A bench test of the cooling system capacity of an oil-cooled motor for a range extender.

Abstract

A test bench for evaluating the cooling system capability of an oil-cooled motor in a range extender belongs to the field of automotive motor testing technology. The motor under test is fixed to the test bench. Its oil inlet and outlet are connected to oil pipes via oil port fixtures and sealing rings. The oil pipes are connected to a plate heat exchanger, and temperature sensors and flow meters are installed on the pipes, all connected to a data acquisition box. A chiller unit is connected to the heat exchanger via water pipes, and a mechanical circulation pump is connected to the motor's internal oil circuit. The test first uses the original oil cooler for a temperature rise test, then replaces it with the test system to simulate the original cooling effect, and records the data. After sealing is checked, the water temperature is adjusted to match the original temperature rise trend, performance is evaluated, and suitable components are selected. This utility model, through a test bench system, achieves a quantitative evaluation of the cooling system capability of an oil-cooled motor in a range extender, improving testing efficiency, reducing development costs, accurately selecting suitable components, ensuring motor performance, and providing test data that closely matches actual application requirements, thus possessing significant technical value and practical significance.

Description

Technical Field

[0001] This utility model belongs to the field of automotive motor testing technology, specifically a test bench for measuring the cooling system capacity of an oil-cooled motor in a range extender. Background Technology

[0002] With the rapid development of new energy vehicle technology, the performance of range extender motors, the main power generation medium for range-extended vehicles, is receiving increasing attention. Among them, permanent magnet synchronous motors are favored by the market due to their high system efficiency, high power factor, simple structure, low noise, and large starting torque. As the market continues to develop range-extended vehicles, the design power of their range extender motors is becoming increasingly larger. This often involves increasing the input speed through the transmission system. However, the greater power and mechanical transmission components lead to more severe heat generation problems, reducing motor efficiency and affecting motor performance.

[0003] To address the overheating issue of electric motors, oil cooling systems are an excellent cooling method. Oil cooling systems can cool the stator and rotor of the motor and provide lubrication and cooling for the transmission components. A good oil cooling cycle can keep the motor's heat generation within its high-performance range. However, most passenger vehicles only have water cooling systems. In these systems, a circulating mechanical pump inside the motor transports lubricating oil to the oil cooler, where cooling water cools the lubricating oil. This makes it difficult to quantify the heat exchange capacity of the oil cooler and the oil distribution capacity of the lubricating oil circulation pump. Therefore, a test bench for evaluating the cooling system capabilities of a range extender oil-cooled motor is urgently needed. Summary of the Invention

[0004] To address the problems existing in the background art, this utility model provides a test bench for the cooling system capacity of an oil-cooled motor in a range extender.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a test bench for measuring the cooling capacity of an oil-cooled motor in a range extender, comprising a test bench mounting plate, a test motor, a mechanical circulating pump, two oil port fixtures, an oil outlet pipe, an oil inlet pipe, an oil outlet temperature sensor, an oil inlet temperature sensor, a plate heat exchanger, an oval gear flow meter, a water outlet pipe, a water return pipe, a chiller unit, a data acquisition box, and an oil pan temperature sensor;

[0006] The tested motor is fixedly mounted on the test bench mounting plate. An oil pan temperature sensor is installed in the oil pan of the tested motor. The oil pan temperature sensor is electrically connected to the data acquisition box via wires. Both the oil inlet and outlet of the tested motor are detachably connected to corresponding oil port fixtures via seals. One end of the oil inlet pipe is detachably connected to the oil port fixture at the oil inlet of the tested motor, and the other end is detachably connected to the oil outlet of the plate heat exchanger. The oil inlet temperature sensor is nested within the oil inlet pipe, and the signal output terminal of the oil inlet temperature sensor is electrically connected to the data acquisition box via wires. One end of the oil outlet pipe is detachably connected to the oil port fixture at the oil outlet of the tested motor, and the other end is detachably connected to the oil inlet of the plate heat exchanger. The outlet temperature sensor is nested with the oil outlet pipe, and the signal output terminal of the outlet temperature sensor is electrically connected to the data acquisition box via a wire. The elliptical gear flow meter is nested with and connected to the inlet pipe, and the signal output terminal of the elliptical gear flow meter is electrically connected to the data acquisition box via a wire. The chiller unit is detachably connected to the plate heat exchanger via an outlet pipe and a return pipe, respectively. One end of the outlet pipe is detachably connected to the outlet end of the chiller unit, and the other end of the outlet pipe is detachably connected to the inlet end of the plate heat exchanger. One end of the return pipe is detachably connected to the inlet end of the chiller unit, and the other end of the return pipe is detachably connected to the outlet end of the plate heat exchanger. The mechanical circulation pump is detachably connected to the tested motor, and the oil outlet of the mechanical circulation pump is connected to the internal oil circuit of the tested motor.

