Circuit for assisting locked-rotor current test of electric vehicle controller, circuit board and controller
By using a circuit design combining a self-locking switch and LED lights in the electric vehicle controller, the operation of switching the direction of the motor Hall stall current is simplified, improving testing efficiency and convenience.
Patent Information
- Application Number
- CN202423109665.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-17
- Publication Date
- 2025-11-14
- Estimated Expiration
- 2034-12-17
AI Technical Summary
Existing electric vehicle controllers are complex and inconvenient to switch the stall current direction by shorting the motor Hall effect sensor, requiring multiple jumpers and memory of the current direction.
The circuit design uses a combination of six self-locking switches (first switch, second switch, third switch, etc.) and LED lights. The direction of the stall current is switched by adjusting the switch state, and the direction of the current is identified by the LED lights.
It simplifies the stall current direction switching operation, improves testing efficiency, reduces memory and jumper steps, and enhances operational convenience.
Smart Images
Figure CN223553176U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electric vehicle controller technology, and in particular to a circuit, circuit board and controller for assisting in the stall current test of an electric vehicle controller. Background Technology
[0002] There are two main methods for testing motor stall current: one is to stall the motor through external loading, and the other is to stall the motor by fixing the logic state of the motor's Hall effect sensor. Stalling the motor through external loading requires a dedicated motor dynamometer, which is costly. While testing stall current by fixing the logic state of the motor's Hall effect sensor is less expensive, it requires shorting the Hall effect sensor with an external wiring harness. Furthermore, the six directions of stall current require six different jumper shorting sequences, making the current direction difficult to remember and the operation more complex. It also requires referring to a stall current phase sequence table to confirm the correctness of the stall current direction.
[0003] Therefore, there is a need for a technical solution that can improve the convenience of switching the stall current direction by shorting the motor Hall effect sensor. Utility Model Content
[0004] To solve the above-mentioned technical problems, this utility model provides a circuit, circuit board and controller for assisting in the stall current test of electric vehicle controllers.
[0005] This utility model provides a circuit for assisting in the stall current test of an electric vehicle controller, comprising: a first switch, a second switch, a third switch, a fourth switch, a fifth switch, a sixth switch, a first LED light, a second LED light, a third LED light, a fourth LED light, a fifth LED light, a sixth LED light, a first resistor, a second resistor, a third resistor, a fourth resistor, a fifth resistor, and a sixth resistor;
[0006] The first normally open pins of the first switch, the second switch, and the third switch are respectively used to electrically connect to the first phase input terminal, the second phase input terminal, and the third phase input terminal of the motor Hall effect sensor, and the first normally open pins of their respective second normally open pins are respectively electrically connected to the negative terminals of the first LED, the second LED, and the third LED.
[0007] The first normally open pins of the first terminals of the fourth, fifth, and sixth switches are respectively used to electrically connect to the first phase input terminal, the second phase input terminal, and the third phase input terminal of the motor Hall effect sensor, and the first pins of the second normally open terminals of each switch are respectively electrically connected to the negative terminals of the fourth, fifth, and sixth LED lights.
[0008] The second pins of the first normally open terminals and the second normally open terminals of the first switch, the second switch, the third switch, the fourth switch, the fifth switch, and the sixth switch are electrically grounded respectively.
[0009] The positive terminals of the first LED, the second LED, the third LED, the fourth LED, the fifth LED, and the sixth LED are respectively electrically connected to the first terminals of the first resistor, the second resistor, the third resistor, the fourth resistor, the fifth resistor, and the sixth resistor.
[0010] The second ends of the first resistor, the second resistor, the third resistor, the fourth resistor, the fifth resistor, and the sixth resistor are electrically connected to serve as a power supply terminal.
[0011] In one possible implementation, the first switch, the second switch, the third switch, the fourth switch, the fifth switch, and the sixth switch are all double-pole self-locking switches.
[0012] This utility model also provides a circuit board for assisting in the stall current test of an electric vehicle controller, including a printed circuit board and the circuit as described above;
[0013] The circuit is mounted on the printed circuit board.
[0014] In one possible implementation, the first switch, the second switch, the third switch, the fourth switch, the fifth switch, and the sixth switch are all provided with switch button caps.
