A motor controller temperature rise testing device

Abstract

This utility model relates to a motor controller temperature rise testing device, which includes a power supply, a first controller, an inductor, a position simulation device, and a first current detection device. The three input terminals of the inductor are respectively connected to the three-phase output terminals of the first controller. The inductor is used to simulate the test motor. The first current detection device is connected to both the inductor and the feedback terminal of the first controller. The position simulation device is connected to the first controller. During the test, the power supply supplies power to the first controller, the first controller drives the inductor, the first current detection device detects the actual current of the inductor, and the position simulation device feeds back the motor position signal to the first controller. Based on the motor position signal and the actual current, the first controller adjusts the first driving current output to the inductor. This motor controller temperature rise testing device uses an inductor to simulate the test motor, which occupies less space, has lower cost, is more convenient and flexible to operate, and provides more accurate testing.

Description

Technical Field

[0001] This utility model relates to the field of motor testing, and in particular to a motor controller temperature rise testing device. Background Technology

[0002] Motor controllers are used in a variety of devices and are important components of those devices. Before being put into use, motor controllers must undergo a temperature rise test to ensure they can reliably control the motor and prevent damage from excessive heat.

[0003] In related technologies, the temperature rise test of motor controllers relies on the actual motor load, and high-power motors are usually selected for testing, which makes the test equipment expensive, occupies a large area, and is inconvenient and inflexible in test operation. Utility Model Content

[0004] The present invention aims to provide a motor controller temperature rise testing device that can achieve accurate testing, has low cost, and is more convenient and flexible for testing.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solutions:

[0006] This utility model provides a motor controller temperature rise testing device, including: a power supply, a first controller, an inductor, a position simulation device, and a first current detection device, wherein the first controller is the motor controller to be tested;

[0007] The power supply provides power to the first controller;

[0008] The three input terminals of the inductor are respectively connected to the three-phase output terminals of the first controller, and the inductor is used to simulate and test the motor;

[0009] The first current detection device is connected to the inductor and the feedback terminal of the first controller respectively, and is used to detect the actual current of the inductor;

[0010] The position simulation device is connected to the first controller and is used to feed back the motor position signal to the first controller according to the motor speed command sent by the first controller;

[0011] The first controller is used to adjust the first drive current output to the inductor based on the motor position signal and the actual current.

[0012] In some embodiments, the position simulation device includes a second controller, a first motor, and a position sensor;

[0013] The second controller is connected to the first controller and is used to output a second drive current to the first motor according to the motor speed command sent by the first controller;

[0014] The position sensor is connected to the first motor and the first controller respectively, and is used to detect the position of the first motor, generate the motor position signal, and send the motor position signal to the first controller.

[0015] In some embodiments, the position sensor is an encoder or a rotary transformer.

[0016] In some embodiments, the rated power of the first motor is less than the set power.

[0017] In some embodiments, the motor controller temperature rise testing device further includes a host computer, a voltage detection device, and a second current detection device;

[0018] The voltage detection device is connected to the drive module in the first controller and the host computer, respectively; the second current detection device is connected to the drive module in the first controller and the host computer, respectively.

[0019] The voltage detection device is used to detect the voltage signal during the switching process of the drive module in the first controller, and the second current detection device is used to detect the current signal of the drive module in the first controller.

[0020] The host computer is used to adjust the dead time of the drive signal corresponding to the drive module of the first controller according to the voltage signal and the current signal.

[0021] In some embodiments, the driving module is an IGBT module or a driving chip.

[0022] In some embodiments, the motor controller temperature rise testing device further includes a temperature detection device connected to the first controller, which is used to detect the temperature of the first controller.

[0023] In some embodiments, the motor controller temperature rise testing device further includes a temperature simulation device for simulating ambient temperature.

[0024] In some embodiments, the power supply includes a high-voltage power supply and a low-voltage power supply;

[0025] The high-voltage power supply is connected to the high-voltage power supply terminal of the first controller and is used to provide high-voltage power supply voltage to the first controller.

[0026] The low-voltage power supply is connected to the low-voltage power supply terminal of the first controller and is used to provide a low-voltage power supply voltage to the first controller.

