CN109238608B - Road simulation test method for power battery pack - Google Patents
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Abstract
The invention discloses a road simulation test method of a power battery pack, which is characterized in that during test, the power battery pack to be tested is fixed on a six-degree-of-freedom platform, and the six-degree-of-freedom platform is utilized to simulate road vibration so as to test the performance of the power battery pack. The invention has the advantages of simulating road jolt, dynamically testing the power battery pack, being beneficial to improving the accuracy of the test result and the like.
Description
Technical Field
The invention relates to the technical field of automobile simulation tests, in particular to a road simulation test method for a power battery pack.
Background
Along with the rapid increase of the number of automobiles, the problem of environmental pollution is more and more severe, in order to improve the increasingly severe environmental pollution, electric automobiles are in operation, the automobiles are driven to operate by the battery pack, and the battery pack is large in size because enough electric power needs to be provided for driving the automobiles to operate, so that performance and service life tests need to be carried out before the power batteries are put into use to ensure the performance and safety of the battery pack.
At present, the test of the power battery is mainly static test, namely the power battery is fixedly placed in the test process, and the test is carried out by only simulating the load of the whole vehicle by using a test system. However, when the power battery pack is actually driven on a road, the power battery pack is vibrated due to the bumpy road surface, and various performances of the power battery pack are affected. Therefore, a test method capable of simulating road jolt and facilitating dynamic test of the power battery pack is urgently needed.
Disclosure of Invention
Aiming at the defects of the prior art, the technical problems to be solved by the invention are as follows: how to provide a road simulation test method for a power battery pack, which can simulate road jolt, can dynamically test the power battery pack and is beneficial to improving the accuracy of a test result.
In order to solve the technical problems, the invention adopts the following technical scheme:
a road simulation test method for a power battery pack is characterized in that during test, the power battery pack to be tested is fixed on a six-degree-of-freedom platform, road vibration is simulated by the six-degree-of-freedom platform, and performance test is carried out on the power battery pack.
Furthermore, before the test, firstly obtaining vibration data of the power battery pack under the working condition of the real vehicle road, mounting the power battery pack with the same model on the real vehicle, arranging at least three-way acceleration sensors on the power battery pack, and obtaining and calculating displacement and corner data of the power battery pack under the working condition of the real vehicle road in real time; during testing, the displacement and the corner data of the power battery pack under the actual vehicle road working condition are used as control parameters to be input into a control system of the six-degree-of-freedom platform, the six-degree-of-freedom platform is controlled to change the pose, and the actual vehicle road working condition of the power battery pack is simulated.
Further, the six-degree-of-freedom platform is a serial six-degree-of-freedom platform and comprises a static platform and a movable platform, and three groups of vertical driving mechanisms and three groups of horizontal driving mechanisms are connected between the movable platform and the static platform; the vertical driving mechanism is an actuator which is vertically arranged, two ends of the actuator are respectively hinged to the movable platform and the static platform, and the vertical driving mechanism is respectively a first actuator A1B1, a second actuator A2B2 and a third actuator A3B 3; each group of transverse driving mechanisms comprises an actuator vertically hinged on the static platform, a connecting rod transversely hinged on the movable platform, and a triangular rotating block hinged between the actuator and the connecting rod, and the three groups of transverse driving mechanisms are respectively corresponding toA third actuator B4E4, a first link A4D1 and a first rotating block C1D1E1, a fifth actuator B5E5, a second link A5D2 and a second rotating block C2D2E2, a sixth actuator B6E6, a second link A6D3 and a second rotating block C3D3E 3; wherein A1-A6 are hinge points on the movable platform; B1-B6 are hinge points on the static platform; C1-C3, D1-D3 and E1-E3 are hinge points on the rotating block; the displacement of the power battery pack in X, Y, Z three directions under the actual road working condition is a1，a2，a3(ii) a The rotating angles of the power battery pack around the Z axis, the Y axis and the X axis are respectively a under the working condition of a real vehicle road4，a5，a6(ii) a During specific control, the elongation of the actuator of the six-degree-of-freedom platform is as follows:
Δl1＝l1-l0
Δl2＝l2-l0
Δl3＝l3-l0
Δl4＝l4-l0
Δl5＝l5-l0
Δl6＝l6-l0
in the formula I0Is the original length of the actuator; l1～l6The lengths of the first actuator to the sixth actuator after the actuators are extended are respectively set;
wherein l1～l3Calculated using the following formula:
wherein i is 1 to 3, Hix、Hiy、HizCoordinates of a hinge point on the movable platform in the x direction, the y direction and the z direction in the static coordinate system are respectively; b isix、 Biy、BizCoordinates of a hinge point on the static platform in the three directions of x, y and z in the static coordinate system are respectively; o isx、Oy、OzX, y and z squares of the origin on the movable platform in the static coordinate systemAn upward coordinate;
l4～l6calculated using the following formula:
wherein E1, E2, E3; b4, B5 and B6 are vectors formed by coordinates of each hinge point in the x direction, the y direction and the z direction in a static coordinate system respectively, T is a transformation matrix, and specifically comprises the following steps:
wherein sna is sina and csa is cosa.
