Test method, system, control circuit and storage medium of motor controller

Abstract

The application provides a motor controller test method, system, control circuit and storage medium, and belongs to the technical field of vehicles. The method comprises the following steps: receiving a first target temperature to be tested; driving the motor controller to operate based on initial control parameters, and obtaining an actual temperature of the motor controller when the motor controller operates under the driving of the control parameters; in the case that the actual temperature is lower than the first target temperature, increasing the control parameters until the difference between the actual temperature and the first target temperature is not greater than a preset threshold, and outputting the current control parameters as the maximum control parameters under the first target temperature. The application can automatically adjust the control parameters according to the temperature change, avoid the situation that the temperature of the motor controller rapidly increases and exceeds the thermal safety boundary due to the excessively large control parameters, and improve the safety of the motor controller in the test process.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and in particular to a test method, system, control circuit, and storage medium for a motor controller. Background Technology

[0002] As a core component of the vehicle's electric drive system, the motor controller generates a large amount of heat during operation, which affects its performance. Therefore, testing the thermal safety boundary of the motor controller is of great significance.

[0003] Currently, during the testing process, multiple sets of control parameters are manually provided, and the temperature of the motor controller is detected under different control parameters to explore the temperature of the motor controller under different control parameters.

[0004] However, since it is difficult to predict the impact of changes in control parameters on temperature manually, when the given control parameters are large, the temperature of the motor controller is very likely to exceed the thermal safety boundary, causing damage to components. Therefore, the above method cannot guarantee the safety of the motor controller. Summary of the Invention

[0005] This application provides a testing method, system, control circuit, and storage medium for a motor controller, which can improve the safety of the motor controller during testing. The technical solution is as follows: On the one hand, a test method for a motor controller is provided, the method comprising: Receive the first target temperature to be tested; The motor controller is driven to run based on the initial control parameters, and the actual temperature of the motor controller under the drive of the control parameters is obtained. If the actual temperature is lower than the first target temperature, the control parameter is increased until the difference between the actual temperature and the first target temperature is no greater than a preset threshold, and the current control parameter is output as the maximum control parameter at the first target temperature.

[0006] In one possible implementation, the method further includes: The environment in which the motor controller is located is controlled to reach the target environmental state; The actual temperature is the actual temperature at which the motor controller operates under the target environmental conditions and driven by the control parameters.

[0007] In one possible implementation, the method further includes: The coolant in the water chiller is controlled to flow through the motor controller to cool the motor controller; The target environmental state includes at least one of the following: the temperature of the coolant in the water chiller reaches the second target temperature; the flow rate of the coolant in the water chiller reaches the target flow rate.

[0008] In one possible implementation, the first target temperature is not greater than the maximum temperature limit of the motor controller.

[0009] In one possible implementation, the control parameters include at least one of the torque or current of the motor controller.

[0010] On the other hand, a test system for a motor controller is provided, the system including a control circuit and a motor controller, the control circuit being connected to the motor controller; The control circuit is used to receive the first target temperature to be tested; The control circuit is also used to drive the motor controller to operate based on the initial control parameters; The motor controller is used to detect the actual temperature during operation under the drive of the control parameters, and transmit the actual temperature to the control circuit. The control circuit is further configured to increase the control parameter when the actual temperature is lower than the first target temperature, until the difference between the actual temperature and the first target temperature is not greater than a preset threshold, and output the current control parameter as the maximum control parameter at the first target temperature.

[0011] In one possible implementation, the control circuit is further configured to control the environment in which the motor controller is located to reach a target environmental state. The actual temperature is the actual temperature at which the motor controller operates under the target environmental conditions and driven by the control parameters.

[0012] In one possible implementation, the system further includes a water chiller connected to the control circuit. The control circuit is also used to control the flow of coolant in the water chiller through the motor controller to cool the motor controller; The target environmental state includes at least one of the following: the temperature of the coolant in the water chiller reaches the second target temperature; the flow rate of the coolant in the water chiller reaches the target flow rate.

[0013] In one possible implementation, the first target temperature is not greater than the maximum temperature limit of the motor controller.

[0014] In one possible implementation, the control parameters include at least one of the torque or current of the motor controller.

[0015] On the other hand, a control circuit is provided, the control circuit including a processor and a memory, the memory storing at least one computer program, the at least one computer program being loaded and executed by the processor to enable the control circuit to implement the test method for the motor controller as described above.

[0016] On the other hand, a computer-readable storage medium is provided that stores at least one piece of program code, which is loaded and executed by a processor to implement the test method for the motor controller as described above.

[0017] On the other hand, a computer program product is provided, the computer program product comprising at least one piece of program code, the at least one piece of program code being loaded and executed by a processor to implement the test method for the motor controller as described above.

