Electronic load device based on closed-loop control three-phase bridge drive and vehicle

Abstract

The utility model relates to the technical field of automobile controller driving signal testing, and discloses an electronic load device based on closed-loop control three-phase bridge driving and a vehicle, the electronic load device comprises a main control module, a driving module, a CAN communication module and a fault processing module, a first end of the main control module is connected with an automobile controller through the CAN communication module, and a second end of the main control module is connected with the automobile controller through the driving module. The second end of the main control module is connected with the first end of the driving module; the first end of the fault processing module is connected with the third end of the master control module, and the second end of the fault processing module is connected with the second end of the driving module. According to the utility model, the test efficiency and the data processing capability are improved, the response speed is fast, the accuracy and the stability of the output current are ensured, and meanwhile, perfect fault diagnosis and active safety protection functions are provided.

Description

Technical Field

[0001] This utility model relates to the field of automotive controller drive signal testing technology, specifically to an electronic load device and vehicle based on closed-loop control three-phase bridge drive. Background Technology

[0002] Electronic loads accurately simulate various load scenarios using constant current, constant voltage, and constant power modes, making them a core tool for power supply testing, battery charge / discharge verification, and power tool performance testing. With the continuous development of automotive electronics and electrification, the application of electronic loads in the automotive industry will become increasingly widespread. The application of electronic loads in the automotive industry ensures the performance and reliability of automotive electrical systems, and is of great significance for improving the overall quality of automotive controllers and reducing controller testing costs.

[0003] With the rapid development of new energy vehicle technology, electronic loads will place greater emphasis on simulating and testing the complex characteristics of complex controllers, and will require electronic loads to have higher precision and efficiency in driving capabilities, as well as more comprehensive fault diagnosis and active safety protection functions. However, conventional electronic loads are far from meeting the driving capability testing and safety protection testing requirements of many vehicle controllers. Utility Model Content

[0004] In view of this, the present invention provides an electronic load device and vehicle based on closed-loop control three-phase bridge drive, so as to solve the problem that conventional electronic loads cannot meet the driving capability test requirements and safety protection test requirements of vehicle controllers.

[0005] In a first aspect, this utility model provides an electronic load device based on closed-loop control three-phase bridge drive. The electronic load device includes: a main control module, a drive module, a CAN communication module, and a fault handling module.

[0006] The first end of the main control module is connected to the vehicle controller via the CAN communication module, and the second end of the main control module is connected to the first end of the drive module.

[0007] The first end of the fault handling module is connected to the third end of the main control module, and the second end of the fault handling module is connected to the second end of the drive module.

[0008] This invention provides an electronic load device based on a closed-loop control three-phase bridge drive. It can control the drive circuit to achieve the target drive current via a CAN communication module, seamlessly integrating with automated testing systems to improve testing efficiency, data processing capabilities, and response speed. Furthermore, the electronic load device features current sampling and closed-loop control. The main control module collects the drive current from the drive module, compares it with the target current value, and dynamically adjusts the output current of the drive module to ensure accuracy and stability. Simultaneously, the electronic load device has comprehensive fault diagnosis and active safety protection functions. The main control module identifies abnormalities by collecting the drive voltage of the drive module and, upon detecting an abnormality, uses a fault handling module to cut off the drive circuit, ensuring system safety.

[0009] In one optional embodiment, the electronic load device further includes: a power processing module, the input terminal of which is connected to a power supply, and the output terminal of which is connected to the power supply terminals of the main control module, the drive module, the CAN communication module, and the fault handling module, respectively.

[0010] In one optional embodiment, the power processing module includes: a rectifier circuit, a power filter circuit, and a voltage conversion circuit, wherein,

[0011] The input terminal of the rectifier circuit is connected to the power supply, and the output terminal of the rectifier circuit is connected to the input terminal of the power filter circuit and the first power supply terminal of the drive module. The output terminal of the power filter circuit is connected to the input terminal of the voltage conversion circuit, and the output terminal of the voltage conversion circuit is connected to the power supply terminal of the main control module, the second power supply terminal of the drive module, the power supply terminal of the CAN communication module, and the power supply terminal of the fault handling module.

[0012] In one optional embodiment, the voltage conversion circuit includes: a boost unit, a buck unit, a first voltage regulator unit, and a second voltage regulator unit, wherein,

[0013] The input terminal of the boost unit is connected to the output terminal of the power filter circuit, and the output terminal of the boost unit is connected to the input terminal of the buck unit.

[0014] The input terminal of the step-down unit is also connected to the output terminal of the power filter circuit, and the output terminal of the step-down unit is connected to the input terminal of the first voltage regulator unit and the input terminal of the second voltage regulator unit, respectively.

[0015] The output terminal of the first voltage regulator unit is connected to the power supply terminal of the main control module, the second power supply terminal of the drive module, the first power supply terminal of the CAN communication module, and the first power supply terminal of the fault handling module, respectively. The output terminal of the second voltage regulator unit is connected to the second power supply terminal of the CAN communication module and the second power supply terminal of the fault handling module, respectively.

