A high-project-compatibility electric drive axle off-line detection bench test device

Abstract

The utility model relates to a kind of high project compatibility electric drive bridge off-line detection bench test device, involve electric drive bridge off-line detection bench configuration technical field, it includes gantry host computer, electric drive bridge controller, electric drive bridge main drive motor double-control controller, double-control load motor controller, electric drive bridge cooling oil pump controller and CAN communication bus, host computer controller is connected with double-control load motor controller by CAN1 bus, and is connected with electric drive bridge controller and electric drive bridge cooling oil pump controller by CAN2 bus, electric drive bridge controller is connected with electric drive bridge main drive motor double-control controller by CAN3 bus;Electric drive bridge controller can be communicated with electric drive bridge main drive motor double-control controller, electric drive bridge cooling oil pump controller by CAN communication bus, realize the control of electric drive bridge main drive motor, cooling oil pump, and gear shifting control of electric drive bridge.The utility model is favorable for solving electric drive bridge off-line detection test device project poor adaptability, maintenance cost higher problem.

Description

Technical Field

[0001] This utility model relates to the technical field of electric drive bridge offline testing bench configuration, and in particular to a test device and implementation scheme for a high-project compatibility electric drive bridge offline testing test bench. Background Technology

[0002] With the advancement of vehicle electrification and the continuous expansion of the electric drive axle market, the demand for electric drive axle products is increasingly strong. To seize this opportunity, more and more powertrain manufacturers are joining the ranks of electric drive axle production. However, due to the fact that the demand for electric drive axles has not yet reached the conditions for large-scale production, each electric drive axle production line faces the challenge of adapting to different electric drive axle products and vehicle models for different projects. Currently, most electric drive axles are in the product pre-research or small-batch stage. Coupled with the uncertainty of the power and performance requirements of electric drive axles, in order to quickly respond to changes in market demand and control costs, the production line equipment for electric drive axles must meet the requirements of high project compatibility and low maintenance costs.

[0003] Most existing electric drive axle off-line testing benches are built in conjunction with electric drive axle projects, tailored to the vehicle's power and configuration requirements. However, this configuration approach suffers from poor project compatibility. Even with the same electric drive axle, different vehicle models may require simultaneous software upgrades for the test bench's host computer or replacement of the testing equipment. Furthermore, software upgrades for the host computer involve substantial costs, and frequent updates to the host computer software and equipment based on project needs inevitably lead to high overall maintenance costs for the test bench. Utility Model Content

[0004] The purpose of this utility model is to provide a test bench for electric drive bridge offline testing with high project compatibility and an implementation control scheme, so as to solve the problems of poor project adaptability and high maintenance cost of electric drive bridge offline testing test equipment.

[0005] To achieve the above objectives, the present invention provides a high-project-compatibility electric drive bridge offline testing bench test device, including a bench host computer, an electric drive bridge controller, a dual-control controller for the electric drive bridge main drive motor, a dual-control load motor controller, an electric drive bridge cooling oil pump controller, and a 3-channel CAN communication bus. The host computer controller is connected to the dual-control load motor controller via CAN1 bus, and to the electric drive bridge controller and the electric drive bridge cooling oil pump controller via CAN2 bus. The electric drive bridge controller is connected to the dual-control controller for the electric drive bridge main drive motor via CAN3 bus. The host computer controller interacts indirectly with the electric drive bridge cooling oil pump controller and the dual-control controller for the electric drive bridge main drive motor through the electric drive bridge controller. The electric drive bridge controller can receive control commands from the bench host computer and communicate with the dual-control controller for the electric drive bridge main drive motor and the electric drive bridge cooling oil pump controller via the CAN communication bus to realize the control of the electric drive bridge main drive motor and cooling oil pump, as well as the gear shifting control of the electric drive bridge.

[0006] Preferably, the dual-control controller for the main drive motor of the electric drive axle is used to control the main drive motor of the electric drive axle, the dual-control load motor controller is used to control the torque loading of the load motor, and the electric drive axle cooling oil pump controller is used to control the cooling oil pump of the electric drive axle.