[0018] The beneficial effects of the technical solutions provided in this application include at least the following: In this application, the target temperature to be tested is received, and the actual temperature of the motor controller under the drive of control parameters is used as feedback. Starting from an initial control parameter, the control parameter is gradually increased until the actual temperature of the motor controller approaches the target temperature, thereby obtaining the control parameters corresponding to different temperatures reached by the motor controller. This testing method transforms the motor controller temperature from a passively detected parameter into an actively controlled target. Compared to the existing method of manually and repeatedly setting control parameters for exploration, this application can automatically adjust the control parameter according to temperature changes, avoiding the situation where the motor controller temperature rises rapidly due to excessively large control parameter settings, exceeding the thermal safety boundary, and improving the safety of the motor controller during the testing process. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is an architecture diagram of a test system for a motor controller provided in an embodiment of this application; Figure 2 This is a flowchart of a test method for a motor controller provided in an embodiment of this application; Figure 3 This is a flowchart of another test method for a motor controller provided in an embodiment of this application; Figure 4This is a schematic diagram of a control circuit provided in an embodiment of this application. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0022] The terms "first," "second," "third," and "fourth," etc., used in the specification, claims, and drawings of this application are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0023] It should be noted that the information (including but not limited to user equipment information, user personal information, etc.), data (including but not limited to data used for analysis, data stored, data displayed, etc.) and signals (including but not limited to signals transmitted between user terminals and other devices) involved in this application have all been fully authorized by the user or relevant parties, and the collection, use and processing of the relevant data shall comply with the relevant laws, regulations and standards of the relevant countries and regions.

[0024] To better understand the technical solution of this application, the inventive concept of this application will be described in detail first.

[0025] With the development of vehicle technology, electric drive systems are gradually evolving towards higher power density and higher reliability. As a core component of vehicle electric drive systems, the motor controller generates significant heat during operation due to the power semiconductor devices within it, such as the IGBTs (Insulated Gate Bipolar Transistors). The junction temperature of the IGBTs directly affects the performance and reliability of the motor controller. Therefore, junction temperature testing of motor controllers and exploring their thermal safety boundaries under different test conditions are crucial for their design, verification, and reliability assessment, and have significant application value in fields such as new energy vehicles, renewable energy, data centers, and high-end manufacturing.

[0026] In related technologies, testing of motor controllers is typically conducted on a single-motor test bench or an inductor test bench. By sending preset torque or current control commands to the motor controller under test, the test bench operates according to the corresponding load conditions, achieving load control of the motor controller to simulate the operating state of the electric drive system in different application scenarios. During the test, torque or current is usually pre-set, and then the temperature change of the motor controller is detected to obtain the correlation between temperature and torque or current. The core logic of this type of testing is "given torque / current—execute load conditions—detect temperature," primarily used for functional verification and performance acceptance of motor controllers.

[0027] However, when exploring the junction temperature boundary of a motor controller, directly inputting torque or current requires setting different test conditions, inputting a preset torque or current to the motor controller, and then detecting the temperature of the motor controller under the corresponding test conditions. However, torque, current, and different test conditions all affect the temperature of the motor controller. Testers need to continuously adjust the torque or current parameters to explore the operating state of the motor controller when it approaches its temperature limit. When the set torque or current is too low, the motor controller's temperature cannot reach the operating state close to its temperature limit, making it difficult to obtain an effective thermal safety boundary. When the set torque or current is too high, it can easily cause the motor controller's temperature to rise rapidly, exceeding the device's temperature resistance, causing damage or even failure of the motor controller.

[0028] Furthermore, when test conditions change, such as changes in the temperature and flow rate of the coolant, the original correlation between torque or current and temperature no longer applies, requiring manual adjustments and exploration. Since the testing process relies primarily on the experience of the testers to adjust parameters, passively observing temperature after setting negative torque or current, it is difficult to control the temperature changes of the motor controller in a timely and accurate manner. This not only results in low testing efficiency but also increases the risk of shutdown due to unexpected overheating, making it difficult to accurately explore the thermal safety boundary when the motor controller approaches its temperature limit while ensuring its safety.

[0029] Based on this, this application provides a testing method for motor controllers, which can achieve dynamic temperature protection during the exploration of the junction temperature boundary of the motor controller and support coordinated control of the cooling system and the testing process. In this application embodiment, the temperature of the motor controller is used as the control target. By acquiring the actual temperature of the motor controller in real time, the control parameters (torque or current) of the motor controller are automatically adjusted according to the difference between the actual temperature and the target temperature, so that the actual temperature of the motor controller approaches the target temperature. This explores the correspondence between temperature and control parameters, as well as the thermal safety boundary of the motor controller, avoiding the over-temperature risk caused by unreasonable control parameter settings in traditional testing processes.

[0030] Unlike the passive testing method of "given torque / current—execute load condition—detect temperature" in related technologies, the embodiments of this application transform the temperature of the motor controller from a passively detected parameter into an actively controlled target, and the torque or current from a fixed input parameter into a control variable used to regulate temperature rise. By dynamically adjusting the torque or current, the maximum torque or current that the motor controller can continuously output under specific temperature conditions can be obtained. Combined with test results under different environmental conditions, the thermal safety boundary under different test conditions can be explored, achieving precise matching between temperature and load, and obtaining more comprehensive and accurate temperature boundary test data. This provides data support for the high power density design and reliability assessment of the motor controller.

[0031] The following provides a detailed description of the testing method and system for the motor controller provided in the embodiments of this application.

[0032] Figure 1 This is an architecture diagram of a test system for a motor controller provided in an embodiment of this application, as shown below. Figure 1 As shown, the test system for the motor controller includes a control circuit 101, a motor controller 102, and a water chiller 103. The control circuit 101 and the motor controller 102 are connected by communication, as are the control circuit 101 and the water chiller 103.

[0033] Among them, the control circuit 101 is the execution control unit of the test system, which is used to control the motor controller 102 under test according to the target temperature sent by the test terminal.

