Testing device for rotary transformer protection function of motor controller of electric vehicle

Abstract

The utility model discloses an electric automobile motor controller rotary transformer protection function testing device, which comprises a control panel, a first adapter connector and a second adapter connector. The first adapter connector and the second adapter connector are connected to a control panel through a rotary transformer wire harness. The resolver wire harness comprises an excitation wire positive EXC +, an excitation wire negative EXC-, a sine wire positive SIN +, a sine wire negative SIN-, a cosine wire positive COS + and a cosine wire negative COS-which are respectively connected to corresponding contacts of the control board; the control panel is provided with contacts used for connecting the two resolver wire harnesses and switches used for controlling short circuit between the contacts of the resolver signal wire. According to the utility model, original matching resolver lines of the driving motor and the motor control are supplemented and optimized, so that the fault protection function of the motor control resolver can be tested and verified without damaging the original wiring harness in the actual application scene, and the authenticity and the safety of the original test result are improved.

Description

Technical Field

[0001] The utility model relates to the field of new energy vehicles, and in particular to a device for testing the rotary transformer protection function of an electric vehicle motor controller. Background Art

[0002] New energy vehicles are developing rapidly. With their increasing market penetration year by year, people are paying more attention to the safety of electric vehicle operation. As the primary source of power for the vehicle, the drive system, consisting of the drive motor and motor controller, plays a crucial role in ensuring the vehicle's proper operation. Its reliability and stability are crucial to the vehicle's operation.

[0003] The reliability of the rotor position signal collected by the resolver significantly impacts motor control stability. During actual vehicle operation, resolver line shorts or breaks can occur due to aging or poor connections, triggering the controller's resolver fault protection.

[0004] Currently, resolver protection testing typically uses hardware-in-the-loop (HIL) testing, with both motor loads and power devices simulated. This environment ignores the interference caused by factors like high voltage and high current, resulting in significant discrepancies between the high voltage and high current scenarios of actual drive systems, potentially leading to overly ideal test results. Furthermore, some tests using actual motor loads require damaging the original wiring harness, posing safety risks. Summary of the Invention

[0005] In order to avoid the existing defects of existing testing schemes, the utility model provides an electric vehicle motor controller resolver protection function test device, which is used to solve the problem of result differences caused by the large difference between the previous test environment and the actual application environment, as well as the safety hazards caused by damage to the original supporting wiring harness during actual load environment testing.

[0006] The technical solution adopted by this utility model is:

[0007] A device for testing the resolver protection function of an electric vehicle motor controller includes a control board, a first adapter plug-in, and a second adapter plug-in; the first adapter plug-in and the second adapter plug-in are connected to the control board via a resolver wiring harness;

[0008] The resolver wiring harness includes an excitation line positive EXC+, an excitation line negative EXC-, a sine line positive SIN+, a sine line negative SIN-, a cosine line positive COS+ and a cosine line negative COS-, which are respectively connected to corresponding contacts on the control board;

[0009] The control board is respectively provided with switches for connecting the positive excitation line EXC+, the negative excitation line EXC-, the positive sine line SIN+, the negative sine line SIN-, the positive cosine line COS+ and the negative cosine line COS- contacts of the two resolver wiring harnesses and controlling the short circuit between the contacts of the resolver signal lines.

[0010] Furthermore, each signal line on one side of the adapter plug of the resolver wiring harness is affixed with a label with the corresponding line number and definition.

[0011] The beneficial effects of the present invention are as follows: by supplementing and optimizing the original supporting resolver lines of the drive motor and motor control, the resolver fault protection function of the motor control can be tested and verified in actual application scenarios without destroying the original wiring harness, thereby improving the authenticity and safety of the original test results; the control board used can simulate the open circuit and short circuit conditions of different resolver signal lines during the test, making the setting of the test scene more diverse and convenient. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 This is the overall test environment diagram of the utility model;

[0013] Figure 2 This is a schematic diagram of the test device of the present utility model;

[0014] Figure 3 This is a schematic diagram of a control panel of a test device of the present invention;

[0015] In the figure: 1-control board, 2-first adapter plug-in, 3-second adapter plug-in, 4-label, 5-resolver wiring harness, 6-motor controller, 7-drive motor. DETAILED DESCRIPTION

[0016] The present invention will be further described below with reference to the accompanying drawings.

[0017] like Figure 1 and Figure 2As shown, the utility model is a resolver protection function test device for an electric vehicle motor controller, comprising a control board 1, a first adapter plug-in 2, and a second adapter plug-in 3; the first adapter plug-in 2 and the second adapter plug-in 3 are connected to the control board 1 via a resolver wiring harness 5; the resolver wiring harness 5 includes six signal lines, namely, an excitation line positive EXC+, an excitation line negative EXC-, a sine line positive SIN+, a sine line negative SIN-, a cosine line positive COS+, and a cosine line negative COS-, which are respectively connected to corresponding contacts on the control board 1. The control board 1 is equipped with switches for connecting the excitation line (EXC+), excitation line (EXC-), sine line (SIN+), sine line (SIN-), cosine line (COS+), and cosine line (COS-) of the two resolver wiring harnesses 5, as well as switches for controlling the disconnection between the resolver signal line contacts. These switches can independently disconnect the EXC+, EXC-, SIN+, SIN-, COS+, and COS- signals, allowing testing of the motor controller's response to resolver signal line disconnection or poor contact. Each signal line in the resolver wiring harness 5 is labeled 4 with the corresponding line number and definition on the adapter plug side.

[0018] like Figure 3 As shown, the method of using the present invention is as follows: during testing, the first adapter plug-in 2 and the second adapter plug-in 3 at both ends of the test device are respectively plugged into the resolver line plugs of the motor controller 6 and the drive motor 7 to achieve communication with the resolver signal at the motor controller end and the resolver signal at the drive motor end.

Claims

1. A device for testing the resolver protection function of an electric vehicle motor controller, characterized in that: The invention comprises a control board, a first adapter plug-in and a second adapter plug-in; the first adapter plug-in and the second adapter plug-in are connected to the control board through a resolver wiring harness; The resolver wiring harness includes an excitation line positive EXC+, an excitation line negative EXC-, a sine line positive SIN+, a sine line negative SIN-, a cosine line positive COS+ and a cosine line negative COS-, which are respectively connected to corresponding contacts on the control board; The control board is respectively provided with switches for connecting the positive excitation line EXC+, the negative excitation line EXC-, the positive sine line SIN+, the negative sine line SIN-, the positive cosine line COS+ and the negative cosine line COS- contacts of the two resolver wiring harnesses and controlling the short circuit between the contacts of the resolver signal lines.

2. The electric vehicle motor controller resolver protection function test device according to claim 1, characterized in that: Each signal line on one side of the adapter plug of the resolver wiring harness is affixed with a label with the corresponding line number and definition.

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