A movable modular high-dynamic-response four-motor power test experiment system

Abstract

The utility model provides a movable modularization high dynamic response four motor power test experiment system relates to motor power test technical field, and this system breaks through the fixed mode of traditional laboratory, adopts modularization container structure, has the ability of quick deployment and nimble migration, can complete installation and put into use in short time, integrates advanced power test equipment, environmental simulation system and digital twin technology inside, can simulate various extreme working conditions from extremely cold to high temperature, supports whole working condition test of whole vehicle, power assembly and spare part simultaneously. The core lies in the highly integrated equipment layout and intelligent control architecture, through optimizing signal transmission and data processing, efficient cooperation among the dynamometer, environment cabin, power analyzer and other equipment is realized. At the same time, based on the real -time data synchronization and 3D visualization function of digital twin technology, intuitive monitoring means is provided for the test process, and remote cooperation and fault diagnosis are supported.

Description

Technical Field

[0001] This utility model relates to the field of motor power testing technology, specifically to a mobile, modular, high dynamic response four-motor power testing experimental system. Background Technology

[0002] Against the backdrop of the rapid development of the automotive industry, the demand for research and testing of new energy vehicles is increasing. Traditional automotive powertrain testing laboratories mostly adopt fixed structures, which have problems such as long construction cycles, site limitations, and limited environmental simulation capabilities. They are unable to meet the complex and ever-changing testing needs of new energy vehicles, especially the requirements for performance verification under extreme environmental conditions and rapid iterative development.

[0003] Furthermore, traditional laboratory data acquisition and analysis systems are mostly closed architectures, lacking sufficient data sharing and remote collaboration capabilities, and unable to fully utilize advanced digital twin technology for intelligent testing and fault diagnosis. Meanwhile, with the continuous development of new energy vehicle technology, higher demands are placed on the dynamic response capabilities, testing accuracy, and multi-condition simulation capabilities of testing systems, while existing laboratory equipment often falls short in these aspects. Therefore, there is an urgent need for a new type of automotive powertrain testing laboratory solution that can overcome the limitations of traditional laboratories to meet the full-condition testing needs of new energy vehicles, powertrains, and components.

[0004] In view of the above, this application is hereby submitted. Utility Model Content

[0005] This invention provides a mobile, modular, high dynamic response four-motor power testing experimental system, which can at least partially improve the above-mentioned problems.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A mobile, modular, high dynamic response four-motor power testing experimental system includes: a vehicle / component support fixture, a power testing module configured on the vehicle / component support fixture, a data acquisition and control module, an environmental simulation module, a digital twin and simulation module, and a power supply and charging module.

[0008] The data terminal of the power test module is electrically connected to the data terminal of the environmental simulation module and the data terminal of the digital twin and simulation module; the input terminal of the power test module is electrically connected to the output terminal of the data acquisition and control module; and the power supply terminal of the power test module is electrically connected to the output terminal of the power supply and charging module.

[0009] The environmental simulation module is configured to provide the test piece with simulated environments of different combinations of high and low temperatures and sunlight; the power testing module is configured to drive the rotation of the motor dynamometer according to a preset test mode; the data acquisition and control module is configured to acquire test signals during the test; and the digital twin and simulation module is configured to simulate the test process based on the test signals.

[0010] In summary, the mobile, modular, high-dynamic-response four-motor powertrain testing system aims to meet the full-condition testing needs of complete vehicles, powertrains, and components. The system adopts a containerized structure, enabling rapid deployment; installation and operation can be completed within 7 days, adapting to various site conditions. Internally, it integrates advanced equipment such as a four-motor dynamometer system, high and low temperature environmental chambers, a sunlight simulation system, a battery simulator, and a digital twin platform, supporting testing of gasoline vehicles, hybrid vehicles, and pure electric vehicles.

[0011] Specifically, the system adopts a fully open architecture, supporting open-source real-time control algorithms and third-party simulation software integration, enabling independent control of four motors, extreme environment simulation, and high-precision data acquisition. The digital twin platform provides intelligent analysis and remote monitoring functions through real-time data synchronization and 3D visualization technology, optimizing testing processes and improving efficiency. Furthermore, the safety design incorporates multiple protection mechanisms, including hard-wired emergency stop, safety bus, and mechanical decoupling, to ensure the safety of equipment and personnel.