[0015] In one possible implementation, the printed circuit board is printed with a first indicator line, a second indicator line, a third indicator line, a fourth indicator line, a fifth indicator line, and a sixth indicator line;
[0016] The first indicator line points from the first LED to the fourth LED;
[0017] The second indicator line points from the first LED to the sixth LED;
[0018] The third indicator line points from the second LED to the fourth LED;
[0019] The fourth indicator line points from the second LED to the fifth LED;
[0020] The fifth indicator line points from the third LED to the fifth LED;
[0021] The sixth indicator line points from the third LED to the sixth LED.
[0022] In one possible implementation, indicator characters are printed on the printed circuit board at positions adjacent to the first LED, the second LED, the third LED, the fourth LED, the fifth LED, and the sixth LED.
[0023] In one possible implementation, the printed circuit board is provided with a terminal block assembly;
[0024] The terminal block is electrically connected to the first pin of the first normally open terminal of the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the sixth switch, and the power supply terminal, respectively.
[0025] In one possible implementation, the printed circuit board has fixing holes along its edge.
[0026] This utility model also provides a controller for electric vehicles, including a controller body and a circuit board as described above;
[0027] The motor Hall effect sensor in the controller body is electrically connected to the circuit board.
[0028] The technical solution provided by this utility model has at least the following beneficial effects:
[0029] By setting up a first, second, third, fourth, fifth, and sixth switch for connecting the first, second, and third phase input terminals of the motor Hall sensor, when it is necessary to switch the direction of the stall current, simply adjust the opening and closing state of the corresponding switch to adjust the short-circuit sequence of the motor Hall sensor, without the need to rewire. Furthermore, by setting up a first, second, third, fourth, fifth, and sixth LED associated with the switch, the direction of the stall current can be directly identified by the LED lights, effectively improving the convenience of switching the stall current direction by shorting the motor Hall sensor. Attached Figure Description
[0030] Figure 1 A schematic diagram of a circuit for assisting in the stall current test of an electric vehicle controller, provided in an embodiment of this utility model;
[0031] Figure 2 A schematic diagram of the motor Hall interface in the electric vehicle controller provided in this embodiment of the utility model;
[0032] Figure 3 A detailed schematic diagram of a circuit for assisting in the stall current test of an electric vehicle controller, provided in an embodiment of this utility model;
[0033] Figure 4A schematic diagram of the circuit board for assisting in the stall current test of an electric vehicle controller, provided in an embodiment of this utility model;
[0034] Figure 5 This is a schematic diagram showing the switch button cap provided in this embodiment of the utility model installed on a switch;
[0035] Figure 6 Provided for the embodiments of this utility model Figure 4 A detailed schematic diagram of area A in the middle;
[0036] Figure 7 This is a schematic diagram of a specific test scenario provided for an embodiment of the present utility model;
[0037] In the attached diagram, 10 is a printed circuit board; 11 is a first switch; 12 is a second switch; 13 is a third switch; 14 is a fourth switch; 15 is a fifth switch; 16 is a sixth switch; 20 is a switch button cap; 21 is a first LED light; 22 is a second LED light; 23 is a third LED light; 24 is a fourth LED light; 25 is a fifth LED light; 26 is a sixth LED light; 30 is a terminal block; 40 is a mounting hole; 101 is a first indicator line; 102 is a second indicator line; 103 is a third indicator line; 104 is a fourth indicator line; 105 is a fifth indicator line; and 106 is a sixth indicator line. Detailed Implementation
[0038] To enhance understanding of this utility model, it will be described in further detail below with reference to the accompanying drawings and embodiments. These embodiments are only used to explain this utility model and do not limit the scope of protection of this utility model.
[0039] Please refer to Figures 1 to 3 The present invention provides a circuit for assisting in the stall current test of an electric vehicle controller, comprising: a first switch 11, a second switch 12, a third switch 13, a fourth switch 14, a fifth switch 15, a sixth switch 16, a first LED light 21, a second LED light 22, a third LED light 23, a fourth LED light 24, a fifth LED light 25, a sixth LED light 26, a first resistor R1, a second resistor R2, a third resistor R3, a fourth resistor R4, a fifth resistor R5, and a sixth resistor R6;
[0040] The first normally open pins of the first normally open terminals of the first switch 11, the second switch 12, and the third switch 13 are respectively used to electrically connect the first phase input terminal HALL_1, the second phase input terminal HALL_2, and the third phase input terminal HALL_3 of the motor Hall, and the first normally open pins of their respective terminals are respectively electrically connected to the negative terminals of the first LED 21, the second LED 22, and the third LED 23;
[0041] The first normally open pins of the first normally open terminals of the fourth switch 14, the fifth switch 15, and the sixth switch 16 are respectively used to electrically connect the first phase input terminal HALL_1, the second phase input terminal HALL_2, and the third phase input terminal HALL_3 of the motor Hall, and the first normally open pins of their respective terminals are respectively electrically connected to the negative terminals of the fourth LED 24, the fifth LED 25, and the sixth LED 26;
[0042] The second pins of the first normally open terminals and the second normally open terminals of the first switch 11, the second switch 12, the third switch 13, the fourth switch 14, the fifth switch 15, and the sixth switch 16 are electrically grounded respectively.
