Background technique
Range-extended electric vehicle is generally considered a kind of new-energy automobile of most industrialization prospect, and countries in the world are all
Start the research and development and industrialization of attention range-extended electric driving skills art.It is domestic that there are no the pure electricity of more mature extended-range at this stage
Motor-car product is introduced to the market, and the research-and-development activity of article is also at the early-stage, in R&D process, finds distance increasing unit system
The connecting shaft of engine and generator is broken frequent occurrence in system, and reliability is not able to satisfy stroke-increasing electric automobile industrialization
Demand.Therefore, range extender of electric vehicle system test rack and reliability test method are established, to develop high performance distance increasing unit
Product provides data supporting, and the range extender system for developing high reliability is applied to electric car, and there is important guidance to anticipate
Justice.
The patent document of Publication No. CN104590041A discloses a kind of combustion gas range extender system for electric vehicle, it is wrapped
Gas engine and generator are included, gas engine is connect by clutch with generator, and the electricity of sending can directly drive vapour
Vehicle.
, there are following two points in the advantages of combustion gas distance increasing unit technology:
1, since combustion gas is cheaper than gasoline and less discharges, mileage can be increased using combustion gas distance increasing unit and reduce pollution;
2, the system can be used for range extender of electric vehicle system, establishes the framework platform of combustion gas distance increasing unit, can not only be total to
There are key components and parts, and can reduce industrialization cost.
In terms of use aspect, this is technically simple convenient.But for bulk production, the shortcomings that technology, is:
1, the technology use scope is limited, is only adapted to gas engine range extender system, is not applied for generally making
Fuel engines (petrol engine and diesel engine) range extender system;
2, the gas engine acceleration time is slower, and power performance is poor, is not able to satisfy client to vehicle good dynamics performance
Demand;
3, the technology does not account for the reliability of engine and generator coupling part, and reliability is that restriction extended-range is electronic
One key factor of vehicle industrialization, it is necessary to consider.
Therefore, it develops a fuel oil range extender system for having both preferable power performance and higher reliability and is applied to
Electric car establishes range extender of electric vehicle System Reliability Test method, is the elementary object of the invention patent.
Summary of the invention
The present invention is directed at least solve one of the technical problems existing in the prior art.For this purpose, the present invention provides a kind of electricity
Electrical automobile range extender system test-bed and range extender system reliability test method, it is therefore an objective to realize range extender of electric vehicle system
The reliability test of system provides data supporting to develop high performance range extender system.
In order to solve the above-mentioned technical problem, the technical scheme adopted by the invention is that: range extender of electric vehicle system test
Rack, including automatic controller, engine, generator, entire car controller, with generator be the engine controller being electrically connected and
Power battery, generator are connect by connecting shaft or shaft coupling with engine, automatic controller and battery management system, vehicle control
Device, engine controller and engine controller processed are electrical connection.
The power battery, engine controller and generator are connect by high-voltage line with the power cabinet for providing high-voltage electricity.
The engine controller is generated electricity or is opened according to the instruction real-time control generator of the entire car controller
Dynamic engine.
When the electricity of the power battery is low or electricity has consumed, engine controller is according to the entire car controller
The work of real-time control engine is instructed, driven by engine generator operation, generates electricity at this time, and the electric energy of generation is used for dynamic
The charging of power battery.
The present invention also provides a kind of range extender of electric vehicle System Reliability Test methods, comprising steps of
The preliminary examination of the monomer performance of S1, progress engine and generator;
The installation of S2, range extender system test-bed;
The adjustment of S3, range extender system test-bed;
S4, range extender system reliability test is carried out;
S5, disassembly range extender system test-bed, carry out the retrial of the monomer performance of engine and generator;
S6, the qualified evaluation for carrying out range extender system reliability.
In the step S1, executed when engine performance preliminary examination according to GB/T19055-2003, carry out generator
It can be executed when preliminary examination according to GB/T18488.2-2006.
In the step S2, the engine after completion performance preliminary examination is connected with generator by connecting shaft or shaft coupling,
And power battery, automatic controller, entire car controller and power cabinet are provided, then by engine controller, engine controller,
Battery management system and entire car controller are electrically connected with automatic controller, and power battery, engine controller and generator are led to
It crosses high-voltage line and is connect with the power cabinet for providing high-voltage electricity.
