An aging test device for motor controllers

Abstract

The utility model discloses an aging test device for motor controller, including alternating current input module and input bus row, the input bus row is equipped with port no.

Description

Technical Field

[0001] This utility model relates to the field of motor controllers, and in particular to an aging test device for motor controllers. Background Technology

[0002] In fields such as new energy vehicles and industrial motor drive systems, the motor controller, as a core control unit, directly determines the safety performance and service life of the terminal equipment through its long-term operational stability and reliability. Existing motor controller aging test benches have significant technical shortcomings: Firstly, they lack compatibility and scalability. Most benches have narrow hardware performance ranges and weak product compatibility, with numerous integrated communication interfaces, making expansion difficult. They only provide a single communication protocol (e.g., supporting only CAN communication), failing to adapt to motor controllers from different manufacturers using CAN and CANFD communication. Furthermore, the integrated structure necessitates large-scale circuit and program modifications for adding new test functions, resulting in high costs and long development cycles. Secondly, test reliability and efficiency need improvement. Some benches have low accuracy in acquiring electrical parameters, weak anti-interference capabilities, and are prone to data fluctuations. They also have low automation levels, requiring manual intervention in parameter setting, operation control, and data recording processes, increasing labor costs and increasing the risk of test failure due to operational errors. Additionally, fault maintenance is difficult; the integrated module and bus-type communication architecture make fault location time-consuming and have a wide impact, failing to meet the industry's demand for efficient and reliable testing. Utility Model Content

[0003] The purpose of this invention is to provide an aging test device for motor controllers to solve the problem of low parameter acquisition accuracy mentioned in the background art.

[0004] To achieve the above objectives, this utility model provides the following technical solution: An aging test device for a motor controller includes an AC input module and an input busbar. The input busbar has ports one, two, three, four, and five. The AC input module is electrically connected to port one of the input busbar. Port two of the input busbar is electrically connected to a communication module. Port three of the input busbar is electrically connected to a high-voltage DC region. Port four of the input busbar is electrically connected to a resolver signal analog region. Port five of the input busbar is electrically connected to a low-voltage DC region.

[0005] Preferably, the input busbar is further provided with port 10 and port 11. The communication module includes a serial port server, a LAN switch and a CAN communication module. The serial port server is electrically connected to port 2 of the input busbar, the LAN switch is electrically connected to port 10 of the input busbar and the CAN communication module is electrically connected to port 11 of the input busbar.

[0006] Preferably, the LAN switch is electrically connected to the peripheral devices, and the CAN communication module is electrically connected to the product under test.

[0007] Preferably, the high-voltage DC zone includes a high-voltage DC power supply group, an electronic control module one, and a high-voltage output interface. The input busbar port three, the high-voltage DC power supply group, the electronic control module one, and the high-voltage output interface are connected in series in sequence. The high-voltage DC power supply group and the electronic control module one are connected in parallel to the data acquisition area.

[0008] Preferably, the data acquisition area includes a sensor and an electrical parameter acquisition module. The sensor has a port six and a port seven. The sensor is connected in parallel between the high-voltage DC power supply and the electrical control module one. The port six of the sensor is electrically connected to the electrical parameter acquisition module, and the port seven of the sensor is electrically connected to the AC sampling module.

[0009] Preferably, the AC sampling module includes an AC input interface and an AC output interface, the AC input interface and the AC output interface are electrically connected, and the AC input interface and the AC output interface are electrically connected to the port of the sensor.

[0010] Preferably, the low-voltage DC zone includes a low-voltage DC regulated power supply and a low-voltage DC output interface. The low-voltage DC regulated power supply includes port eight and port nine. The low-voltage DC regulated power supply is electrically connected to port five of the input busbar. Port eight of the low-voltage DC regulated power supply is electrically connected to the low-voltage DC output interface. The low-voltage DC zone is electrically connected to the safety module. Port nine of the low-voltage DC regulated power supply is electrically connected to the safety module.

[0011] Preferably, the safety module includes a safety component module and a temperature control module, and the port nine of the low-voltage DC regulated power supply, the temperature control module, and the safety component module are connected in series in sequence.

