CN107272662B - Driving motor and controller calibration system and calibration method for electric automobile - Google Patents
Driving motor and controller calibration system and calibration method for electric automobile Download PDFInfo
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
- G05B23/0213—Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
Abstract
The invention discloses a calibration system and a calibration method for a driving motor and a controller for an electric automobile, comprising the following steps: the alternating current dynamometer is coaxially connected with a calibrated driving motor, the driving motor is connected with a calibrated motor controller through a power line, and the motor controller is connected with the battery simulator through a direct current bus; the water cooling circulation system is respectively connected with the driving motor and the motor controller through cooling pipelines, and the power analyzer is connected with the motor controller; the rack monitoring system is respectively connected with the power analyzer, the water cooling circulating system, the dynamometer control cabinet and the battery simulator; the invention has the beneficial effects that: the method has the characteristics of optimizing the test flow and shortening the calibration period, and improves the comprehensive utilization rate of the calibration test bench. The method is widely applied to the technical and research and development fields of manufacturing, matching and optimizing of the driving motor and the controller of the electric automobile, and has great popularization value.
Description
Technical Field
The invention relates to a calibration system and a calibration method for a driving motor and a controller for an electric automobile.
Background
The energy conservation and environmental protection of the electric automobile have become the necessary trend of the future automobile development. Unlike conventional fuel-powered vehicles, the electric vehicle's power system is primarily a motor drive system powered by a power battery. The motor driving system mainly comprises a driving motor and a controller (comprising a motor inverter part), and the performance of the motor driving system directly influences the dynamic property, economy, comfort and the like of the whole electric automobile, so that the performance test and calibration of the driving motor and the controller take an important role in the development of the whole electric automobile system.
The MAP of motor efficiency (also called contour MAP, cloud MAP) is a data graph generated during motor test, and mainly reflects motor efficiency distribution conditions under different rotation speeds and torques. Previously, foreign motor manufacturers have more motor MAP tests, and the data manual of the imported motor is basically attached with the tested motor efficiency MAP. Before the electric automobile is widely popularized in China, the manufacturer of the domestic driving motor rarely gives a MAP of the motor, and the efficiency points of the driving motor under each rotating speed and torque are measured by an electric dynamometer, so that the testing of the whole manufacturer or enterprises of the electric automobile is troublesome. At present, more test instruments and devices are needed in the matching test or calibration process of the driving motor and the controller of the electric automobile, test data are stored in different computers or software platforms, and are not completed in the same software and hardware system platform, so that due to the influences of factors such as data transmission rate, transmission delay, electromagnetic interference and the like, measurement errors caused by poor time consistency of the test data are difficult to ensure, and the test data of different devices are required to be respectively stored and then manually processed, including unified data format, operation, drawing and the like, so that the processing process is complicated and the time is long. In fact, in addition to the MAP of the motor, the efficiency MAP of the motor controller (motor driver), in particular the system efficiency MAP of the whole drive motor and of the controller, is also of great concern to the motor manufacturer, the whole manufacturer of the electric vehicle or the enterprise.
Disclosure of Invention
The invention aims to solve the problems and provides a driving motor and controller calibration system and a calibration method for an electric automobile, wherein the calibration system integrates an alternating current dynamometer, a dynamometer control cabinet, a rack monitoring system, a power analyzer, a water cooling circulation system, a battery simulator and the like, and all test data are transmitted to unified monitoring system software for processing in different communication modes such as CAN, TCP/IP and the like; the calibration system has the characteristics of feasible scheme, convenient use and complete functions; the measuring method has the characteristics of optimizing the test flow and shortening the calibration period, and can improve the comprehensive utilization rate of the calibration test bench.