[0007] The sealing element includes a sealing ring, which is nested in the connection gap between the oil port fixture and the oil inlet and outlet of the tested motor.

[0008] Compared with the prior art, the beneficial effects of this utility model are:

[0009] 1. Quantitative analysis of key performance parameters of the cooling system: This invention uses a bench testing system with temperature sensors, oval gear flow meters, and other equipment to directly acquire data such as inlet oil temperature, outlet oil temperature, circulating oil flow rate, and oil pan temperature. The simulation effectiveness is verified by the rule that "oil pan temperature > outlet oil temperature > inlet oil temperature". Combined with indicators such as inlet and outlet oil temperature difference and flow stability, the performance of the cooling system is quantitatively analyzed, overcoming the limitations of traditional evaluation methods.

[0010] 2. Improve testing efficiency and reduce development costs: This utility model does not rely on vehicle-mounted testing. The working state of the range extender oil-cooled motor in the vehicle can be simulated through a test bench. During the testing process, multiple sets of comparative tests can be completed by adjusting the water temperature of the chiller unit and replacing the mechanical circulation pump. This avoids the high cost and long cycle of vehicle testing, significantly shortens the selection and adaptation cycle of the oil cooler and circulation pump, and saves product development time and costs.

[0011] 3. Precise selection of compatible components to ensure motor performance: This invention uses the cooling state of the original oil cooler as a benchmark. By adjusting the water temperature of the chiller unit to simulate the cooling capacity of oil coolers of different specifications, and by replacing different models of mechanical circulating pumps, multiple sets of test data are compared (prioritizing combinations with "greater inlet and outlet oil temperature difference, lower oil pan temperature, and higher flow stability"). This allows for the precise selection of the oil cooler and circulating pump that best match the tested motor. The optimized cooling system effectively controls motor heat generation, preventing efficiency degradation due to overheating and ensuring the motor operates within its high-performance range.

[0012] 4. The simulated conditions closely resemble reality, and the data is highly instructive: During the testing process of this utility model, the cooling water flow rate, mechanical circulation pump speed, and test ambient temperature are kept consistent with the original oil cooler. The water temperature is adjusted to match the motor temperature rise trend, maximizing the simulation of the actual working environment of the motor in the vehicle. Therefore, the data obtained from the test can directly reflect the performance of the cooling system after actual vehicle installation, and has clear guiding significance for the vehicle adaptation of the range extender oil-cooled motor cooling system.

[0013] 5. Simple operation and wide applicability: The oil port tool of this utility model has the same shape and size as the original oil cooler interface, making installation and disassembly convenient. The sealing components (such as sealing rings) can ensure no leakage during the test process. The test method and steps are clear. The standardized operation (such as sealing test and oil injection after flow stabilization) reduces the difficulty of operation. It is suitable for testing the cooling system of oil-cooled motors of different specifications of range extenders and has strong practicality and versatility.

[0014] In summary, this utility model, through a bench testing system, achieves a quantitative assessment of the cooling system capability of the oil-cooled motor in a range extender, improving testing efficiency, reducing development costs, accurately selecting compatible components, ensuring motor performance, and providing test data that aligns with actual application requirements, thus possessing significant technical value and practical significance. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the connection relationship of this utility model; Detailed Implementation

[0016] The technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this utility model. Obviously, the described embodiments are only some embodiments of the utility model, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the protection scope of this utility model.

[0017] This embodiment describes a test bench for the cooling system capability of an oil-cooled motor in a range extender, including a test bench mounting plate 1, a test motor 2, a mechanical circulating pump 3, two oil port fixtures 4, an oil outlet pipe 5, an oil inlet pipe 6, an oil outlet temperature sensor 7, an oil inlet temperature sensor 8, a plate heat exchanger 9, an oval gear flow meter 10, a water outlet pipe 11, a water return pipe 12, a chiller unit 13, a data acquisition box 14, and an oil pan temperature sensor 15.