[0034] The motor controller 102 is the object under test, also known as the device under test (DUT). In new energy vehicles, the motor controller 102 is used to control the output of electrical energy from the power battery to the drive motor. The motor controller 102 typically includes power semiconductor devices, drive circuits, control chips, and heat dissipation structures. For example, the power semiconductor device in the motor controller 102 is an IGBT. The IGBT is a key component for realizing power conversion and high-power switching control, and is a factor in the heat generated by the motor controller 102 during operation.

[0035] The water chiller 103 is a cooling device used to regulate the heat dissipation environment of the motor controller 102. During the operation of the motor controller 102, it experiences power loss due to the large current it draws, which is converted into heat. If this heat cannot be dissipated in time, the junction temperature will rise. Therefore, the water chiller 103 is configured to dissipate heat from the motor controller 102. Figure 1 As shown, the water chiller 103 and the motor controller 102 are connected by a coolant pipeline ( Figure 1 (Bold lines in the text) connect. The water chiller 103 outputs coolant, which flows through the coolant pipeline to the motor controller 102. After exchanging heat with the motor controller 102, it flows back to the water chiller 103 for circulation. The heat generated by the motor controller 102 can be removed through the circulation of coolant.

[0036] In one possible implementation, such as Figure 1 As shown, in the system architecture of the motor controller testing method, the control circuit 101 is also connected to a test terminal. The test terminal typically refers to a PC or host computer, used by testers to set test parameters, monitor the test process, and analyze test data. Testers can use the test terminal to set test parameters such as the first target temperature of the motor controller 102, the second target temperature of the water chiller 103, the flow rate of the water chiller 103, and initial control parameters. The test terminal then sends these test parameters to the control circuit 101.

[0037] In one possible implementation, such as Figure 1 As shown, the system architecture of the test method for the motor controller also includes a solenoid valve 104, a flow meter 105, and a temperature sensor 106.

[0038] The solenoid valve 104 is a control element that uses electromagnetic driving force to control the opening degree of the valve, and can regulate the flow rate of the coolant in the water chiller 103. The solenoid valve 104 has a communication connection with the control circuit 101, and is installed in the coolant pipeline between the water chiller 103 and the motor controller 102. In this embodiment, the control circuit 101 sends a flow rate control command to the solenoid valve 104. When increased cooling capacity is required, the control circuit 101 can control the solenoid valve 104 to increase its opening, thus widening the coolant flow channel and increasing the coolant flow rate, thereby improving heat dissipation capacity; when decreased cooling capacity is required, the control circuit 101 can control the solenoid valve 104 to decrease its opening, reducing the coolant flow rate and thus reducing heat dissipation capacity.

[0039] The flow meter 105 is a detection element used to detect fluid flow rate, capable of detecting the flow rate of coolant passing through a pipeline per unit time, for example, liters per minute (L / min). The flow meter 105 has a communication link with the control circuit 101, and is installed in the coolant pipeline between the water chiller 103 and the motor controller 102. In this embodiment, after the control circuit 101 sends a flow rate control command to the solenoid valve 104, the actual flow rate needs to be detected and fed back by the flow meter 105.

[0040] The temperature sensor 106 is a detection element used to detect temperature changes, specifically the temperature of the coolant. The temperature sensor 106 has a communication link with the control circuit 101 and is located in the coolant pipeline between the water chiller 103 and the motor controller 102. In this embodiment, after the control circuit 101 sends a temperature control command to the water chiller 103, it needs to detect and report the actual temperature of the coolant through the temperature sensor 106.

[0041] In one possible implementation, such as Figure 1 As shown, after receiving the initial control parameters (torque or current) sent by the test terminal, the control circuit 101 sends a load control command to the motor controller 102. This load control command carries the initial control parameters (torque or current), causing the motor controller 102 to operate according to the set control parameters. The motor controller 102 feeds back its actual temperature and actual control parameters to the control circuit 101 in real time. Based on the difference between the actual temperature of the motor controller 102 and the desired first target temperature, the control circuit 101 gradually increases the control parameters, thereby dynamically influencing the actual temperature of the motor controller 102 in real time, until the difference between the actual temperature and the first target temperature is no greater than a preset threshold.

[0042] In one possible implementation, the motor controller 102 can be a motor controller in a vehicle.

[0043] In summary, testers set the first target temperature for the motor controller via the test terminal. The control circuit drives the motor controller based on the initial control parameters and obtains the actual temperature fed back by the motor controller. The control circuit dynamically adjusts the control parameters according to the difference between the actual temperature and the first target temperature, gradually bringing the actual temperature of the motor controller to and stabilizing at the first target temperature, which does not exceed the maximum temperature limit of the motor controller, thus achieving dynamic temperature protection for the motor controller. Simultaneously, the control circuit also controls the water chiller to adjust the cooling conditions such as the temperature and flow rate of the coolant, allowing the motor controller to operate under different test conditions. This allows for the acquisition of the control parameters corresponding to the motor controller reaching the first target temperature under different test conditions, which is beneficial for exploring the load capacity boundary at specific temperatures and the thermal safety boundary under different cooling conditions, obtaining more comprehensive and accurate test data.

[0044] Compared to traditional junction temperature boundary testing methods, the system architecture of this application embodiment can effectively protect the motor controller, preventing damage or failure caused by unreasonable control parameter settings leading to the motor controller's temperature exceeding the limit. Furthermore, based on the target temperature set by the test terminal, the thermal boundary of the motor controller can be explored, accurately determining the required control parameters for the motor controller at different temperatures. It also features a cooling system collaborative testing function, enabling the exploration and testing of the motor controller's thermal safety boundary under different cooling conditions.