In the step S3, during adjustment, it is ensured that range extender system test-bed can normally complete starting, power generation, add
Speed, deceleration, constant speed and idling operation variation and conversion, it is ensured that the vibration of range extender system test-bed and noise are normal, record
The dynamic following situation of revolving speed and change in torque in the change curve and power generation process of battery SOC.
In the step S4, transport when reliability test by engine test operating condition and generator test load cases combination
Row, and ensure that the continuous working period of range extender system test-bed meets the requirements;If breaking down during test, terminate
Test.
When carrying out range extender system reliability test, comprising steps of
S41, control engine operate and make the revolving speed of engine from nMEquably rise to nP, then control engine and exist
Revolving speed nPLower stable operation for a period of time, then makes the revolving speed of engine from nPEquably drop to nM, finally control engine and exist
Revolving speed nMLower operation a period of time;
S42, the process for repeating step S41, until engine continuous has run the defined time;
S43, the revolving speed of engine is made to drop to ni, and engine is controlled in revolving speed niLower operation a period of time;
The throttle of S44, greater engine make the revolving speed of engine more than rated speed or rise to maximum speed;
S45, the throttle for reducing engine, make the revolving speed of engine drop to nM, so far complete a single test process.
Range extender of electric vehicle system test rack of the invention and test method realize range extender of electric vehicle system
Reliability test, data supporting is provided to develop high performance range extender system, for developing the distance increasing unit system of high reliability
System is applied to electric car, and the quick industrialization of range extender system is promoted to have important directive significance.
Specific embodiment
Below against attached drawing, by the description of the embodiment, making to a specific embodiment of the invention further details of
Explanation, it is therefore an objective to those skilled in the art be helped to have more complete, accurate and deep reason to design of the invention, technical solution
Solution, and facilitate its implementation.
Stroke-increasing electric automobile finds that the connecting shaft of engine and generator is frequent in range extender system in R&D process
It is broken, reliability is not able to satisfy the demand of stroke-increasing electric automobile industrialization.Therefore, a have both is developed preferably to move
The fuel oil range extender system of power performance and higher reliability and it is applied to electric car, this patent of invention establishes electric car
Range extender system installs rack and reliability test method, and the range extender system for developing high reliability is applied to electronic vapour
Vehicle promotes the quick industrialization of range extender system to have important directive significance.
As shown in Figure 1, the present invention provides a kind of range extender of electric vehicle system test rack, including automatic controller,
Engine, entire car controller, power cabinet, with generator is the engine controller and power battery being electrically connected at generator, power generation
Machine is connect by connecting shaft or shaft coupling with engine, automatic controller and battery management system, entire car controller, generator control
Device and engine controller processed are electrical connection.
Specifically, as shown in Figure 1, automatic controller (AUTO CONTROL SYSTEM), it is controlled by CAN bus
The instruction of engine controller, battery management system, entire car controller, engine controller, as in the control of test-bed
The heart.Power battery (BATTERY) is equally to be also used for storing up in test-bed as the component for storing electric energy on electric car
Deposit electric energy.Battery management system (BMS) is for intelligent management on power battery and each battery unit of maintenance, anti-stop
There is overcharge and overdischarge in power battery, extends the service life of power battery, monitors the state of power battery.
Entire car controller (VMS) is responsible for control and coordinates the other controller work (such as: EMS, GCU) of vehicle, realizes and increase
Formula electric car function control.Engine controller (GCU), according to the instruction real-time control generator of VMS carry out power generation or
Person starts engine, avoids working when engine start in inefficient section.Generator (GENENATOR), range extender system
Generator is in addition to power generation, moreover it is possible to the starting motor as engine.Engine (ENGINE) passes through connecting shaft or shaft coupling and hair
Motor is connected.Engine controller (EMS), when the electricity of power battery is lower or has consumed, vehicle, which enters, increases journey mode,
EMS instructs the work of real-time control engine according to VMS, and driven by engine electrical power generators, electric energy can drive driving at this time
Motor gives power battery charging.
