Vehicle test system
By designing a vehicle test system and injecting different types of faults into the driver using the fault injection box, the problem of difficulty in effectively testing the electric vehicle motor controller in the prior art is solved, and a comprehensive coverage of electric vehicle safety testing is achieved.
Patent Information
- Application Number
- CN202420761057.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-04-12
- Publication Date
- 2025-03-04
- Estimated Expiration
- 2034-04-12
AI Technical Summary
The prior art is difficult to effectively test electric vehicle motor controllers, especially in the failure state simulated in the vehicle environment, and cannot meet the requirements of safety specifications.
An automotive test system is designed, including loads, drivers, high voltage suppliers and fault injection boxes. Through the fault injection boxes, different types of line failures are injected into the driver, simulating short circuit, open circuit and overcurrent conditions to test the safety of the driver.
A comprehensive test of the electric vehicle motor controller has been achieved, problems can be discovered and errors can be corrected in advance, and the safety of the electric vehicle is in compliance with the specifications.
Smart Images
Figure CN222561755U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a vehicle testing system, in particular to a vehicle testing system for testing a motor controller. Background Art
[0002] Electric vehicles are a type of transportation equipment that has become increasingly common in recent years. In order to ensure the safety of electric vehicle passengers and road users, various countries have formulated various safety regulations for electric vehicles. Therefore, fault injection testing is used to simulate the fault state of the finished vehicle environment before leaving the factory, so that problems can be discovered and corrected in advance, thereby meeting various safety regulations. Utility Model Content
[0003] Therefore, the utility model provides a vehicle test system. The vehicle test system includes a load, a driver, a high voltage supply, and a fault injection box. The driver is coupled to the load through an AC power line set to drive the load. The high voltage supply is coupled to the driver through a DC power line set. The fault injection box couples the load, the driver, and the high voltage supply. In a first test mode, the fault injection box injects a first line fault into the driver to test the driver. The first line fault indicates a short circuit between the AC power line set and the DC power line set.
[0004] In one or more embodiments of the vehicle test system, the driver is coupled to a casing ground, and in the first test mode, the fault injection box also injects a second line fault into the driver to test the driver, and the second line fault indicates a short circuit between the DC power line group and the casing ground.
[0005] In one or more embodiments of the vehicle testing system, the DC power line group includes a positive voltage power line and a negative voltage power line, and the second line fault indicates a short circuit between one of the positive voltage power line and the negative voltage power line and the casing.
[0006] In one or more embodiments of the vehicle test system, the AC power line group includes a U-phase power line, a V-phase power line, and a W-phase power line, the DC power line group includes a positive voltage power line and a negative voltage power line, and the fault injection box includes: a first switch coupled between the U-phase power line and the positive voltage power line; a second switch coupled between the U-phase power line and the negative voltage power line; a third switch coupled between the V-phase power line and the positive voltage power line; a fourth switch coupled between the V-phase power line and the negative voltage power line; a fifth switch coupled between the W-phase power line and the positive voltage power line; and a sixth switch coupled between the W-phase power line and the negative voltage power line, wherein, in the first test mode, when the fault injection box injects the first line fault into the driver, one of the first to sixth switches is turned on.
[0007] In one or more embodiments of the vehicle test system, the fault injection box also includes: a seventh switch coupled between the positive voltage power line and a casing ground; and an eighth switch coupled between the negative voltage power line and the casing ground, wherein, in the first test mode, when the fault injection box injects a second line fault into the driver, one of the seventh and eighth switches is turned on.
[0008] In one or more embodiments of the vehicle test system, the AC power line group includes a U-phase power line, a V-phase power line, and a W-phase power line, and the fault injection box includes a first inductor coupled between the U-phase power line and a first node; a first switch coupled between the U-phase power line and the first node; a second switch coupled between the first node and the DC power line group; a second inductor coupled between the V-phase power line and a second node; a third switch coupled between the V a W-phase power line and the second node; a fourth switch coupled between the second node and the DC power line group; a third inductor coupled between the W-phase power line and a third node; a fifth switch coupled between the W-phase power line and the third node; and a sixth switch coupled between the first node and the DC power line group; wherein, in a second test mode, the first switch, the third switch, and the fifth switch are turned off, and one of the second switch, the fourth switch, and the sixth switch is turned on.