[0043] The positive terminals of the first LED 21, the second LED 22, the third LED 23, the fourth LED 24, the fifth LED 25, and the sixth LED 26 are respectively electrically connected to the first terminals of the first resistor R1, the second resistor R2, the third resistor R3, the fourth resistor R4, the fifth resistor R5, and the sixth resistor R6.
[0044] The second terminals of the first resistor R1, the second resistor R2, the third resistor R3, the fourth resistor R4, the fifth resistor R5, and the sixth resistor R6 are electrically connected to serve as a power supply terminal.
[0045] In this embodiment, the motor Hall effect sensor can be understood as a motor Hall effect interface. The first switch 11, second switch 12, third switch 13, fourth switch 14, fifth switch 15, and sixth switch 16 can be conventional double-pole self-locking switches. The first normally open pin and the second pin of the first normally open terminal of each switch are normally open, and the first normally open pin and the second pin of the second normally open terminal are connected when the switch button is pressed. The second pin of the first normally open terminal and the second normally open terminal of each of the first switches 11, second switches 12, third switches 13, fourth switches 14, fifth switches 15, and sixth switches 16 can be grounded separately, or they can be connected together and then grounded. The first LED 21, second LED 22, third LED 23, fourth LED 24, fifth LED 25, and sixth LED 26 are all conventional LEDs and can be red or any other color, selected according to actual needs. The states of LEDs 21, 22, 23, 24, 25, and 26 are correlated with the states of switches 11, 12, 13, 14, 15, and 16, making the stall current test more intuitive. Resistors R1, R2, R3, R4, R5, and R6 are standard resistors used for current limiting; their resistance can be 2kΩ. The first phase input (HALL_1), second phase input (HALL_2), and third phase input (HALL_3) of the motor Hall sensor can be in any order of the U, V, and W phases, determined according to actual needs. A 5V power supply can be connected to drive LEDs 21, 22, 23, 24, 25, and 26. The direction of the stall current and the corresponding high and low levels of U, V, and W in the motor Hall effect sensor can be determined using the Hall logic table, which can be determined based on the actual control logic.
[0046] In one specific implementation, the Hall logic table is referenced in Table 1. When the U-phase input of the motor Hall sensor is high, the V-phase input is low, and the W-phase input is low, the controller controls the stall current direction as follows: outflow from the U-phase and inflow from the V-phase. (This is repeated three times in the original text.) When the U-phase input and V-phase input of the motor Hall sensor are low, and the W-phase input is high, the controller controls the stall current direction as follows: outflow from the W-phase and inflow from the U-phase. Conversely, when the U-phase input is high, the V-phase input is low, and the W-phase input is high, the controller controls the stall current direction as follows: outflow from the W-phase and inflow from the V-phase. The correspondence in the Hall logic table is specifically implemented by the electric vehicle's controller.
[0047] Table 1:
[0048]
[0049] For a detailed schematic diagram of the circuit used to assist in the stall current test of the electric vehicle controller, which corresponds to Table 1, please refer to Table 1. Figure 2 and Figure 3The first phase input terminal HALL_1 of the motor Hall sensor is set to the W-phase input terminal HALL_W, the second phase input terminal HALL_2 is set to the U-phase input terminal HALL_U, and the third phase input terminal HALL_3 is set to the V-phase input terminal HALL_V. The first LED 21 can be represented by LED_U1, the second LED 22 by LED_V1, the third LED 23 by LED_W1, the fourth LED 24 by LED_W2, the fifth LED 25 by LED_U2, and the sixth LED 26 by LED_V2. The first switch 11 can be represented by U1, serving as a U-phase current output button to control the stall current flow from the U-phase of the motor. The second switch 12 can be represented by V1, serving as a V-phase current output button to control the stall current flow from the V-phase of the motor. The third switch 13 can be represented by W1, serving as a W-phase current output button to control the stall current flow from the W-phase of the motor. The fourth switch 14, represented by W2, acts as a W-phase current input button, controlling the flow of stall current to the W phase of the motor. The fifth switch 15, represented by U2, acts as a U-phase current input button, controlling the flow of stall current to the U phase of the motor. The sixth switch 16, represented by V2, acts as a V-phase current input button, controlling the flow of stall current to the V phase of the motor.
