A test fixture and test system for motor controller modularization

Abstract

The utility model discloses a kind of motor controller modularization's test fixture and test system, including test fixture main body, and the switching circuit being set in test fixture main body;Switching circuit includes switch unit, function wire harness and power line harness;Switch unit is set on function wire harness and power line harness control function wire harness and the function on-off of power line harness;The output end of function wire harness is configured as multiple multi-hole female head docking plug;One end of switching line is set as the multiple multi-hole male head docking plug of the output end of function wire harness, the other end of switching line is set as the multi-hole plug-in of the function port of corresponding motor controller to be measured;Simplify the motor controller wire harness test connection to be measured, realize the motor controller of adaptation different type port function definition, reduce the connection time consumption when the motor controller of different type is switched over and tested, improve test efficiency.

Description

Technical Field

[0001] This utility model relates to the field of testing technology, and in particular to a modular test fixture and test system for a motor controller. Background Technology

[0002] Because different OEMs define the functions of their controller ports differently, functional and performance tests on a test bench require triggering the functions corresponding to different ports. Current controller testing processes necessitate disassembling the controller's components and the vehicle's wiring harness to build the test environment. This results in cumbersome testing procedures, poor cable connection security, and increased time consumption and reduced testing efficiency when switching between different controllers. Utility Model Content

[0003] This utility model provides a modular test fixture and test system for motor controllers, which simplifies the test connection of the wiring harness of the motor controller under test, enables adaptation to motor controllers with different types of port function definitions, reduces the connection time when switching tests of different types of motor controllers, and improves test efficiency.

[0004] In a first aspect, embodiments of this utility model provide a modular test fixture for a motor controller, comprising:

[0005] The test fixture body and the adapter circuit disposed within the test fixture body; the adapter circuit includes a switching unit, a functional wiring harness and a power wiring harness; the switching unit is disposed on the functional wiring harness and the power wiring harness and is used to control the on / off state of the functional wiring harness and the power wiring harness; the output end of the functional wiring harness is configured as a plurality of multi-hole female connectors.

[0006] The adapter cable has one end configured as a multi-hole male connector capable of connecting to the output end of the functional harness, and the other end configured as a multi-hole plug corresponding to the functional port of the motor controller under test.

[0007] The female connector at the output end of the functional wiring harness is used to connect to the male connector at the adapter cable, the output end of the power wiring harness is used to connect to the power supply terminal of the motor controller under test, and the multi-hole plug of the adapter cable is used to connect to the functional port of the motor controller under test.

[0008] Optionally, the switching unit includes a main control switch and a first switch; the power harness includes a first positive power line, a second positive power line, and a negative power line.

[0009] The positive terminal of the external power supply is connected to the first input terminal of the main control switch; the negative terminal of the external power supply is connected to the second input terminal of the main control switch; one end of the first positive power line and the second positive power line are connected to the first output terminal of the main control switch, and one end of the negative power line is connected to the second output terminal of the main control switch through the first switch.

[0010] The power supply terminal of the motor controller under test includes the positive and negative terminals of the motor controller under test and the ignition switch connection terminal of the motor controller under test.

[0011] The output terminals of the first positive power line and the negative power line are used to connect to the positive and negative terminals of the motor controller under test, respectively; the output terminal of the second positive power line is used to connect to the ignition lock terminal of the motor controller under test.

[0012] Optionally, the switching unit further includes a second switch, and the power harness further includes: a first phase adapter wire, a second phase adapter wire, and a third phase adapter wire; a second switch is provided on each of the first phase adapter wire, the second phase adapter wire, and the third phase adapter wire, and the second switch is used to control the first phase adapter wire, the second phase adapter wire, and the third phase adapter wire to be on or off respectively;

[0013] The power supply terminal of the motor controller under test also includes a first phase line connection terminal, a second phase line connection terminal, and a third phase line connection terminal of the motor controller under test;

[0014] The first end of the first phase adapter wire is used to connect to the first phase wire connection terminal of the motor controller under test; the first end of the second phase adapter wire is used to connect to the second phase wire connection terminal of the motor controller under test; the first end of the third phase adapter wire is used to connect to the third phase wire connection terminal of the motor controller under test.

