual emergency stop button in time, the electrically driven product will continue to operate, the internal temperature of the product will continue to rise, causing product damage or even burnout, and may even lead to more serious safety accidents. Summary of the Invention

[0010] The main technical problem solved by this invention is to provide an emergency stop device for electric drive bench testing, which solves the technical problems of existing electric drive testing systems such as single protection mode, lack of fallback mechanism for software protection failure, lack of protection for unattended operation, and poor test fault tolerance. It realizes emergency stop protection with high reliability and fast response in multiple scenarios under chiller failure, and comprehensively improves the safety and stability of automated testing of electric drive products.

[0011] To solve the above-mentioned technical problems, one technical solution adopted by the present invention is: to provide an emergency stop device for electric drive bench testing, including: a chiller, a flow meter, a control relay, an emergency stop device, a battery simulator, a frequency converter cabinet, a dynamometer, a router, a host computer, and the electric drive product under test.

[0012] The low-pressure contact of the chiller is electrically connected to the low-pressure contact of the flow meter, and the low-pressure contact of the flow meter is electrically connected to the low-pressure contact of the control relay to form a power supply circuit for the flow meter and the control relay.

[0013] The flow meter is equipped with an upper limit alarm signal contact and a lower limit alarm signal contact. The upper limit alarm signal contact is connected to the first signal contact of the control relay, and the lower limit alarm signal contact is connected to the second signal contact of the control relay.

[0014] The second normally closed switch of the control relay, the first normally closed switch of the emergency stop device, and the power switch of the battery simulator are connected in series to form the power-off control circuit of the battery simulator.

[0015] The first normally open switch of the emergency stop device, the 24V power supply, and the low-voltage contact of the frequency converter cabinet relay inside the frequency converter cabinet are connected in series in sequence. The second normally open switch of the control relay is connected in parallel with the first normally open switch of the emergency stop device to form a dual-path trigger control circuit of the frequency converter cabinet.

[0016] The normally closed switch, power supply and power switch of the frequency converter cabinet are connected in series to form the power supply on / off control circuit of the frequency converter cabinet.

[0017] The battery simulator is electrically connected to the electric drive product under test and is used to provide the electric drive product under test with DC high voltage for testing; the frequency converter cabinet is electrically connected to the dynamometer and is used to control the start-up, shutdown and operating conditions of the dynamometer.

[0018] The router establishes LAN communication with the chiller, battery simulator, and frequency converter cabinet respectively. The router establishes LAN communication with the host computer. The host computer establishes CAN bus communication with the tested electric drive product. The host computer is used for overall management and control of the operation, parameter adjustment, and start / stop status of each device.

[0019] In a preferred embodiment of the present invention, the flow meter has a built-in parameter threshold configuration unit that supports custom configuration of upper and lower alarm thresholds for temperature, flow rate, and pressure, and collects the operating parameters of the test system in real time, comparing the measured parameters with the preset thresholds in real time.

[0020] In a preferred embodiment of the present invention, when the measured values ​​of temperature, flow rate or pressure collected by the flow meter are higher than the corresponding upper limit alarm threshold or lower than the corresponding lower limit alarm threshold, the flow meter transmits an abnormal alarm signal to the first signal contact or the second signal contact of the control relay through the corresponding upper limit alarm signal contact or lower limit alarm signal contact, thereby triggering the control relay to operate.

[0021] In a preferred embodiment of the present invention, the emergency stop device integrates an emergency stop button, a first normally closed switch, and a first normally open switch. When the emergency stop button is pressed, the first normally closed switch can be opened and the first normally open switch can be closed simultaneously.

[0022] In a preferred embodiment of the present invention, a three-level redundant emergency stop protection mode is configured, including a field manual emergency stop protection mode, a host computer automatic program emergency stop protection mode, and a hardware backup automatic emergency stop protection mode, to adapt to the full-condition safety protection requirements under the failure of the chiller.

