Multi-channel load testing device for vehicle control unit of electric vehicle

Abstract

The utility model provides a multi-channel load testing device for a vehicle control unit of an electric vehicle. The multi-channel load testing device comprises a main control module, and a power supply conversion module, a communication module and a load resistance switching module which are connected with the main control module, the power supply conversion module is connected with a power supply so as to provide power supply, and the communication module is in communication connection with an upper computer; the load resistance switching module comprises a relay control circuit with a multi-channel mode and a current detection circuit, the relay control circuit of each channel is connected with the corresponding current detection circuit, and the relay control circuit is connected with a tested controller so as to perform a simulation test on the tested controller. Compared with a traditional load box, the load box has the advantages of being small in size and high in adaptability, load channels can be expanded infinitely in a cascading mode, and the load requirement of a controller VCU or similar products during complex working condition simulation testing is met.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of vehicle control unit testing, and particularly relates to a multi-channel load testing device for a vehicle control unit of an electric vehicle. BACKGROUND

[0002] A large number of electronic control units (ECUs) or various controllers are arranged on a vehicle. For these controller products, whether they are produced and leave the factory or are detected before being assembled into a vehicle, their functional characteristics need to be detected and tested to ensure product qualification.

[0003] For a vehicle control unit (VCU) which is a key automotive electronic control product, not only design index parameters need to be met, but also the current channel needs to be undamaged under the condition of overload or even short-circuit fault, and the controller VCU needs to be able to recover to normal after the fault is removed. However, the vehicle control unit VCU is used in various load electrical and electromagnetic environments, and the working conditions are complex and diversified. Therefore, the functional and performance testing, robustness and reliability testing of the controller VCU in a complex environment are particularly important. Therefore, when testing the functional testing of the initial version of the sample or the aging testing of mass production, a detection device needs to be used for corresponding functional and performance testing, which requires a load device that can be used for various complex working condition simulation testing to make related verification.

[0004] The current testing device on the market is not perfect in supporting the testing of the controller, has single function and low efficiency, and especially cannot realize automatic testing, such as cannot realize flexible configuration of function and automatic testing, and has no perfect testing record generation and report generation function. Most of them need to be tested and recorded manually, and have poor support for intelligent and automatic testing. Moreover, the testing device cannot be compatible with multiple controller models, needs to be configured separately, and occupies a large space during production. CONTENT OF THE INVENTION

[0005] Therefore, the application aims to provide a multi-channel load testing device for a vehicle control unit of an electric vehicle to solve at least one of the above problems.

[0006] To achieve the above purpose, the technical scheme of the application is as follows:

[0007] The application provides a multi-channel load testing device for a vehicle control unit of an electric vehicle, which comprises a main control module, a power conversion module, a communication module and a load resistance switching module connected with the main control module; the power conversion module is connected with a power supply to provide power supply, and the communication module is in communication connection with an upper computer.

[0008] The load resistance switching module comprises a relay control circuit with a multi-channel mode and a current detection circuit, the relay control circuit of each channel is connected with the corresponding current detection circuit, and the relay control circuit is connected with a measured controller to perform analog testing on the measured controller.

[0009] Further, the current detection circuit of each channel comprises a current detection amplifier chip, a fourth pin of the current detection amplifier chip is connected with a first resistor, the other end of the first resistor is connected with the relay control circuit through a first connector, a fifth pin of the current detection amplifier chip is connected with the fourth pin thereof through a first capacitor and connected with a load high-low side selection jumper cap through a second resistor respectively, the load high-low side selection jumper cap is configured to select high-side driving or bottom-side driving according to a load mode, and a third resistor is further connected between the first resistor and the second resistor.

[0010] The main control module is a single-chip microcomputer, and a sixth pin of the current detection amplifier chip is connected with an AI01_11 port of the single-chip microcomputer through a fourth resistor.

[0011] The third pin of the current detection amplifier chip is connected with a 5V power supply end, and the first pin and the second pin of the current detection amplifier chip are both grounded.

