DHT high-voltage connector insulation oil product deterioration test device and test method thereof

Abstract

This invention relates to a DHT high-voltage connector insulation oil resistance degradation test apparatus and method, belonging to the field of DHT component testing technology. It includes a base plate serving as a load-bearing foundation; a motor controller for controlling motor operation to apply high-voltage electric field stress; a TCU for regulating the oil circuit operation of the DHT assembly; a dynamometer for providing speed loading to the DHT assembly to create an internal oil mist atmosphere; a bench clamping tilt module for positioning and dynamically adjusting the installation tilt angle of the DHT assembly under test; an oil and power supply module for providing oil temperature control and high-voltage power supply support for the test; a communication module for signal interaction between various devices; and a main control system for centralized control of the test process and acquisition of insulation performance data. This invention effectively improves the authenticity and relevance of the insulation oil resistance degradation test, accurately exposes the aging and failure risks of insulation materials, and improves the reliability and consistency of test results.

Description

Technical Field

[0001] This invention relates to a test apparatus and method for testing the oil resistance of DHT high-voltage connector insulation, belonging to the field of DHT component testing technology. Background Technology

[0002] The DHT (Dual-mode Continuous Transmission) integrates high-voltage drive / generator components, and its high-voltage connectors are constantly immersed in transmission fluid and exposed to oil vapor. Under prolonged high-temperature operation, mechanical shearing, and air contact, the internal ATF (Automatic Transmission Fluid) of the DHT gradually oxidizes and deteriorates, generating corrosive components such as acidic substances, gums, and sludge. These components continuously erode the insulating sheaths and seals of the high-voltage connectors, causing materials to swell, become embrittled, and degrade, leading to problems such as decreased insulation resistance, surface leakage, and partial discharge. In severe cases, this can cause high-voltage breakdown, directly threatening the high-voltage electrical safety of the entire vehicle.

[0003] Existing high-voltage connector insulation performance verification methods mostly employ aging at room temperature or static immersion tests in new oil, which differ significantly from the actual working environment inside the DHT. On the one hand, they do not consider the corrosive characteristics of ATF oil after long-term deterioration, and cannot reflect the oil condition after long-term service in actual vehicles. On the other hand, they do not couple and load multi-dimensional stresses such as high-temperature environment, high-voltage electric field, oil mist dispersion, and oil splashing, and mainly rely on static immersion, which does not match the dynamic oil and gas environment in which the connector is actually located.

[0004] While adding degraded oil to the transmission and supplying high-voltage electricity to the high-voltage connectors, the test bench main control system simulates the oil atomization process and oil splashing process during the high-speed operation of the real vehicle and the transition conditions such as temperature cycle, transmission speed dynamics and transition conditions, and transmission installation angle changes by automatically programming and superimposing test conditions. The test bench conducts a 1000-hour durability test to achieve the purpose of evaluating the insulation durability performance of the high-voltage connectors.

[0005] The aforementioned deficiencies prevent existing tests from accurately replicating the degradation patterns and failure modes of insulating materials. The test results lack authenticity and specificity, making it difficult to meet the reliability verification requirements of high-voltage connectors for hybrid transmissions. Summary of the Invention

[0006] To address the problems existing in the background technology, the present invention provides a test device and test method for oil resistance degradation of DHT high voltage connector insulation.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a DHT high-voltage connector insulation oil resistance degradation test device, comprising a base plate serving as the supporting foundation for the entire test bench, a motor controller for controlling the operation of the DHT built-in motor to apply high-voltage electric field stress, a TCU for regulating the oil circuit operation status of the DHT assembly, a dynamometer for providing speed loading to the DHT assembly under test to form an internal oil mist atmosphere, a bench clamping tilt module for realizing the positioning, clamping and dynamic adjustment of the installation tilt angle of the DHT assembly under test, an oil supply and power supply module for providing oil temperature regulation and high-voltage power supply support for the test, a communication module for realizing signal interaction between various devices, and a main control system for centralized control of the test process and acquisition of insulation performance data.

[0008] Furthermore, the bench clamping tilt module includes a transmission tilting and rotating mechanism for providing tilt adjustment power and driving the upper component to deflect synchronously, and an adapter for providing a positioning and clamping reference for the DHT assembly to be tested.

[0009] Furthermore, the oil supply and power supply module includes an ATF oil temperature control device for regulating the internal ATF oil temperature of the DHT to achieve temperature cyclic loading, and a high-voltage power supply unit for providing high-voltage operating power to the motor controller to load electric field stress.