In conclusion, the dynamic test device has the advantages that the road bump can be simulated, the dynamic test can be performed on the power battery pack, the accuracy of the test result can be improved, and the like.
Drawings
FIG. 1 is a schematic view of a measuring point arrangement position.
FIG. 2 is a schematic diagram of an integral model.
Fig. 3 to 5 are views for solving the rotation angle in the XYZ direction.
Fig. 6 is a mechanical schematic diagram of a tandem six-degree-of-freedom platform.
Fig. 7 to 9 are schematic diagrams of rotational transformations.
Fig. 10 is a schematic view of the rotation of the rotary block.
FIG. 11 is a structural diagram of three-dimensional modeling of a tandem type six-degree-of-freedom platform.
FIG. 12 is a simulation model of a tandem six-DOF platform position inverse solution.
FIG. 13 is a three-dimensional model of a six-DOF platform and battery pack.
Fig. 14 is a graph showing changes in the amount of expansion and contraction of the actuator.
Detailed Description
The present invention will be described in further detail with reference to examples.
1. Battery pack road spectrum collection
In order to obtain a loading spectrum of an indoor road simulation test, it is necessary to acquire an actual road or test field road spectrum.
1.1 determination of the positions of the acquisition points
The arrangement position requirements of the current acquisition measuring points are as follows: 1) the real vibration condition of the tested piece can be comprehensively reflected, and 2) the determined pose of the test bed under vibration can be conveniently obtained. The embodiment selects acceleration as a measurement quantity and synchronously acquires signals. As shown in FIG. 1, the acceleration measurements are as follows:
table 1 table for collecting measuring point information
| Measuring point | Arrangement position | Measured quantity |
| M1 | Under the |
Three-directional acceleration |
| M2 | Under the lifting lug 3 | Three-directional acceleration |
| M3 | Under the lifting lug 5 | Three-directional acceleration |
| M4 | Under the lifting lug 7 | Three-directional acceleration |
| M5 | Center of mass of battery pack | Three-directional acceleration |
1.2 road Spectrum Collection and preprocessing
The method comprises the following steps of finishing the arrangement of acceleration sensors according to selected measuring points, then finishing the acquisition of a road spectrum by using an eDAQ data acquisition system of the American HBM company, and finally preprocessing the road spectrum, wherein the processing process mainly comprises 3 parts: 1) filtering, 2) eliminating singular values, and 3) removing invalid signals.
2. Battery pack vibration pose solution
2.1 Displacement solution in x, y, z directions
In order to accurately obtain the displacement in the x, y and z directions when the battery pack vibrates as much as possible, the displacement of the measuring points M1-M4 is selected and averaged. Now, knowing the three-directional acceleration of each measuring point, the displacement in three directions of each measuring point can be obtained by twice integration through the ncode software integration module, and the integration model is shown in fig. 2. Finally, the average value is taken to obtain the displacement values a of the battery pack in the x, y and z directions when the battery pack vibrates1，a2，a3。
2.2 corner solution in x, y, z directions
The displacement of each measuring point M1-M5 relative to the centroid of the battery pack is L1～L5The displacement of each measuring point after the acceleration in the direction of X, Y, Z is subjected to twice integral conversion is X1～X5，Y1～Y5And Z1～Z5The measuring point 1 and the measuring point 3 are respectively wound around the rotation angle on the x axisIs a41、a43The rotation angles of the measuring point 2 and the measuring point 4 around the y axis are respectively a52、a54The rotation angles of the measuring points 1-5 around the z axis are respectively a61～a65. From FIGS. 3 to 5, it can be seen that:
so that the battery pack can rotate in three directions when vibrating
3. Serial six-freedom platform structure and principle
The tandem six-freedom platform is a mechanism with six-freedom motion capability. As shown in fig. 6, the main components are: 1) the movable platform is used for bearing a tested piece; 2) the hydraulic actuators are respectively A1B1, A2B2, A3B3, E1B4, E2B5 and E3B6, and are used for realizing driving; 3) 3 rotating blocks, namely C1D1E1, C2D2E2 and C3D3E3 in the figure are respectively used for realizing motion reversing; 4) the number of the connecting rods is 3, namely D1A4, D2A5 and D3A6 in the figure, and the connecting rods are used for connecting the movable platform and the rotating block; 5) the hinge comprises 6 spherical hinges and 6 Hooke hinges; a in the figure1～A6Is a spherical hinge, B1～B3And D1～D3The hook joint is used for fixedly connecting two components; 6) a static platform and a base of the mechanism. The tandem type six-degree-of-freedom platform realizes the movements of sideslip, longitudinal movement, lifting, yawing, rolling and yawing with 6 degrees of freedom and the combined movement thereof through the extension and retraction of 6 hydraulic actuators.