[0016] In one optional embodiment, the driving module includes: an A / B / C three-phase driving unit, each phase driving unit including: a first transistor, a second transistor, a first resistor, a third transistor, and a fourth transistor, wherein,

[0017] The first terminal of the first transistor is connected to the power supply pin and voltage acquisition pin of the main control module, the second terminal of the first transistor is connected to the first terminal of the second transistor, the first terminal of the third transistor and the voltage acquisition pin of the main control module, and the control terminal of the first transistor is connected to the control pin of the main control module.

[0018] The control terminal of the second transistor is connected to the control pin of the main control module. The second terminal of the second transistor is connected to the voltage acquisition pin of the main control module and the first terminal of the first resistor, respectively. The second terminal of the first resistor is grounded. The two ends of the first resistor are also connected to the current acquisition pin of the main control module.

[0019] The control terminal of the third transistor is connected to the first terminal of the fourth transistor and the output terminal of the fault handling module, respectively, and the second terminal of the third transistor is connected to the load.

[0020] The control terminal of the fourth transistor is connected to the main control module, and the second terminal of the fourth transistor is grounded.

[0021] In one optional implementation, the fault handling module includes: a three-phase fault handling unit (A / B / C), each phase fault handling unit including: a first transistor unit, a second transistor unit, a fifth transistor, a sixth transistor, and a first capacitor, wherein...

[0022] The first terminal of the first transistor unit is connected to the control terminal of the fifth transistor. The control terminal of the first transistor unit is connected to the control pin of the main control module and the safety pin of the power management chip, respectively. The second terminal of the first transistor unit is grounded.

[0023] The first terminal of the second transistor unit is connected to the output terminal of the second voltage regulator unit, the control terminal of the second transistor unit is connected to the main control module, the second terminal of the second transistor unit is connected to the first terminal and the control terminal of the sixth transistor, and the third terminal of the second transistor unit is grounded.

[0024] The first terminal of the fifth transistor is connected to the output terminal of the first voltage regulator unit, and the second terminal of the fifth transistor is connected to the first terminal of the sixth transistor and the first terminal of the first capacitor, respectively. The second terminal of the first capacitor is grounded.

[0025] In one optional embodiment, the first transistor unit includes a seventh transistor and an eighth transistor, wherein,

[0026] The first terminal of the seventh transistor is connected to the control terminal of the fifth transistor, the control terminal of the seventh transistor is connected to the control pin of the main control module, the second terminal of the seventh transistor is connected to the first terminal of the eighth transistor, the control terminal of the eighth transistor is connected to the safety pin of the power management chip, and the second terminal of the eighth transistor is grounded.

[0027] In one optional embodiment, the second transistor unit includes: a ninth transistor and a tenth transistor, wherein,

[0028] The first terminal of the ninth transistor is connected to the output terminal of the first voltage regulator unit, the second terminal of the ninth transistor is connected to the first terminal and the control terminal of the sixth transistor, the control terminal of the ninth transistor is connected to the first terminal of the tenth transistor, the control terminal of the tenth transistor is connected to the main control module, and the second terminal of the tenth transistor is grounded.

[0029] In one optional implementation, the CAN communication module includes: an A / B / C three-phase CAN communication module unit, each phase CAN communication module unit including: a CAN transceiver, the signal receiving pin, signal transmitting pin and mode switching pin of the CAN transceiver are all connected to the main control module, and the communication pin of the CAN transceiver is connected to the host computer through the CAN bus.

[0030] Secondly, the present invention provides a vehicle, the vehicle including the electronic load device based on closed-loop control three-phase bridge drive according to the first aspect above or any corresponding embodiment.

[0031] This invention provides a vehicle that can use an electronic load device to complete the testing of various controllers, thereby meeting the testing requirements of the vehicle. Attached Figure Description

[0032] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0033] Figure 1 This is a system block diagram of an electronic load device according to an embodiment of the present invention;

[0034] Figure 2 This is a system block diagram of another electronic load device according to an embodiment of the present invention;

[0035] Figure 3 This is a system block diagram of another electronic load device according to an embodiment of the present invention;

[0036] Figure 4 This is a system block diagram of another electronic load device according to an embodiment of the present invention;

[0037] Figure 5 This is a schematic diagram of a power filter circuit according to an embodiment of the present utility model;

[0038] Figure 6 This is a circuit diagram of the main control module according to an embodiment of the present utility model;

[0039] Figure 7 This is a circuit diagram of the driving module according to an embodiment of the present utility model;

[0040] Figure 8 This is a circuit diagram of the fault handling module according to an embodiment of the present utility model;

[0041] Figure 9 This is a circuit diagram of the communication module according to an embodiment of the present utility model;

[0042] Figure 10 This is a software control flowchart of an electronic load device according to an embodiment of the present invention;

[0043] Figure 11 This is a structural tooling for an electronic load device according to an embodiment of the present utility model. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0045] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0046] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can also refer to the internal connection of two components; and they can refer to a wireless connection or a wired connection. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0047] Furthermore, the technical features involved in the different embodiments of this utility model described below can be combined with each other as long as they do not conflict with each other.

[0048] This invention provides an electronic load device based on closed-loop control three-phase bridge drive for testing automotive controller drive signals. Figure 1 As shown, the electronic load device includes: a main control module, a drive module, a CAN communication module, and a fault handling module. The first terminal of the main control module is connected to the vehicle controller via the CAN communication module, and the second terminal of the main control module is connected to the first terminal of the drive module. The first terminal of the fault handling module is connected to the third terminal of the main control module, and the second terminal of the fault handling module is connected to the second terminal of the drive module.