[0027] In various embodiments of this utility model, the motor controller temperature rise testing device includes a power supply, a first controller, an inductor, a position simulation device, and a first current detection device. The three input terminals of the inductor are respectively connected to the three-phase output terminals of the first controller. The inductor is used to simulate the test motor. The first current detection device is connected to both the inductor and the feedback terminal of the first controller. The position simulation device is connected to the first controller. During the test, the power supply supplies power to the first controller, the first controller drives the inductor, the first current detection device detects the actual current of the inductor, and the position simulation device feeds back the motor position signal to the first controller based on the motor speed command sent by the first controller. The first controller adjusts the first driving current output to the inductor based on the motor position signal and the actual current. Therefore, this motor controller temperature rise testing device uses an inductor to simulate the test motor, which occupies less space, has lower cost, and is more convenient and flexible to operate. Furthermore, during the test, the position simulation device provides the motor position signal to the first controller, enabling the first controller to achieve closed-loop control and making the test more accurate. Attached Figure Description

[0028] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0029] Figure 1 This is a schematic diagram of the structure of one of the motor controller temperature rise testing devices provided in this utility model embodiment;

[0030] Figure 2 This is a schematic diagram of the structure of one of the motor controller temperature rise testing devices provided in this utility model embodiment;

[0031] Figure 3 This is a schematic diagram of the structure of one of the motor controller temperature rise testing devices provided in this utility model embodiment;

[0032] Figure 4 This is a schematic diagram of a color gradient map corresponding to one of the timing deviations provided in an embodiment of this utility model;

[0033] Figure 5 This is a schematic diagram of the structure of one of the motor controller temperature rise testing devices provided in this utility model embodiment. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this utility model and are not intended to limit this utility model.

[0035] The motor controller can control the motor to work in a set direction and speed. Before it is put into use, the motor controller needs to be tested for performance, especially the temperature rise test, so that the motor controller can reliably control the motor and prevent the motor controller from being damaged due to excessive temperature.

[0036] The temperature rise test of the motor controller refers to the test of the temperature change of the motor controller when the motor is running under various drive currents, such as the temperature change of the motor controller when the motor is stalled, or the temperature change of the motor controller when the motor is overloaded.

[0037] In related technologies, temperature rise testing of motor controllers relies on actual motor loads. Since high-power motors have higher rated power and load-carrying capacity, they can provide sufficient output power. Moreover, the temperature rise of the motor controller changes gradually during operation, which helps to obtain accurate temperature rise data. Therefore, high-power motors are generally selected for temperature rise testing.

[0038] However, high-power motors are expensive and heavy; for example, a 300kW industrial permanent magnet motor weighs between 300kg and 500kg, making it difficult to move. They also require high-power power supplies, test benches, and cooling systems, requirements that make them impractical in ordinary engineering projects. Furthermore, high-power motors occupy a large area, making replacement inconvenient and impacting testing efficiency. Therefore, using high-power motors for temperature rise testing of motor controllers results in a large testing setup, high costs, and inconvenient and inflexible testing operations.

[0039] To address the aforementioned issues, this utility model provides a motor controller temperature rise testing device that is low in cost, offers more flexible and convenient testing operations, and achieves closed-loop control for more accurate testing.

[0040] Please see Figure 1 , Figure 1 This is a schematic diagram of the structure of a motor controller temperature rise testing device provided in an embodiment of the present invention. The motor controller temperature rise testing device 100 includes a power supply 10, a first controller 20, an inductor 30, a position simulation device 40, and a first current detection device 50, wherein the first controller 20 is the motor controller to be tested.

[0041] The three input terminals of inductor 30 are respectively connected to the three-phase output terminals of the first controller 20. Figure 1The inductor 30 is used to simulate the test motor (U terminal, V terminal and W terminal in the inductor 30, the first current detection device 50 is connected to the feedback terminal of the inductor 30 and the first controller 20 respectively, and the position simulation device 40 is connected to the first controller 20.