[0015] The second end of the first phase transfer wire is used to connect to the first phase wire connection terminal of the test motor; the second end of the second phase transfer wire is used to connect to the second phase wire connection terminal of the test motor; the second end of the third phase transfer wire is used to connect to the third phase wire connection terminal of the test motor.

[0016] Optionally, the switching unit further includes a function switch; the function wiring harness includes a first function line and multiple second function lines.

[0017] One end of the first functional line is connected to the second positive power line via a functional switch; one end of the second functional line is connected to the negative power line via a functional switch; the other ends of the first and second functional lines serve as the output ends of the functional line harness.

[0018] Optionally, the switching circuit further includes a mainline voltmeter, a static power ammeter, and a load ammeter;

[0019] The main line voltmeter is connected to the first input terminal and the second input terminal of the main control switch, respectively; the static power ammeter is connected in series on the second positive power line; and the load ammeter is connected in series on the negative power line.

[0020] Optionally, the adapter circuit may further include a phase meter and a one-wire continuity meter;

[0021] The first end of the phase meter is connected to the second positive power line, and the second end of the phase meter is connected to the negative power line;

[0022] The first end of the one-line communication meter is connected to the first end of the phase meter, and the second end of the one-line communication meter is connected to the negative power line.

[0023] Optionally, the output end of the power harness is provided with an O-type copper-plated terminal block.

[0024] Optionally, the output end of the functional harness is provided with a brass-plated square insert.

[0025] Optionally, the test fixture body is provided with a control panel, which is used to arrange the main control switch, the first switch, the second switch and the function switch;

[0026] The main control switch is a blow-out circuit breaker; the first switch is a toggle switch; and the second switch and the function switch are push-button switches.

[0027] Secondly, this utility model provides a test system for a motor controller, including an external power supply, a test motor, and a modular test fixture for the motor controller as described in any embodiment of this utility model.

[0028] The external power supply is connected to the test fixture;

[0029] The female connector of the functional wiring harness of the test fixture is connected to the male connector of the adapter cable; the power wiring harness of the test fixture is connected to the power supply terminal of the motor controller under test and the power supply terminal of the test electrode.

[0030] The adapter cable has a multi-hole connector that connects to the function port of the motor controller under test.

[0031] The test fixture provided in this embodiment configures the functional wiring harness of the adapter circuit as multiple multi-hole female connectors. One end of the adapter cable is configured as a multi-hole male connector capable of connecting to the output end of the functional wiring harness, and the other end of the adapter cable is configured as a multi-hole plug corresponding to the functional port of the motor controller under test. A switching unit can control the on / off state of the power harness and the functional wiring harness, enabling testing of one or more functions. When replacing with the same type of motor controller under test, simply detach the multi-hole plug of the adapter cable from the multi-hole plug of the motor controller under test for switching. Conversely, when replacing with a different type of motor controller under test, only the corresponding adapter cable needs to be replaced to complete the test environment conversion. This simplifies the test connection of the motor controller wiring harness, enables adaptation to motor controllers with different port function definitions, reduces connection time during switching tests between different types of motor controllers, and improves test efficiency. Attached Figure Description

[0032] Figure 1 This invention provides a schematic diagram of the structure of a modular test fixture for a motor controller, according to an embodiment of the present invention.

[0033] Figure 2 This invention provides a schematic diagram of the structure of an adapter circuit according to an embodiment of the present invention.

[0034] Figure 3 This invention provides a schematic diagram of the instrument surface layout for an embodiment of the present invention.

