A new energy motor controller aging test fixture

Abstract

This utility model discloses an aging test fixture for a new energy motor controller, including a base; an OBC plug pressing assembly is provided on the right side of the base surface, a housing limiting pressing assembly is provided on the left side of the OBC plug pressing assembly, and a Hall effect copper busbar connection assembly is provided in front of the housing limiting pressing assembly; the OBC plug pressing assembly, the housing limiting pressing assembly, and the Hall effect copper busbar connection assembly cooperate to position and fix the new energy motor controller under test; a Hall effect copper busbar pressing assembly is provided above the Hall effect copper busbar connection assembly. This utility model can achieve the function of quickly positioning the new energy motor controller under test and quickly and accurately inserting the wire harness plug into the motor controller socket through the positioning of each component and the control of the clamp. The fixture has a simple structure, is highly efficient and convenient to operate, and is safe and reliable, which greatly reduces the error rate of manual operation and improves the detection efficiency and safety of batch testing of products.

Description

Technical Field

[0001] This utility model relates to the field of aging test technology, and in particular to an aging test fixture for a new energy motor controller. Background Technology

[0002] Electric vehicles, with their clean energy source, have become a research hotspot in the new energy industry. The core technology of electric vehicles is the motor controller, which must undergo aging tests before leaving the factory to expose early failures caused by improper raw materials or manufacturing processes. In current new energy vehicle production processes, traditional motor controller aging test benches typically require manual wiring, which is complex and prone to errors such as incorrect or missing connections during operation. The utility model patent CN221378536U addresses this by using a pedal switch to control the flipping of a placement plate, which in turn flips the controller, bringing the wiring ports at the back of the controller closer to the operator for insertion of the test wires. This eliminates the need for manual rotation or flipping of the controller, making testing more convenient and reducing the risk of collisions caused by the controller's flipping. Summary of the Invention

[0003] To further improve the testing efficiency and safety of batch product testing, and to address the issues of rapid positioning and accurate insertion of wiring harness plugs during batch aging tests of motor controllers, this utility model provides an aging test fixture for new energy motor controllers. Through the guiding and positioning of each component and the control of the fixture, the fixture can achieve rapid positioning of the new energy motor controller under test and rapid and accurate insertion of the wiring harness plug into the motor controller socket.

[0004] To achieve the above objectives, this utility model provides the following technical solution:

[0005] A new energy motor controller aging test fixture is characterized by: a base; an OBC plug pressing assembly on the right side of the base surface, and a housing limiting pressing assembly on the left side of the OBC plug pressing assembly; a Hall effect copper busbar connection assembly in front of the housing limiting pressing assembly; the OBC plug pressing assembly, the housing limiting pressing assembly, and the Hall effect copper busbar connection assembly cooperate to position and fix the new energy motor controller under test; and a Hall effect copper busbar pressing assembly is located above the Hall effect copper busbar connection assembly.

[0006] Furthermore, the base is also provided with a first clamp, which is used to cooperate with the OBC plug pressing assembly, the housing limiting pressing assembly and the Hall copper busbar connection assembly to position and fix the new energy motor controller under test.

[0007] Furthermore, the OBC plug press-fit assembly includes a first guide rail fixed to the surface of the base, on which an OBC plug that can move back and forth along the guide rail direction and a second clamp for fixing the OBC plug are provided.

[0008] Furthermore, the OBC plug pressing assembly is also equipped with a positioning sensor to monitor the plug positioning signal.

[0009] Furthermore, the housing limiting and pressing assembly includes a limiter fixed to the surface of the base, and a movable positioning block is provided between the limiter and the Hall copper busbar connection assembly for cooperating with the Hall copper busbar connection assembly to position and fix the new energy motor controller under test.

[0010] Furthermore, the limiter includes a first limiter and a second limiter arranged in parallel, the first limiter being provided with a third clamp, and the second limiter being provided with a fourth clamp.

[0011] Furthermore, a first positioning block is provided between the first limiter and the Hall busbar connection assembly; a second positioning block is provided between the second limiter and the Hall busbar connection assembly.

[0012] Furthermore, the Hall busbar press-fit assembly includes a bracket vertically fixed on the base, a fifth clamp on the bracket, a lifting mechanism below the fifth clamp, and the lifting mechanism connected to a flexible connecting device.

[0013] Furthermore, the base is made of bakelite.

[0014] Furthermore, the Hall effect copper busbar connection assembly is equipped with an infrared temperature sensor for detecting the temperature of the copper busbar.

