Dual-motor hardware-in-loop test system

Abstract

The utility model discloses a dual-motor hardware-in-the-loop test system, which comprises a dual-motor control panel, a real-time simulation machine and an upper computer, the real-time simulation machine is an RTBOX real-time simulation machine; the dual-motor control panel outputs two groups of rotary transformer excitation signals, outputs two groups of PWM wave signals of a six-phase power switch, stoped motor sin signals and cos signals, and received three-phase current signals and bus voltage signals are respectively connected to the real-time simulation machine through wire harnesses; the two groups of CAN bus signals are respectively connected with the real-time simulation machine through wire harnesses; the upper computer is in communication connection with the real-time simulation machine, and system-level power electronic simulation software runs on the upper computer. The test system can support two groups of motor controllers at the same time, so that the situation that software and hardware possibly interfere with each other when the two groups of motor controllers work at the same time is tested, the problem of CPU load of a main control chip is solved, and the torque distribution situation of two motors can be tested.

Description

Technical Field

[0001] The utility model relates to the technical field of dual-motor control panels, in particular to a dual-motor hardware-in-the-loop test system. Background Art

[0002] As the global demand for sustainable transportation solutions grows, electric vehicles (EVs) and hybrid electric vehicles (HEVs) are becoming the mainstream choice in the market. These vehicles not only help reduce greenhouse gas emissions, but also provide a cleaner and more efficient way to travel. The automotive motor controller, known as the "brain" of electric vehicles, is a key technology to achieve high energy efficiency, optimize driving experience and reduce environmental impact. It ensures the best balance between vehicle power output and energy utilization efficiency by precisely controlling the operation of the motor. In modern high-performance electric and hybrid vehicles, the application of dual motor control board technology is becoming more and more extensive. This advanced control system can independently control two motors and is usually used in four-wheel drive electric vehicles or hybrid vehicles that pursue extreme performance. The dual motor control board can intelligently adjust the power output and torque distribution of the two motors according to the real-time driving conditions and the specific needs of the vehicle. By precisely controlling the coordinated work of the two motors, the dual motor control board brings higher power output, better torque distribution and more excellent driving experience to the car. Whether it is smooth driving on urban roads or fierce driving on winding mountain roads, the dual motor control board can provide stable and reliable performance support. At the same time, the dual-motor control board also brings increased difficulty in development and testing, as well as increased costs.

[0003] Bench testing is known for its ability to simulate real working conditions to a high degree, providing a direct assessment of system performance. However, this method has some limitations. Bench testing has the problems of high cost, poor flexibility, long test cycle, difficulty in fault injection testing and extreme working condition testing, and certain safety risks. Although the test method based on offline simulation can provide an ideal model of the controlled object, it lacks interaction with the actual hardware, which limits its accuracy in simulating the real test environment.

[0004] Hardware-in-the-loop testing is an advanced testing technology that combines the advantages of bench testing and simulation testing while overcoming some of their limitations. However, existing dual-motor control board HIL testing methods mostly use single-motor controller testing, which has some problems.

[0005] The existing solution performs HIL testing on single-motor controllers, but is not comprehensive enough for dual-motor control boards. It is difficult to test the mutual interference between software and hardware when two sets of motor controllers work at the same time, as well as the CPU load problem of the main control chip, and it is impossible to test the torque distribution of the two motors. Summary of the Invention

[0006] The utility model aims to provide a dual-motor hardware-in-the-loop test system to overcome the defects existing in the above-mentioned prior art.

[0007] The specific technical solution is as follows:

[0008] A dual-motor hardware-in-the-loop test system includes a dual-motor control board, a real-time simulator, and a host computer;

[0009] The real-time simulator is an RTBOX real-time simulator, which includes an analog input board, an analog output board, a digital input board, a digital output board, a resolver simulation board, two CAN bus interfaces, and an Ethernet interface;

[0010] Two groups of resolver excitation signals output by the dual-motor control board are respectively connected to the resolver simulation board of the real-time simulator through wiring harnesses;

[0011] Two groups of PWM wave signals of six-phase power switches output by the dual-motor control board are respectively connected to the digital input board of the real-time simulator through wiring harnesses;

[0012] The motor sin+, sin-, cos+, and cos- signals collected by the dual-motor control board are connected to the resolver simulation board of the real-time simulator through wiring harnesses; the three-phase current signals and the bus voltage signal are connected to the analog output board of the real-time simulator through wiring harnesses;

[0013] Two groups of CAN bus signals of the dual-motor control board are respectively connected to the two CAN bus interfaces of the real-time simulator through wiring harnesses;

[0014] The host computer is communicatively connected to the real-time simulator through the Ethernet interface and runs system-level power electronics simulation software.