[0012] Further, the relay control circuit of each channel is composed of a plurality of parallel relay control branches, each relay control branch comprises a relay, a first end of the relay is connected with a BATT2 power supply end through a first fuse, a second end of the relay is connected with a second connector through a first protection circuit, the second connector is used to be connected with the measured controller, a fourth end of the relay is connected with an anode of a first diode and a third end of a first switch tube respectively, a cathode of the first diode is connected with the first end of the relay, a first end of the first switch tube is connected with a fifth resistor, the other end of the fifth resistor is connected with the single-chip microcomputer through a third connector, the other end of the fifth resistor away from the first switch tube is further connected with a sixth resistor and a light-emitting diode in series and grounded, a second end of the first switch tube is grounded, a seventh resistor is arranged between the first end and the second end of the first switch tube, and a fifth end of the relay is connected with the first connector.

[0013] Further, the first protection circuit comprises a second fuse, one end of the second fuse is connected with the second end of the relay of each branch, the other end of the second fuse is connected with the second connector, and the other end of the second fuse is further connected with a bidirectional breakdown diode and grounded.

[0014] Further, the first switch tube comprises a first triode, the first triode is an NPN type triode, the base of the first triode is connected with the fifth resistor, the collector of the first triode is connected with the anode of the first diode, and the emitter of the first triode is grounded.

[0015] Further, a dial switch is further included, the dial switch is arranged on a connecting line between the third plug connector and the fifth resistor, and the dial switch is connected with a 5V power supply end.

[0016] Further, the communication module adopts a CAN communication circuit.

[0017] Compared with the prior art, the electric vehicle whole vehicle controller multi-channel load test device has the following beneficial effects:

[0018] The electric vehicle whole vehicle controller multi-channel load test device has the characteristics of small size and strong adaptability compared with the traditional load box, can load the commonly used load current value of the whole vehicle controller VCU, can be cascaded to expand the load channel infinitely, and meets the load demand of the controller VCU or similar products in various complex condition simulation tests. BRIEF DESCRIPTION OF DRAWINGS

[0019] The drawings constituting a part of the present application are used to provide further understanding of the present application, the illustrative embodiments of the present application and the description thereof are used to explain the present application, and do not constitute improper limitation on the present application. In the drawings:

[0020] Figure 1 The electric vehicle whole vehicle controller multi-channel load test device system block diagram described in the embodiments of the present application;

[0021] Figure 2 The main control module circuit diagram described in the embodiments of the present application;

[0022] Figure 3 The second plug connector and load high-low edge selection jump cap circuit diagram described in the embodiments of the present application;

[0023] Figure 4 The power conversion module circuit diagram described in the embodiments of the present application;

[0024] Figure 5 The first protection circuit and the first plug connector circuit diagram described in the embodiments of the present application;

[0025] Figure 6 The communication module circuit diagram described in the embodiments of the present application;

[0026] Figure 7 The third plug connector circuit diagram described in the embodiments of the present application;

[0027] Figure 8 The main control module circuit diagram for the embodiment of the present application is shown in

[0028] Figure 9 The relay detection circuit diagram for one of the channels of the embodiment of the present application is shown in

[0029] Figure 10 The relay control branch circuit diagram for one of the channels of the embodiment of the present application is shown in

[0030] Figure 11 The DIP switch circuit diagram for one of the branches of the embodiment of the present application is shown in DETAILED DESCRIPTION

[0031] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application is further described in detail below with reference to the embodiments and the accompanying drawings.

[0032] It should be noted that, unless otherwise defined, the technical terms or scientific terms used in the embodiments of the present application should be understood as the common meanings understood by those with ordinary skills in the art to which the present application belongs. The terms “first”, “second” and similar terms used in the embodiments of the present application do not represent any order, number or importance, but are only used to distinguish different components. The terms “include”, “contain” and similar terms mean that the components or objects before the terms encompass the components or objects listed after the terms and their equivalents, and do not exclude other components or objects. The terms “connect” or “connected” and similar terms do not mean physical or mechanical connections, but can be logical or other connections that do not have physical or mechanical connections.

[0033] The terms “include” or “contain” and similar terms mean that the components or objects before the terms encompass the components or objects listed after the terms and their equivalents, and do not exclude other components or objects. The terms “connect” or “connected” and similar terms do not mean physical or mechanical connections, but can be logical or other connections that do not have physical or mechanical connections.

