Electric Vehicle Testing Apparatus for ECU Efficiency
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Solution Overview
Problem
Current methods for testing electric vehicle drive units fail to accurately assess power consumption variations due to the lack of control over motor control ECU algorithms and vehicle parameters without using large-sized devices, and they cannot simulate real-world driving conditions effectively.
Innovation Solution
An electric-vehicle testing apparatus and method that generates driver signals corresponding to accelerator and brake operations, computes running resistance and braking force, and controls torque to simulate real-world driving conditions using a test motor and load motor, allowing for evaluation of motor control ECU efficiency without incorporating the ECU into an actual vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a chassis dynamometer is used to test the drive unit on an actual vehicle, then the evaluation accuracy of power consumption is improved, but the device size and complexity increase significantly
Solution Approach 1:
The patent creates a virtual model that copies the essential characteristics of actual vehicle running conditions, including road gradients, air resistance, and running resistance. This virtual model allows accurate power consumption evaluation without requiring a physical chassis dynamometer, thus resolving the contradiction between measurement accuracy and device complexity
Solution Approach 2:
The patent replaces the mechanical chassis dynamometer system with a computational approach using a personal computer and virtual model. The mechanical testing system is substituted by software-based simulation that calculates power consumption based on vehicle parameters, motor characteristics, and virtual running conditions
2Device complexity
If a simplified test device directly connected to the motor is used, then the device size is reduced, but the ability to simulate real-world driving conditions and assess ECU efficiency deteriorates
Solution Approach 1:
The patent implements dynamic simulation capabilities that allow the virtual model to adapt to various running conditions including different road gradients, speeds, and resistance factors. The system can dynamically adjust test parameters to simulate diverse real-world driving scenarios, maintaining high adaptability while using a compact device
Solution Approach 2:
The testing device is designed with multi-functionality, capable of evaluating not only power consumption but also motor control ECU efficiency, motor characteristics, and various vehicle parameters. The single compact device can perform multiple testing functions that would otherwise require different specialized equipment
3Ease of operation
If the motor is controlled without using the actual motor control ECU, then the testing process is simplified, but the verification of control algorithms and their impact on power consumption is lost
Solution Approach 1:
The patent introduces a signal generation unit as an intermediary that creates simulated driver signals (accelerator and brake operations) based on predetermined running conditions. This intermediary allows the system to maintain simplified testing while still verifying control algorithm performance by analyzing how the ECU responds to realistic control inputs
Data Source
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AI summary
According to one embodiment, an electric-vehicle testing apparatus includes means (201,202,203,204,205). The means (201) for generating generates a first signal corresponding to accelerator operation amount and a second signal corresponding to brake operation amount in accordance with test conditions. The means (203) for computing computes running resistance to be assumed using a rotation speed of a test motor. The means (204) for computing computes braking force using the second signal and an actual vehicle speed obtained from the rotation speed of the test motor. The means (205) for controlling controls torque of a load motor coupled to the test motor, based on a second command value corresponding to the running resistance and the braking force.