[0010] Furthermore, the communication module includes a CAN communication link for establishing control signal connections between the main control system and the motor controller and TCU, and an equipment control link for establishing control connections between the main control system and the power loading module, the oil supply module, and the bench clamping tilt module.

[0011] The present invention discloses a test method for a DHT high-voltage connector insulation oil resistance degradation test device, the method comprising the following steps:

[0012] S1: Install the transmission tilting and rotating mechanism on the base plate, install the adapter and the DHT assembly to be tested on the transmission tilting and rotating mechanism in sequence, and add the same amount of degraded ATF oil as the actual vehicle into the DHT assembly to be tested.

[0013] S2: Connect the oil cooler inlet and outlet of the DHT assembly to be tested to the ATF oil temperature control equipment through pipelines to complete the cooling water circuit connection;

[0014] S3: Connect and fix the power shaft of the dynamometer to the input shaft of the DHT assembly to be tested;

[0015] S4: Connect the TCU low-voltage harness, the motor controller low-voltage harness and the DC high-voltage harness in sequence to complete the hardware wiring;

[0016] S5: The main control system connects to the dynamometer, ATF oil temperature control equipment and transmission tilting and rotating mechanism respectively through the equipment control link to debug equipment control communication;

[0017] S6: The main control system is connected to the CAN communication interfaces of the motor controller and TCU respectively through the CAN harness to debug the communication connection between the main control system and the electronic control unit;

[0018] S7: Develop an automatic test program in the main control system and set up a composite test condition involving oil temperature circulation, speed atomization, angle change and high voltage electric field coupling;

[0019] S8: After completing the initial insulation performance test of the high voltage connector, connect the low voltage and high voltage power supply in sequence, start the automatic program to complete the durability test, and test the insulation performance at the set intervals during the test.

[0020] S9: After confirming that there are no abnormalities in the test results, shut down the high-voltage and low-voltage power supplies in sequence and turn off all equipment on the test bench.

[0021] Furthermore, the composite test conditions described in S7 include oil temperature circulation condition, speed atomization condition, transition speed condition, angle change condition, and high voltage electric field condition.

[0022] Furthermore, the formula for calculating the actual installation angle of the transmission under the aforementioned angle-changing operating conditions is as follows:

[0023]

[0024] In the formula:

[0025] This refers to the actual installation angle of the transmission during operation.

[0026] The angle between the transmission input / output axis and the horizontal plane when the vehicle is parked horizontally;

[0027] The overall tilt angle of the vehicle body when driving on a slope;

[0028] For vehicle slope.

[0029] Furthermore, step S8 includes the following steps:

[0030] S801: Use a safety tester to test and record the initial insulation resistance and DC leakage current of the high-voltage connector under 0h conditions;

[0031] S802: Connect the TCU and motor controller to the low-voltage and high-voltage power supplies in sequence, start the automatic test program, and carry out a 1000-hour durability test;

[0032] S803: During the test, the machine is stopped once every 100 hours of cumulative operation to check and record the insulation resistance and DC leakage current of the high-voltage connector;

[0033] S804: The high-voltage connector is considered qualified if its insulation resistance is ≥1000MΩ and DC leakage current is ≤10μA throughout the entire test.

[0034] Compared with the prior art, the beneficial effects of the present invention are:

[0035] This invention addresses the shortcomings of existing high-voltage connector insulation performance verification methods, which fail to consider the corrosive characteristics of degraded transmission fluid, lack multi-dimensional operating stress coupling, and have low matching degree between static tests and the dynamic environment of actual vehicles. It uses degraded transmission fluid to simulate the fluid state after long-term service in real vehicles. By coupling the combined stress of alternating oil temperature, oil mist dispersion, oil splashing, and high-voltage electric fields, it accurately reproduces the real service environment of high-voltage connectors inside hybrid transmissions. This effectively improves the authenticity and relevance of insulation resistance to oil degradation tests, accurately exposes the aging and failure risks of insulation materials, and enhances the reliability and consistency of test results. It provides effective test basis for the design verification, material selection, and quality control of high-voltage connectors, contributing to improved operational safety and service life of the high-voltage electrical system in hybrid transmissions. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the experimental apparatus of the present invention. Detailed Implementation

[0037] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0038] A DHT high-voltage connector insulation oil resistance degradation test device includes a base plate 1 serving as the support foundation for the entire test bench; a motor controller 5 for controlling the operation of the DHT built-in motor to apply high-voltage electric field stress; a TCU (transmission control unit) 6 for regulating the oil circuit operation of the DHT assembly; a dynamometer 9 for providing speed loading to the DHT assembly 4 under test to form an internal oil mist atmosphere; a bench clamping tilt module for realizing the positioning, clamping, and dynamic adjustment of the installation tilt angle of the DHT assembly 4 under test to reproduce the oil splash impact condition when the vehicle is driving on a slope; an oil supply and power supply module for providing oil temperature regulation and high-voltage power supply support for the test; a communication module for realizing signal interaction between various devices; and a main control system 10 for centralized control of the test process and acquisition of insulation performance data.