[0042] When a temperature rise test is required on the first controller 20, the power supply 10 supplies power to the first controller 20. The first controller 20 includes a drive module, which is an IGBT module or a drive chip. The drive module receives a control signal and turns it on or off, thereby generating a drive current based on the supply voltage of the power supply 10. This drive current flows into the inductor 30, causing the inductor 30 to generate a corresponding back electromotive force and impedance, thus realizing the drive of the inductor 30 by the first controller 20.

[0043] Simultaneously, the first controller 20 sends a motor speed command to the position simulation device 40, and the position simulation device 40 generates a corresponding motor position signal based on the motor speed command and sends the motor position signal to the first controller 20.

[0044] The first current detection device 50 detects the actual current of the inductor 30, and the first controller 20 adjusts the first drive current output to the inductor 30 based on the motor position signal and the actual current.

[0045] For example, the first controller 20 generates a position deviation based on the motor position signal and the desired position signal. Based on the position deviation, it uses a control algorithm (such as a PID control algorithm) to calculate the amount of adjustment required to the set current value. If the position deviation is positive, that is, the actual position is ahead of the desired position, it may be necessary to appropriately reduce the set current; conversely, if the position deviation is negative, it may be necessary to increase the set current.

[0046] The current deviation value between the adjusted set current and the actual current is then obtained, and a corresponding PWM signal is generated using a control algorithm (such as PID control algorithm). The PWM signal is used to control the drive module in the first controller 20 to change its switching process, thereby changing the magnitude of the drive current, so that the actual current of the inductor 30 reaches the adjusted set current, thereby realizing the control of the current.

[0047] During the above test, the temperature rise of the first controller 20 can be tested, and the temperature rise performance of the first controller 20 can be tested when different set currents are output by gradually increasing the set current.

[0048] Because the electromagnetic characteristics of inductor 30 are similar to those of a high-power motor, the relationship between the current in inductor 30 and the generated magnetic field is similar to that of a high-power motor. Inductor 30 can simulate motor characteristics. Taking a permanent magnet synchronous motor as an example, the motor windings have the properties of inductor 30, and their structure is similar to that of inductor 30. A composite rotating magnetic field can be generated by three-phase alternating current to simulate motor torque. Therefore, in this embodiment, using inductor 30 to simulate and test the motor not only achieves the purpose of testing the temperature rise performance of the first controller 20, but also saves space, reduces costs, and makes the testing operation more flexible and convenient.

[0049] Furthermore, since the inductor 30 generates a large amount of reactive power during operation, which is different from the active power of the motor, it cannot generate rotational speed. If there is only the inductor 30, the first controller 20 cannot receive the position signal of rotational feedback and cannot form a closed-loop system.

[0050] Therefore, in this embodiment, the position simulation device 40 feeds back the motor position signal to the first controller 20, so that the first controller 20 can receive the position signal of rotation feedback and realize closed-loop control.

[0051] In summary, this motor controller temperature rise testing device uses inductive simulation to test the motor, which occupies less space, has lower cost, and is more convenient and flexible to operate. Furthermore, during the test, the position simulation device provides the motor position signal to the first controller, enabling the first controller to achieve closed-loop control and making the test more accurate.

[0052] In some embodiments, please refer to Figure 2 , Figure 2 This is a schematic diagram of the structure of a motor controller temperature rise testing device provided in an embodiment of this utility model, as shown below. Figure 2 As shown, the motor controller temperature rise test device 100 also includes a temperature detection device 60, which is connected to the first controller 20.

[0053] The temperature detection device 60 is a temperature sensor and measuring device used to detect the temperature of the first controller 20, mainly for detecting the temperature of key heat-generating components of the first controller 20. For example, a temperature sensor (such as a thermocouple, thermistor, etc.) is installed on the surface of the drive module (such as an IGBT module, drive chip, etc.) of the first controller 20, and the signal output terminal of the temperature sensor is connected to a temperature measuring device (such as a data acquisition unit, temperature tester, etc.) to monitor the temperature changes of each component of the first controller 20 in real time during the temperature rise test process.

[0054] In some embodiments, the motor controller temperature rise testing device 100 further includes a temperature simulation device for simulating ambient temperature.