[0034] Referring to Figure 1 The embodiment provides a kind of electric vehicle whole car controller multi-channel load test device, including main control module, and with the power conversion module, communication module and load resistance switching module of main control module connection;Power conversion module is connected with power supply to provide power supply, communication module and host computer establish communication connection;

[0035] Load resistance switching module includes the relay control circuit and current detection circuit with multiple channel mode (the embodiment is 8 channels as an example), the relay control circuit of each channel is connected with corresponding current detection circuit, relay control circuit is connected to the measured controller, to carry out simulation test to measured controller.

[0036] Specifically, in the embodiment, the test device is composed of three parts: a power supply, a control system and an upper computer, wherein the control system comprises a master control module, a power conversion module connected with the master control module, a communication module and a load resistance switching module, the power supply provides a 24V power supply, the power conversion module is connected with the power supply, the communication module adopts a CAN communication circuit, the communication module is connected with the upper computer through a CAN interface, and the relay control circuit is connected with the measured controller.

[0037] Compared with the traditional load box, the multi-channel load test device of the electric vehicle whole vehicle controller has the characteristics of small size and strong adaptability, can be cascaded to expand the load channel infinitely, meets the load demand of the controller VCU or similar products in various complex condition simulation tests, and will not affect each other.

[0038] For the power supply part:

[0039] System power supply: J201 is connected with an external input DC 24V power supply, which is used for supplying power to relays (S901-S964, as shown in Figure 10 ), and a DC-DC power supply chip (U201, as shown in Figure 4 ), wherein U201 is used as a BUCK voltage reduction chip to provide a 5V reference power supply for an ADC of a single-chip microcomputer, and is used as an input for linear voltage stabilizers U202 and U203, and is used for supplying power to a single-chip microcomputer (U101, as shown in Figure 2 ), a CAN chip (U302 / U304) and a current detection amplifier chip TP181A1-CR (U601-U608, as shown in Figure 9 ).

[0040] For the control system part:

[0041] The minimum system of the single-chip microcomputer (U101) is used for processing the input of the DIP switch (K901-K908, as shown in Figure 11 ), setting the on-off of the relays and the size of the current allowed to pass, and reserving two-way CAN communication to connect an industrial control screen or a computer upper computer (as a man-machine interface to set experimental parameters and record experimental parameters).

[0042] For the communication part:

[0043] The CAN circuit (U302 / U304, as shown in Figure 6CAN bus greatly simplifies wiring in the form of two-wire communication, and uses modbus protocol communication to realize cascade intercommunication between different boards; it can also be used as a human-computer interaction channel, which is suitable for industrial control screen or computer host, and can also be used as a debugging channel of the control board.

[0044] Resistor switching circuit part:

[0045] Relay control part circuit (only one channel in this embodiment is taken as an example): the single-chip microcomputer GPIO directly drives the triode to control the switch of the relay; in order to prevent the control board from failing to reliably control the use of the resistor board, the triode driving the relay coil can be driven by the code switch, so that it is turned on, thereby making the resistor of the channel parallel to the channel to adjust the resistance value of the channel.

[0046] Taking Q904 conduction as an example, IGPIO=ILED+IQ904=((3.3V-1.7V)÷4.7K)+((3.3V-0.7V)÷1K)=2.9mA.

[0047] Each relay drive signal port has an LED for indication, which ensures that the LED will light up when the signal is given to the triode, serving as an indicator light. It is more intuitive during the debugging stage and actual use. If the signal is not given, the LED indicator light will not light up.

[0048] Each channel is controlled by 8 resistors in parallel controlled by 8 relay controllers. The resistors need to be connected with external cooling fins, which are connected to the load board through connectors (J802 / J810 / J818 / J826 / J834 / J42 / J50 / J58, as Figure 5 shown) to the load board. Different resistors can be connected in parallel through different relays, thereby obtaining different resistance values. The power supply voltage 24V is determined, and the current through the high-side and low-side channels of the vehicle controller is realized by adjusting the resistance.

[0049] Each output channel is added with a current limiting fuse F801 to prevent overcurrent failure from occurring and to protect the front and rear circuits from greater damage. The fuse is designed to be replaceable, realizing convenient and fast maintenance and replacement.

[0050] Each channel is also equipped with a TVS (D802) to realize hot plugging. When the high-side and low-side of the vehicle controller are turned on, the test is carried out with live operation, which will cause a certain impact on the circuit. Adding a high-power bidirectional TVS can effectively prevent accidents and protect the circuit from being damaged.

