Electric drive bridge shield status recognition system

Abstract

The utility model relates to electric drive bridge shielding state identification system, relates to electric drive bridge test process shielding function abnormal protection and the technical field of fault source locking, it includes electric drive bridge, and the electric drive bridge both sides are equipped with the dynamometer, and the electric drive bridge both ends are connected with two dynamometers respectively and have the wheel end connecting disc, transmission shaft, torque flange, and the electric drive bridge electric connection has motor controller, and motor controller electric connection has battery simulator, and the electric drive bridge and motor controller are connected with ground respectively through the ground wire, and the mutual connection place of battery simulator, motor controller, electric drive bridge and ground is arranged with current transformer and / or temperature sensor. The utility model can discover in time and adopt corresponding measure when the shielding state of electric drive bridge test development process is abnormal, and be applicable to all kinds of electric drive bridge.

Description

Technical Field

[0001] This utility model relates to an electric drive bridge shielding status identification system, and to the technical field of shielding function abnormality protection and fault source locking during electric drive bridge testing. Background Technology

[0002] In applications with high electromagnetic complexity, such as modern electric vehicles and hybrid vehicles, the shielding status of the electric drive axle, as a core power component, is crucial. The shielding status of the electric drive axle measures its ability to suppress electromagnetic interference and maintain electromagnetic compatibility (EMC). The core objective is to ensure the stable operation of the system itself, avoid interference with surrounding electronic equipment, and guarantee vehicle functional safety and performance standards. Especially in electric vehicles, where numerous high-voltage electrical systems work together in a complex and variable electromagnetic environment, the shielding performance of the electric drive axle directly affects vehicle safety and user experience.

[0003] However, existing electric drive bridge testing methods have significant limitations. They typically rely on a host computer to read sample fault codes for identification, which has the following drawbacks: a) For newly developed electric drive bridge products, their fault code system is often in the development and improvement stage, which makes it impossible to rely on fault codes for effective identification in the early stage of testing, thus limiting the testing support capabilities. b) Fault codes usually point to the affected component rather than the root cause of the fault, which makes it difficult for testers to quickly pinpoint the source of the fault, increasing the difficulty and time cost of troubleshooting; c) When a large number of error frames occur during the operation of the electric drive bridge, it may cause the upper computer communication to be interrupted. The existing test system lacks a timely protection mechanism, and the test bench cannot respond quickly, which leads to the risk of damage to the test samples and affects the continuity of the test and the safety of the equipment.

[0004] Therefore, there is an urgent need for a more advanced and efficient electric drive bridge shielding status identification system to break through the existing technical bottlenecks and meet the pressing needs of electric drive bridge testing in complex electromagnetic environments such as electric vehicles. Utility Model Content

[0005] The purpose of this application is to provide an electric drive bridge shielding status identification system, which can promptly detect and take corresponding measures when the shielding status of the electric drive bridge is abnormal during the test and development process, and is applicable to various types of electric drive bridges.

[0006] To achieve the above objectives, the present invention provides an electric drive bridge shielding status identification system, comprising an electric drive bridge, dynamometers on both sides of the electric drive bridge, wheel end connecting discs, drive shafts, and torque flanges respectively connected to the two dynamometers at both ends of the electric drive bridge, a motor controller electrically connected to the electric drive bridge, a battery simulator electrically connected to the motor controller, the electric drive bridge and the motor controller being connected to the ground via grounding wires, and current transformers and / or temperature sensors arranged at the connection points between the battery simulator, the motor controller, the electric drive bridge and the ground.

[0007] Preferably, the electric drive bridge is connected to the motor controller via an AC power line, and the motor controller is connected to the battery simulator via a DC power line.

[0008] Preferably, it includes a grounding current transformer I, a UVW phase current transformer, a DC current transformer, and a grounding current transformer II, which are respectively arranged on the grounding wire of the electric drive bridge, the AC power line, the DC power line, and the grounding wire of the motor controller.