[0012] Compared with existing technologies, the mobile, modular, high dynamic response four-motor power testing system has the following advantages: First, its modular design facilitates rapid deployment and flexible migration; second, its fully open control system supports third-party software access and algorithm optimization; third, its extreme environment coverage capability fills the gap in traditional laboratories for low-temperature cold start and high-temperature exposure testing; and fourth, the application of digital twin technology enables intelligent and visualized testing processes. It is suitable for OEMs, component suppliers, regulatory certification bodies, and research institutions, providing a one-stop, efficient solution for the R&D, certification, and fault reproduction of new energy vehicles, with broad application prospects and significant economic value. Attached Figure Description

[0013] Figure 1 This is a simplified block diagram of the movable modular high dynamic response four-motor power testing experimental system provided in this embodiment of the utility model;

[0014] Figure 2 This is a complete framework diagram of the movable modular high dynamic response four-motor power testing experimental system provided in this embodiment of the utility model. Detailed Implementation

[0015] 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 a part of the embodiments of this utility model, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model. Therefore, the following detailed description of the embodiments of this utility model provided in the accompanying drawings is not intended to limit the scope of the claimed utility model, but merely represents selected embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0016] The specific embodiments of this utility model are described in detail below with reference to the accompanying drawings.

[0017] Please see Figure 1 , Figure 2 This utility model discloses a mobile modular high dynamic response four-motor power test experimental system, which includes: a vehicle / component support fixture, a power test module configured on the vehicle / component support fixture, a data acquisition and control module, an environmental simulation module, a digital twin and simulation module, and a power supply and charging module.

[0018] The data terminal of the power test module is electrically connected to the data terminal of the environmental simulation module and the data terminal of the digital twin and simulation module; the input terminal of the power test module is electrically connected to the output terminal of the data acquisition and control module; and the power supply terminal of the power test module is electrically connected to the output terminal of the power supply and charging module.

[0019] The environmental simulation module is configured to provide the test piece with simulated environments of different combinations of high and low temperatures and sunlight; the power testing module is configured to drive the rotation of the motor dynamometer according to a preset test mode; the data acquisition and control module is configured to acquire test signals during the test; and the digital twin and simulation module is configured to simulate the test process based on the test signals.

[0020] Preferably, it also includes a mobile laboratory container, with the vehicle / component support fixture configured inside the mobile laboratory container.

[0021] Specifically, in this embodiment, the mobile modular high dynamic response four-motor power test system aims to provide an efficient, flexible, and intelligent solution for full-condition testing of new energy vehicles, powertrains, and components. Its main body is assembled from multiple standard container modules, painted dark blue on the outside, and has a rational internal layout, divided into a test chamber, control room, and auxiliary area. The test chamber is equipped with a four-motor dynamometer system (4×315kW, ±5000Nm), which can independently control the four-wheel drive torque distribution, supporting wheel-side torque up to 4000Nm. It also integrates a high and low temperature environment chamber (-40℃~60℃) and a sunlight simulation system (600~1200W / ㎡), capable of simulating various extreme conditions such as cold start and high-temperature driving range.

[0022] The system's control module adopts a fully open architecture, supporting open-source real-time control algorithms (adjustable PID parameters) and compatibility with third-party simulation software (such as Simulink). The digital twin platform, through real-time data synchronization and 3D visualization technology, enables real-time monitoring of the test bench's operating status, playback of test data, and remote fault diagnosis. Furthermore, the laboratory possesses rapid deployment capabilities, completing disassembly and transportation within 7 days, adapting to various testing scenarios such as fieldwork and temporary sites. Regarding equipment connection and transmission, the dynamometer and frequency converter are connected via hardwiring, using the Modbus RTU / CAN bus protocol for signal transmission; the frequency converter and real-time control system are connected via a high-speed communication bus (such as EtherCAT, CAN FD) to achieve dynamic control at a frequency of 1kHz. The power analyzer is directly connected to the device under test via a high-voltage current transformer and voltage probe, using the TCP / IP protocol to upload data to the main control system. The high and low temperature environmental chamber, sunlight simulation system, and oncoming fan in the environmental control system are all connected to the main control system via industrial Ethernet or RS485, enabling precise control of temperature, humidity, light intensity, and wind speed.

[0023] The mobile, modular, high-dynamic-response four-motor power testing system adopts a modular design, with each module connected via quick-connect interfaces (electrical, hydraulic, and pneumatic), facilitating system assembly, disassembly, and transportation. Its containerized structure meets road transport standards, and internal equipment is shockproof and secured. Oil / gas / water pipelines use quick-release interfaces, and interfaces for external facilities such as power supply vehicles and fire water tanks are reserved, enabling the system to be disassembled and transported within 7 days and quickly deployed to indoor or outdoor sites. This greatly improves testing efficiency and convenience, adapting to various testing scenarios such as field and temporary sites. It provides efficient, flexible, and intelligent testing solutions for new energy vehicle OEMs, component suppliers, regulatory certification bodies, and research institutions, contributing to the rapid development and progress of new energy vehicle technology.