[0049] Specifically, the vehicle controller sends the drive signal to be tested to the host computer in the form of a CAN message, which is then forwarded to the main control module. The main control module can obtain the target operating status of the electronic load through the CAN message sent by the host computer and control the output current of the drive module according to the target operating status. The main control module collects the drive current in real time and dynamically adjusts the magnitude of the drive current through closed-loop control. At the same time, the main control module collects the drive voltage in real time, and when an abnormality is detected, the electronic load device can automatically disconnect the drive module, isolating the vehicle controller from the electronic load.

[0050] In one alternative implementation, such as Figure 2 As shown, the electronic load device also includes a power processing module. The input terminal of the power processing module is connected to the power supply, and the output terminal of the power processing module is connected to the power supply terminals of the main control module, the drive module, the CAN communication module, and the fault handling module, respectively.

[0051] This invention provides an electronic load device based on a closed-loop control three-phase bridge drive. It can control the drive circuit to achieve the target drive current via a CAN communication module, seamlessly integrating with automated testing systems to improve testing efficiency, data processing capabilities, and response speed. Furthermore, the electronic load device features current sampling and closed-loop control. The main control module collects the drive current from the drive module, compares it with the target current value, and dynamically adjusts the output current of the drive module. Simultaneously, the electronic load device has comprehensive fault diagnosis and active safety protection functions. The main control module identifies abnormalities by collecting the drive voltage of the drive module and, upon detecting an abnormality, uses a fault handling module to cut off the drive circuit, ensuring system safety.

[0052] Specifically, such as Figure 3 As shown, the power processing module includes a rectifier circuit, a power filter circuit, and a voltage conversion circuit. The input terminal of the rectifier circuit is connected to the power supply. The output terminal of the rectifier circuit is connected to the input terminal of the power filter circuit and the first power supply terminal of the drive module. The output terminal of the power filter circuit is connected to the input terminal of the voltage conversion circuit. The output terminal of the voltage conversion circuit is connected to the power supply terminals of the main control module, the second power supply terminal of the drive module, the CAN communication module, and the fault handling module.

[0053] Furthermore, such as Figure 4As shown, the voltage conversion circuit includes a boost unit, a buck unit, a first voltage regulator unit, and a second voltage regulator unit. The input terminal of the boost unit is connected to the output terminal of the power filter circuit, and the output terminal of the boost unit is connected to the input terminal of the buck unit. The input terminal of the buck unit is also connected to the output terminal of the power filter circuit, and the output terminal of the buck unit is connected to the input terminals of both the first and second voltage regulator units. The output terminal of the first voltage regulator unit is connected to the power supply terminals of the main control module, the second power supply terminal of the drive module, the first power supply terminal of the CAN communication module, and the first power supply terminal of the fault handling module. The output terminal of the second voltage regulator unit is connected to the second power supply terminals of both the CAN communication module and the fault handling module.

[0054] In this embodiment, the rectifier module ensures that the power supply signal always maintains a constant direction, ensuring that the device can support multiple test modes such as high-drive, low-drive, and bridge drive. After passing through the rectifier circuit, the power supply signal always maintains a constant direction to power the modules in the electronic load device. When the power supply voltage output by the power filter circuit is greater than or equal to 8V, it is directly converted to 5.8V by the step-down unit to power the first and second voltage regulator units. The first voltage regulator unit converts the input voltage to 3.3V to power the main control module, drive module, CAN communication module, and fault handling module. The second voltage regulator unit converts the input voltage to 5V to power the CAN communication module and fault handling module. When the power supply voltage output by the power filter circuit is lower than 8V, it is first converted to above 8V by the boost unit before being supplied to subsequent modules. The main purpose is to ensure that the step-down unit can operate within a stable range and to ensure the stability of the power supply of the entire system. The main purpose of multiple voltage conversions is to achieve more efficient power management. Through multiple voltage conversions, the most suitable voltage conversion range can be selected for each conversion module, improving the energy conversion efficiency of the entire system, achieving electrical isolation to improve the system's safety and anti-interference capabilities, and protecting electronic equipment from power fluctuations through the design of voltage conversion and power filtering circuits.

[0055] like Figure 5The diagram shows the schematic of a power filter circuit. The power filter circuit mainly consists of a filter inductor and a filter capacitor. Its primary function is to prevent noise from the three-phase bridge switch from being transmitted along the power lines to the logic power supply section or other electrical equipment, affecting their normal operation. It also prevents power supply fluctuations from affecting the normal operation of the ECU (Electronic Control Unit). Since the electronic load device is driven and controlled by a 20kHz PWM (Pulse Width Modulation) three-phase bridge, a π filter circuit composed of capacitors C525, C527, C528, C531, C523, C530, and inductor L500 is used in the power supply section to prevent high-frequency interference signals from entering the circuit, reduce ripple, and provide a stable power input. A TVS diode D500 is placed at the input of the power supply to stabilize the voltage value and avoid misdiagnosis of the source voltage range due to transient voltage fluctuations. The main function of capacitors C524 and C529 is ESD (Electrostatic Discharge) protection, to prevent damage to the device due to electrostatic discharge.