[0015] Furthermore, it further includes a power-on control circuit; the power-on control circuit is arranged between the dual-motor control board and the power supply, is controlled by the real-time simulator, and is used to control the power-on and power-off of the dual-motor control board.

[0016] Furthermore, the main device of the power-on control circuit is a relay, and the control end of the relay is connected to the digital output board of the real-time simulator.

[0017] Furthermore, the system-level power electronics simulation software is PLECS.

[0018] The dual-motor hardware-in-the-loop test system of the present utility model can support two sets of motor controllers simultaneously, so as to test the possible mutual interference between software and hardware when the two sets of motor controllers work simultaneously, as well as the CPU load problem of the main control chip, and can realize the test of the torque distribution of two motors. Description of the Drawings

[0019] Figure 1 It is the structure diagram of the dual-motor control board;

[0020] Figure 2 It is the HIL test structure diagram of the dual-motor control board;

[0021] Figure 3 It is the dual-motor HIL topology model based on the RTBOX real-time simulator. Detailed Implementation Manner

[0022] To further illustrate the embodiments, the present utility model provides drawings. These drawings are part of the disclosure of the present utility model, mainly used to illustrate the embodiments, and can be combined with the relevant descriptions in the specification to explain the operating principle of the embodiments. With reference to these contents, those of ordinary skill in the art should be able to understand other possible implementation manners and the advantages of the present utility model. The components in the drawings are not drawn to scale, and similar component symbols are usually used to represent similar components.

[0023] Now, the present utility model will be further described in combination with the drawings and the detailed implementation manner.

[0024] As Figure 1 and Figure 2 shown, the present utility model provides a dual-motor hardware-in-the-loop test system, which is composed of a dual-motor control board 10, an RTBOX real-time simulator 20, a power supply 50, a relay board 40, a host computer 30, etc.

[0025] The two sets of resolver excitation signals Exc+, Exc- output by the dual-motor control board 10 are respectively connected to the resolver simulation board card of the RTBOX real-time simulator 20 through wire harnesses;

[0026] The PWM wave signals of the two sets of six-phase power switches output by the dual-motor control board 10 are respectively connected to the digital input board card of the RTBOX real-time simulator 20 through wire harnesses.

[0027] The sin signal and cos signal collected by the dual-motor control board 10 are respectively connected to the resolver simulation board card of the RTBOX real-time simulator 20 through wire harnesses;

[0028] The three-phase current signal and bus voltage signal collected by the dual-motor control board 10 are connected to the analog output board card of the RTBOX real-time simulator 20 through wire harnesses.

[0029] The CAN1 and CAN2 of the dual-motor control board 10 are connected to the RTBOX real-time simulator 20 through a DB9 wire harness.

[0030] The control signal transfer board and the drive signal transfer board play a role in signal aggregation and can be set according to needs.

[0031] The dual-motor control board 10 can control two motors simultaneously. The controller sends two sets of resolver excitation signals to the resolver simulation board of the RTBOX real-time simulator 20. After receiving the excitation signals, the resolver simulation board calculates the sin+, sin-, cos+, and cos- signals through model calculations and transmits the signals to the corresponding motor controllers through the resolver simulation board. After receiving the sin+, sin-, cos+, and cos- signals, the motor controllers can analyze them to obtain the angle and speed of the motors.

[0032] The dual-motor control board 10 collects the three-phase current Iabc and the sin and cos signals of the motor resolver in real time, and outputs the corresponding PWM signals after calculation.