[0024] Preferably, the power testing module includes a main control system, four sets of frequency converters, four sets of torque sensors, and four motor dynamometers. The output terminals of the motor dynamometers are electrically connected to the input terminals of the frequency converters. The input terminal of the main control system is electrically connected to the output terminals of the frequency converters, the power supply and charging module, and the digital twin and simulation module. The output terminal of the main control system is electrically connected to the input terminal of the frequency converters. The data terminal of the main control system is electrically connected to the data terminal of the environmental simulation module and the data acquisition and control module.

[0025] Specifically, in this embodiment, the vehicle / component support fixture is used to stably fix the vehicle or component under test, ensuring that no displacement or shaking occurs during the test, providing a basic guarantee for accurate testing. The power test module is the core part of the system, which includes four dynamometers. Each dynamometer is equipped with a corresponding frequency converter and torque sensor, and is connected to the frequency converter through hardwiring. It uses the Modbus RTU / CAN bus protocol to transmit torque / speed signals and motor status information, enabling independent control of the four motors, simulating four-wheel drive torque distribution with an error controlled within 0.4%, and supporting wheel-side torque up to 4000Nm. Therefore, it can accurately simulate various complex power output scenarios and meet the testing needs of different types of vehicles and components.

[0026] Specifically, each motor dynamometer is electrically connected to a set of frequency converters. This connection allows the dynamometer to accurately output the required torque and speed according to the instructions from the frequency converters. The frequency converters, acting as an intermediary, not only receive control commands from the main control system, such as target torque, speed, and PID parameters, but also feed back actual operating data from the dynamometers, such as actual torque, speed, and temperature, to the main control system, forming a closed-loop control system to ensure the accuracy and stability of the testing process. The advantages of this design are that it enables independent control of four motors, simulates complex four-wheel drive torque distribution with an error controlled within 0.4%, and supports wheel-side torque up to 4000 Nm. This allows for precise simulation of various vehicle driving conditions, meeting the testing needs of different types of vehicles and components.

[0027] The main control system acts as the "brain" of the experimental system. Its input terminals are electrically connected to the output terminals of the frequency converter, the power supply and charging module, and the digital twin and simulation module, enabling it to receive signals and data from these modules. Simultaneously, the main control system's output terminals are electrically connected to the frequency converter's input terminals, used to send control commands to the frequency converter. Furthermore, the main control system's data terminals are also electrically connected to the data terminals of the environmental simulation module and the data acquisition and control module, allowing the main control system to monitor and coordinate the entire experimental system's operational status in real time. Through this connection method, the main control system can achieve precise control of the power testing module, while also receiving and processing real-time data from the environmental simulation module and the data acquisition and control module, thereby achieving comprehensive monitoring and management of the testing process. The beneficial effects of this design are that it improves the automation and accuracy of the test, reduces human error, and increases testing efficiency.

[0028] During actual testing, the main control system sends control commands to the frequency converter according to the preset test mode. The frequency converter then controls the rotation of the motor dynamometer according to these commands, thereby simulating different vehicle driving conditions. Simultaneously, the main control system can also receive real-time data from the environmental simulation module, such as temperature, humidity, and light intensity, as well as test signals from the data acquisition and control module, such as torque, speed, temperature, and voltage. This data is transmitted through the main control system to the digital twin and simulation module, which performs simulation tests based on this data and feeds back the simulation results to the main control system. This collaborative working mode makes the testing process more intelligent and efficient, enabling real-time and accurate acquisition of test results and timely adjustment of test parameters based on simulation results, thereby improving the accuracy and reliability of the test.

[0029] Furthermore, the experimental system of this invention is modular and portable. The modules are connected via quick-connect interfaces, facilitating system assembly, disassembly, and transportation. Its containerized structure meets road transport standards, internal equipment is shockproof and secured, oil / gas / water pipelines use quick-release interfaces, and interfaces for external facilities such as power supply vehicles and fire water tanks are provided. This allows the system to be disassembled and transported within 7 days, enabling rapid deployment to indoor or outdoor sites. The advantages of this design are that it improves the system's flexibility and adaptability, meeting testing needs under different site conditions, significantly shortening test preparation time, and improving testing efficiency.

[0030] Preferably, the data acquisition and control module includes a sensor network, a data acquisition host, and four power analyzers. The output of the sensor network is electrically connected to the input of the data acquisition host, the data terminal of the data acquisition host is electrically connected to the data terminal of the power testing module, the input of the power analyzer is electrically connected to the test piece, and the output of the power analyzer is electrically connected to the input of the power testing module.