[0012] Preferably, the aging test device further includes a central control host computer module, the software of which is electrically connected to a serial port server, a LAN switch, a CAN communication module, a safety component module, a temperature control module, and an electrical parameter acquisition module.

[0013] The beneficial effects of this utility model are: 1. The communication module adopts a hierarchical star topology, supporting multiple communication types such as serial server, LAN switch and CAN communication module. The entire test bench is modularly designed, with each functional module being relatively independent and compatible with test products and peripheral devices (such as environmental chambers, chillers, etc.) from different manufacturers and with different communication protocols. When new devices are added or test functions are expanded, they can be easily accessed and configured at the corresponding module layer without large-scale modifications to the entire test bench. This solves the problems of poor compatibility and difficulty in expansion that may exist in existing technologies, and improves the applicability and scalability of the test bench.

[0014] 2. The data acquisition area is equipped with sensors and electrical parameter acquisition modules, which can accurately acquire electrical parameter signals such as high-voltage DC and AC sampling. The safety component module (emergency stop switch, audible and visual warning) can intervene in time in case of abnormality. The temperature control module can stably maintain a suitable temperature inside the test bench. During the aging test of the motor controller, it can acquire key data such as electrical parameters in real time and accurately, providing a reliable basis for test result analysis. At the same time, the timely response to abnormal situations and the stable temperature control can ensure the stability of the test environment and avoid the impact of environmental or equipment abnormalities on the test results. This solves the problems of inaccurate test data and insufficient reliability of the test process that may exist in the existing technology, and improves the reliability and accuracy of aging test results.

[0015] 3. The host computer software provides centralized control and management of all modules on the test bench. The communication module ensures smooth information exchange between the modules, the test bench, and peripheral equipment. Modules such as AC input, high-voltage DC, and low-voltage DC can efficiently complete power conversion and distribution, and can realize automated control of the motor controller aging test process. From power supply and parameter acquisition to status monitoring, everything can be automatically coordinated by the software, reducing manual intervention and improving test efficiency. Furthermore, the efficient information transmission between modules makes the test process smoother, solving the problems of low automation and low test efficiency that may exist in existing technologies, and improving the level of automation and efficiency of testing.

[0016] 4. By adopting a modular design for the test bench, each functional module (such as the AC input module, high-voltage DC area, and data acquisition area) is relatively independent. In the star communication architecture, each device is independently connected to the central node. When a module or device fails, the faulty module or device can be quickly located, and only that part needs to be maintained without affecting the normal operation of other parts of the test bench. This reduces maintenance difficulty and time costs, solves the problems of maintenance difficulties and wide fault impact range that may exist in existing technologies, and improves the maintainability of the test bench. Attached Figure Description

[0017] Figure 1 This is a circuit diagram of an embodiment of the present invention. Detailed Implementation

[0018] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0019] See Figure 1 This utility model provides an aging test device for a motor controller, including an AC input module and an input busbar. The input busbar has ports one, two, three, four, and five. The AC input module is electrically connected to port one of the input busbar, port two of the input busbar is electrically connected to a communication module, port three of the input busbar is electrically connected to a high-voltage DC zone, port four of the input busbar is electrically connected to a resolver signal analog zone, and port five of the input busbar is electrically connected to a low-voltage DC zone.

[0020] The AC input module, consisting of a connector, circuit breaker, and surge protector, is the initial stage for AC power input to the test bench. It serves to connect to an external AC power source, control power supply on / off, and suppress grid surge current.

[0021] The input busbar receives electrical energy from the AC input module and acts as a hub for power distribution, transmitting electrical energy to other components that require AC power.

[0022] The resolver signal simulation involves connecting the resolver signal simulator to an external interface via a line, and then to the signal monitoring port of the product under test, to output a controllable resolver signal to the product.

[0023] Specifically, the input busbar is further provided with port 10 and port 11. The communication module includes a serial port server, a LAN switch and a CAN communication module. The serial port server is electrically connected to port 2 of the input busbar, the LAN switch is electrically connected to port 10 of the input busbar and the CAN communication module is electrically connected to port 11 of the input busbar.