[0007] Preferably, the host computer on the test bench is used for sending control commands, monitoring the process, and managing data, and the electric drive bridge controller is used for receiving and processing control commands from the host computer and controlling the operation of the electric drive bridge.

[0008] Preferably, the benchtop host computer interfaces with the controller calibration data management system and the test data cloud storage, which facilitates the offline writing of the electric drive bridge mass production calibration data and the retention and management of the electric drive bridge offline test data.

[0009] Preferably, the electric drive bridge controller has a self-learning control function, which triggers the gear self-learning control command through the test bench host computer or the controller calibration data management system.

[0010] Preferably, the electric drive axle controller supports a shift control function to confirm the engagement and disengagement status of each gear of the electric drive axle.

[0011] Preferably, a communication interaction protocol is established between the electric drive axle controller and the host computer on the test bench, and the signals include target gear command, self-learning control command, gear status feedback signal, self-learning result feedback signal, electric drive axle main drive motor control command, electric drive axle cooling oil pump control command, fault status feedback signal, and vehicle status signal.

[0012] Preferably, the CAN1 bus, the CAN2 bus, and the CAN3 bus are used for communication between the components, the terminating resistor is configurable, and the CAN message format conforms to the J1939 communication protocol.

[0013] Preferably, it also includes a quick-connect platform for the electric drive bridge controller, for quick replacement and calibration of the electric drive bridge controller.

[0014] Preferably, the maximum power of the dual-control controller for the main drive motor of the electric drive bridge is 600kW, supporting a voltage platform of 400-800V; the maximum power of the dual-control load motor controller is 300kW, also supporting a voltage platform of 400-800V.

[0015] In summary, this utility model has the following beneficial technical effects: This invention utilizes a 3-channel CAN communication bus and a special communication interaction protocol to achieve efficient and stable message transmission between the host computer controller and the electric drive axle controller iTCU. It also avoids control signal interference, reducing the need for frequent updates to the host computer software on the test bench, lowering maintenance costs, and improving the test bench's functional compatibility. This allows the test bench to quickly adapt to the testing needs of different electric drive axle products and project vehicle models, meeting the diverse demands of the electric drive axle market.

[0016] This invention utilizes a high-performance dual-control controller for the main drive motor and a dual-control controller for the load motor of the electric drive axle. This allows the device to cover the standard target requirements for commercial vehicle electric drive axles, especially the power and performance demands under extreme operating conditions. Furthermore, key components such as the cooling oil pump controller and the load motor controller are integrated into the CAN bus network, further improving the system's integration and stability. This not only reduces the complexity of equipment maintenance but also shortens the debugging cycle for the electric drive axle's off-line testing, thereby increasing overall production efficiency.

[0017] This invention, through seamless integration with the controller calibration data management system and the cloud storage for test data, forms a complete system for managing electric drive bridge calibration data and retaining test data. This not only facilitates the offline writing of calibration data for mass production of electric drive bridges, but also enables centralized storage and remote monitoring of offline test data, providing strong support for subsequent data analysis and quality traceability. Furthermore, it supports the completion of functions such as self-learning control, gear shifting control, and cooling oil pump control of the electric drive bridge through the benchtop host computer control interface, further enhancing the intelligence level of the equipment and the user experience. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the main equipment connections in the high project compatibility electric drive bridge offline testing bench test device of this utility model; Figure 2This is a schematic diagram of the electric drive bridge offline control process in the high project compatibility electric drive bridge offline testing bench test device of this utility model; Figure 3 This is a schematic diagram of the control flow for the electric drive bridge offline testing project in the high project compatibility electric drive bridge offline testing bench test device of this utility model.