[0056] The electronic load device is driven by a three-phase bridge, which has a large driving capacity. The driving current during long-term operation can reach 75A, and the instantaneous maximum current can reach 95A.

[0057] In one alternative implementation, see the main control module circuit diagram. Figure 6 The main control module controls the drive module to reach the target current via a three-phase bridge drive. It features three current sampling modules for detecting the drive current, enabling closed-loop control. Different fault flags are output for different fault types to facilitate fault diagnosis. When a safety-related fault is detected, the phase isolation switch is closed, entering a safe state. The main control module uses 3.3V as its power supply. Capacitors C534 and C535 primarily filter to ensure power supply stability. The VS and VDHP pins together provide the necessary power to the drive module's control circuitry, ensuring system safety and reliability. Capacitors C563, C532, C564, and C512 are placed close to the chip to reduce parasitic inductance and improve heat dissipation. Capacitor C533 primarily filters to ensure stable power supply. A capacitor C519 connected in series on the CB pin reduces noise in the current detection circuit. Capacitors C510 and C511 connected in series between pins CH1 and CL1, and CH2 and CL2, reduce high-frequency noise, improve output voltage stability, and reduce output current ripple. The three sets of pins, ISP1 and ISN1, ISP2 and ISN2, and ISP3 and ISN3, are... Figure 7The sampling resistor in the drive module is connected and transmits the acquired current signal to the main control module. The main control module amplifies and converts the acquired analog signal to digital, then outputs the detected current value for each phase through pins VO1, VO2, and VO3. Pins VO1, VO2, and VO3 convert the current values ​​into digital signals and output them to the communication module, which then uploads the three-phase current values ​​to the host computer. The VRO pin outputs a stable reference voltage to calibrate the output voltages of pins VO1, VO2, and VO3, ensuring the accuracy of current detection. The three sets of pins are connected to: VDH1, GH1, BH1, SH1, GL1, SL1; VDH2, GH2, BH2, SH2, GL2, SL2; VDH3, GH3, BH3, SH3, GL3, SL3. Figure 7 The three sets of driver modules are connected to each other, controlling their operation and shutdown. All three sets have the same function; the connection and function of the first set will be explained in detail using this example. The VDH1 pin is connected to... Figure 7The source of the high-side MOSFET (Metal-Oxide Semiconductor Field Effect Transistor) in the driver module is connected. Pin GH1 is connected to the gate of the high-side MOSFET, controlling its on / off state. Pin BH1 is connected in series with capacitor C500 to pin SH1 to provide the startup voltage for the high-side MOSFET. The main functions of capacitor C500 are energy storage and filtering. Pin SH1 is connected to the source of the phase-isolated MOSFET, and pin SL1 is connected to the source of the low-side MOSFET. Pin GL1 is connected to the gate of the low-side MOSFET, controlling its on / off state. The outputs of GH1, GL1, GH2, GL2, GH3, and GL3 can be controlled through three sets of pins: IH1, IL1; IH2, IL2; and IH3, IL3. When the IH1 input is low, GH1 outputs a high level, and the corresponding high-side MOSFET is turned on. When the IH1 input is high, GH1 outputs a low level, and the corresponding high-side MOSFET is turned off. When the IL1 input is high, the GL1 output is high, and the corresponding low-side MOSFET is turned on. When the IL1 input is low, the GL1 output is low, and the corresponding low-side MOSFET is turned off. The CLK_SPI pin is used for data transmission with the master device. The CSN pin controls the receive and transmit states of the TLE9183QK chip, ensuring reliable SPI communication. The MOSI pin is used to send data from the SPI master device to the TLE9183QK chip. The MISO pin is used to send data from the TLE9183QK chip to the SPI master device. The SOFF pin is used to turn off external MOSFETs to prevent short circuits or other faults. When the SOFF pin is low, the TLE9183QK chip will turn off all external MOSFETs and enter a safe shutdown mode. The INH pin controls the functions of the TLE9183QK chip, including entering sleep mode and safe shutdown mode. When the INH pin is low, the TLE9183QK chip will turn off its internal clock and enter sleep mode. The APC pin controls the phase isolation circuit. The ERR pin can indicate different error types by outputting a low level. When the chip detects an error, the ERR pin will output a low level and provide more detailed error information through the SPI communication interface, including the error type, location of occurrence, and error behavior.