In order to achieve the above object, the present invention is specifically as follows:
a drive motor and controller calibration system for an electric vehicle, comprising: an alternating current dynamometer, a dynamometer control cabinet, a rack monitoring system, a power analyzer, a water cooling circulation system, a battery simulator and the like;
the alternating current dynamometer is coaxially connected with a calibrated driving motor, the driving motor is connected with a calibrated motor controller through a power line, and the motor controller is connected with a battery simulator through a direct current bus; the water cooling circulation system is respectively connected with the driving motor and the motor controller through cooling pipelines, and the power analyzer is connected with the motor controller;
the rack monitoring system is respectively connected with the power analyzer, the water cooling circulating system, the dynamometer control cabinet and the battery simulator; the rack monitoring system receives motor voltage and current signals acquired by the power analyzer and liquid outlet temperature, liquid return temperature, refrigeration temperature, liquid outlet pressure, liquid return pressure and liquid outlet flow parameters of cooling liquid acquired by the water cooling circulation system, and sends a control instruction to the dynamometer control cabinet according to the received parameter information to control the output rotating speed and torque of the alternating current dynamometer, and meanwhile monitors the operation of the whole rack system.
Further, the dynamometer control cabinet receives a control signal of the rack monitoring system and controls the rotating speed and the torque of the alternating current dynamometer.
Further, the alternating current dynamometer is coaxially connected with the calibrated driving motor through a torque flange, a transmission shaft and an adapter which are sequentially connected, torque and rotation speed of the calibrated driving motor are measured through the torque flange, and a measuring signal is transmitted to the power analyzer.
Further, the input and output voltage, the input and output current, the motor rotating speed and the steering, the motor torque, the motor and the temperature parameters of the controller of the calibrated motor are uploaded to a rack monitoring system through CAN communication.
Further, the battery simulator simulates the external characteristic output of the voltage and the current of the actual battery according to the load condition of the motor by loading a battery model.
Further, the calibrated motor controller is provided with a pre-charging circuit, and a power supply of the motor controller is connected with a storage battery in parallel for supplying power.
Further, the driving motor and the alternating current dynamometer are respectively fixed on a motor base and a dynamometer base, and the motor base and the dynamometer base are fixed on a specific supporting platform; a metal protective cover is arranged between the alternating current dynamometer and the driving motor.
A calibration method of a driving motor and controller calibration system for an electric automobile comprises the following steps:
(1) Initializing a system, setting the temperature of cooling liquid and the flow parameters of liquid discharged from a water cooling system required by calibration, and setting basic parameters and safety protection limit values of a battery simulator, an alternating current dynamometer and a calibrated driving motor;
(2) Defining the efficiency of the drive motor in the electric mode and the generating mode, respectively, includes: driving motor efficiency, motor controller efficiency and motor system overall efficiency;
(3) According to the rotating speed and torque range, the calibrating precision and the testing time limit requirement of the driving motor required to be calibrated, designing a given step length of the rotating speed and the torque during the calibration;
(4) Under the condition of no load of the motor, a certain rotating speed of the alternating current dynamometer is set, the running condition of the motor and the torque of the rack are observed, and if the sound of the rack is abnormal or the torque is overlarge, the motor is not well installed or centered and needs to be readjusted;
(5) The rotating speed of the alternating current dynamometer is given according to a given step length of the rotating speed and is recorded as rotating speed calibration external circulation; setting the torque of a driving motor according to the calibration step length of the torque, and marking the torque as torque calibration internal circulation;
(6) Firstly, the rotating speed of a power measuring machine is set to be 0 by a rotating speed calibration outer loop, the torque of a driving motor is set by a torque calibration inner loop in sequence from 0Nm according to the step length until the maximum torque is set, and the inner loop is tested for one time;
then the outer rotation speed calibration cycle gives the next calibration rotation speed of the dynamometer according to the step length, the inner rotation torque calibration cycle gives the torque of the driving motor again, and the calibration process is completed until the outer rotation speed calibration cycle measures the maximum calibration rotation speed;
(7) The method comprises the steps of reading measurement data of a power analyzer, a torque flange, a motor controller and a water cooling system through a rack monitoring system, calculating efficiency values of a driving motor, the motor controller and the motor system under different working conditions, uniformly drawing data of all different test points in a computer, and further respectively obtaining efficiency MAP diagrams of the driving motor, the motor controller and the motor system;
(8) And (3) obtaining MAP diagrams of driving motor and controller efficiency under different test conditions according to the methods of the steps (4) - (7).