[0051] As to whether the load mode is high-side or low-side, it can be selected by wiring mode (J703, as Figure 3(As shown) Select grounding or power supply. For high-side drive, connect the high side of the vehicle controller to RP_OUT01, and ground one end of the load box; for low-side drive, connect the high side of the vehicle controller to RP_OUT01, and connect one end of the load box to the power supply; J701 is used to connect to the controller under test.

[0052] Therefore, this device is suitable for use as a power load on the high side, low side, and any power output channel of the vehicle controller VCU. It verifies whether the power output channel of the vehicle controller VCU design meets the design rated current parameters, overload protection measures, and heat generation. It also simulates the actual load channel of the vehicle controller VCU to verify the VCU function.

[0053] Current acquisition circuit (this embodiment only uses one channel as an example): The current acquisition circuit consists of a high-side current acquisition circuit composed of U601 / R601 / R604 / C604 / R607 / R610. The voltage acquired by U601 across the sampling resistor R604 is amplified and output to the AI01_11 port of the microcontroller. The TP181A1-CR itself has a 50V / V amplification gain. When current flows through the resistor, a voltage divider will appear on the R604 resistor. The design parameters are a rated current of 6A for each channel, VImax=0.01R×6A×50V / V=3V. The microcontroller will compare the current value with the set current value. If the current value is greater than the set value, it will record the puncture high voltage and the breakdown capacitor channel at this time.

[0054] The microcontroller collects the feedback current value and will implement overcurrent protection. If the current exceeds the set value, the channel will be shut down and an alarm will be triggered. The system can only resume operation after the fault is manually confirmed. It is equipped with both software and hardware overcurrent protection (software has the highest priority) to prevent overcurrent damage to the load.

[0055] like Figure 9 As shown, the following explanation is given for one of the channels:

[0056] Each channel's current detection circuit includes a current detection amplifier chip. The fourth pin of the current detection amplifier chip U601 is connected to a first resistor R601. The other end of the first resistor R601 is connected to a relay control circuit through a first connector J801. The fifth pin of the current detection amplifier chip U601 is connected to its fourth pin through a first capacitor C601 and to a load high / low side selection jumper through a second resistor R607. The load high / low side selection jumper is configured to select high-side drive or low-side drive according to the load mode. A third resistor R604 is also connected between the first resistor R601 and the second resistor R607.

[0057] The main control module is a microcontroller U101. The sixth pin of the current detection amplifier chip is connected to the AI01_11 port of the microcontroller through the fourth resistor R610.

[0058] The third pin of the current sense amplifier chip is connected to the 5V power supply, while the first and second pins of the current sense amplifier chip are grounded.

[0059] For relay control circuits, such as Figure 10 As shown, this embodiment uses one branch of one of the channels for explanation and illustration as an example:

[0060] Each channel's relay control circuit consists of multiple parallel relay control branches (this embodiment uses 8 branches as an example). Each relay control branch includes a relay S904. The first terminal of relay S904 is connected to the BATT2 power supply terminal through a first fuse F913, and the second terminal of relay S904 is connected to a first protection circuit (such as...). Figure 5 As shown, the first protection circuit includes a second fuse F801. One end of the second fuse F801 is connected to the second terminal of the relay in each branch, and the other end of the second fuse F801 is connected to the second connector J701. The other end of the second fuse F801 is also connected to the second connector J701 through a bidirectional breakdown diode (grounded D802). The second connector J701 is used to connect to the controller under test. The fourth terminal of the relay S904 is connected to the anode of the first diode D912 and the third terminal of the first transistor (Q904). The cathode of the first diode D912 is connected to the first terminal of the relay S904. The first terminal of the first transistor Q904 is connected to a fifth resistor R912. The other end of the fifth resistor R912 is connected to the third connector J401 (J401 is as follows). Figure 7 (As shown) Connect to the microcontroller U101 (as shown) Figure 8 As shown, a second protection circuit consisting of a bidirectional breakdown diode D503 and a resistor R503 is provided between the third connector J401 and the microcontroller U101. The end of the fifth resistor R912 away from the first transistor Q904 is grounded through a sixth resistor R904 connected in series and a light-emitting diode D905. The second end of the first transistor Q904 is grounded. A seventh resistor R912 is provided between the first end and the second end of the first transistor Q904. The fifth end of the relay S904 is connected to one of the ports J802 of the first connector.