[0023] In a preferred embodiment of the present invention, the on-site manual emergency stop protection includes two independent execution modes:

[0024] Mode 1: Hardware emergency stop mode. Press the emergency stop button of the emergency stop device. The first normally closed switch of the emergency stop device opens, cutting off the power supply circuit of the battery simulator. The battery simulator stops working. At the same time, the first normally open switch of the emergency stop device closes, connecting the low-voltage contact of the frequency converter cabinet relay to the 24V power supply. This drives the frequency converter cabinet relay to operate and disconnects the normally closed switch of the frequency converter cabinet, cutting off the power supply of the frequency converter cabinet. The frequency converter cabinet and dynamometer stop running, suspending the testing of the electrically driven product under test.

[0025] Mode 2: Software control mode. The host computer issues a shutdown control command, which directly controls the battery simulator, frequency converter cabinet and the tested electric drive product to stop running synchronously through the communication link.

[0026] In a preferred embodiment of the present invention, the host computer automatic program emergency stop protection mode is suitable for unattended testing conditions. When the chiller malfunctions, the host computer automatically calls the built-in emergency stop program and sends shutdown commands to the battery simulator, frequency converter cabinet, and the tested electric drive product, respectively, to complete the automatic emergency stop protection of the test system.

[0027] In a preferred embodiment of the present invention, the hardware fallback automatic emergency stop protection mode is applicable to unattended testing conditions and abnormal scenarios such as failure of the host computer emergency stop program execution, program lag, or communication interruption.

[0028] In a preferred embodiment of the present invention, the protection logic of the hardware-backup automatic emergency stop protection mode includes: after the flow meter detects abnormal system parameters, it transmits an alarm signal to the control relay, triggers the linkage action of the control relay, disconnects the second normally closed switch of the control relay to cut off the power supply circuit of the battery simulator, and simultaneously closes the second normally open switch of the control relay to connect the low-voltage contact of the frequency converter cabinet relay to the 24V power supply, drives the frequency converter cabinet relay to disconnect the first normally closed switch, cuts off the power supply of the frequency converter cabinet, and causes the dynamometer and the tested electric drive product to stop synchronously, thereby realizing hardware-level backup emergency stop protection of the test system.

[0029] In a preferred embodiment of the present invention, at least one dynamometer is provided and connected to the electric drive product being tested.

[0030] The beneficial effects of this invention are as follows: This invention integrates three independent protections: manual hardware emergency stop, automatic emergency stop via host computer software, and pure hardware fallback emergency stop. Even if the host computer program fails or communication is interrupted, the hardware link can still independently complete the emergency stop, completely eliminating the safety risk of protection failure. It can accurately adapt to all mainstream working conditions, including manually monitored routine testing, unattended automated testing, and unattended program anomaly testing, comprehensively covering various electric drive product testing scenarios. It has a wide range of adaptability and strong practicality, solving the technical problems of existing electric drive testing systems such as single protection methods, lack of fallback mechanism for software protection failure, lack of protection in unattended working conditions, and poor test fault tolerance. It achieves multi-scenario, highly reliable, and fast-response emergency stop protection under chiller failure, comprehensively improving the safety and stability of automated testing of electric drive products. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention, wherein:

[0032] Figure 1 This is a flowchart of the fault emergency stop device for an electrically driven test bench according to the present invention. Detailed Implementation

[0033] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. 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.

[0034] Please see Figure 1 The present invention includes: an emergency stop device for electric drive bench testing, comprising: a chiller 1, a flow meter 2, a control relay 7, an emergency stop device 25, a battery simulator 16, a frequency converter cabinet 21, a dynamometer 27, a dynamometer 28, a router 29, a host computer 30, and an electric drive product under test 26.

[0035] The low-pressure contact 10 of the chiller is connected to the low-pressure contact 11 of the flow meter, and the low-pressure contact of the flow meter is electrically connected to the low-pressure contact 12 of the control relay to form a power supply circuit for the flow meter and the control relay, thereby enabling the flow meter 2 and the control relay 7 to be powered normally.

[0036] The flow meter is equipped with an upper limit alarm signal contact 4 and a lower limit alarm signal contact 3. The upper limit alarm signal contact is connected to the first signal contact 6 of the control relay, and the lower limit alarm signal contact is connected to the second signal contact 5 of the control relay. Furthermore, the flow meter has a built-in parameter threshold configuration unit, which supports custom configuration of upper and lower limit alarm thresholds for temperature, flow rate, and pressure. It also collects the operating parameters of the test system in real time and compares the measured parameters with the preset thresholds in real time. When the measured values ​​of temperature, flow rate, or pressure collected by the flow meter are higher than the corresponding upper limit alarm threshold or lower than the corresponding lower limit alarm threshold, the flow meter transmits an abnormal alarm signal to the first or second signal contact of the control relay through the corresponding upper limit alarm signal contact or lower limit alarm signal contact, triggering the control relay to operate.