[0009] In one or more embodiments of the vehicle test system, the DC power line group includes a positive voltage power line and a negative voltage power line, the second switch is coupled between the first node and one of the positive voltage power line and the negative voltage power line, the fourth switch is coupled between the second node and one of the positive voltage power line and the negative voltage power line, and the sixth switch is coupled between the third node and one of the positive voltage power line and the negative voltage power line.
[0010] In one or more embodiments of the vehicle test system, the load is a motor or a motor simulator. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figure 1 is a schematic diagram of a vehicle testing system according to an embodiment.
[0012] Figure 2 FIG. 4 is a schematic diagram of a vehicle testing system according to another embodiment.
[0013] Reference numerals:
[0014] 1: Automotive test system
[0015] 10: Driver
[0016] 11: Fault Injection Box
[0017] 12: Load
[0018] 13: High voltage supply
[0019] 14: Main Controller
[0020] 15: AC power cord set
[0021] 16: DC power cord set
[0022] 17~19: Current monitor
[0023] DC+: Positive DC voltage
[0024] DC-: negative DC voltage
[0025] GND: Chassis ground
[0026] LDC+: Positive voltage power line
[0027] LDC-: Negative voltage power line
[0028] LU:U phase power line
[0029] LU(20),LU(21):U-phase power line section
[0030] LV: V phase power line
[0031] LV(20),LV(21): V-phase power line section
[0032] LW: W phase power line
[0033] LW(20), LW(21): W-phase power line section
[0034] S201~S219: Switching signal
[0035] S220: Status detection signal
[0036] SW201~SW219: Switch
[0037] U, V, W: three-phase AC power supply DETAILED DESCRIPTION
[0038] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and understandable, a preferred embodiment is given below and described in detail with reference to the accompanying drawings.
[0039] Figure 1 FIG. 2 is a diagram showing a vehicle test system according to an embodiment of the present utility model. Figure 1 The vehicle test system 1 includes a driver 10, a fault injection box 11, a load 12, a high voltage supply 13, and a main controller 14. In one embodiment, the load 12 of the present case is a device composed of a plurality of inductors. For example, the load 12 is a three-phase motor, and the driver 1 is a motor driver (inverter). In other embodiments, the load 12 is a motor dummy. In the following, the operation of the vehicle test system 1 of the present case will be described by taking the load 12 as a three-phase motor and the driver 1 as a motor driver as an example.
[0040] The driver 10 is coupled to the load 12 via the fault injection box 11 through the AC power line group 15. In this embodiment, the driver 10 generates a three-phase AC power supply. In a normal operation mode, the driver 10 transmits the three-phase AC power supply to the load 12 through the AC power line group 15 via the fault injection box 11 to drive the load 12. In detail, the AC power line group 15 includes a U-phase power line LU, a V-phase power line LV, and a W-phase power line LW, and the driver 10 transmits the U, V, and W three-phase AC power supplies to the load 12 through the U-phase power line LU, the V-phase power line LV, and the W-phase power line LW and via the fault injection box 11 in the normal operation mode.
[0041] The high voltage supply 13 is coupled to the driver 10 through the DC power line set 16 and through the fault injection box 11. The high voltage supply 13 generates a positive DC voltage DC+ and a negative DC voltage DC-. In one embodiment, the positive DC voltage DC+ is, for example, 400 volts (V) or 800V, and the negative DC voltage DC- is, for example, -400V or -800V. In detail, the DC power line set 16 includes a positive voltage power line LDC+ and a negative voltage power line LDC-, and the high voltage supply 13 provides the positive DC voltage DC+ and the negative DC voltage DC- to the driver 10 through the positive voltage power line LDC+ and the negative voltage power line LDC- and through the fault injection box 11 in the normal operation mode, so as to power the driver 10.
[0042] The fault injection box 11 is coupled to the driver 10, the load 12, and the high voltage supply 13. In addition to the normal mode, the main controller 14 can also control the vehicle test system 1 to operate in a short circuit / open circuit test mode (a first test mode) and an overcurrent test mode (a second test mode). In the short circuit / open circuit test mode, the fault injection box 11 injects at least one line fault into the driver 10 to test whether the driver 10 enters the protection mode due to the fault. In the overcurrent test mode, the fault injection box 11 injects a current measurement line into the driver 10 to test whether the driver 10 enters the protection mode due to an overcurrent on the U-phase power line LU, the V-phase power line LV, or the W-phase power line LW.