[0045] Based on the above system architecture, the test method for the motor controller proposed in this application will be briefly described first.

[0046] Figure 2 This is a flowchart of a test method for a motor controller provided in an embodiment of this application. See also... Figure 2 The method includes: 201. Receive the first target temperature to be tested.

[0047] 202. Drive the motor controller to run based on the initial control parameters, and obtain the actual temperature of the motor controller when it runs under the control parameters.

[0048] 203. When the actual temperature is lower than the first target temperature, increase the control parameter until the difference between the actual temperature and the first target temperature is no greater than the preset threshold, and output the current control parameter as the maximum control parameter under the first target temperature.

[0049] The method provided in this application receives the target temperature to be tested, uses the actual temperature of the motor controller running under control parameters as feedback, and gradually increases the control parameters from the initial level until the actual temperature of the motor controller approaches the target temperature, thereby obtaining the control parameters corresponding to different temperatures reached by the motor controller. This testing method transforms the temperature of the motor controller from a passively detected parameter to an actively controlled target. Compared to the prior art method of manually and repeatedly setting control parameters for exploration, this application can automatically adjust the control parameters according to temperature changes, avoiding situations where the motor controller temperature rises rapidly and exceeds the thermal safety boundary due to excessively high control parameter settings, thus improving the safety of the motor controller during testing.

[0050] In one possible implementation, the method further includes: The environment in which the motor controller is located is controlled to achieve the target environmental state; The actual temperature is the temperature at which the motor controller operates under the target environmental conditions and driven by the control parameters.

[0051] In this possible implementation, the environment in which the motor controller is located is controlled to reach a target environmental state. Under the target environmental state, the motor controller is driven to run based on control parameters, thereby obtaining the actual temperature of the motor controller when it is running under the target environmental state and driven by the control parameters. This allows the temperature test of the motor controller to be carried out under the preset environmental state, thereby exploring the temperature of the motor controller under different control parameters and different environmental states. This is beneficial for comprehensively evaluating the thermal performance of the motor controller and improving the comprehensiveness and accuracy of thermal safety boundary exploration.

[0052] In one possible implementation, the method further includes: The coolant in the water chiller is controlled to flow through the motor controller to cool the motor controller; The target environmental conditions include at least one of the following: the temperature of the coolant in the water chiller reaches the second target temperature; the flow rate of the coolant in the water chiller reaches the target flow rate.

[0053] In this possible implementation, the coolant in the water chiller flows through the motor controller. Since the temperature and flow rate of the coolant affect the heat dissipation capacity of the motor controller, by adjusting the temperature and flow rate of the coolant, the motor controller can be tested under different cooling conditions, thereby obtaining a more comprehensive correspondence between temperature and control parameters, and improving the efficiency and accuracy of thermal safety boundary exploration.

[0054] In one possible implementation, the first target temperature is no greater than the maximum temperature limit of the motor controller.

[0055] In this possible implementation, by limiting the target temperature to no more than the maximum temperature limit of the motor controller, the actual temperature of the motor controller is always kept within a safe range during the test. Compared with the existing technology of manually setting control parameters and observing whether the temperature exceeds the limit, this application can avoid damage to the motor controller due to the target temperature being set too high, which would cause it to exceed its temperature resistance. This is beneficial to obtain control parameters close to the limit temperature while ensuring the safety of the motor controller, thus improving the safety and reliability of the test process.

[0056] In one possible implementation, the control parameters include at least one of the torque or current of the motor controller.

[0057] In this possible implementation, the control parameters include at least one of the torque or current of the motor controller, enabling the load state to be changed during the test by adjusting the torque or current of the motor controller, thereby causing temperature changes in the internal power devices and realizing the correlation between temperature and load.

[0058] The above briefly describes the test method for the motor controller proposed in this application. Based on this, the following section will further introduce the concept of this application in conjunction with the test method for the motor controller proposed in this application.

[0059] Figure 3 This is a flowchart of another test method for a motor controller provided in an embodiment of this application. See also... Figure 3 The method includes: 301. The control circuit receives the first target temperature and target environmental conditions to be tested.

[0060] The first target temperature refers to the temperature that the motor controller is expected to reach and maintain stably during the testing process. This first target temperature can be preset by the tester.

[0061] In traditional testing methods, control parameters (torque or current) are typically given first, causing the motor controller to operate according to these parameters. Then, the actual temperature of the motor controller under these parameters is measured. However, this application's embodiment changes this testing logic, using the motor controller's temperature as the target for active control. By setting different first target temperatures, the maximum control parameters that the motor controller can withstand at different temperatures can be obtained, thus establishing a correspondence between temperature and control parameters. For example, the maximum current or maximum torque corresponding to the motor controller at temperatures of 120℃, 140℃, and 160℃ can be tested to obtain the motor controller's thermal safety boundary.

[0062] The target environmental state refers to the desired external environmental state of the motor controller during testing. This could be the motor controller's cooling conditions, for example. Since the motor controller's temperature is affected not only by its own operating load but also by its cooling conditions, accurately exploring the motor controller's thermal safety boundary requires maintaining the environment within the preset target environmental state.

[0063] In one possible implementation, the first target temperature is no greater than the maximum temperature limit of the motor controller.

