High-temperature test device for high-speed rotor of new energy automobile with hybrid power and pure electric power systems

Abstract

A high-temperature test device for a high-speed rotor of a new energy automobile with a hybrid power and pure electric power system adopts a high-power heat gun to heat the high-speed rotor, an infrared non-contact temperature sensor collects the temperature of the high-temperature rotor, and the temperature sensor feeds back the temperature to a rack upper computer system. And the upper computer system of the rack controls the heating power of the hot air gun, so that the temperature of the rotor is maintained in a target temperature range (140-180 DEG C). According to the utility model, temperature control does not need to depend on a high-power environment chamber (40kW), heating is convenient, and energy is saved; rotor temperature measurement is accurate, dynamic closed-loop accurate temperature control is formed, and a prototype is more convenient to install.

Description

Technical Field

[0001] The utility model relates to a test device for a high-speed rotor of a new energy vehicle, and in particular to a high-temperature test device for a high-speed rotor of a new energy vehicle with a hybrid power system or a pure electric power system. Background Art

[0002] The high temperature tests for new vehicles include engine flameout protection, engine matching test, common rail oil pressure system and temperature test, ECU and sensor temperature test, and vehicle quality test under high temperature environment.

[0003] High temperature test

[0004] Automotive parts are susceptible to thermal expansion, deformation, and aging in high-temperature environments. Therefore, high-temperature testing is an important means of verifying the performance and stability of parts in these conditions. By simulating high-temperature environments, we can test the heat resistance and thermal endurance of parts, as well as the high-temperature stability of materials.

[0005] Before mass production of high-speed motors for new energy vehicles begins, rotor reliability verification is crucial. Because motors operate at high speeds, subject to high temperatures, high power, and rapid acceleration and deceleration, rotor deformation and reliability verification are crucial. Rotor quality issues must be identified promptly.

[0006] Typically, rotor temperature is controlled by heating the rotor to 150°C in a high-temperature environmental chamber for at least two hours to achieve complete heat transfer and equilibrium. The chamber's hot air temperature then replaces the rotor surface temperature. The rotor bearings are cooled through cooling channels in the tooling, maintaining the bearing temperature below 100°C. This prevents the bearing grease from failing due to high temperatures, thereby controlling the high-speed rotor's temperature range.

[0007] However, the current high-speed rotor high-temperature test equipment for hybrid system new energy vehicles has the following disadvantages:

[0008] The rotor temperature cannot be measured directly and will deviate. The rotor temperature cannot be read directly and can only be used as a proxy for the hot air temperature in the environmental chamber.

[0009] The environmental chamber is used to heat the air and maintain the rotor temperature at 150°C, which consumes a lot of energy.

[0010] The temperature range of the existing environmental chamber is -50℃-160℃, which cannot meet the 180℃ rotor high temperature test requirements.

[0011] The reliance on environmental chamber temperature control limits the number of rotor test laboratories, and only laboratories with environmental chambers can meet this type of test. Utility Model Content

[0012] To overcome these issues, this utility model aims to provide a high-temperature test device for high-speed rotors in hybrid and pure electric powertrain new energy vehicles. This device heats the high-speed rotor using a high-power heat gun. A non-contact infrared temperature sensor collects the high-temperature rotor temperature. The temperature sensor then feeds back to the test bench's host computer system, which controls the heat gun's heating power. The heat gun utilizes PID (proportional, integral, and differential) technology for high-precision control of heating power, maintaining the rotor temperature within the target range of 140°-180°C with a control accuracy of ±2°C.

[0013] The technical solution of the utility model is as follows:

[0014] A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles, characterized in that:

[0015] The device comprises:

[0016] High temperature test bench;

[0017] A high-speed drive motor and a high-speed bearing box for driving the rotor to rotate at high speed;

[0018] A rotor dummy housing is provided on the test side of the high-temperature test bench and is used to install the high-speed rotor. The high-speed rotor is supported by high-temperature resistant ball bearings at both ends of the dummy housing;

[0019] A high-power hot air gun installed under the rotor false housing for heating the high-speed rotor;

[0020] Infrared non-contact temperature sensors are installed on both sides of the rotor to collect the temperature of the high-speed rotor;

[0021] A water-cooled cooling channel located adjacent to and fixed to the ball bearing base (bearing support frame) is used to control the surface temperature of the (ball bearing base) bearing support frame to within 100°C by cooling water in the cooling channel, thereby maintaining the rotor temperature within the target temperature range; and

[0022] Telecommunications connects and controls the bench host computer control system that operates the heat drying gun, high-speed motor, infrared temperature sensor and water cooler.