[0050] In practical implementation: the internal control logic of the electric vehicle controller, i.e., the motor controller, is set according to the Hall logic table in Table 1. (Reference) Figure 3 and Figure 7 , Figure 7 The stall current testing tool can be understood as a circuit used to assist in testing the stall current of an electric vehicle controller. When it is necessary to control the stall current direction to flow out of the U phase and into the V phase of the motor, pressing switches U1 and V2 will illuminate LEDs LED_U1 and LED_V2. At this time, the motor Hall effect sensor's U-phase input HALL_U is high, the V-phase input HALL_V is low, and the W-phase input HALL_W is low. The motor controller can then control the stall current direction according to the Hall effect logic table, ensuring it flows out of the U phase and into the V phase. The stall current direction can be switched using the switches, and the LED status can be used to determine if the correct stall current direction is achieved. Stall current tests in all six directions can be performed using a similar method, effectively improving testing efficiency.
[0051] In one possible implementation, the first switch 11, the second switch 12, the third switch 13, the fourth switch 14, the fifth switch 15, and the sixth switch 16 are all double-pole self-locking switches.
[0052] This application uses six self-locking switches instead of external wiring harnesses, and the stall current in six different directions can be tested by pressing a button, simplifying the operation steps for testing stall current.
[0053] Please refer to Figures 4 to 6 The present invention also provides a circuit board for assisting in the stall current test of an electric vehicle controller, comprising a printed circuit board 10 and the circuit described above.
[0054] The circuit is disposed on the printed circuit board 10.
[0055] In this embodiment, the printed circuit board 10 can be a conventional PCB board.
[0056] In one possible implementation, the first switch 11, the second switch 12, the third switch 13, the fourth switch 14, the fifth switch 15, and the sixth switch 16 are all provided with switch button caps 20.
[0057] In this embodiment, the switch button cap 20 can adopt a conventional design, specifically made of silicone material.
[0058] In one possible implementation, refer to Figure 4 and Figure 6 The printed circuit board 10 is printed with a first indicator line 101, a second indicator line 102, a third indicator line 103, a fourth indicator line 104, a fifth indicator line 105, and a sixth indicator line 106.
[0059] The first indicator line 101 points from the first LED light 21 to the fourth LED light 24;
[0060] The second indicator line 102 points from the first LED light 21 to the sixth LED light 26;
[0061] The third indicator line 103 points from the second LED light 22 to the fourth LED light 24;
[0062] The fourth indicator line 104 points from the second LED light 22 to the fifth LED light 25;
[0063] The fifth indicator line 105 points from the third LED light 23 to the fifth LED light 25;
[0064] The sixth indicator line 106 points from the third LED 23 to the sixth LED 26.
[0065] In this embodiment, the first indicator line 101, the second indicator line 102, the third indicator line 103, the fourth indicator line 104, the fifth indicator line 105, and the sixth indicator line 106 are conventional printed lines that can be used to indicate the specific direction of the stall current, making it easier for testers to observe more intuitively.
[0066] In one possible implementation, indicator characters are printed on the printed circuit board 10 at positions adjacent to the first LED 21, the second LED 22, the third LED 23, the fourth LED 24, the fifth LED 25, and the sixth LED 26, respectively.
[0067] In this embodiment, the indicator characters can correspond to the direction of the locked-rotor current. For example, when using the Hall logic table in Table 1, the indicator character "U" can be printed near the first LED 21, "V" near the second LED 22, "W" near the third LED 23, "W" near the fourth LED 24, "U" near the fifth LED 25, and "V" near the sixth LED 26. This allows for direct determination of the inflow and outflow direction of the locked-rotor current controlled by a specific switch through the indicator characters, effectively improving operational convenience.
[0068] In one possible implementation, the printed circuit board 10 is provided with a terminal block 30;
[0069] The terminal block 30 is electrically connected to the first normally open pin of the first switch 11, the second switch 12, the third switch 13, the fourth switch 14, the fifth switch 15, the sixth switch 16, and the power supply terminal, respectively.