[0009] Preferably, the device includes a UVW phase line shielding area temperature sensor and a DC end shielding area temperature sensor, which are respectively arranged at the contact point between the AC power line and the electric drive bridge and the motor controller shielding area, and at the contact point between the positive terminal of the DC power line and the motor controller shielding area.

[0010] Preferably, the host computer is connected to the CAN box and the data acquisition module via communication lines. The CAN box is connected to the electric drive bridge and the motor controller via communication lines. The data acquisition module is connected to each sensor via communication lines.

[0011] Preferably, the host computer identifies the operating status of the electric drive bridge by reading the speed, torque, temperature, pressure, voltage, current, error frames, fault codes, and counter signals transmitted by the data acquisition module and the CAN box.

[0012] Preferably, the host computer controls the dynamometer to work through the data acquisition module and controls the electric drive bridge to work through the CAN box. During normal operation, the dynamometer uses a speed loop to control the output speed of the electric drive bridge, and the electric drive bridge uses a torque loop to control its own output torque.

[0013] The technical solution of this utility model provides a method for identifying the shielding status of an electric drive bridge, including the following steps: Configure shielding status identification and protection settings on the host computer; The host computer activates the data acquisition function and simultaneously initiates protection measures; Adjust the output voltage of the battery simulator to the product's allowable voltage, set the dynamometer control mode to speed loop to control the wheel-side speed of the electric drive axle, and switch the electric drive axle control mode to torque loop; If the electric drive bridge has a gear position, switch to the corresponding gear position and start the test according to the product test requirements; If the protection is triggered during the test, the machine must be stopped for inspection. If the protection is not triggered during the test, the test will continue.

[0014] Preferably, the protection settings include: Configure CAN bus communication error frames to add light alerts and error frame accumulation counts; Set the signal limits for temperature sensors in the shielded areas of each location; Set the signal limits for current transformers at each location; If the sample contains a Hall effect or electromagnetic induction sensor, a script is written to identify whether there are any abnormal jumps in the signal. Configure torque abnormal fluctuation protection; Configure CAN bus communication protection by writing a script to identify whether the CAN bus communication load rate is increasing and accompanied by communication delay or jamming.

[0015] Preferably, the shutdown inspection specifically includes: If the number of CAN bus communication error frames increases or the CAN bus communication protection is triggered, check the shielding structure of each power line, the insulation resistance of the motor system, and the grounding status. If the temperature sensor signal in the shielded area exceeds the limit, the shielding structure at the abnormal temperature location should be checked. If no abnormality is found, the shielding structure of each power line, the insulation resistance of the motor system, and the grounding status should be checked simultaneously. If the current transformer signal exceeds the limit, focus on checking the shielding structure at the location of the abnormal current. If no abnormality is found, simultaneously check the shielding structure of each power line, the insulation resistance of the motor system, and the grounding status. If the Hall effect or electromagnetic induction sensor signal changes abnormally or the torque abnormality protection is triggered, focus on checking the insulation resistance of the motor system. If no abnormality is found, simultaneously check the shielding structure of the power line, the insulation resistance of the motor system, and the grounding status.

[0016] In summary, this utility model has the following beneficial technical effects: This invention solves the testing challenges of newly developed products in the early stages of an incomplete fault code system. By real-time monitoring of various signals during the operation of the electric drive bridge, including current, temperature, torque, and communication status, it overcomes the limitations of traditional fault code-based identification, ensuring efficient and accurate identification of shielding status from the initial testing phase. It enables rapid identification of fault sources. Through real-time monitoring and protection mechanisms for temperature and current changes in the shielded area and communication anomalies, it can quickly capture fault characteristics in the early stages of anomalies, reducing troubleshooting time and improving problem location efficiency. It significantly enhances the safety of the testing process and equipment protection capabilities. By implementing multiple protection measures such as CAN bus communication protection, error frame counting, and light alerts, it effectively avoids communication interruptions to the host computer due to a surge in error frames, promptly triggering shutdown checks and protecting test samples from damage, thus ensuring the stable operation of the test bench.