As shown in Figure 1, power battery, engine controller and generator are by high-voltage line and provide the power cabinet of high-voltage electricity
Connection.Automatic controller (AUTO CONTROL SYSTEM) is the control centre of test-bed, it is controlled by CAN bus and is sent out
The instruction of electric machine controller (GCU), battery management system (BMS), entire car controller (VMS), engine controller (EMS);Hair
Motor (GENENATOR) constitutes range extender system by connecting shaft or shaft coupling and engine (ENGINE).Entire car controller
It is responsible for control and coordinates the other controller work (such as: EMS, GCU) of vehicle, realizes stroke-increasing electric automobile function control: hair
Electric machine controller (GCU) is generated electricity or is started engine according to the instruction real-time control generator of VMS, and engine is avoided to open
It works when dynamic in inefficient section;When the electricity of power battery is lower or has consumed, vehicle, which enters, increases journey mode, and EMS is according to VMS
The work of real-time control engine is instructed, at this time driven by engine electrical power generators, electric energy can drive driving motor or to dynamic
The charging of power battery.Power cabinet is connect with power battery (BATTERY), engine controller, generator by high-voltage line, and mentioned
For high-voltage electricity.It should be strongly noted that assembly installation rack is a simple rack, it is primarily adapted for use in extended-range electric vehicle
The reliability of range extender system assembly mechanical structure and performance is examined when in increasing journey mode.
Range extender system reliability test operating condition figure (single loop) is as shown in Fig. 2, range extender system reliability is tried
It tests by engine test operating condition and the operation of generator test load cases combination, engine is from revolving speed nM(nMFor driven by engine generator
Minimum operating speed when operating is generated electricity) equably rise to np(npWhen being generated electricity for driven by engine generator operation
Highest working speed), last 90s;In revolving speed npLower stable operation 210s;Then equably drop to revolving speed nM, last 90s;
In revolving speed nMLower stable operation 210s.Above-mentioned alternation operating condition is repeated, 1500s is run to.Revolving speed drops to idling (ni) run to
1770s;Engine is in idling mode, and zero load, throttle is opened greatly, and revolving speed is made uniformly to rise to 105% rated speed (nτ) or
Maximum speed as defined in engine shop is risen to, 15s ± 6s is lasted;The oil of type range extender engine is equably turned down immediately
Door, makes revolving speed be down to nM, last 15s ± 6s.So far a circulation is completed, 1800s is lasted.Range extender system test-bed is at least
Run 800 circulations, continuous working period 400h.
Table 1 is single loop corresponding with Fig. 2 each operating condition Operational Timelines: describing in detail the corresponding hair of each operating condition
The situation of change of motivation revolving speed, corresponding load variations situation and the lasting runing time of the operating condition.
1 single loop of table each operating condition Operational Timelines
The present invention also provides a kind of range extender of electric vehicle System Reliability Test methods, as shown in figure 3, including as follows
The step of:
The preliminary examination of the monomer performance of S1, progress engine and generator;
The installation of S2, range extender system test-bed;
The adjustment of S3, range extender system test-bed;
S4, range extender system reliability test is carried out;
S5, disassembly range extender system test-bed, carry out the retrial of the monomer performance of engine and generator;
S6, the qualified evaluation for carrying out range extender system reliability.
In step S1, according to GB/T19055-2003, " automobile engine reliability is tried when carrying out the performance test of engine
Proved recipe method " in the 8.3rd article regulation execute.According to GB/T18488.2-2006 when the test of progress generator and controller performance
The regulation of " click for electric vehicle and its controller part 2: test method " executes, and carries out insulation of the machine winding to casing
The test such as resistance, motor torque characteristic (external characteristics).Just test result should reach manufacture to the performance of engine, generator and controller
The technical conditions requirement that factory provides, otherwise answers termination test.If manufactory is capable of providing the monomer performance of test specimen qualification
Test report can no longer carry out performance preliminary examination.
In step S2, the engine after completion performance preliminary examination is connected with generator by connecting shaft or shaft coupling, and mentions
For power battery, automatic controller, entire car controller and power cabinet, then by engine controller, engine controller, battery
Management system and entire car controller are electrically connected by CAN bus with automatic controller, by power battery, engine controller and hair
Motor is connect by high-voltage line with the power cabinet for providing high-voltage electricity, and range extender system test-bed as shown in Figure 1 is formed.It is true
Insurance system can work normally, and the signal for coping with uninstalled components (influential on system) is simulated or passes through other
Mode carries out signal shielding to director demon, while should increase system protection program in automatic controller (such as: over-voltage, mistake
Stream, overheat protector program), it is ensured that system safety.