[0031] Preferably, the test signals include temperature signals, pressure signals, flow signals, and vibration signals.

[0032] Specifically, in this embodiment, the data acquisition and control module is connected to the device under test (DUT) via a high-voltage current transformer and voltage probe. It uses the TCP / IP protocol to upload test signals, such as electrical parameters, to the main control system. Simultaneously, sensors in the sensor network, including those for temperature, pressure, flow rate, and vibration, transmit their collected signals to the data acquisition system, which then transmits them to the main control system via a high-speed PCIe bus / Ethernet. The main control system then sends control commands, such as target torque, speed, and PID parameters, to the frequency converter based on these signals, achieving precise control of the power testing module. Its 1000Hz high-speed acquisition capability and 28-channel power analysis function enable real-time and accurate acquisition of various data during the testing process, providing a reliable basis for subsequent data analysis and fault diagnosis.

[0033] Specifically, these sensors are distributed at various key locations within the testing system, enabling real-time monitoring of various physical parameters of the test piece and the testing environment. For example, temperature sensors monitor temperature changes in components such as motors and batteries during testing, ensuring they operate within safe ranges; pressure sensors detect pressure in hydraulic or cooling systems, preventing equipment damage due to excessive pressure; flow sensors measure the flow rate of coolant or lubricating oil, ensuring effective heat dissipation and lubrication; and vibration sensors capture vibrations during equipment operation, providing a basis for fault diagnosis. The outputs of these sensors are electrically connected to the inputs of the data acquisition host, transmitting the acquired test signals to the host in the form of electrical signals.

[0034] The data acquisition host, as the core device of the data acquisition and control module, is responsible for receiving test signals from the sensor network and processing and analyzing them. It is electrically connected to the data terminal of the power test module via a high-speed PCIe bus or Ethernet, enabling real-time transmission of the acquired raw data to the main control system within the power test module. Simultaneously, the data acquisition host also possesses data calibration and verification functions, allowing it to correct the acquired data based on calibration parameters issued by the main control system, ensuring data accuracy and reliability. The advantage of this design is that it enables high-precision acquisition and real-time processing of various test signals during the testing process, providing a high-quality data foundation for subsequent data analysis and fault diagnosis.

[0035] The power analyzer is another crucial component of the data acquisition and control module. Its input is electrically connected to the device under test (DUT), enabling direct measurement of its electrical parameters, such as voltage, current, power, and efficiency. These parameters are essential for evaluating the DUT's performance, for example, the efficiency of a motor or the charge / discharge characteristics of a battery. The power analyzer's output is electrically connected to the input of the power test module, transmitting the measured electrical parameter data to the main control system within the module. This connection allows the main control system to dynamically evaluate the DUT's performance based on the real-time acquired electrical parameter data and adjust the test parameters accordingly, thus achieving precise control of the testing process. The advantage of this design is its ability to acquire the DUT's electrical parameter data accurately and in real-time, providing strong support for optimizing the testing process.

[0036] During actual testing, the sensor network collects various test signals in real time, such as temperature, pressure, flow rate, and vibration, and transmits these signals to the data acquisition host. The data acquisition host processes and analyzes these signals, then transmits the processed data to the main control system in the power testing module via a high-speed communication link. Simultaneously, the power analyzer measures the electrical parameters of the test component in real time and transmits this data to the main control system. Based on this real-time data, combined with preset test modes and control algorithms, the main control system sends control commands to the frequency converter to control the operation of the motor dynamometer, thereby achieving accurate testing of the test component. This collaborative working mode makes the testing process more intelligent and efficient, enabling real-time and accurate acquisition of test results and timely adjustment of test parameters based on real-time data, thus improving the accuracy and reliability of the test.

[0037] In simple terms, the data acquisition module collects signals such as temperature, pressure, flow rate, and vibration through analog and digital inputs, and transmits the raw data to the main control system via a high-speed PCIe bus or Ethernet. The digital twin platform interacts with the main control system in real time with the experimental data through the OPCUA / WebSocket protocol, and connects to the cloud database through HTTPS / RESTful API to realize the storage and retrieval of historical experimental data.

[0038] Preferably, the environmental simulation module includes a high and low temperature environmental chamber, a sunlight simulation system, and an oncoming fan, wherein the data terminal of the power test module is electrically connected to the data terminals of the high and low temperature environmental chamber, the sunlight simulation system, and the oncoming fan.