4. Inverse solution algorithm of platform kinematics
The central positions of the three actuators in the vertical direction are taken as static coordinate origins, and the static coordinate origins move to the upper surface of the movable platform along the Z-axis direction to be taken as movable coordinate origins to respectively establish a static coordinate system and a movable coordinate system, as shown in FIG. 6.
The kinematics solution of the serial six-degree-of-freedom platform has a positive solution and a reverse solution, and the known method for solving the elongation of the actuator by the pose of the moving platform in the space is the kinematics reverse solution. The moving platform pose in the static coordinate is represented by coordinates a (a1, a2, a3, a4, a5 and a6), the moving platform position in the static coordinate is represented by a1, a2 and a3, the moving platform position in the static coordinate system is represented by a4, a5 and a6, and the moving platform pose at any point is considered to be translated by x, y and z and then rotated by z, y and x.
The specific conversion sequence is as follows:
first translation a1 is translated along the x-axis,
a second translation of a2 along the y-axis,
a third translation of a3 along the z-axis,
a fourth rotation a4 along the z-axis,
a fifth rotation of a5 along the y-axis,
sixth rotation a6 is rotated along the x-axis.
Namely, the pose of the movable platform at any moment can be obtained through the 6 times of transformation.
And (3) solving a transformation matrix:
first translation along the x-axis1(ii) a Second translation a along the y-axis2(ii) a Third translation along z-axis a3；
Fourth rotation a along z-axis4；
As shown in fig. 7, x ═ OMcos α and y ═ OMsin α
After rotation:
x1＝OM＇cos(α+a4)，y1＝OM＇sin(α+a4)
in the formula: OM is the distance from the projection of a certain point in space to the origin of coordinates in the XY plane, alpha is the included angle between OM and the x axis, and OM' is the rotation a of the point4Later on the projection in the XY plane to the origin of coordinates.
The transformation matrix is therefore:
fifth rotation of a about the y-axis5
As shown in fig. 8, x ═ ONcos β and z ═ ONsin β
After rotation:
x1＝ON＇cos(β-a5)，z1＝ON＇sin(β-a5)
in the formula: ON is the distance from the projection of a certain point in the space in the XZ plane to the origin of coordinates, beta is the included angle between ON and the x axis, and ON' is the rotation a of the point5Later on the distance of the projection in the XZ plane to the origin of coordinates.
The transformation matrix is therefore:
sixth rotation a about the x-axis6
As shown in fig. 9, y ═ OPcos γ, z ═ OPsin γ
After rotation:
y1＝OP＇cos(γ+a6)，z1＝OP＇sin(γ+a6)
in the formula: OP is the distance between the projection of a certain point in space in YZ plane and the origin of coordinates, gamma is the included angle between OP and y axis, and OP' is the rotation a of the point6Later the projection in the YZ plane to the origin of coordinates.
