A motor controller test fixture

Abstract

The application relates to the technical field of motor controller testing, and specifically discloses a motor controller testing tool, which comprises a cabinet, a tool table, a tool box, a plurality of detection devices, a display screen, an industrial computer and a direct-current power supply; a test instruction is sent to a motor controller to be detected by the industrial computer; the motor controller to be detected carries out corresponding function testing according to the received instruction; the corresponding detection device carries out real-time monitoring on the parameters of the motor controller to be detected in the testing and feeds back monitoring data to the industrial computer; and the testing result of the motor controller to be detected can be known according to the monitoring data received by the industrial computer; different function testing of the motor controller to be detected can be carried out according to the corresponding instruction sent by the industrial computer to the motor controller to be detected; the parameters in the testing process are displayed and fed back by the corresponding detection device; all functions of the motor controller can be tested; the operation is more convenient; and the time for detecting by manual operation is shortened.

Description

Technical Field

[0001] This application relates to the field of motor controller testing technology, and specifically to a motor controller testing fixture. Background Technology

[0002] Currently, various tools made of brushless or brushed motors are widely used in all aspects of life. Among them, the motor controller is a key component used to control the motor. Functional testing of the motor controller is a very important production step during its manufacturing process.

[0003] In existing technologies, testing motor controllers requires the use of different types of dynamometers to test each function of the motor controller separately. This results in the need to purchase multiple dynamometers, leading to high testing costs. Furthermore, different dynamometers need to be replaced when testing different functions, resulting in long testing times and low testing efficiency. Utility Model Content

[0004] The purpose of at least one specific embodiment of this utility model is to overcome the defects of the existing technology and provide a test fixture for a motor controller.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] A motor controller testing fixture, comprising:

[0007] Server rack;

[0008] The tooling table is located on one side of the server rack;

[0009] The tooling box is installed on the tooling table. The tooling box includes a motor, a motor controller to be tested, and a switching cylinder. The motor controller to be tested is connected to the motor for communication.

[0010] Multiple testing devices are installed inside the cabinet.

[0011] An industrial control computer is installed in a cabinet. The industrial control computer is connected to multiple testing devices, and the multiple testing devices are connected to the controller of the motor under test. The industrial control computer is connected to a switching cylinder, and the switching cylinder is connected to the controller of the motor under test. The switching cylinder is used to control the start / stop of the controller of the motor under test.

[0012] The DC power supply is installed inside the cabinet and is electrically connected to the controller of the motor under test.

[0013] Furthermore, the tooling box also includes a power supply simulation device, which is equipped with an NTC detection module, and the electrical controller under test is communicatively connected to the power supply simulation device.

[0014] Furthermore, the tooling box also includes an encoder, which is connected to the motor and also communicates with the industrial control computer.

[0015] Furthermore, the industrial control computer includes an MCU module, which is connected to multiple detection devices for communication.

[0016] Furthermore, the DC power supply is a DC adjustable power module, which is electrically connected to the motor controller under test.

[0017] Furthermore, the multiple testing devices include a parametric analyzer, a multimeter, and an electronic load.

[0018] Furthermore, it also includes a display screen, which is installed on the top surface of the cabinet and is connected to the industrial control computer. The display screen is used to display the selection information of the test content and the test result information of the motor controller under test.

[0019] Furthermore, the industrial control computer is equipped with multiple interfaces, and multiple testing devices are connected to the industrial control computer through these interfaces.

[0020] Furthermore, the cabinet is equipped with multiple storage slots, in which the industrial control computer, DC power supply, and multiple testing devices are respectively installed.

[0021] Furthermore, rollers are installed around the bottom of the tooling table.

[0022] The advantages of the motor controller testing fixture provided in this application compared to the prior art are as follows: By using the aforementioned motor controller testing fixture, the industrial control computer sends test commands to the motor controller under test. The motor controller under test performs corresponding functional tests according to the received commands. The corresponding testing equipment monitors the parameters of the motor controller under test in real time and feeds back the monitoring data to the industrial control computer. The test results of the motor controller under test can be known based on the monitoring data received by the industrial control computer. Since different functional tests of the motor controller under test can be performed by sending corresponding commands to the motor controller under test from the industrial control computer, and the parameters during the test are displayed and fed back by the corresponding testing equipment, all functions of the motor controller can be tested in a unified manner, making the operation more convenient and greatly shortening the time required for manual testing. Attached Figure Description

[0023] 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.