[0039] In this embodiment, the environmental simulation module consists of a high and low temperature environment chamber and a sunlight simulation system. The high and low temperature environment chamber is connected to the main control system via industrial Ethernet (TCP / IP) and receives temperature and humidity setpoints sent by the main control system. Its temperature control range is -40℃ to 60℃, with fluctuations controlled within ±2℃, which can simulate various climatic conditions from extreme cold to extreme heat. The sunlight simulation system communicates with the main control system via RS485 / Modbus and adjusts the light intensity within the range of 600 to 1200 W / m² according to the light intensity control command sent by the main control system, with uniformity controlled within 15%. This provides the test piece with simulated environments of different combinations of high and low temperatures and sunlight, enabling the test to be conducted under conditions close to real-world usage scenarios, greatly improving the accuracy and reliability of the test results.

[0040] Specifically, the high and low temperature environment chamber is a core component of the environmental simulation module, capable of simulating various climatic conditions ranging from extreme cold to high temperatures. Through advanced refrigeration and heating technologies, the chamber's temperature control range is -40℃ to 60℃, with temperature fluctuations controlled within ±2℃. This high-precision temperature control allows the chamber to simulate various extreme temperature environments that the test specimen might encounter in actual use, such as low-temperature start-up conditions in cold regions and long-term operation conditions in high-temperature regions. The high and low temperature environment chamber's data terminal is electrically connected to the power test module's data terminal, enabling it to receive real-time temperature and humidity setpoints from the main control system in the power test module and feed back real-time temperature and humidity data from the environment chamber to the main control system. The advantage of this design is that it ensures precise control and real-time monitoring of the test environment, providing stable and repeatable testing conditions for the test specimen.

[0041] The sunlight simulation system is another important component of the environmental simulation module, capable of simulating sunlight conditions of varying intensities. By adjusting the power of the light source, the system can precisely control the light intensity within the range of 600–1200 W / m², with uniformity controlled within 15%. This capability allows the system to simulate various lighting conditions from cloudy to sunny days, providing a realistic lighting environment for the test specimen. The data terminal of the sunlight simulation system is electrically connected to the data terminal of the power test module, enabling it to receive light intensity control commands from the main control system and feed back the actual light intensity to the main control system. The advantage of this design is that it provides a highly realistic lighting environment for the test specimen, thereby more accurately evaluating its performance under different lighting conditions.

[0042] The oncoming fan is an auxiliary device in the environmental simulation module, simulating the headwind encountered by a vehicle during driving. By precisely controlling the fan's rotation speed, the oncoming fan can adjust the wind speed within the range of 0–250 km / h, providing a realistic wind speed environment for the test component. The oncoming fan's data terminal is electrically connected to the power test module's data terminal, receiving the wind speed setpoint from the main control system and feeding back the fan's actual operating status (such as rotation speed and wind pressure) to the main control system. The advantage of this design is that it can simulate various wind speed conditions encountered by a vehicle during driving, thereby providing a more comprehensive evaluation of the test component's performance.

[0043] During actual testing, the main control system in the power testing module sends control commands to the high and low temperature environmental chamber, the sunlight simulation system, and the oncoming fan via electrical connections. The high and low temperature environmental chamber adjusts its internal temperature and humidity according to the received temperature and humidity setpoints; the sunlight simulation system adjusts the light source power according to the light intensity control commands; and the oncoming fan adjusts its speed according to the wind speed setpoints. Simultaneously, these devices feed real-time operating data back to the main control system, which dynamically adjusts the test parameters based on this data to ensure the accuracy and stability of the testing process. This collaborative working mode enables the testing system to provide a highly realistic testing environment for the test piece, thereby more accurately evaluating its performance under various extreme conditions.

[0044] Preferably, the digital twin and simulation module includes a twin system platform, a 3D digital twin model, and a cloud database, wherein the data terminal of the twin system platform is electrically connected to the data terminal of the power testing module, the cloud database, and the 3D digital twin model.

[0045] Specifically, in this embodiment, the digital twin and simulation module interacts with the main control system in real time with test data, including information such as torque, speed, temperature, and voltage, via the OPC UA / WebSocket protocol. The twin platform performs simulations based on this real-time data and feeds back simulation results, such as model predictions and fault diagnoses, to the main control system. At the same time, the twin platform also connects to the cloud database via HTTPS / RESTful API to realize the storage and retrieval of historical test data. Its 3D visualization of the test bench's operating status and real-time playback of test data enable testers to intuitively understand the test process and results, facilitating timely identification of problems and optimization adjustments, greatly improving test efficiency and quality.