Further, if the actual output torque does not reach the target torque under a certain rotation speed condition, the dq-axis current and torque magnitude correspondence table in the motor controller needs to be readjusted.
The invention has the beneficial effects that:
the driving motor and controller calibration system integrates an alternating current dynamometer, a dynamometer control cabinet, a rack monitoring system, a power analyzer, a water cooling circulation system, a battery simulator and the like, and uniformly transmits different test data to monitoring system software through different communication modes such as CAN, TCP/IP, IEEE1394 and the like, and has the characteristics of feasible scheme, convenient use and complete functions; according to the calibration method, through system integration, complex processes of respectively storing and manually processing the data of different test equipment are avoided, and the test data are processed through unified monitoring system software, so that the consistency of test data time is ensured, the complex data processing process is reduced, the method has the characteristics of optimizing the test flow and shortening the calibration period, and the comprehensive utilization rate of the calibration test bench is improved. The method is widely applied to the technical and research and development fields of manufacturing, matching and optimizing of the driving motor and the controller of the electric automobile, and has great popularization value.
Drawings
Fig. 1 is a schematic structural diagram of a calibration system for a driving motor and a controller for an electric vehicle according to the present invention.
The specific embodiment is as follows:
the invention is described in detail below with reference to the attached drawing figures:
the invention discloses a calibration system of a driving motor and a controller for an electric automobile, as shown in fig. 1, comprising: the power meter comprises a calibrated driving motor, a motor controller, an alternating current dynamometer, a battery simulator, a rack monitoring system, a water cooling circulation system, a power analyzer, a dynamometer control cabinet, a storage battery, a precharge circuit, a motor base, a dynamometer base, an adapter, a transmission shaft, a protective cover, a torque flange and the like.
The rack monitoring system comprises monitoring system software, a communication interface, input display equipment and the like, wherein the input display equipment comprises a display, an operation control panel, an emergency stop control switch, operation equipment such as a keyboard, a mouse and the like; the rack monitoring system is respectively connected with the motor controller, the alternating current dynamometer, the battery simulator and the water cooling circulation system; the rack monitoring system sends out control and receives feedback signals, and the whole process monitoring of the rack is realized.
The alternating current dynamometer is connected with a dynamometer control cabinet, and the dynamometer control cabinet receives a control signal of the rack monitoring system and controls the rotating speed and the torque output by the dynamometer; the alternating current dynamometer is coaxially connected with the calibrated driving motor through a torque flange, a transmission shaft and an adapter, the torque flange is used for measuring the torque and the rotating speed of the driving motor, and a measuring signal is transmitted to the power analyzer.
The driving motor is connected with the motor controller through a power line, and the motor controller is connected with the battery simulator through a direct current bus; the motor controller is connected with the rack monitoring system, and parameters such as input and output voltage, input and output current, motor rotation speed and steering, motor torque, motor and controller temperature of the motor controller are transmitted to the rack monitoring system through CAN communication.
The battery simulator can simulate the external characteristic output of the voltage and the current of the actual battery according to the load condition of the motor by loading a battery model.
The power analyzer is connected with a direct current bus, a three-phase power line and a three-phase current sensor of the motor controller; the power analyzer transmits the collected signals such as motor voltage, current and the like to the rack monitoring system through TCP/IP communication.
The water cooling circulation machine is connected with the driving motor and the motor controller through cooling pipelines to realize water cooling circulation; the water cooling circulation machine transmits parameters such as liquid outlet temperature, liquid return temperature, refrigeration temperature, liquid outlet pressure, liquid return pressure, liquid outlet flow and the like of the cooling liquid to the rack monitoring system through CAN communication.