[0064] The maximum temperature limit refers to the highest temperature that the motor controller is allowed to reach during normal operation. It can also be understood as the highest temperature that the internal power devices (IGBTs) of the motor controller can withstand. When the temperature of the motor controller exceeds the maximum temperature limit, it may cause damage or failure of the motor controller.

[0065] Therefore, in this embodiment, the first target temperature is not greater than the maximum temperature limit of the motor controller, so as to avoid damage or failure of the motor controller due to the first target temperature being set too high during the test.

[0066] In this possible implementation, by limiting the target temperature to no more than the maximum temperature limit of the motor controller, the actual temperature of the motor controller is always kept within a safe range during the test. Compared with the existing technology of manually setting control parameters and observing whether the temperature exceeds the limit, this application can avoid damage to the motor controller due to the target temperature being set too high, which would cause it to exceed its temperature resistance. This is beneficial to obtain control parameters close to the limit temperature while ensuring the safety of the motor controller, thus improving the safety and reliability of the test process.

[0067] In one possible implementation, the motor controller is cooled by coolant in a water chiller. The target environmental state refers to the cooling conditions of the motor controller. Therefore, the target environmental state includes at least one of the following: the temperature of the coolant in the water chiller reaches a second target temperature; the flow rate of the coolant in the water chiller reaches a target flow rate.

[0068] For example, the target environmental conditions could be: the coolant temperature is 40°C and the coolant flow rate is 10L / min.

[0069] When the target environmental conditions are changed, such as lowering the coolant temperature or increasing the coolant flow rate, the temperature generated by the motor controller under the same control parameters will also change due to the change in cooling conditions. Therefore, by setting different target environmental conditions and repeating the test process of the embodiments of this application, the correspondence between the temperature of the motor controller and the control parameters under different environmental conditions can be obtained, thereby exploring a more comprehensive thermal safety boundary.

[0070] In one possible implementation, such as Figure 1 The system architecture shown has a communication link between the control circuit and the test terminal. The test terminal sends test parameters to the control circuit. These test parameters include the aforementioned first target temperature and target environmental conditions.

[0071] For example, the target environmental conditions include a second target temperature and a target flow rate of the coolant, and the initial control parameters include initial torque and current. Therefore, the test parameters sent by the test terminal to the control circuit could include: a first target temperature of 120°C, a second target temperature of 40°C, and a target flow rate of 10 L / min.

[0072] 302. The control circuit controls the environment in which the motor controller is located to achieve the target environmental state.

[0073] After determining the first target temperature and target environmental conditions to be tested, the environment where the motor controller is located is first controlled to reach the target environmental conditions, and then the motor controller is controlled to run.

[0074] In one possible implementation, the coolant in the water chiller is controlled to flow through the motor controller to cool the motor controller. The aforementioned target environmental state includes at least one of the following: the temperature of the coolant in the water chiller reaches a second target temperature; the flow rate of the coolant in the water chiller reaches a target flow rate.

[0075] In other words, the environmental state of the motor controller is changed by controlling at least one of the temperature or flow rate of the coolant in the chiller. If the target environmental state includes the coolant temperature in the chiller reaching a second target temperature, the coolant temperature in the chiller is controlled to reach the second target temperature, so that the environmental state of the motor controller reaches the target environmental state. If the target environmental state includes the coolant flow rate in the chiller reaching a target flow rate, the coolant flow rate in the chiller is controlled to reach the target flow rate, so that the environmental state of the motor controller reaches the target environmental state.

[0076] Optionally, such as Figure 1 The system architecture shown has a communication connection between the control circuit and the chiller. The control circuit sends a temperature control command to the chiller, instructing the temperature of the coolant in the chiller to be adjusted to a second target temperature. The chiller responds to this temperature control command and adjusts the temperature of the coolant in the chiller to the second target temperature.

[0077] Optionally, such as Figure 1In the system architecture shown, the control circuit also has a communication connection with a solenoid valve. The solenoid valve is located in the coolant pipeline between the chiller 103 and the motor controller 102, and is used to regulate the flow rate of the coolant in the chiller 103. The control circuit sends a flow rate control command to the solenoid valve, instructing that the flow rate of the coolant in the chiller be adjusted to a target flow rate. The solenoid valve responds to the flow rate control command and adjusts the flow rate of the coolant in the chiller to the target flow rate. For example, if the solenoid valve controls the flow rate of the coolant in the chiller by adjusting the opening degree of the valve, then the command sent by the control circuit to the solenoid valve can be an opening control command, instructing that the valve be adjusted to the opening degree corresponding to the target flow rate.

[0078] In this possible implementation, the coolant in the water chiller flows through the motor controller. Since the temperature and flow rate of the coolant affect the heat dissipation capacity of the motor controller, by adjusting the temperature and flow rate of the coolant, the motor controller can be tested under different cooling conditions, thereby obtaining a more comprehensive correspondence between temperature and control parameters, and improving the efficiency and accuracy of thermal safety boundary exploration.

[0079] 303. When the motor controller is in the target environment state, the control circuit drives the motor controller to run based on the initial control parameters.

[0080] After the environment in which the motor controller is located reaches the target environmental state, the control circuit drives the motor controller to run based on the initial control parameters while the motor controller is in the target environmental state.

[0081] The initial control parameters refer to the control parameters sent by the control circuit to the motor controller at the start of the test. For example, before the test begins, the tester can set a small initial control parameter. The control circuit will first drive the motor controller according to this small initial control parameter, causing the motor controller to generate a small amount of heat. Subsequently, the control parameter will be gradually increased to cause the motor controller to generate more heat, so that the actual temperature of the motor controller gradually approaches the first target temperature.