[0043] The main controller 14 is coupled to the driver 10 and the fault injection box 11. The main controller 14 determines whether the vehicle test system 1 is in a normal mode, a short circuit / open circuit test mode, or an overcurrent test mode. In the short circuit / open circuit test mode, the main controller 14 controls the fault injection box 11 to inject at least one line fault into the driver 10, that is, the main controller 14 determines the type of the injected line fault. In the overcurrent test mode, the main controller 14 controls the fault injection box 11 to inject a current measurement circuit into the driver 10, that is, the main controller 14 determines the current path of the injected current measurement circuit.
[0044] Figure 2 FIG. 4 is a vehicle testing system according to another embodiment of the utility model. Figure 2 The detailed circuit structure of the fault injection box 11 is shown. In order to clearly show the connection and operation of the fault injection box 11, Figure 2 Also shown are a driver 10 , a load 12 , and a high voltage supply 13 .
[0045] like Figure 2As shown, the fault injection box 11 includes switches SW201-SW209 and inductors L21-L23. The main controller 14 generates switching signals S201-S219 to control the switches SW201-SW203 to be turned on or off respectively. In one embodiment, the switches SW201-SW209 are implemented by relays.
[0046] The switches SW201 to SW203 are respectively arranged on the U-phase power line LU, the V-phase power line LV, and the W-phase power line LW. In detail, due to the arrangement of the switches SW201 to SW203, each of the U-phase power line LU, the V-phase power line LV, and the W-phase power line LW is divided into a section connected to the driver 20 and another section connected to the load 12. Figure 2 Based on the setting of the switch SW201, the U-phase power line LU is divided into U-phase power line sections LU (20) and LU (21), the U-phase power line section LU (20) is connected between the driver 20 and the switch SW201, and the U-phase power line section LU (21) is connected between the switch SW201 and the load 12. Based on the setting of the switch SW202, the V-phase power line LV is divided into V-phase power line sections LV (20) and LV (21), the V-phase power line section LV (20) is connected between the driver 20 and the switch SW202, and the V-phase power line section LV (21) is connected between the switch SW202 and the load 12. Based on the setting of the switch SW203, the W-phase power line LW is divided into W-phase power line sections LW(20) and LW(21), wherein the W-phase power line section LW(20) is connected between the driver 20 and the switch SW203, and the W-phase power line section LW(21) is connected between the switch SW203 and the load 12. The on / off state of the switches SW201-SW203 determines whether the driver 10 and the load 12 are disconnected, that is, whether the U, V, W three-phase AC power generated by the driver 10 can be transmitted to the load 12.
[0047] The switch SW204 is coupled between the U-phase power line segment LU (20) and the node N20, and the inductor L21 is coupled between the U-phase power line segment LU (20) and the node N20, that is, the switch SW204 and the inductor L21 are coupled in parallel between the U-phase power line segment LU (20) and the node N20. The switch SW205 is coupled between the V-phase power line segment LV (20) and the node N21, and the inductor L22 is coupled between the V-phase power line segment LV (20) and the node N21, that is, the switch SW205 and the inductor L22 are coupled in parallel between the V-phase power line segment LV (20) and the node N21. The switch SW206 is coupled between the W-phase power line segment LW(20) and the node N22, and the inductor L23 is coupled between the W-phase power line segment LW(20) and the node N22, that is, the switch SW206 and the inductor L23 are coupled in parallel between the W-phase power line segment LW(20) and the node N22. The on / off state of the switches SW204-SW206 is determined according to whether the vehicle test system 1 is in a short circuit / open circuit test mode or in an overcurrent test mode. In this embodiment, in the short circuit / open circuit test mode, the switches SW204-SW206 are turned on; in the overcurrent test mode, the switches SW204-SW206 are turned off or on according to the injected current measurement route.
[0048] See also Figure 2 , switch SW207 is coupled between nodes N20 and N21. Switch SW208 is coupled between nodes N21 and N22. Switch SW209 is coupled between nodes N22 and N20. According to the connection structure of switches SW207-SW209, the on / off state of switches SW207-SW209 determines whether any two of the U-phase power line segment LU(20), the V-phase power line segment LV(20), and the W-phase power line segment LW(20) are short-circuited to each other.