The driving motor and the alternating current dynamometer are respectively fixed on the motor base and the dynamometer base, and the motor base and the dynamometer base are fixed on a specific supporting platform. A metal protective cover is arranged between the alternating current dynamometer and the driving motor.
The motor controller is provided with a pre-charging circuit to prevent large-current starting impact, and meanwhile, a power supply of the motor controller is connected with a storage battery in parallel to supply power to prevent the controller from being powered down accidentally.
On the other hand, the invention discloses a method for calibrating a driving motor and a controller for an electric automobile, which mainly comprises various safety checks before calibration, such as whether each power supply of a rack is normal, whether a motor protective cover is firm and the like; after the rack monitoring system is started, loading a system configuration file, and observing whether warning or error information exists; starting a motor water cooling circulation system, and setting the temperature of cooling liquid required by calibration; starting and setting basic parameters and safety protection limit values of a battery simulator, an alternating current dynamometer and a calibrated driving motor; starting the system to run, starting a calibration test, observing the running condition of the whole rack system through a rack monitoring system, and performing the preservation operation of parameters required by the calibration of the driving motor and the controller; after the calibration task is finished, the test data are saved and read, the system equipment is closed in sequence, the test data are sorted, and a calibration report is written.
The calibration method mainly comprises motor efficiency calibration, controller efficiency calibration and system efficiency calibration. The calibration is to obtain an efficiency MAP (also called contour MAP, cloud MAP) of the motor and the controller through a motor rack test, and a data graph reflecting the efficiency distribution condition of the motor or the controller or the whole system under different rotating speeds and torques. The specific calibration method is as follows:
(1) Before calibration, basic design parameters or ranges of the calibrated motor, such as motor type, motor phase number, bus voltage, rated power, rated rotation speed, peak power, peak torque, peak rotation speed and the like, need to be obtained,
(2) The initialization of the system is completed, the temperature of cooling liquid required by calibration is set, and basic parameters and safety protection limit values of a battery simulator, an alternating current dynamometer and a calibrated driving motor are set;
(3) Defining the efficiency of the drive motor in the electric mode and the generating mode, respectively, includes: drive motor efficiency, motor controller efficiency and motor system overall efficiency, for example, defined in electric mode, drive motor, controller (inverter) and system overall efficiency are ETA1, ETA2 and ETA3 respectively, then there are:
ETA1＝Pm/ΣPA、ETA2＝ΣPA/Pdc、ETA3＝Pm/Pdc(1)
wherein Pm is the motor output mechanical power, ΣPA is the motor three-phase alternating current input electric power, pdc is the motor controller direct current bus input electric power;
correspondingly, in the power generation mode, the total efficiency of the motor, the controller and the motor system corresponds to ETA4, ETA5 and ETA6 respectively, and then:
ETA4＝ΣPA/Pm、ETA5＝Pdc/ΣPA、ETA6＝Pdc/Pm(2)
in the calibration process, the efficiency values of the motor, the controller and the motor system under different working conditions can be calibrated through the test of the power measuring machine on the output power of the motor and the parameter measurement of the input and output current and voltage of the motor and the controller by the power analyzer.
(4) According to the requirements of the rotating speed and torque range, the calibration precision, the test time limit and the like of the driving motor required to be calibrated, a given step length of the rotating speed and the torque during the calibration is reasonably designed, the accuracy of the calibration is affected by the overlarge step length, and the overlong test time is caused by the overlarge step length. For example, assuming that the given steps of rotational speed and torque at calibration are 100r/min and 20Nm, respectively, during testing the rotational speed will be given as 0, 100r/min, 200r/min, 300r/min … or 0, -100r/min, -200r/min, -300r/min … and the torque will be given as 0, 20Nm, 40Nm, 60Nm … or 0, -20Nm, -40Nm, -60Nm … but neither will exceed the maximum rotational speed and maximum torque of the motor design.