[0023] Under the above conditions, the rotor can be subjected to various operating conditions such as high speed, rapid acceleration and deceleration, to detect whether the rotor has deformation, cracking and quality abnormalities, and to perform high-temperature tests on the high-speed rotors of hybrid and pure electric power system new energy vehicles.

[0024] According to the high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles described in the utility model, it is characterized in that:

[0025] On both horizontal radial sides of the rotor, a FULK high-temperature resistant non-contact temperature sensor is installed at the three o'clock and nine o'clock directions of the false shell.

[0026] The high-speed rotor temperature is collected by an infrared non-contact temperature sensor and fed back to the bench host computer system. The bench host computer system controls the heating power of the hot air gun to maintain the rotor temperature within the target temperature range.

[0027] According to the high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles of the utility model, it is characterized in that:

[0028] The heating power of high-power hot air gun is 1000w-7200w.

[0029] According to the high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles described in the utility model, it is characterized in that:

[0030] The rotor false shell for installing the high-speed rotor is a non-standard customized annular rotor false shell. Glass fiber insulation cotton is provided on the outside of the false shell. The rotor is supported by ball bearings of high-temperature resistant bearings at both ends of the false shell. The bearing support surface is cooled by the cooling water channel of the water cooler.

[0031] According to the high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles described in the utility model, it is characterized in that:

[0032] At both ends of the false shell, namely the front and rear high temperature resistant ball bearings, cooling water channels (water tanks) of a water cooler are respectively arranged close to and fixed on the ball bearing base, and the cooling water channels (water tanks) are in contact with the bearing brackets.

[0033] According to the high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles described in the utility model, it is characterized in that:

[0034] The probe of the infrared non-contact temperature sensor used to collect the high-speed rotor temperature is 30-40mm away from the high-speed rotating rotor, and the rotor surface temperature is measured. The measured rotor temperature is fed back to the test bench host computer control system, and the test bench host computer control system controls the hot air gun. When the rotor temperature is lower than the rotor target temperature, the hot air gun heats the rotor; when the rotor temperature is higher than the target temperature, the hot air gun stops heating, thereby forming a closed-loop temperature control.

[0035] According to the high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles described in the utility model, it is characterized in that:

[0036] The structure of the non-standard customized rotor false housing is as follows:

[0037] A heating port of a heat drying gun is arranged directly below the false shell, non-contact temperature sensor collection ports are arranged on both sides in the radial and horizontal directions, and an exhaust hole is arranged directly above.

[0038] According to the high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles described in the utility model, it is characterized in that:

[0039] The high-speed drive motor drives the rotor to run at high speed through a high-speed bearing box. The high-speed drive motor and the high-speed bearing box are connected through a diaphragm coupling, and the high-speed bearing box and the speed rotor are connected through a spline shaft.

[0040] This protects the motor from damage.

[0041] The advantages of this utility model are as follows:

[0042] Flexible and energy-saving heating method: The rotor is directly heated by a high-temperature resistant heat drying gun, without relying on a high-power environmental chamber (40kW) for temperature control, which is energy-saving and flexible.

[0043] More accurate rotor temperature measurement: The rotor temperature is directly measured using a high-temperature resistant infrared non-contact temperature sensor.

[0044] The rotor temperature control is more precise: the temperature of the infrared temperature sensor is transmitted to the test bench host computer and fed back to the hot air gun heating control, forming a dynamic closed-loop temperature control.

[0045] The test prototype is easy and efficient to install: without the interference of the environmental chamber, the prototype installation is more convenient. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 Schematic diagram of the prior art.

[0047] Figure 2 This is a front view of the test side of the high-temperature test device of the present invention.

[0048] Figure 3 for Figure 2 AA cross-sectional view of the high-temperature testing device of the present invention.

[0049] Figure 4 for Figure 2 An enlarged view of the CC portion of the high-temperature test device of the present invention.

[0050] Figure 5 This is a schematic diagram of the installation of a high-temperature test device of the present invention, in which the rear bearing and its bracket are in contact with the cooling water channel (water tank) near the test bench after the rotor is removed from the test side, forming an independent rear bearing circulation cooling circuit.

[0051] Figure 6This is a schematic diagram of the installation of a high-temperature test device of the present invention, in which the front bearing and its bracket are in contact with the cooling water channel (water tank) on the far side of the test bench after the rotor is removed from the test side, forming an independent front bearing circulation cooling circuit.

[0052] Figure 7 This is a front view schematic diagram of a test side of a high-temperature test device of the present invention.

[0053] Figure 8 for Figure 7 AA section view.

[0054] Figure 9 This is a top view of the test side of the high-temperature test device of the present invention.

[0055] Figure 10 for Figure 9 BB cross-section.