[0049] The switch SW210 is coupled between the node N20 and the positive voltage power line LDC+, and the switch SW211 is coupled between the node N20 and the negative voltage power line LDC-. The switch SW212 is coupled between the node N21 and the positive voltage power line LDC+, and the switch SW213 is coupled between the node N21 and the negative voltage power line LDC-. The switch SW214 is coupled between the node N22 and the positive voltage power line LDC+, and the switch SW214 is coupled between the node N22 and the negative voltage power line LDC-. According to the connection structure of the switches SW210-SW215, the on / off state of the switches SW210-SW215 determines whether any one of the U-phase power line segment LU(20), the V-phase power line segment LV(20), and the W-phase power line segment LW(20) is short-circuited with the positive voltage power line LDC+ or the negative voltage power line LDC-.
[0050] See also Figure 2 , the switch SW216 is coupled between the positive voltage power line LDC+ and the driver 10, and the switch SW217 is coupled between the negative voltage power line LDC- and the driver 10. According to the connection structure of the switches SW216 and SW217, the on / off state of the switches SW216 and SW217 determines whether the circuit between the positive voltage power line LDC+ and the negative voltage power line LDC- and the driver 10 is open. In other words, the on / off state of the switches SW216 and SW217 determines whether the positive voltage power supply DC+ is provided to the driver 10 through the positive voltage power line LDC+, and determines whether the negative voltage power line DC- is provided to the driver 10 through the negative voltage power line LDC-.
[0051] like Figure 2 As shown, the switch SW218 is coupled between the positive voltage power line LDC+ and the chassis ground GND, and the switch SW219 is coupled between the negative voltage power line LDC- and the chassis ground GND. According to the connection structure of the switches SW218 and SW219, the on / off state of the switches SW218 and SW219 determines whether any one of the positive voltage power line LDC+ and the negative voltage power line LDC- and the chassis ground GND is short-circuited to each other.
[0052] The following will be passed Figure 2 The operation of the vehicle testing system 1 of the present invention will be described in detail.
[0053] When the vehicle test system 1 is started and enters the initial state, the switches SW201-SW203, SW216 and SW217 are turned on according to the switching signals SW201-S203, S216 and S217, respectively, and the other switches SW204-SW215, SW218 and SW219 are turned off according to the switching signals S204-S215, S218 and S219, respectively. At this time, the vehicle test system 1 is in the normal mode. In the normal mode, the driver 10 transmits the U, V, W three-phase AC power to the load 12 through the U-phase power line LU, the V-phase power line LV, and the W-phase power line LW and through the turned-on switches SW201-SW203. In addition, the high voltage supplier 13 provides the positive DC voltage DC+ and the negative DC voltage DC- to the driver 10 through the positive voltage power line LDC+ and the negative voltage power line LDC- and through the turned-on switches SW216 and SW217.
[0054] In one embodiment, when the vehicle test system 1 enters the short / open test mode from the normal mode, the switches SW204 ˜ SW206 are switched on according to the switching signals S204 ˜ S206 , respectively, and the fault injection box 11 injects at least one line fault into the driver 10 .
[0055] In one embodiment, in the short circuit / open circuit test mode, the injected line fault indicates the AC power line group 15 and the DC power line group 16. Specifically, the injected line fault indicates that any one of the U-phase power line segment LU (20), the V-phase power line segment LV (20), and the W-phase power line segment LW (20) is short-circuited with the positive voltage power line LDC+ or the negative voltage power line LDC- (a first type of line fault). For example, the injected line fault indicates that the U-phase power line segment LU (20) and the positive voltage power line LDC+ are short-circuited with each other. In this case, the switch SW210 is switched to the on state according to the switching signal S210, so that the U-phase power line segment LU (20) and the positive voltage power line LDC+ are short-circuited with each other. At this time, due to this short circuit, a large negative current is generated on the U-phase power line segment LU (20). The main controller 12 monitors whether the driver 10 enters the protection mode based on the large negative current to stop outputting the three-phase AC power of U, V, W. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the U-phase power line section LU (20) and the positive voltage power line LDC+.
[0056] In the short circuit / open circuit test mode, when the injected line fault indicates that the U-phase power line segment LU (20) and the negative voltage power line LDC- are short-circuited, the switch SW211 is switched to the on state according to the switching signal S211, so that the U-phase power line segment LU (20) and the negative voltage power line LDC- are short-circuited. At this time, due to this short circuit, a large positive current is generated on the U-phase power line segment LU (20). The main controller 12 monitors whether the driver 10 enters the protection mode based on this large positive current to stop outputting the U, V, W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the U-phase power line segment LU (20) and the negative voltage power line LDC-.