[0039] The base plate 1 is preferably a steel floor plate, with standardized bolt mounting holes pre-drilled on its surface. The mounting positions of each module of the test bench can be flexibly adjusted according to test requirements to adapt to different models of DHT assemblies.

[0040] The dynamometer 9 is fixedly installed at the corresponding work position on the base plate 1, and its power shaft is connected to the input end of the DHT assembly 4. The dynamometer 9 is used to provide speed loading for the DHT assembly, and cooperates with the gears inside the transmission to agitate the oil so that the ATF oil forms a diffused oil mist atmosphere, restoring the actual oil and gas environment in which the high-voltage connector is located.

[0041] The motor controller 5 and TCU6 are integrated on the DHT assembly 4 to be tested. The DHT assembly 4 has a built-in high-voltage connector to be tested.

[0042] The main control system 10 adopts a desktop / laptop main control computer for centralized issuance of control commands and processing of test data. It has a built-in automatic test control program and insulation data acquisition module. It can adjust the operating parameters of each device and record the insulation test results through the communication link, and simultaneously collect and record the insulation performance test data of the high voltage connector.

[0043] Furthermore, the bench clamping tilt module includes a gearbox tilting and rotating mechanism 2 for providing tilt adjustment power and driving the upper component to deflect synchronously, and an adapter 3 for providing a positioning and clamping reference for the DHT assembly 4 to be tested and which can be replaced to adapt to different models.

[0044] The gearbox tilting and rotating mechanism 2 is fixedly mounted on the surface of the base plate 1 by bolts. As the power base for tilt angle adjustment, it can output deflection power according to the test procedure, drive the tooling mounted on the upper end to adjust the installation angle synchronously with the DHT assembly 4 to be tested, and simulate the vehicle's slope driving state.

[0045] The adapter 3 can be detachably installed on the mounting end face of the gearbox tilting and rotating mechanism 2 as the positioning and clamping reference for the DHT assembly 4 to be tested. The DHT assembly 4 to be tested is positioned and clamped on the adapter 3. By replacing the adapter 3 with different specifications, different models of DHT can be adapted to achieve multi-model compatibility without replacing the entire tilting and rotating mechanism.

[0046] Furthermore, the oil supply and power supply module includes an ATF oil temperature control device 7 for regulating the internal ATF oil temperature of the DHT to achieve temperature cyclic loading, and a high-voltage power supply unit 8 for providing high-voltage operating power to the motor controller 5 to load electric field stress.

[0047] The ATF oil temperature control device 7 is connected to the oil cooler inlet and outlet of the DHT assembly 4 via oil pipe 12, which can precisely control the transmission oil temperature to circulate and alternate within a set range, thereby achieving coupled loading of high-temperature stress.

[0048] The high-voltage power supply unit 8 is preferably a battery simulator, which is connected to the high-voltage power supply terminal of the motor controller 5 through the high-voltage wiring harness 11 to provide a stable high-voltage working power supply for the motor controller 5 and realize high-voltage electric field stress loading.

[0049] Furthermore, the communication module includes a CAN communication link for establishing control signal connections between the main control system 10 and the motor controller 5 and TCU6, and an equipment control link for establishing control connections between the main control system 10 and the power loading module, the oil supply module, and the bench clamping tilt module.

[0050] The CAN communication link is physically connected through a CAN harness. One end is connected to the main control system 10, and the other end is connected to the CAN communication interfaces of the motor controller 5 and TCU6 respectively, for transmitting the operating condition control commands and equipment status data of the electronic control unit.

[0051] The equipment control link connects the main control system 10 to the dynamometer 9, the ATF oil temperature control device 7, and the gearbox tilting and rotating mechanism 2, and is used to enable the main control system to remotely adjust the parameters and read the operating status of the test bench power, temperature control, and tilt angle adjustment devices.