[0056] In the figure, 1 is a high-power hot air gun, 2 is a support leg, 4 is an annular cooling water channel, 5 is a ball bearing, 6 is a high-speed rotor, 7 is a false shell, 8 is a high-speed bearing box, 9 is a high-speed drive motor, 10 is a test bench, 13 is an infrared non-contact temperature sensor, and 16 is an exhaust hole. DETAILED DESCRIPTION

[0057] Example

[0058] High-temperature tests are conducted on high-speed rotors of new energy vehicles using a high-temperature test bench. The high-temperature test bench is equipped with: a high-power hot air gun for heating the high-speed rotor, an infrared non-contact temperature sensor for collecting the temperature of the high-temperature rotor, a test bench host computer control system that connects and controls the hot air gun, high-speed motor, infrared temperature sensor and water cooler operation, a cooling water channel fixedly installed on the base of the ball bearing 5 for controlling the bearing temperature, a rotor false shell for installing the rotor and high-temperature resistant bearing supports at both ends.

[0059] Among them, the core components of the new energy vehicle high-speed motor rotor test equipment include:

[0060]

[0061] During the high temperature test, use a high temperature hot air gun, aim it at the air inlet of the rotor false shell, and pass hot air at about 600℃ to heat the rotor;

[0062] The high-speed rotor temperature is collected by infrared non-contact temperature sensor.

[0063] According to the temperature sensor feedback from the bench host computer system, the bench host computer system controls the heating power of the hot air gun to be controlled within 3600w-7200w, so that the rotor temperature is maintained within the target temperature range.

[0064] According to the present invention, the target range of the rotor temperature is 140°-180°, and the control accuracy is ±2°C.

[0065] The hot air gun uses PID (proportional, integral and differential) technology to control the heating power with high precision.

[0066] To maintain the rotor temperature within the target range, the high-speed rotor bearing temperature is controlled as follows:

[0067] Cooling water is passed through the cooling water channel on the mounting base of the ball bearing. The temperature of the high-temperature bearing is exchanged with the cooling water in the cooling water channel, and the bearing temperature is controlled within 100°C to prevent the high-speed bearing grease from failing due to overheating of the bearing temperature.

[0068] Furthermore, to maintain the rotor temperature within the target range, the rotor is installed in a custom-made rotor dummy housing, which is insulated with fiberglass. The rotor is supported by high-temperature resistant ball bearings at both ends of the dummy housing. The bearing support surfaces are cooled by water from a water chiller. At each end of the dummy housing, the front and rear high-temperature resistant ball bearings are fitted with cooling channels or tanks secured to the ball bearing bases. These channels or tanks are in contact with the bearing brackets.

[0069] like Figure 5-10 As shown, in this embodiment, the cooling water for circulating and cooling the front and rear high-temperature-resistant ball bearing bases can form independent cooling circuits through the cooling water channels. That is, the front high-temperature-resistant ball bearing base has its own independent cooling water channel located on the front side of the dummy housing, which circulates through the water inlet, water reservoir, and water outlet for cooling, while the rear bearing base has its own independent cooling water channel located on the rear side of the dummy housing, which circulates through the water inlet, water reservoir, and water outlet for cooling. This improves cooling efficiency.

[0070] like Figure 5-10 As shown, in this embodiment, the water outlet and water inlet directions of the cooling water circuit for circulating and cooling the front and rear high-temperature resistant ball bearing bases form an angle of about 90°.

[0071] On the two front sides of the rotor test side, a FULK high-temperature resistant non-contact temperature sensor is installed at the three o'clock and nine o'clock positions of the dummy housing respectively;

[0072] The temperature sensor probe is 30-40mm away from the high-speed rotating rotor, measuring the rotor surface temperature. The measured rotor temperature is fed back to the hot air gun. When the rotor temperature is lower than the rotor target temperature, the hot air gun heats the rotor; when the rotor temperature is higher than the target temperature, the hot air gun stops heating, thereby forming a closed-loop temperature control to maintain the rotor temperature.

[0073] The heat gun 1 heats the rotor directly below the dummy housing. High-temperature air flows through the dummy housing's inner cavity and out the top, causing high temperatures at the air outlet directly above the dummy housing. This makes it difficult to install an infrared temperature sensor (the infrared temperature sensor itself has poor heat resistance; the sensor itself has a temperature resistance of 180°C). The airflow at the three and nine o'clock positions is low, and the high-temperature hot air dissipates upward, resulting in lower temperatures at horizontal outlets. Therefore, holes are opened at the three and nine o'clock positions to install a FULK high-temperature, non-contact temperature sensor.