[0058] In one optional implementation, the drive module includes a three-phase drive unit (A / B / C), where the connection and principle of each phase drive circuit are identical; the following explanation will use phase A as an example. Figure 7As shown, the A-phase drive unit includes: a first transistor Q606, a second transistor Q608, a first resistor R621, a third transistor Q607, and a fourth transistor Q611. The first terminal of the first transistor Q606 is connected to the power supply pin VDH1 (A_VDHA) and voltage acquisition pins VS and VDHP (UBD_PR_A) of the main control module. The second terminal of the first transistor Q606 is connected to the first terminal of the second transistor Q608, the first terminal of the third transistor Q607, and the voltage acquisition pin SH1 (A_I_V_A) of the main control module. The control terminal of the first transistor Q606 is connected to the control pin GH1 (A_O_T_GHA) of the main control module. The control terminal of the second transistor Q608 is connected to the control pin GL1 (A_O_T_GLA) of the main control module. The second terminal of the second transistor Q608 is connected to the voltage acquisition pin SL1 (A_I_V_LSSA) of the main control module and the first terminal of the first resistor R621. The second terminal of the first resistor R621 is grounded. The two ends of the first resistor R621 are also connected to the current acquisition pins ISP3 and ISN3 (A_ISENSE_A+ and A_ISENSE_A-) of the main control module. The control terminal of the third transistor Q607 is connected to the first terminal of the fourth transistor Q611 and the output terminal A_PHASE_OFF of the fault handling module. The second terminal of the third transistor Q607 is connected to the load. The control terminal of the fourth transistor Q611 is connected to the main control module, and the second terminal of the fourth transistor Q611 is grounded.

[0059] Specifically, transistors Q606, Q608, and Q607 are all MOSFETs, and transistor Q611 is a transistor. Q606 is a high-side MOSFET, Q608 is a low-side MOSFET, and Q607 is a phase-isolated MOSFET. When the power supply for the drive module control section comes from the main control module, transistors Q606 and Q607 are turned on. When the power supply for the drive module control section comes from an external source, transistors Q608 and Q607 are turned on. Furthermore, during the operation of the electronic load device, the main control module connects to the first resistor R621 through pins ISP3 and ISN3 and samples the drive current. It then compares the drive current with the target current. If the drive current has not yet reached the target current, the duty cycle of transistor Q606 is adjusted until the drive current reaches the target current. Resistors R664 and R665 and capacitors C635, C636, and C637 primarily filter out noise interference to ensure the stability and accuracy of the sampled signal.

[0060] Furthermore, the main control module can detect whether the first transistor Q606 is short-circuited by monitoring the voltage difference between VDH1 (A_VDHA) and SH1 (A_I_V_A). Similarly, the main control module can detect whether the second transistor Q608 is short-circuited by monitoring the voltage difference between SH1 (A_I_V_A) and SL1 (A_I_V_LSSA). When the main control module detects a short circuit in either the first transistor Q606 or the second transistor Q608, the SOFF pin outputs a low level, shutting down all external MOSFETs and entering a safety shutdown mode.

[0061] In this embodiment, a diode D606 and a resistor R615 are connected in series before the gate of the first transistor Q606, followed by a resistor R616 in parallel and then a capacitor C630 in series. The main function of this circuit is to increase the rise time when the first transistor Q606 is turned on and the fall time when it is turned off. Similarly, a circuit consisting of resistors R618 and R619, capacitor C632, and diode D607 is added before the gate of the second transistor Q608 for the same purpose. The main function of resistor R662 is current limiting. The main functions of resistor R617 in series with capacitor C629 and resistor R620 in series with capacitor C631 are filtering and energy storage. The main function of capacitor C627 is electrostatic discharge protection, and the main function of capacitor C628 is filtering.

[0062] To prevent a short circuit caused by the simultaneous conduction of the high-side and low-side MOSFETs, a phase-isolation MOSFET Q607 is added at the three-phase connection point to isolate the driven load from the controller. When the A_PHASE_OFF pin is high, the phase-isolation MOSFET Q607 conducts; when the A_PHASE_OFF pin is low, the phase-isolation MOSFET Q607 is off, achieving isolation between the controller and the load and protecting system safety. Transistor Q611 primarily functions as a switch, indirectly controlling the A_PHASE_OFF pin level by controlling its on / off state, thereby controlling the conduction and off state of the phase-isolation MOSFET. Diodes D673 and D694 ensure unidirectional conduction of the circuit, while resistors R671 and R668 primarily limit current. The main functions of capacitor C640 and resistor R698 connected in parallel are filtering and energy storage. The main function of Zener diode D672 is to maintain the operating state of phase-isolated MOSFET Q607, ensuring its rapid turn-on and turn-off. The capacitor allows for rapid charging and discharging, thereby accelerating gate voltage changes and reducing switching time. A thermistor is placed near phase-isolated MOSFET Q607 to collect real-time temperature data during device operation for over-temperature diagnostics.

[0063] In one optional implementation, the fault handling module includes three-phase fault handling units (A / B / C), with each phase fault handling unit having the same connection and principle; the following explanation uses phase A as an example. Figure 8 As shown, the A-phase fault handling unit includes: a first transistor unit Q504, a second transistor unit Q507, a fifth transistor Q503, a sixth transistor Q506, and a first capacitor C565. The first terminal of the first transistor unit Q504 is connected to the control terminal of the fifth transistor Q503. The control terminal of the first transistor unit Q504 is connected to the control pin APC (A_APC_P32.4) of the main control module and the safety pin A_TLF35584_SS2 of the power management chip. The second terminal of the first transistor unit Q504 is grounded. The first terminal of the second transistor unit Q507 is connected to the output terminal of the second voltage regulator unit. The control terminal of the second transistor unit Q507 is connected to the main control module. The second terminal of the second transistor unit Q507 is connected to both the first terminal and the control terminal of the sixth transistor Q506. The third terminal of the second transistor unit Q507 is grounded. The first terminal of the fifth transistor Q503 is connected to the output terminal VCC_5V_A of the first voltage regulator unit. The second terminal of the fifth transistor Q503 is connected to the first terminal of the sixth transistor Q506 and the first terminal of the first capacitor C565. The second terminal of the first capacitor C565 is grounded.