[0019] Reference numerals in the attached diagram: 1. Dual-control controller for the main drive motor of the electric drive bridge; 2. Dual-control load motor controller; 3. Electric drive bridge controller; 4. Electric drive bridge cooling oil pump controller; 5. CAN1 bus; 6. CAN2 bus; 7. CAN3 bus; 8. Load motor 1; 9. Load motor 2; 10. Electric drive bridge; 11. Host computer controller. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] This utility model discloses a high-project-compatibility electric drive bridge offline testing bench test device, which aims to improve the compatibility, efficiency, and data management capabilities of electric drive bridge offline testing by optimizing equipment selection, communication protocols, and control processes. The device mainly consists of a bench host computer, a high-power electric drive bridge main drive motor dual-control controller 1 (MDD-MCU), a high-power dual-control load motor controller 2 (SDD-MCU), an electric drive bridge cooling oil pump controller 4 (OPC), an electric drive bridge controller 3 (iTCU), a 3-channel CAN communication bus (CAN1 bus 5, CAN2 bus 6, CAN3 bus 7, with configurable terminating resistors), a quick-connect platform for the electric drive bridge controller 3 (iTCU), and related high-torque load motors (load motor 1 8 and load motor 2 9), a cooling oil pump (including at least two variable interface cooling oil pump control harnesses), a barcode scanner, and testing equipment.

[0022] Electric drive bridge 10 connects load motors 1 and 2 to load motors 9. These two load motors are electrically connected to dual-control load motor controller 2 (SDD-MCU). Electric drive bridge 10 is also electrically connected to electric drive bridge controller 3 (iTCU), electric drive bridge cooling oil pump controller 4 (OPC), and electric drive bridge main drive motor dual-control controller 1 (MDD-MCU). The host computer on the test bench serves as the control center of the entire test setup. The host computer controller 11 is connected to dual-control load motor controller 2 (SDD-MCU) via CAN1 bus 5, and to electric drive bridge controller 3 (iTCU) and electric drive bridge cooling oil pump controller 4 (OPC) via CAN2 bus 6. Electric drive bridge controller 3 (iTCU) is connected to electric drive bridge main drive motor dual-control controller 1 (MDD-MCU) via CAN3 bus 7.

[0023] The host computer controller 11 controls the dual-control load motor controller 2 (SDD-MCU) via CAN1 bus 5, and directly interacts with the electric drive bridge controller 3 (iTCU) via CAN2 bus 6. The electric drive bridge controller 3 (iTCU) then directly controls the electric drive bridge cooling oil pump and the electric drive bridge main drive motor via CAN2 bus 6 and CAN3 bus 7. Thus, the host computer controller 11 can indirectly interact with the electric drive bridge cooling oil pump controller 4 (OPC) and the electric drive bridge main drive motor dual-control controller 1 (MDD-MCU) through the electric drive bridge controller 3 (iTCU), thereby achieving the purpose of controlling the electric drive bridge cooling oil pump, the electric drive bridge main drive motor, and the shift control of the electric drive bridge 10.

[0024] The three CAN buses are used for interactive control of the host computer controller 11, electric drive bridge controller 3 (iTCU), electric drive bridge main drive motor dual control controller 1 (MDD-MCU), dual control load motor controller 2 (SDD-MCU), and electric drive bridge cooling oil pump controller 4 (OPC). The host computer controller 11 is used for overall control of the electric drive bridge 10 offline detection control, process monitoring, data monitoring and storage, etc. The electric drive bridge controller 3 (iTCU) is used for electric drive control. The electric drive bridge main drive motor dual control controller 1 (MDD-MCU) is used for electric drive bridge main drive motor control. The dual control load motor controller 2 (SDD-MCU) is used for electric drive bridge 10 offline load motor control, such as torque loading. The electric drive bridge cooling oil pump controller 4 (OPC) is used for electric drive bridge cooling oil pump control. The electric drive bridge main drive motor dual control controller 1 (MDD-MCU), dual control load motor controller 2 (SDD-MCU), and electric drive bridge cooling oil pump controller 4 (OPC) are respectively arranged on the three CAN buses to avoid unnecessary control signal interference.

[0025] A specific communication protocol is established between the host computer controller 11 and the electric drive axle controller 3 (iTCU) to reduce the frequency of host computer software updates and save on bench software maintenance costs. Specifically, the signals cover necessary control commands, such as target gear commands, self-learning control commands, gear status feedback signals, self-learning result feedback signals, electric drive axle main drive motor control commands, electric drive axle cooling oil pump control commands, fault status feedback signals, and vehicle status signals. The CAN message format must conform to the J1939 communication protocol. This special communication protocol between the electric drive axle controller 3 (iTCU) and the host computer controller 11 avoids the cost waste caused by frequent bench host computer software upgrades and improves the project compatibility of the host computer controller 11's functions.