[0024] Figure 1 This is a three-dimensional structural diagram of a motor controller test fixture in one embodiment of this application.

[0025] Figure 2 This is a schematic block diagram of the principle of a motor controller test fixture in one embodiment of this application.

[0026] Figure 3 This is a block diagram illustrating the structural principle of a motor controller testing fixture used to test the motor controller of a brushless motor in one embodiment of this application.

[0027] Figure 4 This is a block diagram illustrating the structural principle of a motor controller testing fixture used to test the motor controller of a brushed motor in one embodiment of this application. Detailed Implementation

[0028] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0029] Reference Figure 1 A motor controller testing fixture includes a cabinet 10, a fixture platform 30, a fixture box 130, multiple testing devices, a display screen 20, an industrial computer 40, and a DC power supply 80.

[0030] Reference Figure 1 As shown, the cabinet 10 is provided with multiple receiving slots 90, which are arranged along the height of the cabinet 10. The industrial control computer 40, DC power supply 80 and multiple testing devices are respectively installed in the multiple receiving slots 90.

[0031] The tooling table 30 is located on one side of the cabinet 10, and the tooling table 30 is also movable. For example, casters are installed around the bottom of the tooling table 30, and the tooling table 30 can be easily moved by pushing the casters. The tooling box 130 is installed on the tooling table 30. The tooling box 130 includes a motor 100, a motor controller under test, and a switching cylinder 120. The motor controller under test is communicatively connected to the motor.

[0032] For ease of testing, the tooling box 130 includes a brushless tooling box and a brushed tooling box. The difference between the brushless and brushed tooling boxes lies in whether the motors they contain are brushed or brushless. For example, the brushed tooling box includes a brushed motor, a brushed motor controller to be tested, and a switching cylinder 120; the brushless tooling box includes a brushless motor, a brushless motor controller to be tested, and a switching cylinder 120. When replacing the brushed motor controller with the brushless motor controller for testing, only the entire tooling box needs to be replaced, and the aviation connector on the tooling box can be plugged into the aviation connector on the rack 10.

[0033] The industrial control computer 40 is connected to multiple testing devices, and the multiple testing devices are connected to the motor controller under test. The industrial control computer 40 is connected to the switching cylinder 120, and the switching cylinder 120 is connected to the motor controller under test. The switching cylinder 120 is used to control the start / stop of the motor controller under test, and the switching cylinder 120 acts as a trigger.

[0034] The DC power supply 80 is electrically connected to the motor controller under test and is used to provide power to the testing system. In some embodiments, the DC power supply 80 is a DC adjustable power module, which is used to power the controller under test and can adjust the output voltage, for example, 20V, 40V, 60V, to meet the testing needs of motor controllers with different voltages.

[0035] See attached document Figure 1 As shown, the display screen 20 is installed on the upper surface of the cabinet 10. The display screen 20 is connected to the industrial control computer 40 for communication. The display screen 20 is used to display the selection information of the test content and the test result information of the motor controller under test.

[0036] In some embodiments, the multiple testing devices correspond to a parametric instrument 50, a multimeter 60, and an electronic load 70. The industrial control computer 40 is provided with multiple interfaces, and the parametric instrument 50, multimeter 60, electronic load 70, and DC power supply 80 are respectively connected to the industrial control computer 40. The controller under test, the motor, and each testing device (parametric instrument 50, electronic load 70, multimeter 60, encoder 110) are connected. On the one hand, some testing devices can input and control the test content of the controller under test; on the other hand, they can detect the changes in various parameters of the controller under test and the motor, and output them to the industrial control computer 40.