[0017] The testing system and method provided by this invention have broad applicability and significant practical value. They are highly versatile, applicable not only to the shielding status detection of electric drive axles in electric vehicles but also applicable to other motor and electronic control testing scenarios, providing a reliable solution for equipment testing in complex electromagnetic environments. Through the organic combination of data monitoring and protection mechanisms, early detection, early response, and early resolution of abnormal states are achieved, effectively shortening product development cycles, reducing costs, and significantly improving user experience. In applications such as electric vehicles where electromagnetic compatibility requirements are extremely high, this invention helps improve the safety and reliability of the entire vehicle, promoting technological progress and product upgrades in the new energy vehicle industry. Attached Figure Description

[0018] Figure 1 A schematic diagram of the structure of the electric drive bridge shielding status identification system; Figure 2 This is a schematic diagram of the signal communication of the electric drive bridge shielding status identification system. Figure 3 This is a flowchart illustrating the steps for using an electric drive bridge shielding status identification system.

[0019] Attached reference numerals: 1. Dynamometer I; 2. Torque Flange I; 3. Drive Shaft I; 4. Wheel End Connecting Plate I; 5. Electric Drive Axle; 6. Wheel End Connecting Plate II; 7. Drive Shaft II; 8. Torque Flange II; 9. Dynamometer II; 10. Grounding Wire Current Transformer I; 11. Grounding Wire I; 12. AC Power Line; 13. UVW Phase Line Shielded Area Temperature Sensor; 14. UVW Phase Line Current Transformer; 15. Battery Simulator; 16. DC Power Line; 17. DC Terminal Current Transformer; 18. DC Terminal Shielded Area Temperature Sensor; 19. Motor Controller; 20. Grounding Wire II; 21. Grounding Wire Current Transformer II. 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 shielding status identification system for an electric drive bridge 5, comprising a dynamometer, torque flange, drive shaft, wheel end connecting plate, electric drive bridge 5, battery simulator 15, DC power line 16, AC power line 12, grounding wire, communication line, current transformer, temperature sensor, data acquisition module H, CAN box F, and host computer G, among other key components. The various modules of this system cooperate with each other through carefully designed mechanical, electrical, and communication connections to achieve comprehensive identification and monitoring of the shielding status of the electric drive bridge 5. The system's working principle and usage steps are closely centered on the monitoring and abnormal protection of the electric drive bridge 5's operating status, aiming to provide a safe and efficient detection method for testing the electric drive bridge 5.

[0022] Specifically, one end of the electric drive bridge 5 is connected to the dynamometer 1 via wheel end connecting plate 4, drive shaft 3, and torque flange 2, while the other end is connected to the dynamometer 9 via wheel end connecting plate 6, drive shaft 7, and torque flange 8, forming a mechanical power transmission chain. The electric drive bridge 5 is connected to the motor controller 19 (i.e., MCU) via AC power line 12, and the motor controller 19 is then connected to the battery simulator 15 via DC power line 16, forming a complete power transmission path. Furthermore, the electric drive bridge 5 and the motor controller 19 are connected to the ground via grounding wire 11 and grounding wire 20, respectively, to ensure the safety and stability of the system. At these critical connection points, grounding current transformer 10, UVW phase current transformer 14, DC current transformer 17, and grounding current transformer 21 are installed to monitor the current changes of the grounding wire at the end of the electric drive bridge 5, the AC power line 12 (UVW three-phase), the DC power line 16 (positive), and the grounding wire at the end of the motor controller 19, respectively. Meanwhile, the UVW phase line shielding area temperature sensor 13 and the DC end shielding area temperature sensor 18 are respectively arranged at the contact points of the AC power line 12 (UVW three phases) and the electric drive bridge 5 and the motor controller 19 shielding area, and the contact point of the DC power line 16 (positive) and the motor controller 19 shielding area, to monitor temperature changes in real time and provide temperature anomaly warnings for the system.