[0018] The test motor 2 is fixedly mounted on the test bench mounting plate 1. An oil pan temperature sensor 15 is installed at the oil pan of the test motor 2. The oil pan temperature sensor 15 is detachably connected to the oil pan of the test motor 2. The oil pan temperature sensor 15 is electrically connected to the data acquisition box 14 via a wire. Both the oil inlet and outlet of the test motor 2 are detachably connected to the corresponding oil port fixture 4 via a sealing element. The interface shape and size of the oil port fixture 4 are consistent with the original oil cooler interface of the test motor 2. One end of the oil inlet pipe 6 is detachably connected to the oil port fixture 4 at the oil inlet of the test motor 2. The other end of the oil inlet pipe 6... One end of the oil outlet pipe 5 is detachably connected to the oil outlet end of the plate heat exchanger 9. The oil inlet temperature sensor 8 is nested with the oil inlet pipe 6 and installed on the oil inlet pipe 6 near the oil inlet of the tested motor 2. The signal output terminal of the oil inlet temperature sensor 8 is electrically connected to the data acquisition box 14 via a wire. One end of the oil outlet pipe 5 is detachably connected to the oil outlet fixture 4 at the oil outlet of the tested motor 2, and the other end of the oil outlet pipe 5 is detachably connected to the oil inlet end of the plate heat exchanger 9. The oil outlet temperature sensor 7 is installed on the oil outlet pipe 5 near the oil outlet of the tested motor 2. The oil outlet temperature sensor 7 is nested with the oil outlet pipe 6. The oil outlet pipe 5 is nested and connected. The signal output terminal of the oil outlet temperature sensor 7 is electrically connected to the data acquisition box 14 via a wire. The elliptical gear flow meter 10 is nested and connected to the oil inlet pipe 6. The elliptical gear flow meter 10 is installed on the oil inlet pipe 6, located between the oil inlet temperature sensor 8 and the plate heat exchanger 9. The signal output terminal of the elliptical gear flow meter 10 is electrically connected to the data acquisition box 14 via a wire. The chiller unit 13 is detachably connected to the plate heat exchanger 9 via the water outlet pipe 11 and the water return pipe 12. One end of the water outlet pipe 11 is detachably connected to the water outlet of the chiller unit 13. The other end of pipe 11 is detachably connected to the inlet end of plate heat exchanger 9. One end of return pipe 12 is detachably connected to the inlet end of chiller unit 13. The other end of return pipe 12 is detachably connected to the outlet end of plate heat exchanger 9. The oil circuit (from oil inlet to oil outlet) and water circuit (from water inlet to water outlet) of plate heat exchanger 9 are in a convection state. The mechanical circulation pump 3 is detachably connected to the test motor 2. The oil outlet of mechanical circulation pump 3 is connected to the internal oil circuit of test motor 2, forming a closed-loop oil circuit of internal oil circuit of test motor 2 - oil outlet pipe 5 - plate heat exchanger 9 - oil inlet pipe 6 - internal oil circuit of test motor 2.

[0019] The sealing element includes a sealing ring, which is nested in the connection gap between the oil port fixture 4 and the oil inlet and outlet of the tested motor 2.

[0020] The test motor 2 is fixed to the test bench mounting plate 1. An oil pan temperature sensor 15 is installed on the oil pan of the test motor 2. The first temperature rise test is carried out through the original oil cooler of the test motor 2. The temperature rise trend of the test motor 2 is recorded, including the slope of temperature change over time and the temperature values ​​at key nodes.

[0021] Remove the original oil cooler from the test motor 2. Install oil port fixture 4 at the oil inlet and oil outlet of the test motor 2 respectively. Connect the oil outlet pipe 5 and oil inlet pipe 6 through the oil port fixture 4. Then install the oil outlet temperature sensor 7, oil inlet temperature sensor 8, oval gear flow meter 10, plate heat exchanger 9 and chiller unit 13 in sequence to ensure that the oil and water circuits are sealed without leakage.

[0022] Start the test bench and make the test motor 2 idle. Fill the oil circuit with oil through the mechanical circulation pump 3 installed in the test motor 2. After the flow rate is stable as shown by the elliptical gear flow meter 10, add new oil to the oil filling hole of the test motor 2 until it is full, and then close the oil filling hole.

[0023] A secondary temperature rise test was conducted. The water temperature of the chiller unit 13 was adjusted to make the temperature rise trend of the tested motor 2 consistent with the state of the original oil cooler in S1. The oil inlet temperature, the oil inlet temperature sensor 8, the oil outlet temperature, the oil outlet temperature sensor 7, the oil pan temperature, the oil pan temperature sensor 15, the circulating oil flow rate, and the oval gear flow meter 10 were recorded through the data acquisition box 14.

[0024] If the oil temperature in the oil pan > the oil temperature at the oil outlet > the oil temperature at the oil inlet, then the plate heat exchanger 9 is determined to have successfully simulated the cooling capacity of the original oil cooler. Based on the recorded data, the performance of the current cooling system is evaluated, including the inlet and outlet oil temperature difference and the heat dissipation per unit time. Then, the cooling capacity of different specifications of oil coolers is simulated by adjusting the water temperature of the chiller unit 13, and different models of mechanical circulation pumps 3 are replaced. Steps S3-S4 are repeated, and multiple sets of test data are compared. The combination of "greater inlet and outlet oil temperature difference, lower oil pan temperature, and higher flow stability" is selected first to screen out the oil cooler and mechanical circulation pump that best match the tested motor 2.

[0025] The method for testing the sealing of the oil and water circuits is as follows: Start the mechanical circulation pump 3 and keep it running for 10-15 minutes. Observe whether there is any oil or water leakage at the connection between the oil port tool 4 and the oil pipe, the interface of the plate heat exchanger 9, and the water pipe joint. If there is leakage, the connection must be tightened again or the seals must be replaced before testing again.