[0024] Specifically, the LAN switch is electrically connected to the peripheral devices, and the CAN communication module is electrically connected to the product under test.

[0025] Specifically, the high-voltage DC zone includes a high-voltage DC power supply group, an electronic control module one, and a high-voltage output interface. The input busbar port three, the high-voltage DC power supply group, the electronic control module one, and the high-voltage output interface are connected in series in sequence. The high-voltage DC power supply group and the electronic control module one are connected in parallel to the data acquisition area.

[0026] The high-voltage DC power supply group consists of multiple high-voltage DC power supplies operating in parallel. It obtains electrical energy from the input busbar, converts AC power into DC power, and transmits it to the electrical control module 1. After being regulated by the electrical control module 1, it provides high-voltage DC power to the product through the high-voltage output interface.

[0027] The electrical control module 1 mainly controls the on / off state of the circuit. It has 3 high-voltage output ports and controls the on / off state of the circuit according to the number of products being tested.

[0028] Specifically, the data acquisition area includes a sensor and an electrical parameter acquisition module. The sensor has a port six and a port seven. The sensor is connected in parallel between the high-voltage DC power supply and the electrical control module one. The port six of the sensor is electrically connected to the electrical parameter acquisition module, and the port seven of the sensor is electrically connected to the AC sampling module.

[0029] The sensor is connected to the electrical parameter acquisition module via a data cable. The electrical parameter signals (such as voltage and current) acquired by the sensor are transmitted to the electrical parameter acquisition module for processing.

[0030] Specifically, the AC sampling module includes an AC input interface and an AC output interface, which are electrically connected and electrically connected to the port of the sensor.

[0031] The AC input / output interface is as follows: the AC input interface is connected to the AC output port of the product under test, the AC output interface is connected to the load reactor equipment, and the AC input interface and the output interface are directly connected through a copper busbar. A sensor is connected to the copper busbar to provide sampling points for AC line sampling.

[0032] Specifically, the low-voltage DC zone includes a low-voltage DC regulated power supply and a low-voltage DC output interface. The low-voltage DC regulated power supply includes port eight and port nine. The low-voltage DC regulated power supply is electrically connected to port five of the input busbar. Port eight of the low-voltage DC regulated power supply is electrically connected to the low-voltage DC output interface. The low-voltage DC zone is electrically connected to the safety module. Port nine of the low-voltage DC regulated power supply is electrically connected to the safety module.

[0033] The low-voltage DC regulated power supply has an input busbar connected to it via wires to transmit AC power, which is then converted into a stable low-voltage DC output by the low-voltage DC regulated power supply.

[0034] Specifically, the safety module includes a safety component module and a temperature control module, and the port nine of the low-voltage DC regulated power supply, the temperature control module, and the safety component module are connected in series in sequence.

[0035] The safety component module mainly consists of AC / DC contactors, control relays, PLCs, audible and visual alarm lights, and manual switches. These are installed on the output lines of high-voltage DC, AC, and low-voltage DC zones.

[0036] Specifically, the aging test device also includes a central control host computer module, whose software is electrically connected to a serial port server, a LAN switch, a CAN communication module, a safety component module, a temperature control module, and an electrical parameter acquisition module.

[0037] The safety component module (emergency stop switch, audible and visual alarm): The emergency stop switch is connected to the main control circuit of the test bench through a control line, which can cut off the main circuit; the audible and visual alarm is associated with the host computer software through a line, and can receive alarm commands from the host computer or trigger an audible and visual alarm based on the abnormal situation detected by itself.

[0038] The temperature control module (temperature controller, fan): The temperature controller is connected to the fan via a circuit. The temperature controller detects the internal temperature of the test bench and controls the start / stop or speed of the fan according to the temperature.

[0039] The central control host computer software centrally controls and manages the operation of the entire test bench, including parameter setting, status monitoring, test plan configuration, and automatic test execution.