[0035] Figure 4 This is a structural schematic diagram of a control panel layout provided for an embodiment of the present utility model. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0037] Figure 1 This is a schematic diagram of the structure of a modular test fixture for a motor controller provided in an embodiment of the present invention. See also... Figure 1 ,include:

[0038] The test fixture body 110 and the adapter circuit 111 disposed within the test fixture body 110; the adapter circuit 111 includes a switching unit 112, a functional wiring harness 113 and a power wiring harness 114; the switching unit 112 is disposed on the functional wiring harness 113 and the power wiring harness 114 and is used to control the on / off state of the functional wiring harness 113 and the power wiring harness 114; the output end of the functional wiring harness 113 is configured as a plurality of multi-hole female connectors;

[0039] The adapter cable 120 has one end configured as a multi-hole male connector that can connect to the output end of the functional harness 113, and the other end configured as a multi-hole plug corresponding to the functional port of the motor controller 130 under test.

[0040] The female connector at the output end of the functional wiring harness 113 is used to connect to the male connector at the adapter cable 120. The output end of the power wiring harness 114 is used to connect the power supply terminal of the motor controller under test 130 and the power supply terminal of the test motor. The multi-hole plug of the adapter cable 120 is used to connect to the functional port of the motor controller under test 130.

[0041] Specifically, the test fixture body 110 can be made of a rigid material, such as bakelite pressure plate, to form a box structure that can accommodate the adapter circuit 111. A wiring inlet / outlet can be provided on one surface of the test fixture body 110. External connection lines to the adapter circuit 111 can be introduced through the wiring inlet, and the output lines of the adapter circuit 111 can be led out through the wiring outlet. The adapter circuit 111 provides a functional wiring harness 113 and a power wiring harness 114. The functional wiring harness 113 can be configured according to the functional interface of the motor controller 130 under test. For example, the functional interface of the electric vehicle motor controller may include a communication serial port TX / TR, an overspeed warning port, wheel type selection, EABS port selection, cruise control, anti-theft, reversing, low braking, speed limit, fault indication, programming signal, gear shifting (high gear), gear shifting (low gear), one-line communication, P gear, one-key repair, voltage switching, and high braking, etc. The functional wiring harness 113 is configured with corresponding wiring harnesses. The output end of functional harness 113, i.e., the end from which the harness leads out, can be configured with multi-pin female connectors (two-pin, three-pin, and four-pin, etc.) according to its functional attributes. These connectors should be clearly labeled with waterproof and wear-resistant synthetic paper labels for easy identification and accurate subsequent connection. Based on functional attributes, such as high / low voltage classification, high-voltage braking, and wheel movement signals, a two-pin female connector can be used. For example, within the same functional classification, three-speed shifting; gear shifting to high gear, gear shifting to low gear can use a two-pin female connector; cruise control / reverse / Park can use a three-pin female connector.

[0042] Adapter cable 120 is the connection line between adapter circuit 111 and the motor controller under test (MDT) 130. According to the port function definition of the MDT 130, one end of adapter cable 120 can be configured as a multi-pin male connector with two, three, or four pins. It should be noted that when connecting functional harness 113 and adapter cable 120, female connectors with the same number of pins do not necessarily need to be connected to male connectors. Instead, the connection should be based on the port function definition of the MDT 130. For example, according to the port function definition of the MDT 130, two two-pin female connectors can be connected to a four-pin male connector. Therefore, depending on the model type of the MDT 130, the male and female connectors can be connected according to the markings on adapter cable 120 and the lead wire markings on functional harness 113. The other end of adapter cable 120 needs to be connected to the MDT 130; therefore, the other end of adapter cable 120 can be configured as multiple multi-pin connectors according to the port function definition of the MDT 130. For example, the commonly used multi-hole plugs for electric vehicle motor controllers can be 6-hole, 8-hole, and 16-hole plugs, etc.

[0043] The power harness 114 is connected to the power supply terminal of the motor controller 130 under test. For example, the power supply terminal of the motor controller for an electric vehicle may include positive and negative terminals and an ignition switch connection terminal. In this embodiment, an external power supply 140 can be connected to the adapter circuit 111, and power can be supplied to the motor controller 130 under test via the power harness 114. A switching unit 112 is disposed on the power harness 114 and the functional harness 113, thus the switching unit 112 can control the on / off state of the power harness 114 and the functional harness 113, thereby enabling testing of one or more functions.