[0055] The temperature simulation device simulates the ambient temperature, thereby ensuring that the first controller 20 operates at a set temperature for more accurate testing. For example, the temperature simulation device includes a water pump and a temperature chamber. The water pump is turned on, and the water temperature is set to T℃, such as 65℃, so that the temperature chamber reaches 65℃ to simulate the outdoor temperature. The testing device is then placed in the temperature chamber, allowing the first controller 20 to operate in an environment of 65℃.

[0056] During the test, the temperature of the temperature chamber can be changed by adjusting the water temperature, thereby changing the ambient temperature of the first controller 20, so as to test the temperature rise performance of the first controller 20 under different ambient temperatures, thus simulating the temperature rise performance of the first controller 20 under different outdoor temperatures.

[0057] In some embodiments, please continue reading Figure 2 The power supply 10 includes a high-voltage power supply 11 and a low-voltage power supply 12. The high-voltage power supply 11 is connected to the high-voltage power supply 11 of the first controller 20, and the low-voltage power supply 12 is connected to the low-voltage power supply 12 of the first controller 20. The high-voltage power supply 11 provides a high-voltage supply voltage to the first controller 20, and the low-voltage power supply 12 provides a low-voltage supply voltage to the first controller 20. In other embodiments, the low-voltage power supply 12 also supplies power to the inductor 30 to reduce energy loss.

[0058] During the test, timing abnormalities may occur during the switching process of the drive module in the first controller 20. Timing abnormalities can cause abnormal temperature rise of the drive module, thereby affecting the test results.

[0059] Based on the above issues, such as Figure 3 As shown in the figure, this utility model embodiment provides a structural schematic diagram of a motor controller temperature rise testing device 100. The motor controller temperature rise testing device 100 also includes a host computer 90, a voltage detection device 70 and a second current detection device 80. The voltage detection device 70 is connected to the drive module in the first controller 20 and the host computer 90, respectively. The second current detection device 80 is connected to the drive module in the first controller 20 and the host computer 90, respectively.

[0060] If the driving module of the first controller 20 is an IGBT module, then the voltage detection device 70 and the second current detection device 80 are connected between the gate and collector of the IGBT module to detect the voltage and current signals during the IGBT switching process. If the driving module of the first controller 20 is a driver chip, then the voltage detection device 70 and the second current detection device 80 are respectively connected to the driver chip to detect the voltage and current signals of the driver chip during the switching process.

[0061] The second current detection device 80 can be a Hall current sensor with a sampling frequency ≥2MHz to capture transient current waveforms. The voltage detection device 70 can be a parallel differential voltage probe, which monitors voltage spikes during the switching process at the hardware level with an accuracy of ±1%.

[0062] The host computer 90 receives voltage and current signals, analyzes voltage and current changes, and determines whether the timing of the drive module in the first controller 20 is abnormal based on these changes.

[0063] In some embodiments, the host computer 90 uses a switching sequence heatmap algorithm to map timing deviations into color gradients. The color gradient map corresponding to the timing deviations is shown below. Figure 4 As shown, the first color block represents a timing deviation of 5 ns, the second color block represents a timing deviation of 45 ns, the third color block represents a timing deviation of 15 ns, the fourth color block represents a timing deviation of 10 ns, the fifth color block represents a timing deviation of 25 ns, and the sixth color block represents a timing deviation of 40 ns. Color blocks with a timing deviation greater than 5 ns can use the same color identifier, such as red; color blocks with a timing deviation greater than 10 ns can use a different color identifier, such as yellow; and color blocks with a timing deviation greater than 40 ns can use the same color identifier, such as green.

[0064] By employing a switching sequence heatmap algorithm, the switching timing deviation is visualized. The color gradient intuitively reflects the differences in the turn-on / turn-off times of each IGBT module or driver chip, thereby quickly locating the temperature rise hotspots caused by timing anomalies.

[0065] When the host computer 90 determines that the timing of the drive module of the first controller 20 is abnormal based on the voltage or current signal, it will introduce adaptive PID feedback. The host computer 90 or the first controller 20 will automatically adjust the dead time of the PWM signal of the drive IGBT module or drive chip to compensate for timing errors, eliminate timing abnormalities, and thus reduce the impact of temperature rise caused by timing errors of individual drive modules on the temperature rise test of the first controller 20, thereby improving the test results.