[0061] In some implementations, such as Figure 11 As shown, it also includes a DIP switch K901, which is set on the connection line between the third connector and the fifth resistor R912. The DIP switch K901 is connected to the 5V power supply terminal.

[0062] In the embodiment, the load design is controlled by manual and program control, which is convenient for daily research and development, test or production aging use. For the manual control, a DIP switch is arranged in each channel to drive the triode of the relay coil, so that the triode is turned on, and the resistance of the channel is connected in parallel to the channel to adjust the resistance value of the channel.

[0063] For the program control, a single-chip microcomputer, a power conversion module and a communication module are used to drive the triode directly by the GPIO of the single-chip microcomputer to control the switch of the relay.

[0064] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the utility model, but not to limit them; although the utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that: the technical solutions recorded in the above embodiments can still be modified, or some or all of the technical features can be replaced equivalently; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the utility model, and they should be covered in the scope of the claims and the specification of the utility model.

[0065] The embodiments of the present application are intended to cover all such alternatives, modifications and variations as fall within the broad scope of the appended claims. Therefore, any omission, modification, equivalent replacement, improvement, etc. made within the spirit and principle of the embodiments of the present application should be included in the protection scope of the present application.

Claims

1. A multi-channel load testing device for electric vehicle whole vehicle controller, characterized in that: it comprises a main control module, a power conversion module, a communication module and a load resistance switching module connected with the main control module; the power conversion module is connected with a power supply to provide power supply, and the communication module is connected with an upper computer; the load resistance switching module comprises a relay control circuit and a current detection circuit with a multi-channel mode, the relay control circuit of each channel is connected with the corresponding current detection circuit, and the relay control circuit is connected with a measured controller to simulate the test of the measured controller.

2. The device according to claim 1, characterized in that: the current detection circuit of each channel comprises a current detection amplifier chip, a fourth pin of the current detection amplifier chip is connected with a first resistor, the other end of the first resistor is connected with the relay control circuit through a first connector, a fifth pin of the current detection amplifier chip is connected with the fourth pin through a first capacitor and connected with a load high-low side selection jumper through a second resistor respectively, the load high-low side selection jumper is configured to select high side drive or bottom side drive according to the load mode, and a third resistor is further connected between the first resistor and the second resistor; the main control module is a single-chip microcomputer, a sixth pin of the current detection amplifier chip is connected with an AI01_11 port of the single-chip microcomputer through a fourth resistor; a third pin of the current detection amplifier chip is connected with a 5V power supply end, and a first pin and a second pin of the current detection amplifier chip are both grounded.

3. The device according to claim 2, characterized in that: the relay control circuit of each channel is composed of a plurality of parallel relay control branches, each relay control branch comprises a relay, a first end of the relay is connected with a BATT2 power supply end through a first fuse, a second end of the relay is connected with a second connector through a first protection circuit, the second connector is used for connecting with the measured controller, a fourth end of the relay is connected with an anode of a first diode and a third end of a first switch tube respectively, a cathode of the first diode is connected with the first end of the relay, a first end of the first switch tube is connected with a fifth resistor, the other end of the fifth resistor is connected with the single-chip microcomputer through a third connector, the other end of the fifth resistor away from the first switch tube is further connected with a sixth resistor and a light emitting diode in series and grounded, a second end of the first switch tube is grounded, a seventh resistor is arranged between the first end and the second end of the first switch tube, and a fifth end of the relay is connected with the first connector.

4. The device according to claim 3, characterized in that: the first protection circuit comprises a second fuse, one end of the second fuse is connected with the second end of the relay of each branch, the other end of the second fuse is connected with the second connector, and the other end of the second fuse is further connected with a ground through a bidirectional breakdown diode.

5. The device according to claim 3, characterized in that: ​ ​ ​ ​ The first switch tube comprises a first triode, the first triode is an NPN type triode, a base of the first triode is connected with the fifth resistor, an anode of the first diode is connected with a collector of the first triode, and an emitter of the first triode is grounded.

6. The apparatus of claim 3, wherein: Further comprising a dial switch, the dial switch is arranged on a connecting line between the third plug connector and the fifth resistor, and the dial switch is connected with a 5V power supply end.

7. The apparatus of claim 1, wherein: The communication module adopts a CAN communication circuit.

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