[0037] Furthermore, the emergency stop device 25 integrates an emergency stop button 13, a first normally closed switch 14, and a first normally open switch 17. When the emergency stop button is pressed, the first normally closed switch opens and the first normally open switch closes simultaneously. The second normally closed switch 8 of the control relay, the first normally closed switch 14 of the emergency stop device, and the power switch 15 of the battery simulator 16 are connected in series to form the power-off control circuit of the battery simulator. The first normally open switch 17 of the emergency stop device, the 24V power supply 23, and the low-voltage contact 24 of the frequency converter cabinet relay 19 inside the frequency converter cabinet 21 are connected in series. The second normally open switch 9 of the control relay 7 and the first normally open switch 17 of the emergency stop device are connected in parallel to form the dual-path trigger control circuit of the frequency converter cabinet. The normally closed switch 20 of the frequency converter cabinet, the power supply 22 of the frequency converter cabinet, and the power switch 18 of the frequency converter cabinet are connected in series to form the power supply on / off control circuit of the frequency converter cabinet.

[0038] The battery simulator 16 is electrically connected to the electric drive product under test 26 to provide the electric drive product under test with DC high voltage for testing. The frequency converter cabinet is electrically connected to the dynamometer to control the start-up, shutdown and operating conditions of the dynamometer 27 or dynamometer 28.

[0039] Router 29 communicates with battery simulator 16, frequency converter cabinet 21 and chiller 1 via LAN (local area network); router 29 communicates with host computer 30 via LAN, host computer 30 communicates with the tested electric drive product 26 via CAN. Host computer 30 can control the operation of battery simulator 16, frequency converter cabinet 21, chiller 1 and tested electric drive product 26. The host computer is used for overall management of the operation, parameter adjustment and start / stop status of each device.

[0040] This device is equipped with a three-level redundant emergency stop protection mode, including on-site manual emergency stop protection mode, host computer automatic program emergency stop protection mode, and hardware backup automatic emergency stop protection mode, to meet the full-condition safety protection requirements under the condition of chiller failure.

[0041] On-site manual emergency stop protection includes two independent execution modes:

[0042] Mode 1: Hardware emergency stop mode. Press the emergency stop button of the emergency stop device. The first normally closed switch of the emergency stop device opens, cutting off the power supply circuit of the battery simulator. The battery simulator stops working. At the same time, the first normally open switch of the emergency stop device closes, connecting the low-voltage contact of the frequency converter cabinet relay to the 24V power supply. This drives the frequency converter cabinet relay to operate and open its normally closed switch, cutting off the power supply of the frequency converter cabinet. The frequency converter cabinet and dynamometer stop running, suspending the testing of the electrically driven product under test.

[0043] Mode 2: Software control mode. The host computer issues a shutdown control command, which directly controls the battery simulator, frequency converter cabinet and the tested electric drive product to stop running synchronously through the communication link.

[0044] On-site manual emergency stop protection mode:

[0045] ①When the chiller 1 malfunctions, if the staff is on site, there are two ways to suspend the test of the electric drive product 26 under test.

[0046] By pressing the emergency stop button 13 of the emergency stop device 25 or operating the host computer 30, the battery simulator 16 and the frequency converter cabinet 21 can be made to stop working. Specifically, after pressing the emergency stop button 13 of the emergency stop device 25, the first normally closed switch 14 of the emergency stop device 25 is opened, thereby disconnecting the power supply 31 of the battery simulator 16 and preventing it from working; at the same time, the first normally open switch 17 of the emergency stop device 25 is closed, thereby connecting the low-voltage contact 24 of the frequency converter cabinet relay 19 in the frequency converter cabinet to the 24V power supply 23, thereby making the frequency converter cabinet relay 19 work and causing the normally closed switch 20 of the frequency converter cabinet to open, thereby disconnecting the power supply 22 of the frequency converter cabinet and preventing it from working, that is, pausing the test of the tested electric drive product 26;

[0047] ② Operate the host computer 30 to control and stop the operation of the battery simulator 16, the frequency converter cabinet 21 and the tested electric drive product 26.