[0064] Specifically, the first transistor unit Q504 includes a seventh transistor Q7 and an eighth transistor Q8. The first terminal of the seventh transistor Q7 is connected to the control terminal of the fifth transistor Q503, and the control terminal of the seventh transistor Q7 is connected to the control pin APC (A_APC_P32.4) of the main control module. The second terminal of the seventh transistor Q7 is connected to the first terminal of the eighth transistor Q8. The control terminal of the eighth transistor Q8 is connected to the safety pin A_TLF35584_SS2 of the power management chip, and the second terminal of the eighth transistor Q8 is grounded. The second transistor unit includes a ninth transistor Q9 and a tenth transistor Q10. The first terminal of the ninth transistor Q9 is connected to the output terminal VCC_5V_A of the first voltage regulator unit. The second terminal of the ninth transistor Q9 is connected to both the first terminal and the control terminal of the sixth transistor Q506. The control terminal of the ninth transistor Q9 is connected to the first terminal of the tenth transistor Q10, and the control terminal of the tenth transistor Q10 is connected to the main control module. The second terminal of the tenth transistor Q10 is grounded. Among them, the fifth transistor, the seventh transistor Q7, the eighth transistor Q8, the ninth transistor Q9, and the tenth transistor Q10 are all bipolar transistors. The sixth transistor is a MOSFET.

[0065] In this embodiment, the APC pin is the control pin for turning off the MOSFET Q607. Active safety protection is achieved by controlling the triggering mode of the APC pin. This pin's triggering mode can be set to watchdog timer or overvoltage / undervoltage mode on the VCC pin. The SS2 pin is the safety status signal for the power management chip. When both SS2 and APC pins are high, the first transistor Q504 and the fifth transistor Q503 are turned on. The voltage of the A_PHASE_OFF pin is approximately equal to the high voltage of the A_VCPH pin. At this time, the phase-isolated MOSFET is turned on, and the drive circuit operates normally. When an abnormal current, voltage, or temperature is detected, either SS2 or APC pin goes low. The first transistor Q504 and the fifth transistor Q503 are turned off, and the voltage of the A_PHASE_OFF pin goes low. At this time, the phase-isolated MOSFET is turned off, and the drive circuit stops working. When either the APC or SS2 pin is low, the emergency shutdown function is triggered. This protects the system by identifying voltage anomalies in the main control module and drive module, or by triggering a safety status signal from the power management module. The fault handling module monitors the outputs of the SS2 and APC pins based on the sampled A_PHASE_OFF voltage. Each bridge arm of the drive module has a voltage acquisition circuit that collects the phase voltage when driving the load, allowing for diagnosis of the phase isolation MOSFET's state through voltage changes. The control signal output from the main control module is converted and processed to obtain the A_CUTGND_P13.0 pin signal. When the A_CUTGND_P13.0 pin outputs a high level, the second transistor Q507 and the sixth transistor Q506 are turned on, discharging the energy stored in the first capacitor C565. At this time, the voltage of the A_PHASE_OFF pin is low, preventing misdiagnosis that could lead to abnormal opening or closing of the phase isolation MOSFET. The main functions of resistors R503, R504, R564, R562, and R563 are current limiting. The main functions of capacitor C538 are filtering and energy storage, while the main functions of capacitor C539 are filtering and electrostatic discharge protection.

[0066] The electronic load device can provide multiple protection functions such as overvoltage, undervoltage, overcurrent, and temperature detection. When an abnormality is detected, the main control module can automatically cut off the drive circuit by controlling the phase isolation MOSFET, and supports programmable thresholds and fault diagnosis to ensure the safety and reliability of the system.

[0067] In one optional implementation, the CAN communication module includes: a three-phase CAN communication module unit (A / B / C), where the connection and principle of each phase CAN communication module unit are identical; the following explanation will use phase A as an example. Figure 9As shown, the A-phase CAN communication module unit includes: CAN transceiver U201. The signal receiving pin RXD, signal transmitting pin TXD, and mode switching pin STB of CAN transceiver U201 are all connected to the main control module. The communication pins CANH and CANL of CAN transceiver U201 are connected to the host computer through the CAN bus.