[0046] The twin system platform is the core component of the digital twin and simulation module, responsible for receiving and processing real-time data from the power testing module. This data includes operating parameters such as torque, speed, and temperature from the motor dynamometer, as well as environmental parameters such as temperature, humidity, and light intensity from the environmental simulation module. The twin system platform is electrically connected to the data terminal of the power testing module via high-speed communication protocols (such as OPC UA or WebSocket) to ensure real-time data transmission and synchronization. The advantage of this connection method is that it enables real-time monitoring and dynamic adjustment of the testing process, ensuring the accuracy and reliability of the test results.

[0047] The 3D digital twin model is a crucial component of the twin system platform, creating a digital copy of the testing system through virtual modeling technology. This model reflects the real-time status of various devices and components during testing, including the operating status of the motor dynamometer, temperature and humidity changes in the environmental chamber, and light intensity from the sunlight simulation system. Through 3D visualization technology, testing personnel can intuitively observe changes in various parameters during the testing process on the monitoring screen in the control room, enabling faster problem identification and adjustments. The benefits of this design lie in its enhanced visualization of the testing process, allowing testing personnel to more intuitively understand the test results, and facilitating remote monitoring and fault diagnosis.

[0048] The cloud database is another crucial component of the digital twin and simulation module. It is electrically connected to the twin system platform via a secure network connection (such as HTTPS or RESTful API). The cloud database can store large amounts of historical test data and supports data retrieval, analysis, and sharing. This data is stored in a standardized format (such as ASAM-ODS) for easy subsequent data processing and analysis. Through the cloud database, testers can access historical test data at any time for comparative analysis, thereby optimizing test strategies and improving test processes. Furthermore, the cloud database supports multi-user access, facilitating collaboration and communication among testers in different locations. The benefits of this design lie in its improved data storage and management efficiency, while also providing testers with a wider range of data resources and analytical tools.

[0049] The main control system in the powertrain testing module transmits real-time collected test data to the digital twin platform. The platform processes and analyzes the received data, updating the results in real-time to the 3D digital twin model. Simultaneously, the platform also uploads the test data to a cloud database for storage and backup. Test personnel can observe the real-time status of the 3D digital twin model on the monitoring screen in the control room and adjust test parameters accordingly. Furthermore, the platform can provide optimization suggestions based on real-time and historical data analysis results, such as adjusting PID parameters or improving test conditions, thereby improving testing efficiency and accuracy. For example, when testing the powertrain of a new energy vehicle, the platform can receive real-time torque and speed data from the dynamometer, as well as temperature and humidity data from the environmental chamber. This data is synchronously updated to the 3D digital twin model, allowing test personnel to visually observe the vehicle's performance under different environmental conditions on the monitoring screen. Simultaneously, the platform uploads this data to the cloud database, enabling test personnel to retrieve historical data for comparative analysis and optimization of testing strategies. This collaborative working model makes the testing process more intelligent and efficient, enabling real-time and accurate acquisition of test results and timely adjustment of test parameters based on real-time data, thereby improving the accuracy and reliability of the test.

[0050] Preferably, the power supply and charging module includes two sets of battery simulators and charging piles, wherein the battery simulators are connected to the test piece through the charging piles, and the output end of the battery simulators is electrically connected to the power test module.

[0051] Specifically, in this embodiment, the power supply and charging module provides stable power support for the entire system. Its output terminal is electrically connected to the power supply terminal of the power testing module to ensure that equipment such as the dynamometer can operate normally. At the same time, the module also has an interface with external power supply facilities, which facilitates fast charging and power supply switching under different site conditions, improving the flexibility and practicality of the system.

[0052] Each battery simulator has a 2×400kW output capacity, providing up to 1200V / 1200A of voltage and current output. This high-power and high-voltage design allows the battery simulator to meet the needs of different types and power levels of test components, providing sufficient power support for everything from battery testing of small electric vehicles to powertrain testing of large commercial vehicles. The output of the battery simulator is electrically connected to the power test module via a high-voltage DC cable, ensuring real-time and stable power supply to the dynamometer and test component during testing.

[0053] Furthermore, the charging station, working in conjunction with the battery simulator, enables rapid charging of the device under test (DUT). The charging station not only provides charging services to the DUT but also communicates with the battery simulator to monitor voltage, current, and battery status (such as SOC, i.e., remaining battery capacity) in real time during the charging process. The advantage of this design is that it can quickly restore the DUT's charge during testing, reducing test interruptions caused by insufficient power and significantly improving testing efficiency. Simultaneously, the intelligent design of the charging station can automatically adjust the charging strategy based on the battery characteristics of the DUT, ensuring the safety and efficiency of the charging process.