[0074] The temperature sensor probe is 30-40mm away from the high-speed rotating rotor. The temperature sensor emits infrared rays, which are irradiated on the high-speed rotor and then reflected on the temperature sensor probe. The sensor outputs 4-20mA current to the host computer system, which is converted into the measured temperature value.

[0075] High-temperature test: The rotor is raised from a specified speed (2000 rpm) to a specified target speed (e.g., 19200 rpm) at a specified acceleration rate (e.g., 1700 rpm / min). After stabilizing at the highest speed (e.g., 1 second), the speed is then lowered from the highest speed to the lowest speed (2000 rpm) at a specified acceleration rate (e.g., 1700 rpm / min). The speed is then stabilized at the lowest speed (e.g., 1 second). This cycle is repeated 5000 times. After the test, the rotor is inspected for deformation, cracking, or other quality abnormalities.

[0076] According to the utility model, there is no need to rely on a high-power environmental chamber (40kW) for temperature control, heating is convenient and energy-saving; the rotor temperature is accurately measured, forming a dynamic closed-loop temperature precise control, and the prototype installation is more convenient.

Claims

1. A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles, characterized in that: The device comprises: High temperature test bench; A high-speed drive motor and a high-speed bearing box for driving the rotor to rotate at high speed; A rotor dummy housing is provided on the test side of the high-temperature test bench and is used to install the high-speed rotor. The high-speed rotor is supported by high-temperature resistant ball bearings at both ends of the dummy housing; A high-power hot air gun installed under the rotor false housing for heating the high-speed rotor; Infrared non-contact temperature sensors are installed on both sides of the rotor to collect the temperature of the high-speed rotor; A cooling water channel of a water-cooled machine, which is adjacent to and fixed to the ball bearing base, is used to cool the ball bearing base by cooling water in the cooling water channel, thereby controlling the temperature of the ball bearing base to be within 100°C, thereby maintaining the rotor temperature within the target temperature range; and Telecommunications connects and controls the bench host computer control system that operates the heat drying gun, high-speed motor, infrared temperature sensor and water cooler.

2. A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles as claimed in claim 1, characterized in that: On both sides of the rotor horizontal radial direction, a FULK high temperature resistant non-contact temperature sensor is installed at the three o'clock and nine o'clock directions of the false shell. The high-speed rotor temperature is collected by an infrared non-contact temperature sensor and fed back to the bench host computer system. The bench host computer system controls the heating power of the hot air gun to maintain the rotor temperature within the target temperature range.

3. The high-temperature test device for high-speed rotors of hybrid and pure electric power system new energy vehicles according to claim 1 or 2, characterized in that: The heating power of high-power hot air gun is 1000w-7200w.

4. A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles as claimed in claim 1, characterized in that: The rotor false shell for installing the high-speed rotor is a non-standard customized annular rotor false shell. Glass fiber insulation cotton is provided on the outside of the false shell. The rotor is supported by ball bearings of high-temperature resistant bearings at both ends of the false shell. The bearing support surface is cooled by the cooling water channel of the water cooler.

5. A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles as claimed in claim 4, characterized in that: Both ends of the false shell, namely the front and rear high temperature resistant ball bearings, are respectively provided with cooling water channels of a water cooler, namely water tanks, which are close to and fixed on the ball bearing base, and the cooling water channels are in contact with the bearing brackets.

6. A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles as claimed in claim 5, characterized in that: Through the cooling water channel, the cooling water for circulating and cooling the front and rear high-temperature resistant ball bearing bases can form independent circulating cooling loops.

7. A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles as claimed in claim 1, characterized in that: The probe of the infrared non-contact temperature sensor used to collect the high-speed rotor temperature is 30-40mm away from the high-speed rotating rotor, and the rotor surface temperature is measured. The measured rotor temperature is fed back to the test bench host computer control system, and the test bench host computer control system controls the hot air gun. When the rotor temperature is lower than the rotor target temperature, the hot air gun heats the rotor; when the rotor temperature is higher than the target temperature, the hot air gun stops heating, thereby forming a closed-loop temperature control.

8. A high-temperature test device for high-speed rotors of hybrid and pure electric power systems of new energy vehicles as claimed in claim 1, characterized in that: A heating port of a heat drying gun is arranged directly below the false shell, non-contact temperature sensor collection ports are arranged on both sides in the radial and horizontal directions, and an exhaust hole is arranged directly above.

9. A high-temperature test device for high-speed rotors of hybrid and pure electric power system new energy vehicles as claimed in claim 1, It is characterized by: The rotor is driven to run at high speed through a high-speed bearing box. The high-speed driving motor is connected to the high-speed bearing box through a diaphragm coupling, and the high-speed bearing box is connected to the speed rotor through a spline shaft.

Images