(5) The calibration test process comprises the following steps: firstly, setting parameters such as the temperature of cooling liquid of a water cooling system, the flow rate of discharged liquid and the like required by calibration; because the dynamometer is mechanically connected with the driving motor by adopting the coupler, the centering condition of the motor shaft has great influence on the test result, a certain rotating speed of the dynamometer can be given under the condition of no-load of the motor at first, such as 500r/min, 1000r/min and the like, the running condition of the motor and the torque of the rack are observed, and if the sound of the rack is abnormal or the torque of the rack is overlarge, the motor is not good in installation or centering and needs to be readjusted; the rotating speed of the alternating current dynamometer is given according to the step length of the calibrated rotating speed (marked as rotating speed calibration outer circulation), meanwhile, the torque of the driving motor is given according to the step length of the torque (marked as torque calibration inner circulation), firstly, the rotating speed of the alternating current dynamometer is given by the rotating speed calibration outer circulation, the rotating speed of the dynamometer is 0, the torque of the driving motor is given by the torque calibration inner circulation in sequence from 0Nm according to the step length until the maximum torque is given, and the inner circulation is tested for one time; and then the rotation speed calibration outer circulation gives the next calibration rotation speed of the dynamometer according to the step length, the torque calibration inner circulation gives the torque of the driving motor again, and the calibration process is completed until the rotation speed calibration outer circulation measures the maximum calibration rotation speed.
In the calibration process, the motor power limit value is to be noted, and the rotation speed calibration outer loop and the torque calibration inner loop are not both capable of being given to the maximum calibration value. In the test process, measuring data of a power analyzer, a torque flange, a motor controller and a water cooling system are read through a rack monitoring system, the rotating speed and torque of a driving motor at the moment and parameters such as direct current bus voltage at the input end of the controller, direct current bus current, three-phase current at the output end, three-phase voltage, motor temperature, controller temperature, liquid outlet temperature of the water cooling system, liquid return temperature, refrigeration temperature, liquid outlet pressure, liquid return pressure, liquid outlet flow and the like are recorded, efficiency values of the driving motor, the motor controller and the motor system under different working conditions are calculated, data of all different test points are plotted in a computer in a unified mode, and further efficiency MAP diagrams of the driving motor, the controller and the system are obtained respectively;
(5) According to the test method (4), the efficiency MAP of the driving motor and the controller under different test conditions can be obtained, such as the efficiency MAP under the conditions that the power supply voltage is lower than the rated bus voltage (under-voltage of the power battery), and different water cooling temperatures.
While the foregoing description of the embodiments of the present invention has been presented in conjunction with the drawings, it should be understood that it is not intended to limit the scope of the invention, but rather, it is intended to cover all modifications or variations within the scope of the invention as defined by the claims of the present invention.
Claims (6)
1. The calibration method of the calibration system of the driving motor and the controller for the electric automobile is characterized by comprising the following steps of: the system comprises an alternating current dynamometer, a dynamometer control cabinet, a rack monitoring system, a power analyzer, a water cooling circulation system and a battery simulator;
the alternating current dynamometer is coaxially connected with a calibrated driving motor, the driving motor is connected with a calibrated motor controller through a power line, and the motor controller is connected with a battery simulator through a direct current bus; the water cooling circulation system is respectively connected with the driving motor and the motor controller through cooling pipelines, and the power analyzer is connected with the motor controller;
the alternating current dynamometer is coaxially connected with the calibrated driving motor through a torque flange, a transmission shaft and an adapter which are sequentially connected, the torque flange is used for measuring the torque and the rotating speed of the calibrated driving motor, and a measuring signal is transmitted to the power analyzer;
uploading the input and output voltage, input and output current, motor rotation speed and steering, motor torque, motor and controller temperature parameters of the calibrated motor controller to a rack monitoring system through CAN communication;