[0026] When adjusting the water temperature of chiller unit 13, keep the cooling water flow rate, mechanical circulation pump 3 speed, and test ambient temperature consistent with the original oil cooler status, and achieve temperature rise trend matching through water temperature adjustment.

[0027] The working principle of this invention is based on the cooling state of the original oil cooler of the tested motor as a benchmark. A simulation system is built on a test bench to quantify and screen the cooling capacity. First, an initial temperature rise test is conducted using the original oil cooler, and the motor temperature rise trend is recorded as a reference standard for subsequent simulations. Then, the original oil cooler is removed, and oil pipes, a plate heat exchanger, a chiller unit, and other components are connected through an oil port fixture with the same interface as the original oil cooler to form a closed-loop oil circuit. Temperature sensors and flow meters are installed to monitor relevant parameters. After starting the test bench, a mechanical circulation pump drives the lubricating oil to circulate in the closed-loop oil circuit. After the flow rate stabilizes and oil filling is completed, a second temperature rise test is conducted. By adjusting the chiller unit's water temperature, the motor temperature rise trend is made consistent with the first test. If the oil temperature at the oil pan > the oil temperature at the oil outlet > the oil temperature at the oil inlet, it indicates that the plate heat exchanger has successfully simulated the cooling capacity of the original oil cooler. The synchronously recorded inlet and outlet oil temperatures, flow rates, and other data can quantify the cooling performance. Subsequently, by replacing different mechanical circulation pumps and adjusting the water temperature of the chiller unit to simulate different oil coolers, the experiment was repeated and the data was compared to finally select the combination that best matches the tested motor.

[0028] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of the equivalents of the claims are intended to be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A test bench for measuring the cooling capacity of an oil-cooled motor cooling system for a range extender, characterized in that: The test bench includes a mounting plate (1), a motor under test (2), a mechanical circulating pump (3), two oil port fixtures (4), an oil outlet pipe (5), an oil inlet pipe (6), an oil outlet temperature sensor (7), an oil inlet temperature sensor (8), a plate heat exchanger (9), an oval gear flow meter (10), a water outlet pipe (11), a water return pipe (12), a chiller unit (13), a data acquisition box (14), and an oil pan temperature sensor (15). The test motor (2) is fixedly installed on the test bench mounting plate (1). An oil pan temperature sensor (15) is provided at the oil pan of the test motor (2). The oil pan temperature sensor (15) is electrically connected to the data acquisition box (14) through a wire. The oil inlet and outlet of the test motor (2) are detachably connected to the corresponding oil port fixture (4) through a sealing element. One end of the oil inlet pipe (6) is detachably connected to the oil port fixture (4) at the oil inlet of the test motor (2). The other end of the pipe (6) is detachably connected to the oil outlet of the plate heat exchanger (9). The oil inlet temperature sensor (8) is nested with the oil inlet pipe (6). The signal output terminal of the oil inlet temperature sensor (8) is electrically connected to the data acquisition box (14) via a wire. One end of the oil outlet pipe (5) is detachably connected to the oil outlet fixture (4) at the oil outlet of the tested motor (2). The other end of the oil outlet pipe (5) is detachably connected to the oil inlet of the plate heat exchanger (9). The oil outlet temperature sensor (6) is detachably connected to the oil outlet of the plate heat exchanger (9). 7) The oil outlet pipe (5) is nested and connected to the oil outlet temperature sensor (7). The signal output terminal of the oil outlet temperature sensor (7) is electrically connected to the data acquisition box (14) via a wire. The elliptical gear flow meter (10) is nested and connected to the oil inlet pipe (6). The signal output terminal of the elliptical gear flow meter (10) is electrically connected to the data acquisition box (14) via a wire. The chiller unit (13) is detachably connected to the plate heat exchanger (9) via the water outlet pipe (11) and the water return pipe (12). The water outlet pipe (11) One end of the water pipe (11) is detachably connected to the outlet end of the chiller (13), and the other end of the water pipe (11) is detachably connected to the inlet end of the plate heat exchanger (9). One end of the return water pipe (12) is detachably connected to the inlet end of the chiller (13), and the other end of the return water pipe (12) is detachably connected to the outlet end of the plate heat exchanger (9). The mechanical circulation pump (3) is detachably connected to the test motor (2), and the oil outlet of the mechanical circulation pump (3) is connected to the internal oil circuit of the test motor (2).

2. The test bench for measuring the cooling capacity of an oil-cooled motor cooling system for a range extender according to claim 1, characterized in that: The sealing element includes a sealing ring, which is nested in the connection gap between the oil port fixture (4) and the oil inlet and outlet of the tested motor (2).

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