Vehicle thermal management test system
By combining the HIL test system with the automated testing of the thermal management bench, the problems of low efficiency and insufficient accuracy in automotive thermal management testing have been solved, achieving an efficient and accurate testing process and shortening the development cycle.
Patent Information
- Application Number
- CN202423222344.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-25
- Publication Date
- 2026-01-23
- Estimated Expiration
- 2034-12-25
AI Technical Summary
Existing technologies for automotive thermal management testing are inefficient and lack accuracy, especially HIL testing, which fails to reflect real-world load conditions.
By combining the HIL test system and the thermal management bench, automated testing is achieved. The HIL test system generates analog signals and connects to the thermal management controller and the bench. The thermal management controller manages the cabin air conditioning, battery system, and electric drive and control system. The thermal management bench simulates real loads and generates test reports.
It improves the efficiency of thermal management bench testing, shortens the controller development cycle, ensures the accuracy of testing and the true load reflection, reduces manual intervention, and improves the degree of automation of testing.
Smart Images
Figure CN223827993U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of automotive thermal management technology, and more particularly to a vehicle thermal management testing system. Background Technology
[0002] With the development of technology, automobiles have become one of the most important means of transportation in daily life. At the same time, competition in the automotive industry is becoming increasingly fierce. For automobiles, thermal management is a crucial aspect that needs attention, as it affects not only the overall vehicle performance but also the user experience. Therefore, relevant tests are typically conducted on the thermal management aspects of automobiles.
[0003] In existing technologies, the correctness of the thermal management controller function of the TMS (Thermal Management System) is usually verified by HIL (Hardware-in-the-Loop) test system to ensure that the thermal management function control logic is correct before traditional thermal management bench testing is performed. However, traditional thermal management bench testing requires human supervision and recording of test problems, which leads to low efficiency in automotive thermal management testing. In addition, HIL testing alone cannot reflect the real load conditions and it is difficult to guarantee the accuracy of the test. Utility Model Content
[0004] In view of this, this application provides a vehicle thermal management testing system to solve the problems of low efficiency and difficulty in ensuring the accuracy of vehicle thermal management testing in the prior art.
[0005] To achieve the above objectives, this application provides the following technical solution:
[0006] The first aspect of this application discloses a vehicle thermal management test system, including a HIL test system, a thermal management controller, and a thermal management bench;
[0007] The HIL testing system is connected to the thermal management controller via a connector.
[0008] The thermal management controller is connected to the thermal management stand via a connector.
[0009] The HIL testing system is used to generate simulated signals under different vehicle operating conditions, perform thermal management tests, and generate test reports.
[0010] The thermal management controller is used for thermal management of the cabin air conditioning, battery system and electric drive and control system;
[0011] The thermal management bench is used to simulate the operating conditions of a real load.
[0012] Optionally, in the above-described system, the thermal management bench includes:
[0013] Compressor, electronic expansion valve, in-vehicle evaporator, condenser assembly, motor radiator assembly, battery pack, battery cooling plate heat exchanger, battery charging and discharging cabinet and control platform, three-way valve, four-way valve, water pump, temperature sensor T, temperature and pressure sensor PT, first water heating PTC, second water heating PTC, air heating PTC and expansion tank.
[0014] Optionally, in the above system, the PTC includes a first water-heating PTC, a second water-heating PTC, and a fan-heating PTC;
[0015] The first water-heating PTC is used to assist in battery preheating;
[0016] The second water heating PTC is used to replace the actual heat generation of the motor and electronic control system;
[0017] The air-cooled PTC is used to assist in cabin heating.
[0018] Optionally, the HIL testing system described above includes a simulation hardware platform and a host computer;
[0019] The simulation hardware platform is connected to the host computer via a USB interface;
[0020] The host computer is used to write test cases and manage test data;
[0021] The simulation hardware platform is used to generate simulated signals of vehicle operating conditions based on test cases written by the host computer.
[0022] Optionally, in the above-mentioned system, the host computer includes a vehicle dynamics model, test management software, and a motor electrical control thermal model;
[0023] The vehicle dynamics model is connected to the test management software and the simulation hardware platform via network.