[0023] In terms of communication connectivity, the host computer G is connected to the CAN box F and the data acquisition module H via communication lines. The CAN box F is then connected to the electric drive bridge & motor controller signal E via a communication line, while the data acquisition module H is connected to the current transformer signal A at each location, the temperature sensor signal B in each location's shielded area, the torque flange torque signal C, and the dynamometer signal D via a communication line. This communication architecture enables the host computer G to acquire various key signals during the operation of the electric drive bridge 5 in real time, including speed, torque, temperature, pressure, voltage, current, error frames, fault codes, counters, etc., thereby accurately identifying the operating status of the electric drive bridge 5.

[0024] The working principle of the experimental system of this utility model is as follows: a) Battery simulator 15 replaces the real battery to provide DC power to electric drive bridge 5, ensuring that electric drive bridge 5 can still operate normally without a real battery; b) The host computer G controls the dynamometer to work through the data acquisition module H and controls the electric drive bridge 5 to work through the CAN box F. Under normal working conditions, the dynamometer uses a "speed loop" to control the output speed of the electric drive bridge 5, while the electric drive bridge 5 uses a "torque loop" to control its own output torque, thereby achieving precise control of the performance of the electric drive bridge 5. c) The host computer G reads signals such as speed, torque, temperature, pressure, voltage, current, error frames, fault codes, and counters transmitted by the data acquisition module H and CAN box F to identify and monitor the operating status of the electric drive bridge 5 in real time. d) Implement protection settings for relevant signals that may be affected by shielding abnormalities; once a fault is detected, the host computer G will take corresponding protection measures according to the fault type, such as buzzer alarm, emergency stop, and high voltage reduction, and indicate the cause of the fault so that it can be investigated and resolved in a timely manner.

[0025] The steps for using the testing system of this utility model are as follows: Step 1: Configure the shielding status identification and protection settings on the host computer G, as follows: a) Protection ①: Add light reminder and error frame accumulation count for CAN bus communication error frames. When there is an error frame on the bus, the red light flashes. The flashing rate of the red light is proportional to the growth rate of the error frame. If only one error frame is added, the red light flashes once. If the increase is rapid, the light flashes continuously. b) Protection ②: Set the temperature sensor signal B limit for each location's shielded area. The temperature limit for each location is determined based on the characteristics of each location. c) Protection ③: Set the current transformer signal A limit for each position. The current limit for each position is determined according to the characteristics of each position. d) Protection ④: If the sample contains a Hall effect or electromagnetic induction sensor (generally a position or angle sensor), then a script is compiled to identify whether there is an abnormal jump in the signal E of the electric drive bridge & motor controller collected by the CAN box F. e) Protection ⑤: Set torque abnormal jump protection. If there is a large fluctuation in the ratio of the torque flange detection value (torque flange torque signal C) to the output torque value of the electric drive bridge 5 motor, protection troubleshooting is required. f) Protection ⑥: Set up CAN bus communication protection, and identify whether the CAN bus communication load rate is increased and accompanied by communication delay or blockage by compiling a script; Step 2: The host computer G enables the data acquisition function and simultaneously activates the above-mentioned protection measures to put the system in a monitoring state. Step 3: Adjust the output voltage of the battery simulator 15 to the product's allowable voltage, set the control mode of dynamometer 1 and dynamometer 2 to "speed loop" to control the wheel side speed of electric drive axle 5, and switch the control mode of electric drive axle 5 from "Standby" mode to "torque loop". Step 4: If the electric drive bridge 5 has a gear, switch to the corresponding gear and start the test according to the product test requirements; Step 5: If the arbitrary protection in "Step 1" is triggered during the test, the machine must be stopped for inspection, as follows: a) If protection ① and ⑥ are triggered, the inspection items are the shielding structure of each power line, the insulation resistance of the motor system, and the grounding status. b) If protection ② is triggered, focus on checking the shielding structure at the location of the temperature anomaly. If no anomaly is found, check item a) simultaneously. c) If protection ③ is triggered, focus on checking the shielding structure at the location of the abnormal current. If no abnormality is found, check item a) simultaneously. d) If protection ④ and ⑤ are triggered, focus on checking the insulation resistance of the motor system. If no abnormality is found, check item a) simultaneously. Step 6: If the protection is not triggered during the test, continue the test.