[0057] In the short circuit / open circuit test mode, when the line fault injected indicates that the V-phase power line segment LV(20) and the positive voltage power line LDC+ are short-circuited to each other, the switch SW212 is switched to the on state according to the switching signal S212; when the line fault injected indicates that the V-phase power line segment LV(20) and the negative voltage power line LDC- are short-circuited to each other, the switch SW213 is switched to the on state according to the switching signal S213. In the short circuit / open circuit test mode, when the line fault injected indicates that the W-phase power line segment LW(20) and the positive voltage power line LDC+ are short-circuited to each other, the switch SW214 is switched to the on state according to the switching signal S214; when the line fault injected indicates that the W-phase power line segment LW(20) and the negative voltage power line LDC- are short-circuited to each other, the switch SW215 is switched to the on state according to the switching signal S215. In the case of any of the above short circuits, the main controller 12 monitors whether the driver 10 enters a protection mode based on the large positive / negative current to stop outputting the three-phase AC power U, V, W. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit.
[0058] In one embodiment, in the short circuit / open circuit test mode, the injected line fault indicates a short circuit between the DC power line group 16 and the chassis ground GND. Specifically, the injected line fault indicates a short circuit between one of the positive voltage power line LDC+ and the negative voltage power line LDC- and the chassis ground GND (a second type of line fault). For example, the injected line fault indicates a short circuit between the positive voltage power line LDC+ and the chassis ground GND. In this case, the switch SW218 is switched to a conducting state according to the switching signal S218, so that the positive voltage power line LDC+ and the chassis ground GND are short-circuited. At this time, based on this short circuit, the driver 10 receives the negative DC voltage DC- and the voltage of the chassis ground GND (for example, 0V), but does not receive the positive DC voltage DC+. The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, and W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against a fault caused by a short circuit between the positive voltage power line LDC+ and the chassis ground GND.
[0059] In the short circuit / open circuit test mode, when the injected line fault indicates that the negative voltage power line LDC- and the chassis ground GND are short-circuited, the switch SW219 is switched to the on state according to the switching signal S219, so that the negative voltage power line LDC- and the chassis ground GND are short-circuited. At this time, based on this short circuit, the driver 10 receives the positive DC voltage DC+ and the voltage of the chassis ground GND, but does not receive the negative DC voltage DC-. The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, and W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the negative voltage power line LDC- and the chassis ground GND.
[0060] In one embodiment, in the short circuit / open circuit test mode, the injected line fault indicates that the driver 10 is open circuited with one of the positive voltage power line LDC+ and the negative voltage power line LDC- (the third type of line fault). For example, the injected line fault indicates that the driver 10 is switched with the positive voltage power line LDC+. In this case, the switch SW216 is switched to the off state according to the switching signal S216, so that the driver 10 is open circuited with the positive voltage power line LDC+. At this time, based on this open circuit, the driver 10 is only connected to the negative DC voltage DC-, but not to the positive DC voltage DC+. The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, and W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety for the fault caused by the open circuit between the driver 10 and the positive voltage power line LDC+.
[0061] In the short circuit / open circuit test mode, when the injected line fault indicates that the driver 10 and the negative voltage power line LDC- are switched to each other, the switch SW217 is switched to the off state according to the switching signal S217, so that the driver 10 and the negative voltage power line LDC- are open to each other. At this time, based on this open circuit, the driver 10 is only connected to the positive DC voltage DC+, but not the negative DC voltage DC-. The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, and W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety for the fault caused by the open circuit between the driver 10 and the negative voltage power line LDC-.
[0062] In one embodiment, in the short circuit / open circuit test mode, the injected line fault indicates that the U-phase power line segment LU (20) and the U-phase power line segment LU (21) are disconnected from each other, the V-phase power line segment LV (20) and the V-phase power line segment LV (21) are disconnected from each other, or the W-phase power line segment LW (20) and the W-phase power line segment LW (21) are disconnected from each other (the fourth type of line fault). For example, the injected line fault indicates that the U-phase power line segment LU (20) and the U-phase power line segment LU (21) are open-circuited. In this case, the switch SW201 is switched to the off state according to the switching signal S201, so that the U-phase power line segment LU (20) and the U-phase power line segment LU (21) are open-circuited from each other. At this time, due to this open circuit, no AC power is carried in the U-phase power line segment LU (20). The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the three-phase AC power of U, V, W. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the U-phase power line section LU (20) and the U-phase power line section LU (21).