the rack monitoring system is respectively connected with the power analyzer, the water cooling circulating system, the dynamometer control cabinet and the battery simulator; the rack monitoring system receives motor voltage and current signals acquired by the power analyzer and liquid outlet temperature, liquid return temperature, refrigeration temperature, liquid outlet pressure, liquid return pressure and liquid outlet flow parameters of cooling liquid acquired by the water cooling circulation system, and sends a control instruction to the dynamometer control cabinet according to the received parameter information to control the output rotating speed and torque of the alternating current dynamometer, and meanwhile monitors the operation of the whole rack system;
the calibration process specifically comprises the following steps:
(1) Initializing a system, setting the temperature of cooling liquid and the flow parameters of liquid discharged from a water cooling system required by calibration, and setting basic parameters and safety protection limit values of a battery simulator, an alternating current dynamometer and a calibrated driving motor;
(2) Defining the efficiency of the drive motor in the electric mode and the generating mode, respectively, includes: driving motor efficiency, motor controller efficiency and motor system overall efficiency;
(3) According to the rotating speed and torque range, the calibrating precision and the testing time limit requirement of the driving motor required to be calibrated, designing a given step length of the rotating speed and the torque during the calibration;
(4) Under the condition of no load of the motor, a certain rotating speed of the alternating current dynamometer is set, the running condition of the motor and the torque of the rack are observed, and if the sound of the rack is abnormal or the torque is overlarge, the motor is not well installed or centered and needs to be readjusted;
(5) The rotating speed of the alternating current dynamometer is given according to a given step length of the rotating speed and is recorded as rotating speed calibration external circulation; setting the torque of a driving motor according to the calibration step length of the torque, and marking the torque as torque calibration internal circulation;
(6) Firstly, the rotating speed of a power measuring machine is set to be 0 by a rotating speed calibration outer loop, the torque of a driving motor is set by a torque calibration inner loop in sequence from 0Nm according to the step length until the maximum torque is set, and the inner loop is tested for one time;
then the outer rotation speed calibration cycle gives the next calibration rotation speed of the dynamometer according to the step length, the inner rotation torque calibration cycle gives the torque of the driving motor again, and the calibration process is completed until the outer rotation speed calibration cycle measures the maximum calibration rotation speed;
(7) The method comprises the steps of reading measurement data of a power analyzer, a torque flange, a motor controller and a water cooling system through a rack monitoring system, calculating efficiency values of a driving motor, the motor controller and the motor system under different working conditions, uniformly drawing data of all different test points in a computer, and further respectively obtaining efficiency MAP diagrams of the driving motor, the motor controller and the motor system;
(8) And (3) obtaining MAP diagrams of driving motor and controller efficiency under different test conditions according to the methods of the steps (4) - (7).
2. The method for calibrating a driving motor and controller calibration system for an electric vehicle according to claim 1, wherein the dynamometer control cabinet receives a control signal of a rack monitoring system and controls the rotation speed and torque of the ac dynamometer.
3. The calibration method of the calibration system of the driving motor and the controller for the electric automobile according to claim 1, wherein the battery simulator simulates the external characteristic output of the voltage and the current of the actual battery according to the load condition of the motor by loading a battery model.
4. The method for calibrating a driving motor and controller calibration system for an electric vehicle according to claim 1, wherein the calibrated motor controller has a precharge circuit, and a power supply of the motor controller is connected in parallel with a battery.
5. The method for calibrating a calibration system of a driving motor and a controller for an electric vehicle according to claim 1, wherein the driving motor and the ac dynamometer are respectively fixed on a motor base and a dynamometer base, and the motor base and the dynamometer base are fixed on a specific supporting platform; a metal protective cover is arranged between the alternating current dynamometer and the driving motor.
6. The method for calibrating a driving motor and controller calibration system for an electric vehicle according to claim 1, wherein if the actual output torque does not reach the target torque under a certain rotation speed condition, the dq-axis current and torque corresponding relation table in the motor controller is required to be readjusted.
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| CN106502124A (en) * | 2016-10-26 | 2017-03-15 | 中国北方车辆研究所 | Power stage rapid control prototyping platform for motor control algorithms exploitation |
| CN106970279A (en) * | 2017-03-29 | 2017-07-21 | 福州大学 | The pure electric automobile pilot system and its test method of a variety of driving cycles can be achieved |
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