[0082] For example, testers can determine the control parameters corresponding to a certain safe temperature based on their own experience. This safe temperature is much lower than the maximum temperature limit of the motor controller. The control parameters corresponding to this safe temperature are those that can keep the motor controller at this safe temperature. Therefore, the control parameters corresponding to this safe temperature can be used as the initial control parameters.

[0083] By setting initial control parameters, it can be ensured that the test process does not directly apply large control parameters to the motor controller, but starts from a relatively safe operating state. The thermal boundary of the motor controller is explored by gradually adjusting the control parameters. This can avoid the actual temperature of the motor controller rising rapidly and exceeding the maximum temperature limit due to inputting too large control parameters at the beginning.

[0084] In one possible implementation, the control parameters include at least one of the torque or current of the motor controller.

[0085] Among them, current refers to the amount of charge flowing through the motor controller. During the operation of the motor controller, when the current flowing through the motor controller increases, the conduction loss and switching loss of the motor controller will usually also increase, thereby generating more heat and causing the junction temperature of the motor controller to rise.

[0086] Torque refers to the magnitude of the rotational torque output by the motor, used to represent the motor's ability to generate driving force. For example, when a car accelerates, the motor needs to output greater torque to drive the vehicle. Under the same operating conditions, when the motor needs to output greater torque, the motor controller needs to provide greater current, causing the motor controller to bear a greater power load, thereby generating more heat and raising the junction temperature of the motor controller.

[0087] In this possible implementation, the control parameters include at least one of the torque or current of the motor controller, enabling the load state to be changed during the test by adjusting the torque or current of the motor controller, thereby causing temperature changes in the internal power devices and realizing the correlation between temperature and load.

[0088] 304. The control circuit obtains the actual temperature of the motor controller when it is running under the control parameters.

[0089] The actual temperature refers to the actual temperature at which the motor controller operates under the control parameters while in the target environment.

[0090] In this embodiment, the environment in which the motor controller is located is controlled to reach a target environmental state. Under the target environmental state, the motor controller is driven to run based on control parameters, thereby obtaining the actual temperature of the motor controller when it is running under the control parameters in the target environmental state. This allows the temperature test of the motor controller to be carried out under a preset environmental state, thereby exploring the temperature of the motor controller under different control parameters and different environmental states. This is beneficial for comprehensively evaluating the thermal performance of the motor controller and improving the comprehensiveness and accuracy of thermal safety boundary exploration.

[0091] In one possible implementation, the motor controller has a temperature sensor that detects its own actual temperature and feeds back the actual temperature of the motor controller to the control circuit.

[0092] In one possible implementation, the motor controller includes a power semiconductor device that generates a large amount of heat during operation, and the actual temperature can be the actual temperature of the power semiconductor device in the motor controller.

[0093] For example, the power semiconductor device can be an IGBT (Insulated Gate Bipolar Transistor). In this embodiment, performing junction temperature testing on the motor controller refers to performing junction temperature testing on the IGBT in the motor controller.

[0094] 305. When the actual temperature is lower than the first target temperature, the control circuit increases the control parameters until the difference between the actual temperature and the first target temperature is no greater than the preset threshold, and outputs the current control parameters as the maximum control parameters at the first target temperature.

[0095] In this embodiment, the initial control parameters are small, resulting in a low initial actual temperature of the motor controller, typically lower than the first target temperature. Therefore, the control circuit gradually increases the control parameters based on the actual temperature feedback from the motor controller, increasing the load on the motor controller and causing it to generate more power loss, thus gradually raising its temperature. The control circuit repeatedly performs the process of adjusting the control parameters, obtaining the actual temperature, and judging the temperature difference until the difference between the actual temperature and the first target temperature is no greater than a preset threshold. At this point, the control parameter adjustment stops, and the control parameters at which the difference between the actual temperature and the first target temperature is no greater than the preset threshold are obtained; this is the maximum control parameter at the first target temperature.

[0096] The maximum control parameter at the first target temperature refers to the maximum control parameter when the temperature of the motor controller is not greater than the first target temperature under the current target environmental conditions.

[0097] For example, if the first target temperature is 140℃, the control circuit drives the motor controller based on initial control parameters and acquires the actual temperature of the motor controller in real time. If the actual temperature of the motor controller is lower than 140℃, the control circuit gradually increases the torque or current, causing the motor controller to generate more losses and heat up. When the actual temperature of the motor controller approaches 140℃, the control circuit stops increasing the torque or current, stabilizing the actual temperature of the motor controller near the first target temperature. The torque or current at this point is the maximum control parameter at the first target temperature, thus exploring the correspondence between the first target temperature and the maximum control parameter.

[0098] The method provided in this application receives the target temperature to be tested, uses the actual temperature of the motor controller running under control parameters as feedback, and gradually increases the control parameters from the initial level until the actual temperature of the motor controller approaches the target temperature, thereby obtaining the control parameters corresponding to different temperatures reached by the motor controller. This testing method transforms the temperature of the motor controller from a passively detected parameter to an actively controlled target. Compared to the prior art method of manually and repeatedly setting control parameters for exploration, this application can automatically adjust the control parameters according to temperature changes, avoiding situations where the motor controller temperature rises rapidly and exceeds the thermal safety boundary due to excessively high control parameter settings, thus improving the safety of the motor controller during testing.