[0063] In the short circuit / open circuit test mode, when the injected line fault indicates that the V-phase power line section LV (20) and the V-phase power line section LV (21) are open circuited, the switch SW202 is switched to the off state according to the switching signal S202, so that the V-phase power line section LV (20) and the V-phase power line section LV (21) are open circuited. At this time, due to the open circuit, no AC power is carried in the V-phase power line section LV (20). The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, and W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the V-phase power line section LV (20) and the V-phase power line section LV (21).
[0064] In the short circuit / open circuit test mode, when the injected line fault indicates that the W-phase power line segment LW(20) and the W-phase power line segment LW(21) are open circuited, the switch SW203 is switched to the off state according to the switching signal S203, so that the W-phase power line segment LW(20) and the W-phase power line segment LW(21) are open circuited. At this time, due to the open circuit, no AC power is carried on the W-phase power line segment LW(20). The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, and W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the W-phase power line segment LW(20) and the W-phase power line segment LW(21).
[0065] In one embodiment, in the short circuit / open circuit test mode, the injected line fault indicates that the U-phase power line segment LU (20) and the V-phase power line segment LV (20) are short-circuited to each other, the V-phase power line segment LV (20) and the W-phase power line segment LW (20) are short-circuited to each other, or the W-phase power line segment LW (20) and the U-phase power line segment LU (20) are short-circuited to each other (the fifth type of line fault). For example, the injected line fault indicates that the U-phase power line segment LU (20) and the V-phase power line segment LV (20) are short-circuited to each other. In this case, the switch SW207 is switched to the conducting state according to the switching signal S207, so that the U-phase power line segment LU (20) and the V-phase power line segment LV (20) are short-circuited to each other. The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, and W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the U-phase power line segment LU (20) and the V-phase power line segment LV (20).
[0066] In the short circuit / open circuit test mode, when the injected line fault indicates that the V-phase power line segment LV (20) and the W-phase power line segment LW (20) are short-circuited, the switch SW208 is switched to the on state according to the switching signal S208, so that the V-phase power line segment LV (20) and the W-phase power line segment LW (20) are short-circuited. The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the V-phase power line segment LV (20) and the W-phase power line segment LW (20).
[0067] In the short circuit / open circuit test mode, when the injected line fault indicates that the W-phase power line segment LW (20) and the U-phase power line segment LU (20) are short-circuited, the switch SW209 is switched to the on state according to the switching signal S209, so that the W-phase power line segment LW (20) and the U-phase power line segment LU (20) are short-circuited. The main controller 12 monitors whether the driver 10 enters the protection mode to stop outputting the U, V, W three-phase AC power. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the fault caused by the short circuit between the W-phase power line segment LW (20) and the U-phase power line segment LU (20).
[0068] According to an embodiment of the present invention, the fault injection box 11 can inject one of the first to fifth types of line faults into the driver 10 in the short circuit / open circuit test mode, or inject multiple types non-simultaneously.
[0069] In one embodiment, when the vehicle test system 1 enters the overcurrent test mode from the normal mode or the short circuit / open circuit test mode, the fault injection box 11 injects a current measurement line into the driver 10. For example, the injected current measurement line refers to the current path from the U-phase power line segment LU (20) to the positive voltage power line LDC+ or the negative voltage power line LDC-. In this case, the switch SW204 is maintained or switched to the off state according to the switching signal S204, and the switch SW210 is switched to the on state according to the switching signal S210, so that a current path is formed between the U-phase power line segment LU (20) and the positive voltage power line LDC+ through the inductor L21; or the switch SW204 is maintained or switched to the off state according to the switching signal S204, and the switch SW211 is switched to the on state according to the switching signal S211, so that a current path is formed between the U-phase power line segment LU (20) and the negative voltage power line LDC- through the inductor L21. At this time, the driver 20 detects whether a current abnormality (e.g., an excessive current) occurs in the U-phase power line segment LU (20). The main controller 12 monitors whether the driver 10 enters a protection mode to stop outputting the U, V, W three-phase AC power due to the detection of the current abnormality on the U-phase power line segment LU (20). If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the current abnormality on the U-phase power line segment LU (20).