[0024] The motor electrical control thermal model is connected to the test management software and the simulation hardware platform via a network connection.
[0025] The test management software is connected to the vehicle dynamics model, the motor electronic control thermal model, and the simulation hardware platform via network.
[0026] The vehicle dynamics model is used to simulate the workload of a real vehicle under actual operating conditions.
[0027] The motor control thermal model is used to calculate the heat generated by the motor control and to request battery power from the battery pack.
[0028] The test management software is used to write test cases, configure test parameters, record test data, and generate test reports.
[0029] Optionally, in the above system, the simulation hardware platform includes a low-voltage power supply unit, a fault injection unit, a real-time processor unit, and an I / O board unit.
[0030] Optionally, in the above system, the I / O board unit includes a three-way board.
[0031] Optionally, in the above system, the thermal management controller communicates via network using CAN or LIN signals.
[0032] As can be seen from the above technical solution, the vehicle thermal management testing system provided in this application includes a HIL testing system, a thermal management controller, and a thermal management bench. The HIL testing system is connected to the thermal management controller via connectors; the thermal management controller is connected to the thermal management bench via connectors. The HIL testing system is used to generate simulated signals under different vehicle operating conditions, perform thermal management tests, and generate test reports. The thermal management controller is used to manage the heat of the cabin air conditioning, battery system, and electric drive and control system. The thermal management bench is used to simulate the operating state of real loads. Therefore, this application achieves automated testing of the thermal management controller simultaneously through the HIL testing system and the thermal management bench, eliminating the need for manual supervision and automatically generating test reports. Simultaneously, by simulating real load conditions through the thermal management bench, it improves the testing efficiency of the thermal management bench, shortens the controller development cycle, and reflects real load conditions to ensure test accuracy. This solves the problems of low efficiency and difficulty in ensuring test accuracy in existing automotive thermal management testing technologies. Attached Figure Description
[0033] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.
[0034] Figure 1 A schematic diagram of a vehicle thermal management testing system provided in an embodiment of this application;
[0035] Figure 2 A schematic diagram of another thermal management bench provided for another embodiment of this application;
[0036] Figure 3 A schematic diagram of another vehicle thermal management test system provided in another embodiment of this application;
[0037] Figure 4 This is a schematic diagram of another vehicle thermal management test system provided in another embodiment of this application. Detailed Implementation
[0038] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0039] In this application, the terms "comprising," "including," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0040] Furthermore, in this document, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.
[0041] As can be seen from the background technology, in the existing technology, the correctness of the TMS thermal management controller function is usually verified by the HIL test system to ensure that the thermal management function control logic is correct before the traditional thermal management bench test is performed. Furthermore, the traditional thermal management bench test requires human supervision and recording of test problems, which leads to low efficiency in automotive thermal management testing. At the same time, performing HIL testing alone cannot reflect the real load conditions and it is difficult to guarantee the accuracy of the test.
[0042] In view of this, this application provides a vehicle thermal management testing system to solve the problems of low efficiency and difficulty in ensuring the accuracy of vehicle thermal management testing in the prior art.
[0043] This embodiment provides a vehicle thermal management testing system, such as Figure 1 As shown, it includes a HIL test system, a thermal management controller, and a thermal management bench;
[0044] The HIL test system is connected to the thermal management controller via connectors;
[0045] The thermal management controller is connected to the thermal management bench via connectors;
[0046] The HIL test system is used to generate simulated signals for vehicles under different operating conditions, perform thermal management tests, and generate test reports.
[0047] The thermal management controller is used to manage the thermal properties of the cabin air conditioning, battery system, and electric drive and control system.
[0048] Thermal management benches are used to simulate the operating conditions of real loads.
[0049] It should be noted that the vehicle thermal management test system provided in this embodiment includes a HIL test system, a thermal management controller, and a thermal management bench. The HIL test system has a dedicated slide rail box for placing the controller. The HIL test system is connected to the thermal management controller via connectors. The thermal management controller is connected to the thermal management bench via connectors. The wiring harness connectors may be different in different test scenarios.