[0099] The following description uses the junction temperature test of the IGBT in the motor controller as an example to illustrate the test process.

[0100] During testing, the test terminal sets a first target temperature for the IGBT and sends this target temperature to the control circuit. The control circuit uses the IGBT temperature as the controlled variable and the torque or current of the motor controller as the control variable. It sends load control commands to the motor controller, causing the motor controller to operate according to the corresponding torque or current. The control circuit also receives the actual IGBT temperature from the motor controller, compares it with the set first target temperature, and dynamically adjusts the load control commands based on the difference between the actual and first target temperatures, gradually bringing the actual IGBT temperature closer to the first target temperature.

[0101] During the control process, when the actual temperature of the IGBT is lower than the first target temperature, the control circuit gradually increases the torque or current, causing the IGBT inside the motor controller to generate more heat. When the actual temperature of the IGBT approaches the first target temperature, the control circuit stops adjusting the torque or current to prevent the actual temperature of the IGBT from continuing to rise and exceeding the safe range. By setting the first target temperature as the maximum temperature limit of the IGBT in this way, the load capacity corresponding to the IGBT when it approaches its temperature limit can be explored while protecting the IGBT from overheating damage, thus realizing the testing of the IGBT's thermal safety boundary.

[0102] Furthermore, the motor controller feeds back the torque or current during actual operation to the control circuit, enabling monitoring of the motor controller's torque or current. By adjusting the torque or current in conjunction with the actual temperature of the IGBT, closed-loop control of the motor controller is achieved.

[0103] Furthermore, the control circuit communicates with the water chiller to achieve coordinated control of the cooling system and the electrothermal testing process. The control circuit regulates the coolant flow rate by adjusting the solenoid valve connected to the water chiller, and obtains the actual flow rate and temperature of the coolant through a flow meter and temperature sensor, achieving closed-loop regulation of the environmental conditions. By changing the coolant temperature and flow rate, the motor controller can be placed under different cooling conditions, thereby exploring the junction temperature boundary of the IGBT under different cooling conditions.

[0104] For example, by controlling the torque or current to make the IGBT reach the same target temperature under different water temperatures and flow rates, and recording the corresponding torque or current, the relationship between the temperature and output capability of the IGBT under different cooling conditions can be obtained. This allows for the quantification of the impact of the water chiller on the output capability of the motor controller and the realization of thermal safety boundary testing of the IGBT under different cooling conditions.

[0105] This application embodiment also provides a test system for a motor controller, the system including a control circuit and a motor controller, the control circuit being connected to the motor controller; Control circuitry, used to receive the first target temperature to be tested; The control circuit is also used to drive the motor controller to operate based on initial control parameters; The motor controller is used to detect the actual temperature during operation under the drive of control parameters and transmit the actual temperature to the control circuit. The control circuit is also used to increase the control parameters when the actual temperature is lower than the first target temperature, until the difference between the actual temperature and the first target temperature is no greater than a preset threshold, and output the current control parameters as the maximum control parameters at the first target temperature.

[0106] The motor controller testing system provided in this application receives the target temperature to be tested, uses the actual temperature of the motor controller running under control parameters as feedback, and gradually increases the control parameters from the initial level until the actual temperature of the motor controller approaches the target temperature, thereby obtaining the control parameters corresponding to different temperatures reached by the motor controller. This testing method transforms the temperature of the motor controller from a passively detected parameter to an actively controlled target. Compared to the prior art method of manually and repeatedly setting control parameters for exploration, this application can automatically adjust the control parameters according to temperature changes, avoiding situations where the motor controller temperature rises rapidly and exceeds the thermal safety boundary due to excessively high control parameter settings, thus improving the safety of the motor controller during testing.

[0107] In one possible implementation, the control circuit is also used to control the environment in which the motor controller is located to reach the target environmental state; The actual temperature is the temperature at which the motor controller operates under the target environmental conditions and driven by the control parameters.

[0108] In this possible implementation, the environment in which the motor controller is located is controlled to reach a target environmental state. Under the target environmental state, the motor controller is driven to run based on control parameters, thereby obtaining the actual temperature of the motor controller when it is running under the target environmental state and driven by the control parameters. This allows the temperature test of the motor controller to be carried out under the preset environmental state, thereby exploring the temperature of the motor controller under different control parameters and different environmental states. This is beneficial for comprehensively evaluating the thermal performance of the motor controller and improving the comprehensiveness and accuracy of thermal safety boundary exploration.

[0109] In one possible implementation, the system also includes a water chiller connected to the control circuitry; The control circuit is also used to control the flow of coolant in the water chiller through the motor controller to cool the motor controller; The target environmental conditions include at least one of the following: the temperature of the coolant in the water chiller reaches the first target temperature; the flow rate of the coolant in the water chiller reaches the target flow rate.

[0110] In this possible implementation, the coolant in the water chiller flows through the motor controller. Since the temperature and flow rate of the coolant affect the heat dissipation capacity of the motor controller, by adjusting the temperature and flow rate of the coolant, the motor controller can be tested under different cooling conditions, thereby obtaining a more comprehensive correspondence between temperature and control parameters, and improving the efficiency and accuracy of thermal safety boundary exploration.

[0111] In one possible implementation, the first target temperature is no greater than the maximum temperature limit of the motor controller.