[0068] Specifically, the main function of the communication module is to transmit data between different control units. Through the communication module, the operating status of the electronic load can be monitored in real time, providing data support for closed-loop control and fault diagnosis. The communication module uses 5V as its power supply and is connected to the VCC pin of the CAN transceiver TJA1042TK / 3 / 1. Capacitors C220, C221, C218, and C219 mainly provide ESD protection, ensuring the stability of the power supply and input signals. Capacitor C222 and resistors R228 and R229 form an RC filter circuit to remove high-frequency noise from the signal and improve the signal-to-noise ratio. By configuring the high and low levels of the STB pin of the TJA1042TK / 3 / 1, the normal mode and standby mode of the CAN transceiver 201 can be switched. When the STB pin is low, the CAN transceiver 201 can send and receive data normally; in this mode, the CAN transceiver 201 operates normally. When the STB pin is high, the CAN transceiver 201 stops sending and receiving data to reduce power consumption. At this time, only one low-power differential receiver monitors the activity on the bus line, and CAN transceiver 201 operates in standby mode. In standby mode, CAN transceiver 201 stops sending and receiving data, thereby reducing power consumption. When the low-power receiver in standby mode detects a message on the CAN bus, it outputs a low-level signal through the RXD pin to request waking up CAN transceiver 201 to enter normal mode. The TXD pin is mainly used to input data sent by other modules into CAN transceiver 201 for transmission via the CAN bus. The main function of pull-up resistor R232 is to pull the STB pin high in standby mode, thereby reducing power consumption. When the CAN bus is in recessive state, the RXD pin outputs a high level, and pull-up resistor R224 ensures stable output. Resistor R226 mainly serves to limit current. Vio provides an independent power supply for the low-power mode of the CAN transceiver 201, enabling monitoring of CAN bus activity even when the VCC power is off. It also adjusts the signal levels of the TXD, RXD, and STB pins to ensure compatibility with the automotive controller's I / O levels. The CANH and CANL pins connect to the CAN bus and are responsible for sending and receiving message data. Sending CAN messages controls the current of the drive module, while receiving CAN messages from the main control module allows for real-time assessment and adjustment of the drive current output. Furthermore, it can determine the operating status of electronic loads based on real-time feedback messages, providing data support for fault diagnosis.

[0069] The electronic load device has an independent heat dissipation and communication system, capable of controlling the drive current via CAN messages. It seamlessly integrates with automated testing systems, serving both as an adjustable load for drive capability testing and as a control system for vehicle controllers, meeting the testing needs of various controllers. The electronic load device controls the drive circuit to achieve the target drive current via CAN message commands, using the same communication method as the vehicle controller, facilitating overall control with high speed and efficiency. The drive current information of the electronic load device can be uploaded via CAN messages and can also be displayed in real-time on an LCD screen.

[0070] In one alternative implementation, Figure 10 This is a flowchart of the software control process for an electronic load device. The software program for this device is as follows: Start → Power-on initialization → Enter configuration mode to configure parameters: drive mode, diagnostic threshold, filtering time, voltage feedback, short circuit detection, over-temperature detection, etc. → Enter operating mode: When the main control module's SPI pin receives the correct parameter configuration information, it enters normal operating mode. When the SPI key receives a sleep command, it enters sleep mode to reduce power consumption, at which time the INH pin is set to low level. When a wake-up message is detected internally, the INH pin is set high, and the main control module is woken up from sleep mode, then reconfigures the corresponding control parameters via the SPI pin → Enter normal drive mode → Data acquisition → Analyze and process the acquired data: power monitoring, temperature monitoring, drive output stage monitoring, data acquisition interface monitoring, etc. By using these fault diagnosis functions, the normal operation of the drive module can be guaranteed, and any fault conditions can be handled in a timely manner, thereby improving the reliability and safety of the system. → Current detection: Adjust the drive current of the drive module according to the real-time collected current data to realize closed-loop control of the drive current. → Continuous monitoring of various diagnostic functions: When an abnormal signal is detected, the diagnostic module will turn off the phase isolation MOS to protect the system's safety and stability.

[0071] In one alternative implementation, Figure 11This is the structural fixture for the electronic load. Component 1 is the power supply interface for the device, providing power. Component 2 is the power supply interface for the cooling fan, using 24V power and isolated from the device's power supply interface to ensure accurate and stable operation. Component 3 is the fuse interface, mainly providing hardware safety protection. Component 4 is the interface for the LCD screen displaying the real-time drive current, capable of displaying the real-time drive current magnitude. Component 5 is the communication interface, mainly for transmitting control commands and acquired signals. Component 6 is the heat dissipation hole, preventing system overheating and malfunctions. Component 7 is the mounting and fixing position for the circuit board, fixing the circuit board in the middle of the fixture for easy heat dissipation. Component 8 is the mounting and fixing interface for the cooling fan, increasing the device's heat dissipation. Component 9 is the overall side view of the electronic load.

[0072] This invention provides a vehicle that includes the electronic load device based on closed-loop control three-phase bridge drive as described in the above embodiments.

[0073] This invention provides a vehicle that can use an electronic load device to complete the testing of various controllers, thereby meeting the testing requirements of the vehicle.

[0074] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. An electronic load device based on closed-loop control three-phase bridge drive, characterized in that, The electronic load device includes: a main control module, a drive module, a CAN communication module, and a fault handling module, wherein... The first end of the main control module is connected to the vehicle controller via the CAN communication module, and the second end of the main control module is connected to the first end of the drive module. The first end of the fault handling module is connected to the third end of the main control module, and the second end of the fault handling module is connected to the second end of the drive module.

2. The electronic load device based on closed-loop control three-phase bridge drive according to claim 1, characterized in that, The electronic load device further includes a power processing module, the input terminal of which is connected to a power supply, and the output terminal of which is connected to the power supply terminals of the main control module, the drive module, the CAN communication module, and the fault handling module, respectively.