[0037] In some embodiments, the tooling box further includes a power simulation device 140 and an encoder 110. The controller under test is connected to the power simulation device 140, which is equipped with an NTC (Negative Temperature Coefficient) module to simulate the temperature changes of the battery pack and perform high and low temperature protection tests on the controller under test. It should also be noted that the power simulation device 140 is primarily for simulating the battery pack of the motor controller under test in a real operating environment. The power simulation device 140 mainly serves a communication function and does not provide power to the controller under test.

[0038] The encoder 110 is connected to both the motor and the industrial computer 40 for communication. It is used to monitor the motor speed and feed back the monitored speed data to the industrial computer 40.

[0039] The industrial computer 40 includes an MCU module (Microcontroller Unit; MCU), which is used to send and receive signals, record the feedback test results, determine whether the test content is passed, and transmit the data to the display screen 20 for easy viewing and export of test results.

[0040] The MCU module and the tooling box 130 work together to perform the corresponding test operations and feed the test results back to the MCU module. The test content includes: static parameter test, dynamic performance test and protection mechanism test.

[0041] Among them, static parameter testing includes static leakage current detection, single-packet over-discharge protection voltage detection, and single-packet over-discharge recovery voltage detection;

[0042] During static leakage current detection: In standby mode, the MCU module sends a command, and the multimeter 60 measures the tiny current at the input terminal of the motor controller (performance requirement ≤30μA). The parameter data measured and detected by the multimeter 60 is fed back to the MCU module. The MCU module analyzes the data in real time and outputs the "pass / fail" result, which is displayed on the display screen 20.

[0043] When detecting over-discharge protection voltage in a single package: the MCU module sends a command to adjust the DC power supply voltage (0-100V), the parameter instrument monitors the input voltage, and detects whether the motor controller is powered off outside the set threshold (e.g., 50V±1V).

[0044] When detecting the over-discharge recovery voltage of a single package: when the voltage recovers from the abnormal value to the normal range, check whether the motor controller restarts the motor 100.

[0045] Dynamic performance testing includes motor no-load speed and direction detection, motor no-load current detection, brake stop time detection, and soft start detection;

[0046] Specifically, during the detection of motor no-load speed and direction: the MCU module sends a command to switch cylinder 120 to start motor 100. After motor 100 starts, encoder 110 collects the speed (performance requirement 100-35,000rpm) and rotation direction (forward / reverse) in real time and feeds the data back to the MCU module. The MCU module analyzes the data in real time and outputs "pass / fail" results, which are displayed on display screen 20.

[0047] When detecting the no-load current of the motor: When the motor is running under no-load conditions, the parameter instrument measures the output current of the motor controller (performance index 0-60A).

[0048] During brake stop time detection: the MCU module sends a brake command, the encoder 110 monitors the time it takes for the motor 100 speed to drop to 0 (performance index ≤3000ms), the parameter instrument 50 records the current change and feeds the data back to the MCU module, which is then displayed on the display screen 20.

[0049] During soft start testing: Electronic load 70 simulates a normal load, detects the current rise time and peak value when motor 100 starts, parameter instrument 50 records relevant parameter data, and feeds the data back to the MCU module, which displays it on display screen 20.

[0050] Protection mechanism testing includes phase line / power line short circuit protection testing, NTC high and low temperature protection testing, overcurrent protection testing, and locked rotor protection testing;

[0051] When the motor is a brushless motor, the protection mechanism test also includes phase loss detection.

[0052] Specifically, during phase / power line short circuit protection testing: a short circuit is simulated using a relay (brushless: three-phase short circuit; brushed: positive and negative short circuit), and the parameter meter checks whether the current returns to zero (indicating that the protection is effective).

[0053] During NTC high and low temperature protection testing: The NTC testing module can simulate a temperature change range of -50 to 200℃ and detect whether the motor controller 600 is powered off outside the set threshold (such as 100℃±10℃). If it is powered off, it means that the motor controller is qualified.

[0054] During overcurrent protection detection: The electronic load 70 gradually increases the current (0-60A) and checks whether the motor controller cuts off the output when the set threshold (e.g., 60A) is reached.