[0044] In the application scenario of the test fixture, according to the model and type of the motor controller under test 130, the male and female connectors are connected according to the corresponding markings on the adapter cable 120 and the lead wire markings on the functional harness 113. The multi-hole plug of the adapter cable 120 is connected to the multi-hole plug of the motor controller under test 130, the power harness 114 is connected to the motor controller under test 130, and the motor controller under test 130 is connected to the test motor 150. The switching unit 112 can control the on / off state of the power harness 114 and the functional harness 113, enabling testing of one or more functions. When replacing the motor controller under test 130 with the same type, simply disconnect the multi-hole plug of the adapter cable 120 from the multi-hole plug of the motor controller under test 130 to switch. When replacing the motor controller under test 130 with a different type, only the corresponding adapter cable 120 needs to be replaced to complete the test environment conversion. This simplifies the test connection of the motor controller under test 130 wiring harness, enables adaptation to motor controllers with different port function definitions, reduces connection time when switching between different types of motor controllers, and improves test efficiency.

[0045] Figure 2 A schematic diagram of the adapter circuit provided in this embodiment of the present invention is shown below. Figure 2 The switching unit 112 includes a main control switch 210 and a first switch 220; the power harness 114 includes a first positive power line D+, a second positive power line + and a negative power line D-.

[0046] The positive terminal of the external power supply 140 is connected to the first input terminal of the main control switch 210; the negative terminal of the external power supply 140 is connected to the second input terminal of the main control switch 210; one end of the first positive power line D+ and the second positive power line + is connected to the first output terminal of the main control switch 210; and one end of the negative power line D- is connected to the second output terminal of the main control switch 210 through the first switch 220.

[0047] The power supply terminals of the motor controller under test 130 include the positive and negative terminals of the motor controller under test 130 and the ignition switch connection terminal of the motor controller under test 130.

[0048] The output terminals of the first positive power line D+ and the negative power line D- are used to connect to the positive and negative terminals of the motor controller 130 under test, respectively; the output terminal of the second positive power line + is used to connect to the ignition lock connection terminal of the motor controller 130 under test.

[0049] Specifically, the power harness 114 provided by the test fixture is connected to the power supply terminal of the motor controller 130 under test. The adapter circuit 111 can be powered by an external power supply 140, which can be a DC power supply. The input side of the main control switch 210 is connected to the positive and negative terminals of the external power supply 140. The output side of the main control switch 210 is connected to the first positive power line D+ and the negative power line D-. The first positive power line D+ and the negative power line D- are led out from the test fixture and can be connected to the positive and negative terminals of the motor controller 130 under test, respectively. By controlling the on or off state of the main control switch 210, power is supplied to the motor controller 130 under test. The second positive power line + is connected in parallel with the first positive power line D+. The second positive power line + is connected to the ignition switch connection terminal of the motor controller 130 under test. The first switch 220 is connected in series between the second positive power line + and the ignition switch connection terminal of the motor controller 130 under test. By controlling the on or off state of the first switch 220, the control circuit of the motor controller 130 under test is powered.

[0050] To improve the connection stability between the first positive power line D+, the second positive power line +, and the negative power line D- and the power terminal of the motor controller 130 under test, a junction box can be used for connection. For easy identification of the first positive power line D+, the second positive power line +, and the negative power line D-, a red wire harness can be used for the first positive power line D+ and the second positive power line +, and a black wire harness can be used for the negative power line D-. The wires should be 6 square millimeters or larger, made of high-temperature resistant, extra-soft silicone copper core wire. The leads of the first positive power line D+, the second positive power line +, and the negative power line D- can be fitted with copper-plated O-type terminals for easy connection to the junction box. The O-type copper-plated terminals can have a 5.5mm diameter hole, and the crimping points of the O-type copper-plated terminals and the leads can be protected with heat-shrink tubing.