Step S3 carries out the adjustment of range extender system test-bed, during adjustment, it is ensured that range extender system test-bed energy
Enough normally complete starting, power generation, acceleration, deceleration, constant speed and idling operation variation and conversion, it is ensured that range extender system test-bed
Vibration and noise it is normal, record battery SOC (SOC full name is State of Charge) change curve and power generation process
The dynamic following situation of middle revolving speed and change in torque.
In step S4, run when reliability test by engine test operating condition and generator test load cases combination, and
Ensure that the continuous working period of range extender system test-bed meets the requirements;If breaking down during test, termination test.
In step S4, the process of range extender system reliability test is carried out, as shown in table 1 and Fig. 2, including following step
It is rapid:
S41, control engine start running and make the revolving speed of engine from nMEquably rise to nP, this accelerator
Last 90s;Then control engine is in revolving speed nPFor a period of time, which is preferably 210s for lower stable operation;Then make
The revolving speed of engine is from nPEquably drop to nM, this moderating process lasts 90s;Finally control engine is in revolving speed nMIt is lower steady
Fixed operation a period of time, a period of time are preferably 210s;
S42, the process for repeating step S41 alternation operating condition, until engine continuous has operated the defined time, this is defined
Time be preferably 1500s (the defined time refer to from step S41 engine start running after engine continuous operate operating condition
Cumulative time);
S43, the revolving speed of engine is made to drop to ni(niRevolving speed when for engine idle conditions), engine is in idling
State, and engine is controlled in revolving speed niLower operation a period of time, until engine continuous has operated the defined time, the regulation
Time be preferably 1770s (the defined time refer to from step S41 engine start running after engine continuous operate work
The condition cumulative time);
S44, engine is made to be in idling mode, engine no-load, then the throttle of greater engine makes engine
Revolving speed uniformly rises, until the revolving speed size of engine is more than 105%*nτ(nτFor the rated speed of engine) or rise to hair
Motivation manufactures the fixed maximum speed of factory rules and regulations, this accelerator lasts 15s ± 6s;
S45, the throttle for equably reducing engine, make the revolving speed of engine drop to nM, this moderating process lasts 15s
±6s。
By step S41 to S45, a single test process of range extender system reliability test is so far completed, is completed
One circulation, entire single test process last 1800s.
In step S4, when carrying out range extender system reliability test, 800 above-mentioned single test mistakes need to be at least carried out
Journey, even if also range extender system test-bed at least runs 800 circulations, the range extender system test-bed continuous working period is
400h。
As shown in figure 3, if broken down in range extender system test-bed operational process, terminating examination in step S4
It tests;If do not broken down in operational process, but 400h is not achieved in the range extender system test-bed continuous working period, weight
New design and improvement range extender system test-bed, re-start reliability test, until range extender system test-bed continues
Runing time reaches 400h, can carry out in next step.
As shown in figure 3, in step S5, range extender system test-bed is dismantled, engine, generator are dismantled as monomer,
Convenient for carrying out monomer performance retrial in next step.
As shown in figure 3, carrying out the qualified evaluation of range extender system reliability in step S6, evaluation criterion is as follows:
1. the practical accumulated running time of range extender system test-bed should be greater than or be equal to 400h;
2. range extender system test-bed does not have extraordinary noise after completing reliability test, can run well;
3. the judgement of engine, generator does not occur catastrophe failure, and range extender system test-bed does not occur key zero
Component (connecting shaft or shaft coupling) damage, needs replacing the phenomenon that could restoring function.
When being evaluated, only meet above three standards simultaneously, range extender system test-bed just calculates qualification.If closed
Lattice, reliability test terminate;If unqualified, return to step S4 and re-start reliability test.
The present invention is exemplarily described above in conjunction with attached drawing, it is clear that the present invention implements not by aforesaid way
Limitation, as long as the improvement for the various unsubstantialities that the inventive concept and technical scheme of the present invention carry out is used, or without changing
It is within the scope of the present invention into the conception and technical scheme of the invention are directly applied to other occasions.