[0052] The present invention discloses a test method for a DHT high-voltage connector insulation oil resistance degradation test apparatus, the method comprising the following steps:

[0053] S1: Install and fix the transmission tilting and rotating mechanism 2 onto the base plate 1. Install the adapter 3 and the DHT assembly to be tested 4 on the transmission tilting and rotating mechanism 2 in sequence. Add the same amount of degraded ATF oil as the actual vehicle into the DHT assembly 4 to be tested.

[0054] S2: Connect the oil cooler inlet and outlet of the DHT assembly 4 to be tested to the ATF oil temperature control device 7 through pipe 12, and connect the inlet and outlet of the ATF oil temperature control device 7 to the workshop cooling water pipe 13 to complete the cooling water connection.

[0055] S3: Adjust the position of the dynamometer 9 and align and fix the power shaft of the dynamometer 9 with the input shaft of the DHT assembly 4 to be tested;

[0056] S4: Connect the TCU low-voltage harness, the motor controller low-voltage harness and the DC high-voltage harness in sequence. Connect the high-voltage harness to the high-voltage power supply unit 8 to complete the hardware wiring.

[0057] S5: The main control system 10 connects to the dynamometer 9, the ATF oil temperature control device 7 and the transmission tilting and rotating mechanism 2 respectively through the equipment control link, and debugs the equipment control communication to confirm that the command issuance and status reading are normal.

[0058] S6: The main control system 10 is connected to the CAN communication interfaces of the motor controller 5 and TCU6 respectively through the CAN harness to debug the communication connection between the main control system and the electronic control unit and confirm that the signal interaction is normal.

[0059] S7: In the main control system 10, an automatic test program is developed, and composite test conditions of oil temperature circulation, speed atomization, angle change and high voltage electric field coupling are set, and the threshold values ​​and operating logic of each parameter are defined.

[0060] The composite test conditions include oil temperature circulation condition, speed atomization condition, transition speed condition, angle change condition, and high voltage electric field condition.

[0061] The corresponding parameters are: oil temperature circulation range of 115℃~125℃, transmission output shaft speed not less than 4000rpm, to ensure that the internal oil agitation during transmission operation can make the oil atomize. At the same time, in order to simulate the impact of transmission fluid level changes on the high-voltage connector during vehicle driving uphill and downhill, transition speed conditions are superimposed to match the transmission installation angle changes corresponding to the uphill and downhill slopes of the actual vehicle; the total duration of the durability test is 1000h, and the insulation performance test interval is once every 100h of operation; the insulation resistance of the high-voltage connector is not less than 1000MΩ and the DC leakage current is not higher than 10μA throughout the test.

[0062] The formula for calculating the actual installation angle of the transmission under the aforementioned angle change condition is as follows:

[0063]

[0064] In the formula:

[0065] This refers to the actual installation angle of the transmission during operation.

[0066] The angle between the transmission input / output axis and the horizontal plane when the vehicle is parked horizontally;

[0067] The overall tilt angle of the vehicle body when driving on a slope;

[0068] For vehicle slope;

[0069] If the static installation tilt angle is... The angle of inclination with the vehicle ramp Since they are in opposite directions, they cancel each other out, thus reducing the actual total tilt angle during installation.

[0070] S8: After completing the initial insulation performance test of the high-voltage connector, connect the low-voltage and high-voltage power supplies sequentially, start the automatic program to complete the durability test, and test the insulation performance at set intervals during the test; including the following steps:

[0071] S801: Use a safety tester to test and record the initial insulation resistance and DC leakage current of the high-voltage connector under 0h conditions;

[0072] S802: Connect the TCU and motor controller to the low-voltage and high-voltage power supplies in sequence, start the automatic test program, and carry out a 1000-hour durability test;

[0073] S803: During the test, the machine is stopped once every 100 hours of cumulative operation to check and record the insulation resistance and DC leakage current of the high-voltage connector;

[0074] S804: The high-voltage connector is considered qualified if its insulation resistance is ≥1000MΩ and DC leakage current is ≤10μA throughout the entire test.

[0075] S9: After confirming that there are no abnormalities in the test results, shut down the high-voltage and low-voltage power supplies in sequence and turn off all equipment on the test bench.