[0026] To meet the potential application scenarios and power requirements of the electric drive axle 10, high-performance parameters are required as much as possible when selecting core equipment for the electric drive axle 10's off-line testing to improve equipment compatibility. For example, the maximum output power of the dual-control controller 1 (MDD-MCU) for the main drive motor and the dual-control load motor controller 2 (SDD-MCU) for the electric drive axle should cover the extreme scenario requirements of the electric drive axle 10 as much as possible. Preferably, the maximum power of the dual-control controller 1 (MDD-MCU) for the main drive motor is 600kW, supporting a voltage platform of 400-800V; the maximum power of the dual-control load motor controller 2 (SDD-MCU) for the load motor is 300kW, also supporting a voltage platform of 400-800V. This selection aims to cover the conventional target vehicle model requirements of the electric drive axle 10 for commercial vehicles, improving the applicability and compatibility of the equipment.

[0027] The test bench host computer needs to interface with the controller calibration data management system (EOL) and the test data cloud storage to facilitate the offline writing of mass production calibration data for the electric drive bridge 10 and the retention and management of offline test data for the electric drive bridge 10. The offline control of the electric drive bridge 10 of this utility model mainly includes three parts: software writing, electric drive bridge 10 control, and data storage. The mass production calibration data of the electric drive bridge controller 3 (iTCU) is released to the controller calibration data management system (EOL). The writing of the mass production data of the electric drive bridge controller 3 (iTCU), as well as self-learning control and gear shifting control, are completed through the control terminal software interface of the controller calibration data management system (EOL) installed on the test bench host computer. The offline operator controls the electric drive bridge 10 through the control interface of the test bench host computer, including self-learning control, gear shifting control, main drive motor control, and cooling oil pump control. The host computer controller 11 is responsible for recording data throughout the process and is responsible for packaging and uploading the test data to the test data cloud storage (Cloud) after the test is completed.

[0028] The control flowchart for the offline testing of the electric drive bridge 10 of this utility model is shown below. Figure 3This includes electrical signal detection, cooling system status confirmation, gear position self-learning, shift status confirmation, and load break-in. The control process for the electric drive axle 10's off-line testing includes: Perform power-on electrical signal detection; Determine if the electrical signals are normal; if so, then control the thermal management system (TMS, mainly referring to the electric drive bridge cooling oil pump). Determine if the thermal management system (TMS) is responding normally; if so, trigger the self-learning command. Determine if self-learning is complete; if so, trigger the shift command. Determine if the gear shifting is normal; if so, begin the break-in process. Determine if the break-in period is normal; if so, the process ends.

[0029] in: ① Electrical signal testing is required for the electric drive axle 10, including various sensors and actuators (such as oil temperature sensor, oil pressure sensor, shift position sensor, speed sensor and shift motor, etc.) to confirm whether any faults are reported. If not, proceed to the next verification step. ② It is necessary to confirm the working status of the oil pump. Input the oil pump control command (speed) through the host computer control interface on the test bench, and confirm the oil pump speed response status. If the oil pump speed response is normal, proceed to the next verification step. ③ Self-learning of the 10 gears of the electric drive bridge is required. The gear self-learning control command is triggered through the controller calibration data management system (EOL) terminal control interface or the bench host computer control interface to complete the self-learning of the 10 gears of the electric drive bridge. After the self-learning result is displayed as successful, the next verification step is entered. ④ The shifting status of each gear of the electric drive axle 10 needs to be confirmed. If each gear can be smoothly engaged and disengaged, then proceed to the next verification stage. ⑤ Finally, dynamic break-in and NVH status confirmation of each gear of the electric drive are required. After engaging each gear in sequence, load operation (speed and torque) is performed through the wheel end load motor according to the verification requirements. At the same time, NVH status monitoring is carried out. After all indicators are confirmed, the off-line testing of electric drive axle 10 is completed.