[0054] In actual testing, the battery simulator connects to the device under test (DUT) via a charging station to simulate the real output characteristics of a battery. For example, when testing the power system of a new energy vehicle, the battery simulator can accurately output the required voltage and current according to preset test conditions, simulating the battery's discharge characteristics under different conditions. Simultaneously, the output of the battery simulator is electrically connected to the main control system in the power test module. The main control system can dynamically adjust the output parameters of the battery simulator based on real-time acquired test data to ensure the accuracy and stability of the testing process. The advantage of this design is that it provides a highly realistic testing environment for the DUT while supporting dynamic adjustment of test parameters, thereby more accurately evaluating the performance of the DUT.

[0055] Preferably, the system further includes a safety and monitoring module, which includes a camera, a safety sensor, a fire protection system, a rapid decoupling device, and an emergency stop device. The output of the emergency stop device is electrically connected to the input of the power testing module, the output of the safety sensor is electrically connected to the input of the fire protection system, the data terminal of the fire protection system is electrically connected to the data terminal of the power testing module, the rapid decoupling device is mechanically connected to the test piece, and the camera is electrically connected to the input of the power testing module through a monitoring center.

[0056] Specifically, in this embodiment, the safety and emergency mechanism adopts a triple protection mechanism of hard-wired emergency stop, safety bus, and mechanical decoupling to ensure rapid response and protection of equipment and personnel safety in emergency situations. The mobile, modular, high-dynamic-response four-motor power testing experimental system features complete hardware testing capabilities, open-source software control and digital twin platform support, modular design, and rapid deployment. It can meet the one-stop testing needs of new energy vehicle R&D, certification, and fault reproduction, filling the gaps in traditional laboratories regarding extreme environment coverage and rapid response.

[0057] First, the emergency stop device is the last line of defense for the safety of testing personnel and equipment. The output of the emergency stop device is electrically connected to the input of the power test module. Once the tester triggers the emergency stop button, the emergency stop signal is immediately transmitted to the main control system of the power test module. The main control system will issue a shutdown command within a very short time, stopping the operation of all test equipment and ensuring a rapid response to emergencies during the testing process. The advantage of this design is that it can quickly cut off the power and stop the equipment in an emergency, minimizing potential dangers and losses.

[0058] Secondly, safety sensors are used to monitor potential hazards in the test environment in real time. For example, safety sensors can include smoke sensors, temperature sensors, and combustible gas sensors, which can monitor smoke concentration, temperature changes, and combustible gas leaks in the test environment in real time. The output of the safety sensors is electrically connected to the input of the fire protection system. Once an abnormality is detected, such as excessively high temperature or smoke concentration, the safety sensor will immediately send an alarm signal to the fire protection system. Upon receiving the alarm signal, the fire protection system will quickly activate fire extinguishing devices, such as a heptafluoropropane fire extinguishing system, to extinguish the fire in the test area. Simultaneously, the data terminal of the fire protection system is electrically connected to the data terminal of the power test module, enabling real-time feedback of the fire protection system's status information to the main control system of the power test module, allowing test personnel to promptly understand the safety situation and take appropriate measures. The beneficial effect of this design is that it enables real-time monitoring and automatic early warning of the test environment, ensuring that timely measures can be taken in the event of a dangerous situation to prevent the accident from escalating.

[0059] Secondly, the rapid decoupling device is mechanically connected to the test piece. During testing, in the event of a battery fire or other emergency, the rapid decoupling device can mechanically and electrically separate the test piece from the test equipment within a very short time (e.g., within 3 seconds), thus preventing the dangerous situation from escalating further. The advantage of this design is that it can quickly disconnect the test piece from the test equipment in an emergency, reducing the risk of equipment damage and personal injury.

[0060] Finally, cameras are used for real-time monitoring of the test area. The cameras are electrically connected to the input of the power test module via the monitoring center, which transmits the video signals captured by the cameras to the main control system of the power test module in real time. Test personnel can observe the test area in real time through the monitoring screen of the main control system, promptly identify potential safety hazards, and take appropriate measures. The advantage of this design is that it provides test personnel with an intuitive view of the test site, facilitating real-time monitoring and timely handling of emergencies.

[0061] The various devices in the safety and monitoring module work collaboratively to ensure the safety of the testing process. For example, when testers discover an anomaly and trigger the emergency stop device, the emergency stop signal is immediately transmitted to the main control system of the power testing module. The main control system then quickly issues a shutdown command, stopping the operation of all test equipment. Simultaneously, safety sensors monitor potential hazards in the test environment in real time. Once an anomaly is detected, an alarm signal is immediately sent to the fire suppression system, which quickly activates the fire extinguishing equipment. A rapid decoupling device quickly disconnects the test piece from the test equipment in emergencies, preventing the dangerous situation from spreading further. Cameras transmit real-time images of the test area to the main control system through the monitoring center, allowing testers to promptly understand the situation on-site and take appropriate measures.