[0055] During stall protection testing: The electronic load 70 simulates stall (high current for 2-3 seconds) to check whether the motor controller triggers protection and stops the machine.

[0056] During phase loss detection (brushless only): The relay disconnects one phase, and the parameter meter 50 detects whether the current of the remaining two phases is unbalanced, and determines whether the motor controller recognizes the phase loss fault.

[0057] See attached document Figure 2 To be continued Figure 4 As shown, the test circuit module of the brushless motor controller includes a three-phase rectifier, while the test circuit module of the brushed motor controller does not have a three-phase rectifier.

[0058] See attached document Figure 3 As shown, the brushless test circuit is equipped with a three-phase rectifier, which is connected to the brushless motor to rectify the three-phase lines of the brushless motor into two-phase lines (converting the AC power output by the three-phase brushless motor into DC power). The rectified phase lines (DC+ / - terminals) are connected to the electronic load to achieve accurate loading of the electronic load.

[0059] When the brushless motor is under no-load functional testing, the three-phase rectifier and the controller under test are disconnected through a relay; under load, the three-phase rectifier and the controller under test are connected to simulate the state under load.

[0060] See attached document Figure 4 As shown, when the brushed motor is undergoing no-load functional testing, the industrial computer 40 directly shuts down the electronic load, disconnecting the electronic load from the controller under test, thereby avoiding the electronic load from affecting the no-load functional test and the accuracy of the no-load functional test results.

[0061] When under load, the electronic load is connected to the controller under test, and the controller under test is disconnected from the motor using a relay. At this time, the electronic load can be used to directly simulate the state of the motor under load.

[0062] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. 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 or all of the technical features therein. Such 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 utility model.

Claims

1. A testing fixture for a motor controller, characterized in that, include: Server rack; A tooling table is located on one side of the cabinet; A tooling box is installed on the tooling table. The tooling box includes a motor, a motor controller to be tested, and a switching cylinder. The motor controller to be tested is communicatively connected to the motor. Multiple testing devices are installed inside the cabinet. An industrial control computer is installed in the cabinet. The industrial control computer is communicatively connected to multiple testing devices. The multiple testing devices are communicatively connected to the motor controller under test. The industrial control computer is communicatively connected to the switching cylinder. The switching cylinder is communicatively connected to the motor controller under test. The switching cylinder is used to control the motor controller under test to start / stop. A DC power supply is installed inside the cabinet and is electrically connected to the controller of the motor under test.

2. The motor controller testing fixture according to claim 1, characterized in that, The tooling box also includes a power simulation device, which is equipped with an NTC detection module. The electrical controller under test is communicatively connected to the power simulation device.

3. A motor controller testing fixture according to claim 1 or 2, characterized in that, The tooling box also includes an encoder, which is connected to the motor and also communicates with the industrial computer.

4. The motor controller testing fixture according to claim 1, characterized in that, The industrial control computer includes an MCU module, which is communicatively connected to multiple detection devices.

5. The motor controller testing fixture according to claim 1, characterized in that, The DC power supply is a DC adjustable power module, which is electrically connected to the motor controller under test.

6. The motor controller testing fixture according to claim 1, characterized in that, The various testing devices include a parametric instrument, a multimeter, and an electronic load.

7. The motor controller testing fixture according to claim 1, characterized in that, It also includes a display screen, which is installed on the upper surface of the cabinet and is communicatively connected to the industrial control computer. The display screen is used to display the selection information of the test content and the test result information of the motor controller under test.

8. A motor controller testing fixture according to claim 1 or 6, characterized in that, The industrial control computer is equipped with multiple interfaces, and the multiple testing devices are respectively connected to the industrial control computer through the multiple interfaces.

9. A motor controller testing fixture according to claim 1, characterized in that, The cabinet is provided with multiple receiving slots, and the industrial control computer, DC power supply and multiple testing devices are respectively installed in the multiple receiving slots.

10. A motor controller testing fixture according to claim 1, characterized in that, The tooling table is equipped with rollers around its bottom perimeter.

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