[0050] It should also be noted that the HIL testing system is used to generate simulated signals under different vehicle operating conditions, perform thermal management tests, and generate test reports. The HIL testing system uses a real-time processor to run simulation models to simulate the operating state of the controlled object. By connecting with the controller under test, it performs comprehensive and systematic testing of the controller. Considering safety, feasibility, and reasonable cost, HIL testing has become a crucial part of the controller development process, reducing the number of real-vehicle road tests, shortening development time, reducing costs, improving controller software quality, and reducing risks for automakers.
[0051] As one of the determining factors of vehicle energy consumption and vehicle comfort, the thermal management controller supports multi-channel sensor acquisition and multi-channel pump and valve drive, and with the help of sophisticated thermal management control algorithms, it can realize thermal management of cabin air conditioning, battery system and electric drive and electronic control system.
[0052] Thermal management benches are used to simulate real-world load conditions. Through software or hardware, they simulate other devices that work in conjunction with the thermal management controller, verifying whether the controller performs as expected under different load conditions. Real-world loads ensure testing accuracy and make it easier to identify control logic problems and compatibility issues between the controller and thermal management equipment in advance.
[0053] The vehicle thermal management testing system provided in this application includes a HIL testing system, a thermal management controller, and a thermal management bench. The HIL testing system is connected to the thermal management controller via connectors. The thermal management controller is connected to the thermal management bench via connectors. The HIL testing system is used to generate simulated signals under different vehicle operating conditions, perform thermal management tests, and generate test reports. The thermal management controller is used to manage the heat of the cabin air conditioning, battery system, and electric drive and control system. The thermal management bench is used to simulate the operating state of real loads. Therefore, this application achieves automated testing of the thermal management controller simultaneously through the HIL testing system and the thermal management bench, eliminating the need for manual operation and automatically generating test reports. Simultaneously, by simulating real load conditions using the thermal management bench, it improves the testing efficiency of the thermal management bench, shortens the controller development cycle, and reflects real load conditions to ensure test accuracy. This solves the problems of low efficiency and difficulty in ensuring test accuracy in existing automotive thermal management testing technologies.
[0054] Optionally, in another embodiment of this application, the architecture of the aforementioned thermal management platform is as follows: Figure 2 As shown, it specifically includes:
[0055] Compressor, electronic expansion valve, in-vehicle evaporator, condenser assembly, motor radiator assembly, battery pack, battery cooling plate heat exchanger, battery charging and discharging cabinet and control platform, three-way valve, four-way valve, water pump, temperature sensor T, temperature and pressure sensor PT, first water heating PTC, second water heating PTC, air heating PTC and expansion tank.
[0056] It should be noted that the compressor, electronic expansion valve, in-vehicle evaporator, air-heating PTC, temperature sensor T, temperature and pressure sensor PT, and condenser assembly constitute the cabin cooling / heating circuit; the battery pack, battery cooling plate heat exchanger, first water-heating PTC, expansion tank, water pump, and four-way valve constitute the battery cooling / heating circuit; the motor radiator assembly, three-way valve, four-way valve, water pump, expansion tank, and second water-heating PTC constitute the motor electronic control cold / waste heat recovery circuit. The first water-heating PTC is used to assist in battery preheating; the second water-heating PTC is used to replace the actual heat generated by the motor electronic control; and the air-heating PTC is used to assist in cabin heating. The battery charging / discharging cabinet and control platform can control the battery's charging and discharging status.
[0057] Optionally, in another embodiment of this application, such as Figure 3 As shown, the HIL testing system includes a simulation hardware platform and a host computer.
[0058] The simulation hardware platform is connected to the host computer via a USB interface;
[0059] The host computer is used to write test cases and manage test data;
[0060] The simulation hardware platform is used to generate simulated signals of vehicle operating conditions based on test cases written by the host computer.
[0061] It should be noted that the aforementioned HIL testing system consists of a simulation hardware platform and a host computer. The simulation hardware platform is connected to the host computer via a USB interface. The host computer can write test cases. After the test begins, the host computer can observe the real-time status of the test bench and record the data during the test process. Then, it automatically analyzes the test data and generates the corresponding test report. The simulation hardware platform is used to generate simulated signals of vehicle operating conditions based on the test cases written by the host computer, and sends the relevant simulated signals to the thermal management controller, or forwards them to the thermal management test bench through the thermal management controller, so as to trigger the thermal management controller or the thermal management test bench to perform corresponding operations based on the simulated signals.