3. The electronic load device based on closed-loop control three-phase bridge drive according to claim 2, characterized in that, The power processing module includes: a rectifier circuit, a power filter circuit, and a voltage conversion circuit, wherein... The input terminal of the rectifier circuit is connected to the power supply, and the output terminal of the rectifier circuit is connected to the input terminal of the power filter circuit and the first power supply terminal of the drive module. The output terminal of the power filter circuit is connected to the input terminal of the voltage conversion circuit, and the output terminal of the voltage conversion circuit is connected to the power supply terminal of the main control module, the second power supply terminal of the drive module, the power supply terminal of the CAN communication module, and the power supply terminal of the fault handling module.

4. The electronic load device based on closed-loop control three-phase bridge drive according to claim 3, characterized in that, The voltage conversion circuit includes: a boost unit, a buck unit, a first voltage regulator unit, and a second voltage regulator unit, wherein... The input terminal of the boost unit is connected to the output terminal of the power filter circuit, and the output terminal of the boost unit is connected to the input terminal of the buck unit. The input terminal of the step-down unit is also connected to the output terminal of the power filter circuit, and the output terminal of the step-down unit is connected to the input terminal of the first voltage regulator unit and the input terminal of the second voltage regulator unit, respectively. The output terminal of the first voltage regulator unit is connected to the power supply terminal of the main control module, the second power supply terminal of the drive module, the first power supply terminal of the CAN communication module, and the first power supply terminal of the fault handling module, respectively. The output terminal of the second voltage regulator unit is connected to the second power supply terminal of the CAN communication module and the second power supply terminal of the fault handling module, respectively.

5. The electronic load device based on closed-loop control three-phase bridge drive according to claim 4, characterized in that, The drive module includes: a three-phase drive unit (A / B / C), each phase drive unit including: a first transistor, a second transistor, a first resistor, a third transistor, and a fourth transistor, wherein... The first terminal of the first transistor is connected to the power supply pin and voltage acquisition pin of the main control module, the second terminal of the first transistor is connected to the first terminal of the second transistor, the first terminal of the third transistor and the voltage acquisition pin of the main control module, and the control terminal of the first transistor is connected to the control pin of the main control module. The control terminal of the second transistor is connected to the control pin of the main control module. The second terminal of the second transistor is connected to the voltage acquisition pin of the main control module and the first terminal of the first resistor, respectively. The second terminal of the first resistor is grounded. The two ends of the first resistor are also connected to the current acquisition pin of the main control module. The control terminal of the third transistor is connected to the first terminal of the fourth transistor and the output terminal of the fault handling module, respectively, and the second terminal of the third transistor is connected to the load. The control terminal of the fourth transistor is connected to the main control module, and the second terminal of the fourth transistor is grounded.

6. The electronic load device based on closed-loop control three-phase bridge drive according to claim 5, characterized in that, The fault handling module includes: a three-phase fault handling unit (A / B / C), and each phase fault handling unit includes: a first transistor unit, a second transistor unit, a fifth transistor, a sixth transistor, and a first capacitor. The first terminal of the first transistor unit is connected to the control terminal of the fifth transistor. The control terminal of the first transistor unit is connected to the control pin of the main control module and the safety pin of the power management chip, respectively. The second terminal of the first transistor unit is grounded. The first terminal of the second transistor unit is connected to the output terminal of the second voltage regulator unit, the control terminal of the second transistor unit is connected to the main control module, the second terminal of the second transistor unit is connected to the first terminal and the control terminal of the sixth transistor, and the third terminal of the second transistor unit is grounded. The first terminal of the fifth transistor is connected to the output terminal of the first voltage regulator unit, and the second terminal of the fifth transistor is connected to the first terminal of the sixth transistor and the first terminal of the first capacitor, respectively. The second terminal of the first capacitor is grounded.

7. The electronic load device based on closed-loop control three-phase bridge drive according to claim 6, characterized in that, The first transistor unit includes: a seventh transistor and an eighth transistor, wherein, The first terminal of the seventh transistor is connected to the control terminal of the fifth transistor, the control terminal of the seventh transistor is connected to the control pin of the main control module, the second terminal of the seventh transistor is connected to the first terminal of the eighth transistor, the control terminal of the eighth transistor is connected to the safety pin of the power management chip, and the second terminal of the eighth transistor is grounded.

8. The electronic load device based on closed-loop control three-phase bridge drive according to claim 6, characterized in that, The second transistor unit includes: a ninth transistor and a tenth transistor, wherein, The first terminal of the ninth transistor is connected to the output terminal of the first voltage regulator unit, the second terminal of the ninth transistor is connected to the first terminal and the control terminal of the sixth transistor, the control terminal of the ninth transistor is connected to the first terminal of the tenth transistor, the control terminal of the tenth transistor is connected to the main control module, and the second terminal of the tenth transistor is grounded.

9. The electronic load device based on closed-loop control three-phase bridge drive according to claim 4, characterized in that, The CAN communication module includes: A / B / C three-phase CAN communication module units. Each phase CAN communication module unit includes: a CAN transceiver. The signal receiving pin, signal transmitting pin, and mode switching pin of the CAN transceiver are all connected to the main control module. The communication pins of the CAN transceiver are connected to the host computer through the CAN bus.

10. A vehicle, characterized in that, The vehicle includes an electronic load device based on a closed-loop control three-phase bridge drive, as described in any one of claims 1 to 9.

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