[0070] In the overcurrent test mode, when the injected current measurement line is a current path from the V-phase power line segment LV (20) to the positive voltage power line LDC+ or the negative voltage power line LDC-, the switch SW205 is maintained or switched to the off state according to the switching signal S205, and the switch SW212 is switched to the on state according to the switching signal S212, so that a current path is formed between the V-phase power line segment LV (20) and the positive voltage power line LDC+ through the inductor L22; or the switch SW205 is maintained or switched to the off state according to the switching signal S205, and the switch SW213 is switched to the on state according to the switching signal S213, so that a current path is formed between the V-phase power line segment LV (20) and the negative voltage power line LDC- through the inductor L22. At this time, the driver 20 detects whether a current abnormality occurs in the V-phase power line segment LV (20). The main controller 12 monitors whether the driver 10 enters a protection mode due to detecting an abnormal current on the V-phase power line section LV (20) to stop outputting the three-phase AC power of U, V, and W. If the controller 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the abnormal current on the V-phase power line section LV (20).
[0071] In the overcurrent test mode, when the injected current measurement line is a current path from the W-phase power line segment LW(20) to the positive voltage power line LDC+ or the negative voltage power line LDC-, the switch SW206 is maintained or switched to an off state according to the switching signal S206, and the switch SW214 is switched to an on state according to the switching signal S214, so that a current path is formed between the W-phase power line segment LW(20) and the positive voltage power line LDC+ through the inductor L23; or the switch SW206 is maintained or switched to an off state according to the switching signal S206, and the switch SW215 is switched to an on state according to the switching signal S215, so that a current path is formed between the W-phase power line segment LW(20) and the negative voltage power line LDC- through the inductor L23. At this time, the driver 20 detects whether a current abnormality occurs in the W-phase power line segment LW(20). The main controller 12 monitors whether the driver 10 enters a protection mode to stop outputting the three-phase AC power of U, V, and W due to detecting an abnormal current on the W-phase power line segment LW (20). If the driver 10 enters the protection mode, the main controller 12 determines that the driver 10 has reliable safety against the abnormal current on the W-phase power line segment LW (20).
[0072] In one embodiment, the vehicle test system 1 further includes current monitors 17 to 19. The current monitor 17 is connected to the U-phase power line segment LU (20) to sense and monitor the current on the U-phase power line segment LU (20). The current monitor 18 is connected to the V-phase power line segment LV (20) to sense and monitor the current on the V-phase power line segment LV (20). The current monitor 19 is connected to the W-phase power line segment LW (20) to sense and monitor the current on the W-phase power line segment LW (20). The current monitors 17 to 19 respectively display the current changes on the U-phase power line segment LU (20), the V-phase power line segment LV (20), and the W-phase power line segment LW (20). In this way, it is possible to observe the time required for at least one of the U-phase power line segment LU (20), the V-phase power line segment LV (20), and the W-phase power line segment LW (20) to complete discharge after the controller 10 enters the protection mode due to current abnormality in the overcurrent test mode, so as to further determine whether the time required for discharge complies with the current safety regulations.
[0073] In one embodiment, when the vehicle test system 1 is started and enters the initial state, the vehicle test system 1 performs a self-test operation. Under the self-test operation, the main controller 14 transmits a state detection signal S220 to the fault injection box 11 to detect whether each switch in the fault injection box 11 is in a normal state. Once the main controller 14 detects that any switch in the fault injection box 11 is abnormal, the main controller 14 prohibits the related operations of the short circuit / open circuit test mode and the overcurrent test mode. After the switch that is not in the normal state (i.e., the faulty) is replaced, the main controller 14 can control the vehicle test system 1 to operate in the short circuit / open circuit test mode or the overcurrent test mode.
[0074] According to the above embodiment, the vehicle test system 1 provided in this case is used to test the safety of the driver 10. The fault injection box 11 is controlled by the main controller 12 to inject at least one line fault into the driver 10. In particular, the line fault injected in this case indicates a short circuit between the AC power cord set 15 and the high voltage supply 13 (a first type of line fault). In addition, the main controller 12 also controls the fault injection box 11 to inject a current measurement circuit into the driver 10 to confirm the fault caused by the overcurrent on the AC power cord set 15. The vehicle test system 1 of this case can automatically test the safety of the driver 10, especially automatically verify the high-voltage safety mechanism. Compared with manual testing by testers, the vehicle test system 1 of this case can ensure the safety of testers.