[0062] In summary, the mobile, modular, high-dynamic-response four-motor power testing system integrates advanced power testing modules, data acquisition and control modules, environmental simulation modules, digital twin and simulation modules, power supply and charging modules, and safety and monitoring modules. It aims to provide an efficient, flexible, and intelligent solution for full-condition testing of new energy vehicles, powertrains, and components. The system adopts a modular design, with modules connected via quick-plug interfaces, facilitating system assembly, disassembly, and transportation. Its containerized structure meets road transport standards, enabling disassembly and transportation within 7 days for rapid deployment to indoor or outdoor sites. This design not only improves the system's flexibility and adaptability but also meets testing requirements under different site conditions, significantly shortening test preparation time and improving testing efficiency.

[0063] In summary, the mobile, modular, high dynamic response four-motor power testing system integrates multiple advanced modules and technologies to achieve efficient, flexible, and intelligent testing functions. Its high-precision power testing capabilities, extreme environment simulation capabilities, real-time data acquisition and processing capabilities, digital twin and simulation functions, stable power supply support, and comprehensive safety monitoring system make it a one-stop, efficient testing solution for new energy vehicle R&D, certification, and fault reproduction.

[0064] The above are merely preferred embodiments of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions that fall within the scope of this utility model's concept are protected by this utility model.

Claims

1. A mobile, modular, high dynamic response four-motor power testing experimental system, characterized in that, include: Vehicle / component support fixture, power testing module, data acquisition and control module, environmental simulation module, digital twin and simulation module, and power supply and charging module configured on the vehicle / component support fixture; The data terminal of the power test module is electrically connected to the data terminal of the environmental simulation module and the data terminal of the digital twin and simulation module; the input terminal of the power test module is electrically connected to the output terminal of the data acquisition and control module; and the power supply terminal of the power test module is electrically connected to the output terminal of the power supply and charging module. The environmental simulation module is configured to provide the test piece with simulated environments of different combinations of high and low temperatures and sunlight; the power testing module is configured to drive the rotation of the motor dynamometer according to a preset test mode; the data acquisition and control module is configured to acquire test signals during the test; and the digital twin and simulation module is configured to simulate the test process based on the test signals.

2. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, The test signals include temperature signals, pressure signals, flow signals, and vibration signals.

3. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, The power testing module includes a main control system, four sets of frequency converters, four sets of torque sensors, and four motor dynamometers. The output of each motor dynamometer is electrically connected to the input of the frequency converter. The input of the main control system is electrically connected to the output of the frequency converter, the output of the power supply and charging module, and the output of the digital twin and simulation module. The output of the main control system is electrically connected to the input of the frequency converter. The data terminal of the main control system is electrically connected to the data terminal of the environmental simulation module and the data acquisition and control module.

4. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, The data acquisition and control module includes a sensor network, a data acquisition host, and four power analyzers. The output of the sensor network is electrically connected to the input of the data acquisition host, the data terminal of the data acquisition host is electrically connected to the data terminal of the power testing module, the input of the power analyzer is electrically connected to the test piece, and the output of the power analyzer is electrically connected to the input of the power testing module.

5. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, The environmental simulation module includes a high and low temperature environment chamber, a sunlight simulation system, and an oncoming fan. The data terminal of the power test module is electrically connected to the data terminals of the high and low temperature environment chamber, the sunlight simulation system, and the oncoming fan.

6. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, The digital twin and simulation module includes a twin system platform, a 3D digital twin model, and a cloud database. The data terminal of the twin system platform is electrically connected to the data terminal of the power testing module, the cloud database, and the 3D digital twin model.

7. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, The power supply and charging module includes two sets of battery simulators and a charging pile. The battery simulator is connected to the test piece through the charging pile, and the output of the battery simulator is electrically connected to the power test module.

8. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, It also includes a safety and monitoring module, which includes a camera, safety sensors, a fire protection system, a rapid decoupling device, and an emergency stop device. The output of the emergency stop device is electrically connected to the input of the power test module, the output of the safety sensor is electrically connected to the input of the fire protection system, the data terminal of the fire protection system is electrically connected to the data terminal of the power test module, the rapid decoupling device is mechanically connected to the test piece, and the camera is electrically connected to the input of the power test module through a monitoring center.

9. The mobile modular high dynamic response four-motor power testing experimental system according to claim 1, characterized in that, It also includes a mobile laboratory container, with the vehicle / component support fixtures configured inside the mobile laboratory container.

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