[0026] The experimental method provided in this application has the following advantages: A. When the fault codes of a newly developed product are in the development stage, this test method can be used to support the test of the electric drive bridge 5 to ensure the smooth progress of the test; B. Through data monitoring and protection measures, the source of the fault can be identified in the early stages of anomalies, enabling early detection, early response, and early resolution, thereby improving development efficiency; C. When a large number of error frames cause the host computer's G communication to be interrupted, the test bench can be protected in time to avoid damage to the test sample; D. This test method has reference value for various types of motor and electronic control tests and has wide applicability.

[0027] The experimental system of this invention uses a host computer (G) to monitor whether the sample torque changes abnormally, to monitor whether the sample Hall effect or electromagnetic induction sensor signals are abnormal, to use a script compiled by the host computer (G) to identify whether there is communication lag or increased delay, to use a CAN box (F) to monitor the growth of error frames, and to use sensors to monitor the temperature and current changes in the shielded area. This ensures that abnormal shielding conditions can be detected in a timely manner and corresponding measures can be taken, thus providing a safe and efficient detection method for testing the electric drive bridge 5.

[0028] 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. An electric drive bridge shielding status identification system, characterized in that, The device includes an electric drive bridge (5), on both sides of which are provided dynamometers. The two ends of the electric drive bridge (5) are respectively connected to the two dynamometers via wheel end connecting discs, drive shafts, and torque flanges. The electric drive bridge (5) is electrically connected to a motor controller (19), which is electrically connected to a battery simulator (15). The electric drive bridge (5) and the motor controller (19) are respectively connected to the ground via grounding wires. Current transformers and / or temperature sensors are arranged at the connection points between the battery simulator (15), the motor controller (19), the electric drive bridge (5), and the ground.

2. The electric drive bridge shielding status identification system according to claim 1, characterized in that, The electric drive bridge (5) is connected to the motor controller (19) via an AC power line (12), and the motor controller (19) is connected to the battery simulator (15) via a DC power line (16).

3. The electric drive bridge shielding status identification system according to claim 2, characterized in that, It includes a grounding current transformer one (10), a UVW phase current transformer (14), a DC current transformer (17), and a grounding current transformer two (21), which are respectively arranged on the grounding wire of the electric drive bridge (5), the AC power line (12), the DC power line (16), and the grounding wire of the motor controller (19).

4. The electric drive bridge shielding status identification system according to claim 3, characterized in that, The device includes a UVW phase line shielding area temperature sensor (13) and a DC end shielding area temperature sensor (18), which are respectively arranged at the contact point between the AC power line (12) and the electric drive bridge (5) and the motor controller shielding area, and at the contact point between the positive terminal of the DC power line (16) and the motor controller shielding area.

5. The electric drive bridge shielding status identification system according to claim 1, characterized in that, The host computer is connected to the CAN box and the data acquisition module via communication lines. The CAN box is connected to the electric drive bridge (5) and the motor controller (19) via communication lines. The data acquisition module is connected to each sensor via communication lines.

6. The electric drive bridge shielding status identification system according to claim 5, characterized in that, The host computer identifies the operating status of the electric drive bridge (5) by reading the speed, torque, temperature, pressure, voltage, current, error frames, fault codes, and counter signals transmitted by the data acquisition module and the CAN box.

7. The electric drive bridge shielding status identification system according to claim 6, characterized in that, The host computer controls the dynamometer to work through the data acquisition module and controls the electric drive bridge (5) to work through the CAN box. When working normally, the dynamometer uses a speed loop to control the output speed of the electric drive bridge (5) and the electric drive bridge (5) uses a torque loop to control its own output torque.

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