[0066] For example, if the host computer 90 detects that the turn-on delay of the third IGBT module is 35ns, the temperature rise is 8℃ higher than that of other modules. Adaptive PID feedback adjusts the dead time from 1μs to 1.3μs, reduces the delay to 12ns, and narrows the temperature rise difference to 3℃, thereby reducing the impact on the temperature rise test of the first controller 20.

[0067] In some embodiments, please refer to Figure 5 , Figure 5 This is a schematic diagram of the structure of a motor controller temperature rise testing device provided in an embodiment of this utility model, as shown below. Figure 5As shown, the position simulation device 40 includes a second controller 41, a first motor 42, and a position sensor 43. The second controller 41 is connected to the first controller 20, and the position sensor 43 is connected to both the first motor 42 and the first controller 20.

[0068] The first controller 20 and the second controller 41 are connected via wireless or wired means. Figure 5 (Taking a wired connection as an example), the first controller 20 can send control commands or reference signals to the second controller 41, and the second controller 41 will feed back feedback information to the first controller 20, realizing data interaction between the two.

[0069] The first controller 20 sends a motor speed command to the second controller 41. This motor speed command can be determined based on a set current. The second controller 41 outputs a second drive current to the first motor 42 according to the motor speed command. If the second controller 41 uses a PID control algorithm, it obtains a drive signal from the drive module in the second controller 41. This drive signal drives the drive module in the second controller 41 to turn on / off, causing the drive module in the second controller 41 to convert the power supply 10 into a second drive current. The second drive current is then output to the first motor 42, controlling the operation of the first motor 42.

[0070] Position sensor 43 detects the position of the first motor 42, generates a motor position signal, and sends the motor position signal to the first controller 20. This allows the first controller 20 to adjust the first drive current output to the inductor 30 based on the motor position signal and the actual current of the inductor 30, thereby achieving closed-loop control. In some embodiments, position sensor 43 can transmit the motor position signal to the second controller 41, which then feeds the motor position signal back to the first controller 20.

[0071] Therefore, inductor 30 cannot generate a motor position signal, and the first controller 20 cannot achieve closed-loop control. Thus, in this embodiment, the first motor 42 is used to generate the actual motor position signal, enabling the first controller 20 to achieve closed-loop control and improving the test results.

[0072] The first motor 42 is an actual motor, typically a low-power motor. In some embodiments, the power of the first motor 42 is less than its rated power. Using a low-power motor to generate the actual motor position signal reduces costs. Furthermore, since the first motor 42 is a low-power motor, it can be powered by a low-voltage power supply 12, reducing energy loss.

[0073] Combination Figure 5 The testing process of this temperature rise testing device can be described as follows:

[0074] First, correctly connect the power supply line 10, the resolver signal line, and the U, V, and W phase connection lines. Then, power on the control boards corresponding to the first controller 20 and the second controller 41 to ensure the program is correct and to avoid damage to the control boards due to program issues. Use a simulator to burn the program into the control boards; the software includes a protection program to prevent damage to the control boards. A dual-drive board is used and configured: one drive board drives the first motor 42, and the other drive the inductor 30. Therefore, dual-drive boards are required, and I / F start-up is simulated.

[0075] The first controller 20 is powered by a high-voltage power supply 11 and a low-voltage power supply 12, while the inductor 30 and the first motor 42 are powered by the low-voltage power supply 12 to reduce energy loss.

[0076] Turn on the water pump and set the temperature chamber to 65°C to simulate outdoor temperature, with a threshold allowed to handle severe weather. Wait for the water temperature to rise; once the temperature chamber reaches 65°C, begin the test.

[0077] The temperature detection device 60 is used to measure the temperature change of key components in the first controller 20, such as the drive module, to measure the temperature rise of the device, and gradually increase the first drive current output to the inductor 30 to adjust the first drive current to the set current.