[0015] Compared with the prior art, the beneficial effects of this utility model are: the aging test fixture for the new energy motor controller has a simple structure, is efficient, convenient and safe to operate, greatly reduces the error rate of manual operation, and improves the detection efficiency and safety of batch testing of products. Attached Figure Description

[0016] Figure 1 This is an isometric view of an aging test fixture for a new energy motor controller according to this utility model.

[0017] Figure 2 yes Figure 1 An isometric view of an aging test fixture for a new energy motor controller, in which the new energy motor controller under test is installed.

[0018] Explanation of reference numerals in the attached figures:

[0019] 1. Base;

[0020] 2. OBC plug press-fit assembly; 21. First guide rail; 22. OBC plug; 23. Second clamp; 24. Position sensor;

[0021] 3. Box body limiting and pressing assembly; 31. First limiter; 32. Second limiter; 33. Third clamp; 34. Fourth clamp; 35. First positioning block; 36. Second positioning block;

[0022] 4. Hall effect copper busbar connection assembly; 41. Infrared temperature sensor;

[0023] 5. Hall effect copper busbar press-fit assembly; 51. Bracket; 52. Lifting mechanism; 53. Fifth clamp; 54. Flexible connection device;

[0024] 6. First clamp;

[0025] 7. The new energy motor controller being tested. Detailed Implementation

[0026] The technical solution of this utility model will be further described clearly and completely below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and 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. The technical term "OBC plug" refers to an on-board charger plug.

[0027] This embodiment provides an aging test fixture for a new energy motor controller, such as... Figure 1-2 As shown, it includes a base 1; an OBC plug pressing assembly 2 is provided on the right side of the base surface, and a housing limiting pressing assembly 3 is provided on the left side of the OBC plug pressing assembly 2; a Hall copper busbar connection assembly 4 is provided in front of the housing limiting pressing assembly 3; the OBC plug pressing assembly 2, the housing limiting pressing assembly 3 and the Hall copper busbar connection assembly 4 cooperate to position and fix the new energy motor controller 7 under test; a Hall copper busbar pressing assembly 5 is provided above the Hall copper busbar connection assembly 4.

[0028] The OBC plug pressing assembly 2 and the housing limiting pressing assembly 3 on the surface of the base 1 achieve physical constraint of the controller along the X-axis through positional cooperation; the Hall copper busbar connecting assembly 4 is set in front of the housing limiting pressing assembly 3 to form a positioning reference along the Y-axis, and together they construct a two-dimensional positioning system; the Hall copper busbar pressing assembly 5 is set above the Hall copper busbar connecting assembly 4 to form vertical pressure along the Z-axis. Through the linkage of the multi-dimensional positioning mechanism, the controller is ensured to maintain a precise position during the test, avoiding errors caused by manual adjustment, and realizing the automated positioning function of the test fixture.

[0029] In some embodiments, the base 1 is further provided with a first clamp 6. The first clamp 6 serves as a core fixing unit and forms a cooperative positioning structure with the OBC plug pressing assembly 2, the housing limiting pressing assembly 3, and the Hall copper busbar connection assembly 4.

[0030] In some embodiments, the OBC plug pressing assembly 2 includes a first guide rail 21 fixed to the surface of the base 1. The first guide rail 21 has an OBC plug 22 that can move back and forth along the guide rail direction, and a second clamp 23 for fixing the OBC plug 22. The first guide rail 21 fixed to the base surface provides a stable guiding reference for the moving assembly, ensuring that the OBC plug 22 maintains linear trajectory accuracy during its back-and-forth movement and adaptively adjusts according to the controller interface position, avoiding the need for repeated manual alignment. The second clamp 23 uses a mechanical locking method to rigidly fix the plug after it has moved into place, ensuring the stability of the insertion process and effectively solving the positioning deviation problem existing in traditional manual wiring.

[0031] In some embodiments, a position sensor 24 is installed in the OBC plug pressing assembly 2 to achieve real-time monitoring of the pressing position of the OBC plug 22. When the OBC plug 22 does not reach the preset installation position, the position sensor 24 can trigger an alarm and automatically power off to pause the test process, avoiding loose or incorrect connections caused by human error. This closed-loop detection mechanism effectively replaces the traditional manual visual inspection method, solves the problem of test errors caused by human judgment, and improves the automation level of the test fixture.

[0032] In some embodiments, the housing limiting and pressing assembly 3 includes limiters fixed to the surface of the base; the limiters include a first limiter 31 and a second limiter 32 arranged in parallel, the first limiter 31 is provided with a third clamp 33, and the second limiter 32 is provided with a fourth clamp 34; a first positioning block 35 is provided between the first limiter 31 and the Hall busbar connecting assembly 4, and a second positioning block 36 is provided between the second limiter 32 and the Hall busbar connecting assembly 4. A basic positioning reference is formed by the limiters fixed to the surface of the base, and combined with the setting of the movable positioning blocks, dynamic positioning compensation of the controller housing is achieved. This structure ensures positioning accuracy and adapts to the testing requirements of controllers of different specifications, overcoming the rigid constraint defects of traditional fixed limiting devices, making the positioning system adaptive, and effectively avoiding positioning deviations caused by product size tolerances.