[0062] Optionally, in another embodiment of this application, the above-described HIL testing system is as follows: Figure 4 As shown, the host computer includes: a vehicle dynamics model, test management software, and a motor electronic control thermal model;
[0063] The vehicle dynamics model is connected to the test management software and simulation hardware platform via network.
[0064] The electric motor control thermal model is connected to the test management software and simulation hardware platform via network.
[0065] The test management software is connected to the vehicle dynamics model, the motor electronic control thermal model, and the simulation hardware platform via network.
[0066] Vehicle dynamics models are used to simulate the workload of real vehicles under actual operating conditions;
[0067] The motor and electronic control thermal model is used to calculate the heat generated by the motor and electronic control system and to request battery power from the battery pack.
[0068] Test management software is used to write test cases, configure test parameters, record test data, and generate test reports.
[0069] It should be noted that since a standalone thermal management system is insufficient to reflect the impact of thermal effects on vehicle dynamics, driving range, and the three key electrical components (battery, motor, and electronic control system), a vehicle dynamics model and a motor / electronic control thermal model are constructed. The vehicle dynamics model simulates the workload of a real vehicle under actual operating conditions. The motor / electronic control thermal model calculates the heat generated by the motor / electronic control system and requests battery power from the battery pack. The test management software can write test cases and configure test parameters, such as setting ambient temperature, solar radiation, wind speed, driving mode, vehicle speed, brake pedal depth, and cabin temperature according to the test cases. After the test begins, the real-time status of the test bench can be observed and the test process data can be recorded. The test data is then automatically analyzed to generate corresponding test reports. The vehicle dynamics model is connected to the host computer and the simulation hardware platform via network; the motor / electronic control thermal model is also connected to the host computer and the simulation hardware platform via network; and the test management software is connected to the vehicle dynamics model, the motor / electronic control thermal model, and the simulation hardware platform via network.
[0070] Optionally, in another embodiment of this application, the above-mentioned simulation hardware platform includes a low-voltage power supply unit, a fault injection unit, a real-time processor unit, and an I / O board unit.
[0071] It should be noted that the simulation hardware platform includes a low-voltage power supply unit, a fault injection unit, a real-time processor unit, and an I / O board unit. The low-voltage power supply unit provides power to the system; the fault injection unit performs fault simulation; the real-time processor unit is responsible for the deterministic execution of various components in the HIL test system, such as hardware I / O communication, data logging, and model execution; and the I / O board unit provides electrical and communication I / O interfaces.
[0072] Optionally, in another embodiment of this application, the above-mentioned I / O board unit includes a three-way board for realizing real / virtual real-time switching of thermal management bench I / O signals.
[0073] Optionally, in another embodiment of this application, the thermal management controller communicates via CAN (Controller Area Network) signals or LIN (Local Interconnect Network) signals.
[0074] Based on the vehicle thermal management test system described above, the performance of the thermal management controller can be tested, for example, simultaneously verifying the controller's functionality and bench performance. The test process is as follows:
[0075] 1. After connecting the thermal management bench to the high and low voltage power supply, start the host computer and HIL test system.
[0076] 2. Write test cases on the test management software and configure the required input and output interface signals. The input interfaces include cabin / battery / refrigeration pipe temperature, refrigeration pipe pressure, compressor speed, condenser fan speed, expansion valve opening, position of each damper, position of three / four-way valve, and water pump PWM value. The output interfaces include cab set temperature, ambient temperature, radiation intensity, wind speed, driving mode, vehicle speed, brake pedal depth, road load, and wheel hub resistance.
[0077] 3. The environmental setup in the test chamber simulates the external environment temperature, humidity, wind speed, and solar radiation of the real vehicle based on the test cases. The power battery is charged to the target SOC under the test conditions, and the test is started according to the test cases.