[0070] In this embodiment, the terminal block group 30 can adopt a conventional design, which can be a combination of multiple independent terminals or an integrated structure, depending on the actual implementation needs.
[0071] In one possible implementation, the edge of the printed circuit board 10 is provided with a fixing hole 40.
[0072] In this embodiment, the fixing hole 40 can be used to fix the printed circuit board 10, thereby providing a stable testing environment.
[0073] This utility model also provides a controller for electric vehicles, including a controller body and a circuit board as described above;
[0074] The motor Hall effect sensor in the controller body is electrically connected to the circuit board.
[0075] In this embodiment, the motor Hall effect sensor can be understood as a motor Hall effect interface. By combining the circuit board used to assist in the stall current test of the electric vehicle controller with the controller body, the stall current test efficiency can be effectively improved when performing stall current tests in six directions by fixing the logic state of the motor Hall effect sensor.
[0076] The above embodiments should not limit the present invention in any way. All technical solutions obtained by equivalent substitution or equivalent conversion fall within the protection scope of the present invention.
Claims
1. A circuit for assisting in the stall current test of an electric vehicle controller, characterized in that, include: First switch, second switch, third switch, fourth switch, fifth switch, sixth switch, first LED light, second LED light, third LED light, fourth LED light, fifth LED light, sixth LED light, first resistor, second resistor, third resistor, fourth resistor, fifth resistor, sixth resistor; The first normally open pins of the first switch, the second switch, and the third switch are respectively used to electrically connect to the first phase input terminal, the second phase input terminal, and the third phase input terminal of the motor Hall effect sensor, and the first normally open pins of their respective second normally open pins are respectively electrically connected to the negative terminals of the first LED, the second LED, and the third LED. The first normally open pins of the first terminals of the fourth, fifth, and sixth switches are respectively used to electrically connect to the first phase input terminal, the second phase input terminal, and the third phase input terminal of the motor Hall effect sensor, and the first pins of the second normally open terminals of each switch are respectively electrically connected to the negative terminals of the fourth, fifth, and sixth LED lights. The second pins of the first normally open terminals and the second normally open terminals of the first switch, the second switch, the third switch, the fourth switch, the fifth switch, and the sixth switch are electrically grounded respectively. The positive terminals of the first LED, the second LED, the third LED, the fourth LED, the fifth LED, and the sixth LED are respectively electrically connected to the first terminals of the first resistor, the second resistor, the third resistor, the fourth resistor, the fifth resistor, and the sixth resistor. The second ends of the first resistor, the second resistor, the third resistor, the fourth resistor, the fifth resistor, and the sixth resistor are electrically connected to serve as a power supply terminal.
2. The circuit according to claim 1, characterized in that, The first switch, the second switch, the third switch, the fourth switch, the fifth switch, and the sixth switch are all double-pole self-locking switches.
3. A circuit board for assisting in the stall current test of an electric vehicle controller, characterized in that, Includes a printed circuit board and the circuitry as described in claim 1 or 2; The circuit is mounted on the printed circuit board.
4. The circuit board according to claim 3, characterized in that, The first switch, the second switch, the third switch, the fourth switch, the fifth switch, and the sixth switch are all equipped with switch button caps.
5. The circuit board according to claim 3, characterized in that, The printed circuit board is printed with a first indicator line, a second indicator line, a third indicator line, a fourth indicator line, a fifth indicator line, and a sixth indicator line; The first indicator line points from the first LED to the fourth LED; The second indicator line points from the first LED to the sixth LED; The third indicator line points from the second LED to the fourth LED; The fourth indicator line points from the second LED to the fifth LED; The fifth indicator line points from the third LED to the fifth LED; The sixth indicator line points from the third LED to the sixth LED.
6. The circuit board according to claim 3, characterized in that, Indicator characters are printed on the printed circuit board at positions adjacent to the first LED, the second LED, the third LED, the fourth LED, the fifth LED, and the sixth LED.
7. The circuit board according to claim 3, characterized in that, The printed circuit board is provided with a terminal block assembly; The terminal block is electrically connected to the first pin of the first normally open terminal of the first switch, the second switch, the third switch, the fourth switch, the fifth switch, the sixth switch, and the power supply terminal, respectively.
8. The circuit board according to claim 3, characterized in that, The printed circuit board has fixing holes along its edge.
9. A controller for an electric vehicle, characterized in that, Includes the controller body and the circuit board as described in any one of claims 3 to 7; The motor Hall effect sensor in the controller body is electrically connected to the circuit board.