[0030] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A test bench for testing electric drive bridges with high project compatibility, characterized in that, The system includes a host computer, an electric drive bridge controller (3), a dual-control controller for the main drive motor of the electric drive bridge (1), a dual-control load motor controller (2), an electric drive bridge cooling oil pump controller (4), and a 3-channel CAN communication bus. The host computer controller (11) is connected to the dual-control load motor controller (2) via the CAN1 bus (5), and to the electric drive bridge controller (3) and the electric drive bridge cooling oil pump controller (4) via the CAN2 bus (6). The electric drive bridge controller (3) is connected to the dual-control controller for the main drive motor of the electric drive bridge via the CAN3 bus (7). The controller (1) is connected; the host computer controller (11) interacts indirectly with the electric drive bridge cooling oil pump controller (4) and the electric drive bridge main drive motor dual control controller (1) through the electric drive bridge controller (3). The electric drive bridge controller (3) can receive control commands from the host computer on the test bench and communicate with the electric drive bridge main drive motor dual control controller (1) and the electric drive bridge cooling oil pump controller (4) through the CAN communication bus to realize the control of the electric drive bridge main drive motor and cooling oil pump, as well as the shift control of the electric drive bridge (10).

2. The high-project-compatibility electric drive bridge offline testing bench device according to claim 1, characterized in that, The dual-control controller (1) for the main drive motor of the electric drive bridge is used to control the main drive motor of the electric drive bridge, the dual-control load motor controller (2) is used to control the torque loading of the load motor, and the electric drive bridge cooling oil pump controller (4) is used to control the cooling oil pump of the electric drive bridge.

3. The high-project-compatibility electric drive bridge offline testing bench device according to claim 2, characterized in that, The host computer on the test bench is used for sending control commands, monitoring the process and managing data. The electric drive bridge controller (3) is used to receive and process control commands from the host computer and control the operation of the electric drive bridge (10).

4. The high-project-compatibility electric drive bridge offline testing bench test device according to claim 3, characterized in that, The bench computer is connected to the controller calibration data management system and the test data cloud storage, which facilitates the offline writing of the mass production calibration data of the electric drive bridge (10) and the retention and management of the offline test data of the electric drive bridge (10).

5. The high-project-compatibility electric drive bridge offline testing bench device according to claim 4, characterized in that, The electric drive bridge controller (3) has a self-learning control function, and triggers the gear self-learning control command through the host computer on the test bench or the controller calibration data management system.

6. The high-project-compatibility electric drive bridge offline testing bench device according to claim 4, characterized in that, The electric drive bridge controller (3) supports shift control function, which is used to confirm the engagement and disengagement status of each gear of the electric drive bridge (10).

7. The high-project-compatibility electric drive bridge offline testing bench test device according to claim 4, characterized in that, The electric drive axle controller (3) establishes a communication interaction protocol with the host computer on the test bench. The signals include target gear command, self-learning control command, gear status feedback signal, self-learning result feedback signal, main drive motor control command of the electric drive axle (10), cooling oil pump control command of the electric drive axle (10), fault status feedback signal, and vehicle status signal.

8. The high-project-compatibility electric drive bridge offline testing bench device according to claim 1, characterized in that, The CAN1 bus (5), the CAN2 bus (6), and the CAN3 bus (7) are used for communication between components. The terminating resistor is configurable, and the CAN message format conforms to the J1939 communication protocol.

9. The high-project-compatibility electric drive bridge offline testing bench device according to claim 1, characterized in that, It also includes a quick-connect platform for the electric drive bridge controller, for quick replacement and calibration of the electric drive bridge controller (3).

10. The high-project-compatibility electric drive bridge offline testing bench device according to claim 1, characterized in that, The maximum power of the dual-control controller (1) for the main drive motor of the electric drive bridge is 600kW, and it supports a voltage platform of 400-800V; the maximum power of the dual-control load motor controller (2) is 300kW, and it also supports a voltage platform of 400-800V.

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