[0051] See also Figure 2 Optionally, the switching unit 112 further includes a second switch 230, and the power harness 114 further includes: a first phase transfer wire U, a second phase transfer wire V, and a third phase transfer wire W; a second switch 230 is provided on each of the first phase transfer wire U, the second phase transfer wire V, and the third phase transfer wire W, and the second switch 230 is used to control the first phase transfer wire U, the second phase transfer wire V, and the third phase transfer wire W to be on or off respectively;

[0052] The power supply terminal of the motor under test controller 130 also includes the first phase line connection terminal, the second phase line connection terminal and the third phase line connection terminal of the motor under test controller 130; the power supply terminal of the test motor 150 includes the first phase line connection terminal, the second phase line connection terminal and the third phase line connection terminal of the test motor 150.

[0053] The first end of the first phase adapter wire U is used to connect to the first phase wire connection terminal of the motor controller 130 under test; the first end of the second phase adapter wire V is used to connect to the second phase wire connection terminal of the motor controller 130 under test; the first end of the third phase adapter wire W is used to connect to the third phase wire connection terminal of the motor controller 130 under test.

[0054] The second end of the first phase transfer wire U is used to connect to the first phase wire connection terminal of the test motor 150; the second end of the second phase transfer wire V is used to connect to the second phase wire connection terminal of the test motor 150; the second end of the third phase transfer wire W is used to connect to the third phase wire connection terminal of the test motor 150.

[0055] Specifically, during the testing of the motor controller under test (MDT) 130, the three-phase terminals of the test motor 150 and the MDT 130 need to be connected accordingly, and the Hall effect wires of the test motor 150 are connected to the Hall effect terminals of the MDT 130. When replacing the MDT 130, the test motor 150 and the MDT 130 also need to be disconnected. To further reduce the time consumed in wiring harness connection, the adapter circuit 111 can be equipped with a first-phase adapter wire U, a second-phase adapter wire V, and a third-phase adapter wire W. Each phase adapter wire is equipped with a second switch 230. By controlling the on or off state of the second switch 230, the on / off control of each phase wire can be achieved. The first ends of the first-phase adapter wire U, the second-phase adapter wire V, and the third-phase adapter wire W are respectively connected to the first-phase line connection terminal, the second-phase line connection terminal, and the third-phase line connection terminal of the motor controller under test 130. The second ends of the first-phase adapter wire U, the second-phase adapter wire V, and the third-phase adapter wire W are respectively connected to the first-phase line connection terminal, the second-phase line connection terminal, and the third-phase line connection terminal of the test motor. Therefore, in the application scenario of the test fixture, the test fixture is connected to the motor controller under test 130 through the adapter wire 120, and the three-phase terminals of the test motor 150 are connected to the three-phase terminals of the motor controller under test 130 through the adapter wire 120. When replacing the motor controller under test 130, it is only necessary to disconnect the motor controller under test 130 from the adapter wire 120 and the Hall wire of the test motor 150 from the Hall terminal of the motor controller under test 130, thereby disconnecting the test motor 150 from the motor controller under test 130, further reducing the connection time during motor controller switching tests and improving test efficiency.

[0056] Furthermore, the functional wiring harness 113 may include a Hall effect adapter cable 120; the first end of the Hall effect adapter cable 120 is connected to the Hall effect wire of the test motor 150, and the second end of the Hall effect adapter cable 120 is connected to the Hall effect terminal of the motor controller under test 130. The Hall effect wire of the test motor and the Hall effect terminal of the motor controller under test 130 can be connected through the Hall effect adapter cable 120. In the application scenario of the test fixture, the test fixture is connected to the motor controller under test 130 through the adapter cable 120, and the three-phase terminals and Hall effect wires of the test motor 150 are connected to the three-phase terminals and Hall effect terminals of the motor controller under test 130 through the adapter cable 120. When replacing the motor controller under test 130, it is only necessary to disconnect the motor controller under test 130 from the adapter cable 120 to disconnect the test motor 150 from the motor controller under test 130, further reducing the connection time during motor controller switching tests and improving test efficiency.