[0048] Automatic emergency stop protection mode for host computer programs:

[0049] When the chiller 1 malfunctions, if the staff is not on site and the host computer 30 successfully executes the emergency stop procedure, the host computer 30 will automatically send instructions to the battery simulator 16, the frequency converter cabinet 21 and the tested electric drive product 26 to stop their operation.

[0050] Hardware-backup emergency stop protection mode:

[0051] When chiller 1 malfunctions, if the staff is not on site and the host computer 30 experiences program freezes, crashes, communication interruptions, or other abnormalities, and the emergency stop procedure fails to execute, flow meter 2 transmits the abnormal signal to signal 1 contact 6 or signal 2 contact 5 of control relay 7 via upper limit alarm signal contact 4 or lower limit alarm signal contact 3. Upon receiving the abnormal signal, control relay 7 operates, causing the second normally closed switch 8 to open, thereby disconnecting the power supply 31 of battery simulator 16 and preventing it from working. Simultaneously, upon receiving the abnormal signal, control relay 7 operates, causing the second normally open switch 9 to close, thereby connecting the low-voltage contact 24 of frequency converter cabinet relay 19 to the 24V power supply 23. This causes frequency converter cabinet relay 19 to operate, causing the normally closed switch 20 of frequency converter cabinet to open, thereby disconnecting the power supply 22 of frequency converter cabinet 21 and preventing it from working, thus suspending the test of the tested electric drive product 26.

[0052] The beneficial effects of the fault emergency stop device for electric drive bench testing of the present invention are as follows: The present invention integrates three independent protections: manual hardware emergency stop, automatic emergency stop by host computer software, and pure hardware backup emergency stop. Even if the host computer program fails or communication is interrupted, the hardware link can still independently complete the emergency stop, completely eliminating the safety risk of protection failure. It can accurately adapt to all mainstream working conditions such as manually operated routine testing, unattended automated testing, and unattended program abnormal testing, comprehensively covering various electric drive product testing scenarios. It has a wide range of adaptability and strong practicality, solving the technical problems of existing electric drive testing systems such as single protection method, no backup mechanism for software protection failure, lack of protection in unattended working conditions, and poor test fault tolerance. It realizes multi-scenario, highly reliable, and fast-response emergency stop protection under chiller failure, comprehensively improving the safety and stability of automated testing of electric drive products.

[0053] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A fault emergency stop device for electric drive bench testing, characterized in that, include: Chillers, flow meters, control relays, emergency stop devices, battery simulators, frequency converters, dynamometers, routers, host computers, and the electric drive products under test; The low-pressure contact of the chiller is electrically connected to the low-pressure contact of the flow meter, and the low-pressure contact of the flow meter is electrically connected to the low-pressure contact of the control relay to form a power supply circuit for the flow meter and the control relay. The flow meter is equipped with an upper limit alarm signal contact and a lower limit alarm signal contact. The upper limit alarm signal contact is connected to the first signal contact of the control relay, and the lower limit alarm signal contact is connected to the second signal contact of the control relay. The second normally closed switch of the control relay, the first normally closed switch of the emergency stop device, and the power switch of the battery simulator are connected in series to form the power-off control circuit of the battery simulator. The first normally open switch of the emergency stop device, the 24V power supply, and the low-voltage contact of the frequency converter cabinet relay inside the frequency converter cabinet are connected in series in sequence. The second normally open switch of the control relay is connected in parallel with the first normally open switch of the emergency stop device to form a dual-path trigger control circuit of the frequency converter cabinet. The normally closed switch, power supply and power switch of the frequency converter cabinet are connected in series to form the power supply on / off control circuit of the frequency converter cabinet. The battery simulator is electrically connected to the electric drive product under test and is used to provide the electric drive product under test with DC high voltage for testing; the frequency converter cabinet is electrically connected to the dynamometer and is used to control the start-up, shutdown and operating conditions of the dynamometer. The router establishes LAN communication with the chiller, battery simulator, and frequency converter cabinet respectively. The router establishes LAN communication with the host computer. The host computer establishes CAN bus communication with the tested electric drive product. The host computer is used for overall management and control of the operation, parameter adjustment, and start / stop status of each device.