[0033] In some embodiments, the Hall effect copper busbar press-fit assembly 5 includes a bracket 51 vertically fixed to a base, a fifth clamp 53 on the bracket 51, and a lifting mechanism 52 below the fifth clamp 53. The lifting mechanism 52 is connected to a flexible connection device 54. The flexible connection device 54 is equipped with a spring to ensure that the motor controller 6 under test is properly engaged with the DC busbar. The spring engagement pressure can be adjusted according to the product testing conditions to ensure reliable connection of a DC busbar current of up to 400A.

[0034] In some embodiments, the base 1 is made of bakelite to ensure structural stability and the insulation performance of the tooling.

[0035] In some embodiments, the Hall effect copper busbar connection assembly 4 is equipped with an infrared temperature sensor 41 for detecting the copper busbar temperature. When the copper busbar temperature is too high, the test is interrupted to protect the product and tooling.

[0036] During operation, the new energy motor controller 7 under test is transported to the base 1. The third clamp 33 and the fourth clamp 34 are moved to achieve the overall rapid positioning of the new energy motor controller 7 under test through the guiding positioning of the housing limiting pressing assembly 3 and the Hall copper busbar connecting assembly 4. The second clamp 23 is moved to move the OBC plug 22 along the first guide rail 21 to ensure that the OBC plug 22 is accurately and quickly inserted into the socket of the new energy motor controller 7 under test. The fifth clamp 53 is moved to move the lifting mechanism 52 down to install the Hall copper busbar pressing assembly 5 into place. The clamps are clamped to fix the new energy motor controller 7 under test in position. The aging test fixture is started to begin the reactive power aging test. After the automatic test is completed, all clamps are released and the new energy motor controller 7 under test is removed.

[0037] The present invention has been described above with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or direct application to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A new energy motor controller aging test tool, characterized in that: The device includes a base; an OBC plug pressing assembly is provided on the right side of the base surface, and a housing limiting pressing assembly is provided on the left side of the OBC plug pressing assembly; a Hall effect copper busbar connection assembly is provided in front of the housing limiting pressing assembly; the OBC plug pressing assembly, the housing limiting pressing assembly, and the Hall effect copper busbar connection assembly work together to position and fix the new energy motor controller under test; a Hall effect copper busbar pressing assembly is provided above the Hall effect copper busbar connection assembly.

2. The new energy motor controller aging test tool of claim 1, wherein: The base is also provided with a first clamp, which is used to cooperate with the OBC plug pressing assembly, the housing limiting pressing assembly and the Hall copper busbar connection assembly to position and fix the new energy motor controller under test.

3. The new energy motor controller aging test tool of claim 1, wherein: The OBC plug press-fit assembly includes a first guide rail fixed to the surface of the base, on which an OBC plug that can move back and forth along the guide rail direction and a second clamp for fixing the OBC plug are provided.

4. The new energy motor controller aging test tool of claim 3, wherein: The OBC plug pressing assembly is also equipped with a positioning sensor to monitor the plug positioning signal.

5. The new energy motor controller aging test tool of claim 1, wherein: The housing limiting and pressing assembly includes a limiter fixed to the surface of the base. A movable positioning block is provided between the limiter and the Hall copper busbar connection assembly for cooperating with the Hall copper busbar connection assembly to position and fix the new energy motor controller under test.

6. The new energy motor controller aging test tool of claim 5, wherein: The limiter includes a first limiter and a second limiter arranged in parallel. The first limiter is provided with a third clamp, and the second limiter is provided with a fourth clamp.

7. The new energy motor controller aging test tool of claim 6, wherein: A first positioning block is provided between the first limiter and the Hall busbar connection assembly; a second positioning block is provided between the second limiter and the Hall busbar connection assembly.

8. The new energy motor controller aging test tool of claim 1, wherein: The Hall busbar press-fit assembly includes a bracket vertically fixed on a base, a fifth clamp on the bracket, a lifting mechanism below the fifth clamp, and a flexible connecting device connected to the lifting mechanism.

9. The new energy motor controller aging test tool of claim 1, wherein: The base is made of bakelite.

10. The new energy motor controller aging test tool of claim 1, wherein: The Hall effect copper busbar connection assembly is equipped with an infrared temperature sensor for detecting the temperature of the copper busbar.

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