[0057] See also Figure 2 Optionally, the switch unit 112 may also include a function switch 240; the function harness 113 includes a first function line and multiple second function lines.

[0058] One end of the first functional line is connected to the second positive power line + via a functional switch 240; one end of the second functional line is connected to the negative power line D- via a functional switch 240; the other ends of the first and second functional lines serve as the output terminals of the functional wiring harness 113.

[0059] Specifically, the functions of the motor controller 130 under test can be configured such that the first function line is connected to the second positive power line +, and the second function line is connected to the negative power line D-. For example, the first function line may include the high brake line HH. The second function line may include: serial data transmission line LD1, serial data reception line LD2, overspeed warning line LD3, wheel signal line LD4, EABS port selection line ABS, cruise control line CLD, anti-theft line YK, reversing line DSP, low brake line HL, speed limiter line XS, fault indication line LED, programming line DIO, gear shifting - high gear HBD, gear shifting - low gear LBD, one-line communication MSP, P gear 12 / 6, one-key repair SVM, and voltage switching Z / F. The leads of each function harness 113 can be fitted with brass-plated square inserts to improve the conductivity and mechanical strength of the leads.

[0060] Optionally, the adapter circuit 111 may also include a mainline voltmeter V, a static power ammeter A3, and a load ammeter A1;

[0061] The main line voltmeter V is connected to both the first and second input terminals of the main control switch 210; the static power ammeter A3 is connected in series with the second positive power line +; and the load ammeter A1 is connected in series with the negative power line D-. The main line voltmeter V can be a 200V DC digital display meter to detect the total input voltage. The static power ammeter A3 can be a 100mA digital display ammeter connected in series with a 2A fuse to detect the current data at the ignition lock terminal of the motor controller 130 under test. Optionally, the adapter circuit 111 also includes a phase meter and a continuity meter; the first terminal of the phase meter is connected to the second positive power line +, and the second terminal is connected to the negative power line D-; the phase meter can measure the phase difference between voltage and current.

[0062] The first terminal of the one-line communication meter is connected to the first terminal of the phase meter, and the second terminal of the one-line communication meter is connected to the negative power supply line D-. The one-line communication meter can monitor AC voltage and current amplitude in real time, detect power frequency, and calculate active power, reactive power, and power factor, etc. To observe the parameters of the main line voltmeter V, static power ammeter A3, load ammeter A1, phase meter, and one-line communication meter in real time, Figure 3 This utility model provides a schematic diagram of the instrument surface layout. Multiple observation windows 310 are provided on the surface of the test fixture body 110. Each observation window 310 can be correspondingly set with the reading surface of each surface, thereby facilitating the rapid reading of parameters.

[0063] Optionally, the test fixture body 110 is provided with a control panel, which is used to arrange the main control switch 210, the first switch 220, the second switch 230 and the function switch 240.

[0064] Among them, the main control switch 210 adopts a blow-out circuit breaker; the first switch 220 adopts a toggle switch; and the second switch 230 and the function switch 240 adopt push-button switches.

[0065] Specifically, Figure 4 This utility model provides a schematic diagram of a control panel layout. To facilitate the adjustment of the switching state of the switch unit 112, the actuating parts of each switch are located on the surface of the test fixture body 110 and clearly marked. The second switch 230 and function switch 240 can be push-button switches, which are self-locking and do not reset after being pressed, making it easy to distinguish between the on and off states. The main control switch 210 can be a circuit breaker with leakage protection, improving electrical safety. The first switch 220 uses a copper-plated, silver-point flame-retardant shell toggle switch to distinguish it from other switches. Using this test fixture to build a test environment, the adapter circuit 111, instruments, indicator lights, switches, etc., are integrated internally. The functional wiring harness 113, power wiring harness 114, and adapter cable 120 are labeled, resulting in a clean, clear, and orderly test environment, reducing the electrical risks caused by incorrect wiring connections.