[0075] Although the present invention is disclosed as above in terms of preferred embodiments, it is not intended to limit the scope of the present invention. Any person with ordinary knowledge in the technical field may make some changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be based on the definition of the previously attached claims.
Claims
1. A vehicle testing system, characterized in that: include: One load; A driver coupled to the load via an AC power line set to drive the load; A high voltage supply is coupled to the driver via a DC power line set; as well as a fault injection box coupled to the load, the driver, and the high voltage supply, for injecting a first line fault into the driver in a first test mode to test the driver, The first line fault indicates a short circuit between the AC power line set and the DC power line set.
2. The vehicle testing system according to claim 1, characterized in that: in: The AC power line set includes a U-phase power line, a V-phase power line, and a W-phase power line. The DC power line set includes a positive voltage power line and a negative voltage power line, and The first line fault indicates a short circuit between one of the U-phase power line, the V-phase power line, and the W-phase power line and one of the positive voltage power line and the negative voltage power line.
3. The vehicle testing system according to claim 1, characterized in that: in: The driver is coupled to a chassis ground. In the first test mode, the fault injection box also injects a second line fault into the driver to test the driver, and The second line fault indicates a short circuit between the DC power line set and the chassis ground.
4. The vehicle testing system according to claim 3, characterized in that: in: The DC power line set includes a positive voltage power line and a negative voltage power line, and The second line fault indicates a short circuit between one of the positive voltage power line and the negative voltage power line and the chassis.
5. The vehicle testing system according to claim 1, characterized in that: Also includes: a main controller, during an initial period of the first test mode, detecting whether the drive is in a normal state, When the main controller detects that the driver is not in the normal state, the main controller disables the first test mode.
6. The vehicle testing system according to claim 1, characterized in that: in: The AC power line set includes a U-phase power line, a V-phase power line, and a W-phase power line. The DC power line set includes a positive voltage power line and a negative voltage power line, and The fault injection box includes: a first switch coupled between the U-phase power line and the positive voltage power line; a second switch coupled between the U-phase power line and the negative voltage power line; a third switch coupled between the V-phase power line and the positive voltage power line; a fourth switch coupled between the V-phase power line and the negative voltage power line; a fifth switch coupled between the W-phase power line and the positive voltage power line; and a sixth switch coupled between the W-phase power line and the negative voltage power line, Wherein, in the first test mode, when the fault injection box injects the first line fault into the driver, one of the first to sixth switches is turned on.
7. The vehicle testing system according to claim 6, characterized in that: in, The fault injection box also includes: a seventh switch coupled between the positive voltage power line and a chassis ground; and an eighth switch, coupled between the negative voltage power line and the chassis ground, Wherein, in the first test mode, when the fault injection box injects a second line fault into the driver, one of the seventh and eighth switches is turned on.
8. The vehicle testing system according to claim 1, characterized in that: in: The AC power line set includes a U-phase power line, a V-phase power line, and a W-phase power line. The fault injection box includes: a first inductor coupled between the U-phase power line and a first node; a first switch coupled between the U-phase power line and the first node; a second switch coupled between the first node and the DC power line set; a second inductor coupled between the V-phase power line and a second node; a third switch coupled between the V-phase power line and the second node; a fourth switch coupled between the second node and the DC power line set; a third inductor coupled between the W-phase power line and a third node; a fifth switch coupled between the W-phase power line and the third node; and a sixth switch coupled between the first node and the DC power line set; In a second test mode, the first switch, the third switch, and the fifth switch are turned off, and one of the second switch, the fourth switch, and the sixth switch is turned on.
9. The vehicle testing system according to claim 8, characterized in that: in: The DC power line set includes a positive voltage power line and a negative voltage power line. The second switch is coupled between the first node and one of the positive voltage power line and the negative voltage power line. The fourth switch is coupled between the second node and one of the positive voltage power line and the negative voltage power line, and The sixth switch is coupled between the third node and one of the positive voltage power line and the negative voltage power line.
10. The vehicle testing system according to claim 1, characterized in that: in, The load is a motor or a motor simulator.