2. The fault emergency stop device for an electrically driven test bench according to claim 1, characterized in that, The flow meter has a built-in parameter threshold configuration unit that supports custom configuration of upper and lower alarm thresholds for temperature, flow rate, and pressure. It also collects the operating parameters of the test system in real time and compares the measured parameters with the preset thresholds in real time.

3. The fault emergency stop device for an electrically driven test bench according to claim 2, characterized in that, When the measured values ​​of temperature, flow rate, or pressure collected by the flow meter are higher than the corresponding upper limit alarm threshold or lower than the corresponding lower limit alarm threshold, the flow meter transmits an abnormal alarm signal to the first signal contact or the second signal contact of the control relay through the corresponding upper limit alarm signal contact or lower limit alarm signal contact, thereby triggering the control relay to operate.

4. The fault emergency stop device for an electrically driven test bench according to claim 1, characterized in that, The emergency stop device integrates an emergency stop button, a first normally closed switch, and a first normally open switch. When the emergency stop button is pressed, the first normally closed switch opens and the first normally open switch closes simultaneously.

5. The fault emergency stop device for an electrically driven test bench according to claim 3, characterized in that, It is equipped with a three-level redundant emergency stop protection mode, including on-site manual emergency stop protection mode, host computer automatic program emergency stop protection mode, and hardware backup automatic emergency stop protection mode, to adapt to the full-condition safety protection requirements under the failure of the chiller.

6. The fault emergency stop device for an electrically driven test bench according to claim 5, characterized in that, The on-site manual emergency stop protection includes two independent execution modes: Mode 1: Hardware emergency stop mode. Press the emergency stop button of the emergency stop device. The first normally closed switch of the emergency stop device opens, cutting off the power supply circuit of the battery simulator. The battery simulator stops working. At the same time, the first normally open switch of the emergency stop device closes, connecting the low-voltage contact of the frequency converter cabinet relay to the 24V power supply. This drives the frequency converter cabinet relay to operate and disconnects the normally closed switch of the frequency converter cabinet, cutting off the power supply of the frequency converter cabinet. The frequency converter cabinet and dynamometer stop running, suspending the testing of the electrically driven product under test. Mode 2: Software control mode. The host computer issues a shutdown control command, which directly controls the battery simulator, frequency converter cabinet and the tested electric drive product to stop running synchronously through the communication link.

7. The fault emergency stop device for an electrically driven test bench according to claim 5, characterized in that, The host computer's automatic emergency stop protection mode is suitable for unattended testing conditions. When the chiller malfunctions, the host computer automatically calls the built-in emergency stop program and sends shutdown commands to the battery simulator, frequency converter cabinet, and the tested electric drive product, respectively, to complete the automatic emergency stop protection of the test system.

8. The fault emergency stop device for an electrically driven test bench according to claim 5, characterized in that, The hardware-backup automatic emergency stop protection mode is applicable to unattended testing conditions and abnormal scenarios such as host computer failure, emergency stop program execution failure, program lag, or communication interruption.

9. The fault emergency stop device for an electrically driven test bench according to claim 8, characterized in that, The protection logic of the hardware-backup automatic emergency stop protection mode includes: after the flow meter detects abnormal system parameters, it transmits an alarm signal to the control relay, triggers the linkage action of the control relay, disconnects the second normally closed switch of the control relay to cut off the power supply circuit of the battery simulator, and at the same time closes the second normally open switch of the control relay, connects the low-voltage contact of the frequency converter cabinet relay to the 24V power supply, drives the frequency converter cabinet relay to disconnect the first normally closed switch, cuts off the power supply of the frequency converter cabinet, and causes the dynamometer and the tested electric drive product to stop synchronously, realizing hardware-level backup emergency stop protection of the test system.

10. The fault emergency stop device for an electrically driven test bench according to claim 1, characterized in that, At least one dynamometer is provided and connected to the electric drive product being tested.

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