[0040] Working principle of this utility model: Before use, the AC input module is connected to an external AC power supply. After being processed by the connector, circuit breaker, and surge protector, the power is distributed through the input busbar. Part of the power enters the high-voltage DC zone, where the high-voltage DC power supply converts the AC power into high-voltage DC power. After being controlled by the electrical control module, the power is output from the high-voltage output interface to provide high-voltage DC power to the product under test. Another part of the power enters the low-voltage DC regulated power supply, which converts it into stable low-voltage DC power and outputs it from the low-voltage DC output interface to provide auxiliary low-voltage DC power to the product under test. The remaining power supplies other equipment on the test bench.

[0041] The sensors in the data acquisition area collect relevant electrical parameter signals such as high voltage DC and AC sampling, and transmit them to the electrical parameter acquisition module for processing. The processed data and other information are monitored and managed by the system software (central control host computer software).

[0042] The communication module ensures information exchange between the various modules within the test bench and between the test bench and peripheral devices. Among the other modules, the safety component module ensures the safe operation of the test bench, the temperature control module maintains a suitable internal temperature to ensure stable operation of all components, and the peripheral devices simulate the actual working environment and load of the motor controller under test, working in conjunction with the test bench to complete the aging test.

[0043] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An aging test device for a motor controller, comprising an AC input module and an input busbar, characterized in that, The input busbar has ports one, two, three, four, and five. The AC input module is electrically connected to port one of the input busbar, port two of the input busbar is electrically connected to the communication module, port three of the input busbar is electrically connected to the high-voltage DC zone, port four of the input busbar is electrically connected to the resolver signal analog zone, and port five of the input busbar is electrically connected to the low-voltage DC zone.

2. The aging test device for a motor controller according to claim 1, characterized in that: The input busbar is also provided with port 10 and port 11. The communication module includes a serial port server, a LAN switch and a CAN communication module. The serial port server is electrically connected to port 2 of the input busbar, the LAN switch is electrically connected to port 10 of the input busbar and the CAN communication module is electrically connected to port 11 of the input busbar.

3. The aging test device for a motor controller according to claim 2, characterized in that: The LAN switch is electrically connected to the peripheral devices, and the CAN communication module is electrically connected to the product under test.

4. The aging test device for a motor controller according to claim 3, characterized in that: The high-voltage DC zone includes a high-voltage DC power supply group, an electronic control module one, and a high-voltage output interface. The input busbar port three, the high-voltage DC power supply group, the electronic control module one, and the high-voltage output interface are connected in series in sequence. The high-voltage DC power supply group and the electronic control module one are connected in parallel to the data acquisition area.

5. An aging test device for a motor controller according to claim 4, characterized in that: The data acquisition area includes a sensor and an electrical parameter acquisition module. The sensor has a port six and a port seven. The sensor is connected in parallel between the high-voltage DC power supply and the electrical control module one. The sensor's port six is ​​electrically connected to the electrical parameter acquisition module, and the sensor's port seven is electrically connected to the AC sampling module.

6. An aging test apparatus for a motor controller according to claim 5, characterized in that: The AC sampling module includes an AC input interface and an AC output interface, which are electrically connected. The AC input interface and the AC output interface are also electrically connected to the port of the sensor.

7. An aging test apparatus for a motor controller according to claim 6, characterized in that: The low-voltage DC zone includes a low-voltage DC regulated power supply and a low-voltage DC output interface. The low-voltage DC regulated power supply includes port eight and port nine. The low-voltage DC regulated power supply is electrically connected to port five of the input busbar. Port eight of the low-voltage DC regulated power supply is electrically connected to the low-voltage DC output interface. The low-voltage DC zone is electrically connected to the safety module. Port nine of the low-voltage DC regulated power supply is electrically connected to the safety module.

8. An aging test apparatus for a motor controller according to claim 7, characterized in that: The safety module includes a safety component module and a temperature control module. The port nine of the low-voltage DC regulated power supply, the temperature control module, and the safety component module are connected in series in sequence.

9. An aging test apparatus for a motor controller according to claim 8, characterized in that: The aging test device also includes a central control host computer module, which is electrically connected to a serial port server, a LAN switch, a CAN communication module, a safety component module, a temperature control module, and an electrical parameter acquisition module.

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