[0112] In this possible implementation, by limiting the target temperature to no more than the maximum temperature limit of the motor controller, the actual temperature of the motor controller is always kept within a safe range during the test. Compared with the existing technology of manually setting control parameters and observing whether the temperature exceeds the limit, this application can avoid damage to the motor controller due to the target temperature being set too high, which would cause it to exceed its temperature resistance. This is beneficial to obtain control parameters close to the limit temperature while ensuring the safety of the motor controller, thus improving the safety and reliability of the test process.

[0113] In one possible implementation, the control parameters include at least one of the torque or current of the motor controller.

[0114] In this possible implementation, the control parameters include at least one of the torque or current of the motor controller, enabling the load state to be changed during the test by adjusting the torque or current of the motor controller, thereby causing temperature changes in the internal power devices and realizing the correlation between temperature and load.

[0115] It should be noted that the test system for the motor controller provided in the above embodiments and the test method embodiments for the aforementioned motor controller belong to the same concept. For details of its specific implementation process, please refer to the method embodiments, which will not be repeated here.

[0116] This application also provides a control circuit, which includes a processor and a memory. The memory stores at least one computer program, which is loaded and executed by the processor to implement the operations performed in the test method of the motor controller in the above embodiments.

[0117] Figure 4 A schematic diagram of a control circuit provided in an exemplary embodiment of this application is shown. The control circuit includes a processor 401 and a memory 402.

[0118] Processor 401 may include one or more processing cores, such as a quad-core processor or an octa-core processor. Processor 401 may be implemented using at least one hardware form of DSP (Digital Signal Processing), FPGA (Field Programmable Gate Array), or PLA (Programmable Logic Array). Processor 401 may also include a main processor and a coprocessor. The main processor, also known as a CPU (Central Processing Unit), is used to process data in the wake-up state; the coprocessor is a low-power processor used to process data in the standby state.

[0119] Memory 402 may include one or more computer-readable storage media, which may be non-transitory. Memory 402 may also include high-speed random access memory and non-volatile memory, such as one or more disk storage devices or flash memory devices. In some embodiments, the non-transitory computer-readable storage media in memory 402 are used to store at least one computer program, which is used by processor 401 to implement the test method of the motor controller provided in the method embodiments of this application.

[0120] Those skilled in the art will understand that Figure 4 The structure shown does not constitute a limitation on the electronic device and may include more or fewer components than shown, or combine certain components, or use different component arrangements.

[0121] This application also provides a computer-readable storage medium storing at least one piece of program code, which is loaded and executed by a processor to implement the test method for the motor controller as described in any of the above implementations.

[0122] This application also provides a computer program product, which includes at least one piece of program code, which is loaded and executed by a processor to implement the test method for the motor controller as described in any of the above implementations.

[0123] The above are merely optional embodiments of this application and are not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A test method for a motor controller, characterized in that, The method includes: Receive the first target temperature to be tested; The motor controller is driven to run based on the initial control parameters, and the actual temperature of the motor controller under the drive of the control parameters is obtained. If the actual temperature is lower than the first target temperature, the control parameter is increased until the difference between the actual temperature and the first target temperature is no greater than a preset threshold, and the current control parameter is output as the maximum control parameter at the first target temperature.

2. The method according to claim 1, characterized in that, The method further includes: The environment in which the motor controller is located is controlled to reach the target environmental state; The actual temperature is the actual temperature at which the motor controller operates under the target environmental conditions and driven by the control parameters.

3. The method according to claim 2, characterized in that, The method further includes: The coolant in the water chiller is controlled to flow through the motor controller to cool the motor controller; The target environmental state includes at least one of the following: the temperature of the coolant in the water chiller reaches the second target temperature; the flow rate of the coolant in the water chiller reaches the target flow rate.

4. The method according to claim 1, characterized in that, The first target temperature is not greater than the maximum temperature limit of the motor controller.

5. The method according to claim 1, characterized in that, The control parameters include at least one of the torque or current of the motor controller.

6. A testing system for a motor controller, characterized in that, The system includes a control circuit and a motor controller, and the control circuit is connected to the motor controller. The control circuit is used to receive the first target temperature to be tested; The control circuit is also used to drive the motor controller to operate based on the initial control parameters; The motor controller is used to detect the actual temperature during operation under the drive of the control parameters, and transmit the actual temperature to the control circuit. The control circuit is further configured to increase the control parameter when the actual temperature is lower than the first target temperature, until the difference between the actual temperature and the first target temperature is not greater than a preset threshold, and output the current control parameter as the maximum control parameter at the first target temperature.

7. The system according to claim 6, characterized in that, The control circuit is also used to control the environment in which the motor controller is located to reach the target environmental state; The actual temperature is the actual temperature at which the motor controller operates under the target environmental conditions and driven by the control parameters.

8. The system according to claim 7, characterized in that, The system also includes a water chiller, which is connected to the control circuit. The control circuit is also used to control the flow of coolant in the water chiller through the motor controller to cool the motor controller; The target environmental state includes at least one of the following: the temperature of the coolant in the water chiller reaches the first target temperature; the flow rate of the coolant in the water chiller reaches the target flow rate.

9. A control circuit, characterized in that, The control circuit includes a processor and a memory, the memory storing at least one computer program, which is loaded and executed by the processor to enable the control circuit to implement the test method for the motor controller as described in any one of claims 1 to 5.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores at least one piece of program code, which is loaded and executed by a processor to implement the test method for the motor controller as described in any one of claims 1 to 5.

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