[0078] 4. The motor control thermal model within the HIL test system calculates the motor control heating power and the battery pack requested power. The hardware simulation platform forwards this signal to the thermal management bench via the thermal management controller in the form of a CAN signal. Other test condition simulation signals are sent to the thermal management controller via CAN signals. After the thermal management logic within the thermal management controller makes a judgment, it drives each component of the thermal management bench. The thermal management bench then provides real-time feedback to the HIL test system for data interaction via message forwarding.
[0079] 5. The host computer is used to observe the real-time status of the thermal management test bench and record the data throughout the process. The test management software automatically analyzes whether the feedback messages meet the expected results of the test cases. It is used to test the logic function of the thermal management controller. At the same time, it can complete the performance verification based on data such as the temperature and energy consumption of the three electric components / cabin. It provides data support for system optimization design, control strategy optimization and subsequent vehicle-level calibration tests, and shortens the vehicle development cycle.
[0080] Alternatively, the performance of the thermal management controller can be tested under some extreme operating conditions. The test process is as follows:
[0081] 1. After connecting the high and low voltage power supplies to the test bench, power it on and start the host computer and HIL test system.
[0082] 2. Write test cases on the test management software and configure the required input and output interface signals. The input interfaces include temperature, pressure, compressor speed, expansion valve opening, damper position, three-way valve position, and water pump PWM. The output interfaces include ambient temperature, indoor set temperature, refrigerant side temperature / pressure, coolant side temperature, oncoming wind speed, air conditioning set parameters, air volume, PTC power, driving mode, driving speed, brake pedal depth, road load, and wheel hub resistance.
[0083] 3. Start running the test according to the test cases. The I / O board in the HIL test system provides the thermal management controller with simulated values of ambient temperature, oncoming wind speed, or temperature / pressure in the circulating pipeline of the thermal management bench to simulate extreme working conditions. The actual temperature / pressure values in the thermal management bench are transmitted to the safety protection logic of the thermal management controller to ensure that no components of the thermal management bench are damaged.
[0084] 4. The thermal management controller receives analog signals from the I / O board, performs judgments through the thermal management logic, drives each component, and finally transmits the status of each component of the thermal management bench back to the HIL test system via message forwarding. The test management software automatically verifies whether the thermal management bench is operating according to the internal logic of the thermal management controller and finally generates a test report.
[0085] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. In particular, for system or system embodiments, since they are basically similar to method embodiments, the description is relatively simple, and relevant parts can be referred to the descriptions in the method embodiments. The systems and system embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without creative effort.
[0086] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this invention.
[0087] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A vehicle thermal management testing system, characterized in that, Includes HIL test system, thermal management controller and thermal management bench; The HIL testing system is connected to the thermal management controller via a connector. The thermal management controller is connected to the thermal management stand via a connector. The HIL testing system is used to generate simulated signals under different vehicle operating conditions, perform thermal management tests, and generate test reports. The thermal management controller is used for thermal management of the cabin air conditioning, battery system and electric drive and control system; The thermal management bench is used to simulate the operating conditions of a real load.
2. The system according to claim 1, characterized in that, The thermal management stand includes: Compressor, electronic expansion valve, in-vehicle evaporator, condenser assembly, motor radiator assembly, battery pack, battery cooling plate heat exchanger, battery charging and discharging cabinet and control platform, three-way valve, four-way valve, water pump, temperature sensor T, temperature and pressure sensor PT, first water heating PTC, second water heating PTC, air heating PTC and expansion tank.
3. The system according to claim 2, characterized in that, The first water-heating PTC is used to assist in battery preheating; The second water heating PTC is used to replace the actual heat generation of the motor and electronic control system; The air-cooled PTC is used to assist in cabin heating.
4. The system according to claim 1, characterized in that, The HIL testing system includes a simulation hardware platform and a host computer. The simulation hardware platform is connected to the host computer via a USB interface; The host computer is used to write test cases and manage test data; The simulation hardware platform is used to generate simulated signals of vehicle operating conditions based on test cases written by the host computer.
5. The system according to claim 4, characterized in that, The simulation hardware platform includes a low-voltage power supply unit, a fault injection unit, a real-time processor unit, and an I / O board unit.
6. The system according to claim 5, characterized in that, The I / O board unit includes a three-way board.
7. The system according to claim 1, characterized in that, The thermal management controller communicates via network using CAN or LIN signals.