[0066] This utility model provides a test system for a motor controller, including an external power supply 140, a test motor 150, and a modular test fixture for the motor controller according to any embodiment of this utility model; wherein, the external power supply 140 is connected to the test fixture; the female connector of the functional wiring harness 113 of the test fixture is connected to the male connector of the adapter cable 120; the power wiring harness 114 of the test fixture is connected to the power terminal of the motor controller under test 130; and the multi-hole plug of the adapter cable 120 is connected to the functional port of the motor controller under test 130.

[0067] Specifically, adapter cable 120 is the connection line between adapter circuit 111 and the motor controller under test (MDT) 130. According to the port function definition of the MDT 130, one end of adapter cable 120 can be configured as a multi-pin male connector with two, three, or four pins. It should be noted that when connecting functional harness 113 and adapter cable 120, female connectors with the same number of pins do not necessarily need to be connected to male connectors. Instead, the connection should be based on the port function definition of the MDT 130. For example, according to the port function definition of the MDT 130, two two-pin female connectors can be connected to a four-pin male connector. Therefore, depending on the model type of the MDT 130, the male and female connectors can be connected according to the markings on adapter cable 120 and the lead wire markings on functional harness 113. The other end of adapter cable 120 needs to be connected to the MDT 130; therefore, the other end of adapter cable 120 can be configured as multiple multi-pin connectors according to the port function definition of the MDT 130. For example, the commonly used multi-hole plugs for electric vehicle motor controllers can be 6-hole, 8-hole, and 16-hole plugs, etc.

[0068] The power harness 114 is connected to the power supply terminals of the motor controller 130 under test and the test motor 150. For example, the power supply terminals of the motor controller for an electric vehicle may include positive and negative terminals and an ignition switch connection terminal. In this embodiment, an external power supply 140 can be connected to the adapter circuit 111, and power can be supplied to the motor controller 130 under test via the power harness 114. A switching unit 112 is disposed on the power harness 114 and the functional harness 113, thus the switching unit 112 can control the on / off state of the power harness 114 and the functional harness 113, thereby enabling the testing of one or more functions.

[0069] In the application scenario of the test fixture, according to the model and type of the motor controller under test 130, the male and female connectors are connected according to the corresponding markings on the adapter cable 120 and the lead wire markings on the functional harness 113. The multi-hole plug of the adapter cable 120 is connected to the multi-hole plug of the motor controller under test 130, the power harness 114 is connected to the motor controller under test 130, and the motor controller under test 130 is connected to the test motor 150. The switching unit 112 can control the on / off state of the power harness 114 and the functional harness 113, enabling testing of one or more functions. When replacing the motor controller under test 130 with the same type, simply disconnect the multi-hole plug of the adapter cable 120 from the multi-hole plug of the motor controller under test 130 to switch. When replacing the motor controller under test 130 with a different type, only the corresponding adapter cable 120 needs to be replaced to complete the test environment conversion. This simplifies the test connection of the motor controller under test 130 wiring harness, enables adaptation to motor controllers with different port function definitions, reduces connection time when switching between different types of motor controllers, and improves test efficiency.

[0070] 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. 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. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A test fixture for motor controller modularization, characterized in that, include: The main body of the test fixture, and the adapter circuit installed inside the main body of the test fixture; The adapter circuit includes a switching unit, a functional wiring harness, and a power wiring harness. The switching unit is disposed on the functional harness and the power harness and is used to control the on / off state of the functional harness and the power harness; the output end of the functional harness is configured as a plurality of multi-hole female connectors. The adapter cable has one end configured as a multi-hole male connector capable of connecting to the output end of the functional harness, and the other end configured as a multi-hole plug corresponding to the functional port of the motor controller under test. The female connector at the output end of the functional wiring harness is used to connect to the male connector at the adapter cable, the output end of the power wiring harness is used to connect to the power supply terminal of the motor controller under test, and the multi-hole plug of the adapter cable is used to connect to the functional port of the motor controller under test.