[0078] Wait for a period of time, such as about ten minutes, and observe the temperature change reported by the temperature detection device 60. If the temperature rises too quickly, it indicates that the performance of the first controller 20 is substandard. Power should be cut off immediately to prevent overheating and damage to the control board. Check the wiring for correctness and ensure the temperature rise meter is properly wired. If the temperature of the tested device is within the normal range, it indicates that the method of using the inductor 30 instead of the motor for temperature rise testing is successful, and the temperature rise process can be recorded.

[0079] Furthermore, during the test, the voltage detection device 70 and the second current detection device 80 are used to detect the voltage and current signals of the drive module in the first controller 20. The host computer 90 generates a color gradient map corresponding to the timing deviation based on the voltage and current signals, and adjusts the dead time of the PWM signal of the drive module based on the color gradient map to reduce the impact of timing abnormalities on the temperature rise test results.

[0080] In summary, this motor controller temperature rise testing device uses inductive simulation to test the motor, which occupies less space, has lower cost, and is more convenient and flexible to operate. Furthermore, during the test, the position simulation device provides the motor position signal to the first controller, enabling the first controller to achieve closed-loop control and making the test more accurate.

[0081] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it; under the concept of this utility model, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of this utility model as described above. For the sake of brevity, they are not provided in detail; although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. An electric machine controller temperature rise test apparatus, characterized by, include: The device includes a power supply, a first controller, an inductor, a position simulation device, and a first current detection device, wherein the first controller is the controller of the motor under test. The power supply provides power to the first controller; The three input terminals of the inductor are respectively connected to the three-phase output terminals of the first controller, and the inductor is used to simulate and test the motor; The first current detection device is connected to the inductor and the feedback terminal of the first controller respectively, and is used to detect the actual current of the inductor; The position simulation device is connected to the first controller and is used to feed back the motor position signal to the first controller according to the motor speed command sent by the first controller; The first controller is used to adjust the first drive current output to the inductor based on the motor position signal and the actual current.

2. The motor controller temperature rise test apparatus of claim 1, wherein, The position simulation device includes a second controller, a first motor, and a position sensor; The second controller is connected to the first controller and is used to output a second drive current to the first motor according to the motor speed command sent by the first controller; The position sensor is connected to the first motor and the first controller respectively, and is used to detect the position of the first motor, generate the motor position signal, and send the motor position signal to the first controller.

3. The motor controller temperature rise test apparatus of claim 2, wherein, The position sensor is an encoder or a rotary transformer.

4. The motor controller temperature rise test apparatus of claim 2, wherein, The rated power of the first motor is less than the set power.

5. The motor controller temperature rise test apparatus of any one of claims 1-4, wherein, The motor controller temperature rise testing device also includes a host computer, a voltage detection device, and a second current detection device; The voltage detection device is connected to the drive module in the first controller and the host computer, respectively; the second current detection device is connected to the drive module in the first controller and the host computer, respectively. The voltage detection device is used to detect the voltage signal during the switching process of the drive module in the first controller, and the second current detection device is used to detect the current signal of the drive module in the first controller. The host computer is used to adjust the dead time of the drive signal corresponding to the drive module of the first controller according to the voltage signal and the current signal.

6. The motor controller temperature rise test apparatus of claim 5, wherein, The driving module is an IGBT module or a driving chip.

7. The motor controller temperature rise test apparatus of any one of claims 1-4, wherein, The motor controller temperature rise testing device also includes a temperature detection device, which is connected to the first controller and is used to detect the temperature of the first controller.

8. The motor controller temperature rise testing device according to any one of claims 1-4, characterized in that, The motor controller temperature rise testing device also includes a temperature simulation device, which is used to simulate ambient temperature.

9. The motor controller temperature rise testing device according to any one of claims 1-4, characterized in that, The power supply includes a high-voltage power supply and a low-voltage power supply; The high-voltage power supply is connected to the high-voltage power supply terminal of the first controller and is used to provide high-voltage power supply voltage to the first controller. The low-voltage power supply is connected to the low-voltage power supply terminal of the first controller and is used to provide a low-voltage power supply voltage to the first controller.

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