[0076] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0077] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A DHT high-voltage connector insulation oil resistance degradation test device, characterized in that: It includes a base plate (1) for serving as the support foundation for the entire test bench, a motor controller (5) for controlling the operation of the DHT built-in motor to load high-voltage electric field stress, a TCU (6) for regulating the oil circuit operation status of the DHT assembly, a dynamometer (9) for providing speed loading to the DHT assembly (4) to be tested to form an internal oil mist atmosphere, a bench clamping tilt module for realizing the positioning, clamping and dynamic adjustment of the installation tilt angle of the DHT assembly (4) to be tested, an oil supply and power supply module for providing oil temperature regulation and high-voltage power supply support for the test, a communication module for realizing signal interaction between various devices, and a main control system (10) for centralized control of the test process and acquisition of insulation performance data.

2. The DHT high-voltage connector insulation oil resistance degradation test device according to claim 1, characterized in that: The bench clamping tilt module includes a transmission tilting and rotating mechanism (2) for providing tilt adjustment power and driving the upper component to deflect synchronously, and a transition tool (3) for providing a positioning and clamping reference for the DHT assembly (4) to be tested.

3. The DHT high-voltage connector insulation oil resistance degradation test device according to claim 1, characterized in that: The oil supply and power supply module includes an ATF oil temperature control device (7) for regulating the internal ATF oil temperature of the DHT to achieve temperature cyclic loading, and a high-voltage power supply unit (8) for providing high-voltage working power to the motor controller (5) to load electric field stress.

4. The DHT high-voltage connector insulation oil resistance degradation test device according to claim 1, characterized in that: The communication module includes a CAN communication link for establishing control signal connections between the main control system (10) and the motor controller (5) and TCU (6), and an equipment control link for establishing control connections between the main control system (10) and the power loading module, the oil supply and power supply module, and the bench clamping tilt module.

5. A test method for the DHT high-voltage connector insulation oil resistance degradation test apparatus according to any one of claims 1-4, characterized in that: The method includes the following steps: S1: Install the transmission tilting and rotating mechanism (2) on the base plate (1), install the adapter (3) and the DHT assembly to be tested (4) on the transmission tilting and rotating mechanism (2) in sequence, and add the same amount of degraded ATF oil as the actual vehicle into the DHT assembly to be tested (4). S2: Connect the oil cooler inlet and outlet of the DHT assembly (4) to be tested to the ATF oil temperature control device (7) through the pipeline (12) to complete the cooling water circuit connection; S3: Connect and fix the power shaft of the dynamometer (9) to the input shaft of the DHT assembly (4) to be tested; S4: Connect the TCU low-voltage harness, the motor controller low-voltage harness and the DC high-voltage harness in sequence to complete the hardware wiring; S5: The main control system (10) connects to the dynamometer (9), ATF oil temperature control device (7) and transmission tilting and rotating mechanism (2) respectively through the equipment control link to debug the equipment control communication; S6: The main control system (10) is connected to the CAN communication interfaces of the motor controller (5) and TCU (6) respectively through the CAN harness to debug the communication connection between the main control system and the electric control unit; S7: In the main control system (10), an automatic test program is developed to set up a composite test condition involving oil temperature circulation, speed atomization, angle change and high voltage electric field coupling. S8: After completing the initial insulation performance test of the high voltage connector, connect the low voltage and high voltage power supply in sequence, start the automatic program to complete the durability test, and test the insulation performance at the set intervals during the test. S9: After confirming that there are no abnormalities in the test results, shut down the high-voltage and low-voltage power supplies in sequence and turn off all equipment on the test bench.

6. The test method according to claim 5, characterized in that: The composite test conditions described in S7 include oil temperature circulation condition, speed atomization condition, transition speed condition, angle change condition, and high voltage electric field condition.

7. The test method according to claim 6, characterized in that: The formula for calculating the actual installation angle of the transmission under the aforementioned angle change condition is as follows: In the formula: This refers to the actual installation angle of the transmission during operation. The angle between the transmission input / output axis and the horizontal plane when the vehicle is parked horizontally; The overall tilt angle of the vehicle body when driving on a slope; For vehicle slope.

8. The test method according to claim 7, characterized in that: S8 includes the following steps: S801: Use a safety tester to test and record the initial insulation resistance and DC leakage current of the high-voltage connector under 0h conditions; S802: Connect the TCU and motor controller to low-voltage and high-voltage power supplies in sequence, start the automatic test program, and carry out a 1000-hour durability test; S803: During the test, the machine is stopped once every 100 hours of cumulative operation to check and record the insulation resistance and DC leakage current of the high-voltage connector; S804: The high-voltage connector is considered qualified if its insulation resistance is ≥1000MΩ and DC leakage current is ≤10μA throughout the entire test.

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