2. The test fixture for motor controller modularization of claim 1, wherein, The switching unit includes a main control switch and a first switch; the power harness includes a first positive power line, a second positive power line and a negative power line. The positive terminal of the external power supply is connected to the first input terminal of the main control switch; the negative terminal of the external power supply is connected to the second input terminal of the main control switch; one end of the first positive power line and the second positive power line are connected to the first output terminal of the main control switch, and one end of the negative power line is connected to the second output terminal of the main control switch through the first switch. The power supply terminal of the motor controller under test includes the positive and negative terminals of the motor controller under test and the ignition switch connection terminal of the motor controller under test. The output terminals of the first positive power line and the negative power line are used to connect to the positive and negative terminals of the motor controller under test, respectively; the output terminal of the second positive power line is used to connect to the ignition lock terminal of the motor controller under test.

3. The test fixture for motor controller modularization of claim 2, wherein, The switching unit further includes a second switch, and the power harness further includes: a first phase adapter wire, a second phase adapter wire, and a third phase adapter wire; a second switch is provided on each of the first phase adapter wire, the second phase adapter wire, and the third phase adapter wire, and the second switch is used to control the first phase adapter wire, the second phase adapter wire, and the third phase adapter wire to be on or off respectively; The power supply terminal of the motor controller under test also includes a first phase line connection terminal, a second phase line connection terminal, and a third phase line connection terminal of the motor controller under test; The first end of the first phase adapter wire is used to connect to the first phase wire connection terminal of the motor controller under test; the first end of the second phase adapter wire is used to connect to the second phase wire connection terminal of the motor controller under test; the first end of the third phase adapter wire is used to connect to the third phase wire connection terminal of the motor controller under test. The second end of the first phase transfer wire is used to connect to the first phase wire connection terminal of the test motor; the second end of the second phase transfer wire is used to connect to the second phase wire connection terminal of the test motor; the second end of the third phase transfer wire is used to connect to the third phase wire connection terminal of the test motor.

4. The test fixture for motor controller modularization of claim 3, wherein, The switching unit further includes a function switch; the function wiring harness includes a first function line and multiple second function lines; One end of the first functional line is connected to the second positive power line via a functional switch; one end of the second functional line is connected to the negative power line via a functional switch; the other ends of the first and second functional lines serve as the output ends of the functional line harness.

5. The test fixture for motor controller modularization of claim 2, wherein, The switching circuit also includes a mainline voltmeter, a static power ammeter, and a load ammeter; The main line voltmeter is connected to the first input terminal and the second input terminal of the main control switch, respectively; the static power ammeter is connected in series on the second positive power line; and the load ammeter is connected in series on the negative power line.

6. The test fixture for motor controller modularization of claim 2, wherein, The adapter circuit also includes a phase meter and a one-wire continuity meter; The first end of the phase meter is connected to the second positive power line, and the second end of the phase meter is connected to the negative power line; The first end of the one-line communication meter is connected to the first end of the phase meter, and the second end of the one-line communication meter is connected to the negative power line.

7. The test fixture for motor controller modularization of claim 3, wherein, The output end of the power harness is equipped with an O-type copper-plated terminal block.

8. The test fixture for motor controller modularization of claim 1, wherein, The output end of the functional wiring harness is equipped with a brass-plated square insert.

9. The test fixture for motor controller modularization of claim 4, wherein, The main body of the test fixture is provided with a control panel, which is used to arrange the main control switch, the first switch, the second switch and the function switch; The main control switch is a blow-out circuit breaker; the first switch is a toggle switch; and the second switch and the function switch are push-button switches.

10. A test system for a motor controller, characterized by, The test fixture includes an external power supply, a test motor, and a modular motor controller as described in any one of claims 1-9; The external power supply is connected to the test fixture; The female connector of the functional wiring harness of the test fixture is connected to the male connector of the adapter cable; the power wiring harness of the test fixture is connected to the power supply terminal of the motor controller under test and the power supply terminal of the test electrode. The adapter cable has a multi-hole connector that connects to the function port of the motor controller under test.

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