[0033] The RTBOX real-time simulator 20 is configured with 2 analog input boards, 2 analog output boards, 2 digital input boards, 2 digital output boards, 2 resolver simulation boards, 2 CAN bus interfaces, and 1 Ethernet interface. The digital input channels of the digital input board can collect PWM signals and ordinary digital signals. Correspondingly, the digital output channels of the digital output board can output PWM signals and ordinary digital signals. The analog input board is used to collect analog signals, and the analog output board is used to output analog signals. CAN is used to communicate with the dual-motor control board 10; Ethernet is used to communicate with the upper computer 30.

[0034] After receiving the resolver excitation signal, the RTBOX real-time simulator 20 calculates in combination with the motor speed signal in the model and sends the sin+, sin-, cos+, and cos- signals to the controller through the resolver simulation board.

[0035] After the digital input board of the RTBOX real-time simulator 20 receives the PWM signal output by the controller, it distributes the signal to the MOSFET module in the model, calculates in combination with the model, and outputs the calculated three-phase current Iabc through the analog output board.

[0036] The core of the relay board 40 is a relay. The RTBOX real-time simulator 20 controls the relay in the relay board 40 to close through a digital output signal (DO signal), thereby realizing the power-on and power-off of the dual-motor control board 10.

[0037] The PLECS software (system-level power electronics simulation software) runs on the host computer 30. The following functions can be realized based on the PLECS software:

[0038] (1) Build a physical topology model of the dual-motor, and configure the channels of the analog input board, analog output board, digital input board, digital output board, resolver simulation board and CAN bus interface, as Figure 3 shown.

[0039] (2) Configure relevant parameters according to different motor types. The relevant parameters include motor inductance, motor permanent magnet flux linkage, motor stator resistance, number of motor pole pairs, motor moment of inertia, motor damping and spring coefficient, etc.

[0040] (3) Adjust the DC bus voltage, speed and torque in real time online.

[0041] (4) Monitor the three-phase current and PWM signals in real time online.

[0042] Compared with the existing HIL test solution, the dual-motor hardware-in-the-loop test system of the present invention can support two groups of motor controllers at the same time, so that the possible mutual interference between the software and hardware when the two groups of motor controllers work simultaneously, and the CPU load problem of the main control chip can be tested. At the same time, the torque distribution of the two motors can be tested.

[0043] Although the present invention is specifically shown and described in combination with the preferred embodiments, those skilled in the art should understand that various changes can be made to the present invention in terms of form and details without departing from the spirit and scope of the present invention defined by the appended claims, and all of them are within the protection scope of the present invention.

Claims

1. A dual-motor hardware-in-the-loop test system, characterized in that: It includes a dual-motor control board, a real-time simulator, and a host computer; The real-time simulator is an RTBOX real-time simulator, which includes an analog input board, an analog output board, a digital input board, a digital output board, a resolver simulation board, two CAN bus interfaces, and one Ethernet interface; The two sets of resolver excitation signals output by the dual-motor control board are respectively connected to the resolver simulation board of the real-time simulator through wiring harnesses; The PWM wave signals of the two sets of six-phase power switches output by the dual-motor control board are respectively connected to the digital input board of the real-time simulator through wiring harnesses; The motor sin+, sin-, cos+, and cos- signals collected by the dual-motor control board are connected to the resolver simulation board of the real-time simulator through wiring harnesses; the three-phase current signals and the bus voltage signal are connected to the analog output board of the real-time simulator through wiring harnesses; The two sets of CAN bus signals of the dual-motor control board are respectively connected to the two CAN bus interfaces of the real-time simulator through wiring harnesses; The host computer is communicatively connected to the real-time simulator through the Ethernet interface and runs system-level power electronics simulation software.

2. The dual-motor hardware-in-the-loop test system according to claim 1, wherein: It further includes a power-on control circuit; the power-on control circuit is arranged between the dual-motor control board and the power supply, is controlled by the real-time simulator, and is used to control the power-on and power-off of the dual-motor control board.

3. The dual-motor hardware-in-the-loop test system according to claim 2, characterized in that: The main device of the power-on control circuit is a relay, and the control end of the relay is connected to the digital output board of the real-time simulator.

4. The dual-motor hardware-in-the-loop test system according to claim 1, wherein: The system-level power electronics simulation software is PLECS.

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