The transformation matrix is therefore:
from this, the transformation matrix from static coordinates to dynamic coordinates can be:
T＝T1×T2×T3×T4×T5×T6
i.e. the transformation matrix T is:
wherein sna ═ sina, csa ═ cosa;
setting the homogeneous coordinate of the hinged point on the movable platform in the movable coordinate system as Ai＝(Aix，Aiy，Aiz，1)TThe homogeneous coordinate in the static coordinate system after coordinate conversion is Hi＝TAi＝(Hix，Hiy，Hiz，1)TThe homogeneous coordinate of the hinge point on the static platform in the static coordinate system is Bi＝(Bix， Biy，Biz，1)TThe homogeneous coordinate of the origin of the dynamic coordinate in the static coordinate system is Oi＝(Ox，Oy，Oz，1)T。
The length vector of actuator number 1,2, and 3 can be expressed in the static coordinate system as:
Li＝TAi+O-Bi
therefore, the rod length equation of the actuator 1,2, and 3 is:
therefore, the elongation of actuator No. 1,2,3 is:
Δli＝li-l0
wherein i is 1,2,3, liThe length of the actuator after the position change; l0The original rod length of the actuator.
For the inverse solution of the positions of the actuators No. 4,5 and 6, the actuator No. 4 is selected as a research object, the xz plane is taken as a reference plane, and the rotation point C is assumed1Has the coordinate of C1＝(C1x，C1y，C1z1) the position corresponding to the Hooke's hinge point is D1＝(D1x，D1y，D1z，1)。
As can be seen from FIG. 10, D1The motion locus of the point is C1Long arm with point as centre of circle and rotating block
Is the locus of the radius.
And (3) knowing the constraint position relation:
when the movable platform is changed in posture, the spatial position of the connecting rod is changed, but the mode is not changed, namely the length L of the connecting rodg1And is not changed. Therefore, the method comprises the following steps:
(TA4 T-D1)T(TA4 T-D1)＝Lg1 2
the rotation angle beta can be obtained, and the hinge point E on the No. 4 actuator is calculated through the rotation angle1The coordinates of (a):
therefore, the length of actuator No. 4 can be obtained:
this gives a number 4 actuator elongation of:
Δl4＝l4-l0
the length of 5,6 # actuator can be obtained by the same method:
further obtains that the elongation of No. 5 and No. 6 actuators is:
Δl5＝l5-l0
Δl6＝l6-l0
5. platform kinematics inverse solution simulation analysis and verification
5.1 tandem type six-degree-of-freedom platform three-dimensional modeling
The CATIA is utilized to carry out three-dimensional modeling on the platform, and the modeling process mainly comprises 3 steps: (1) firstly, determining the sizes of a movable platform and a static platform and the arrangement positions of hinge points according to the size of a tested piece and the excitation condition; (2) drawing a sketch, stretching, cutting and punching to establish a three-dimensional model of each component of the platform; (3) the assembly is completed in the product module according to the constraint relation among the components, and the model is shown in FIG. 11.
5.2 inverse kinematics solution Simulick modeling
As shown in fig. 12, a serial six-degree-of-freedom platform position inverse solution simulation model is established in a Matlab simulk module, and the simulation model includes 3 modules: (1) the input module is used for giving the pose of the movable platform; (2) the function module is used for realizing mathematical operation in the reverse solution process in a program compiling mode; (3) and the output module outputs the elongation of the actuator.
5.3 position derolution of ADAMS kinematics
As shown in fig. 13 and 14, a six-degree-of-freedom platform three-dimensional model established by CATIA and a battery pack model are introduced into ADAMS, kinematic pair constraints are added, then a model checking tool box is clicked, the system checks whether the added kinematic pair is in agreement with a theory or not according to the number of components, the type of the kinematic pair and the type of driving, the result is displayed on an information window, finally, 6 actuators are given to a Motion module for displacement driving, and the pose change of the mobile platform is monitored through a measurement function; conversely, the extension amount of the actuator can be monitored by giving a platform posture.
5.4 comparison of simulation results
In order to verify the feasibility of the ADAMS position inverse solution simulation, poses in 6 directions are given in the Matlab Simulick model, the elongation of 6 actuators is obtained through simulation, then the same pose drive is applied to the ADAMS simulation model to conduct kinematic simulation, meanwhile, the stretching amount of each actuator is monitored, and the correctness of an inverse solution algorithm is verified through comparison and analysis with Matlab simulation results. The simulation results are shown in table 2 below.
TABLE 2 simulation results of actuator expansion amount
TABLE 3 platform pose simulation results
Through comparison, the maximum error between the ADAMS pose simulation result value and the Matlab input value is 2.7%, the error ratio is small, and the error ratio is within a reasonable error allowable range; the maximum error between the simulation result value of the actuator and the Matlab simulation result is 2.8%, the error is not more than 10%, and the error is also within the allowable range.
The above description is only exemplary of the present invention and should not be taken as limiting, and any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (1)
1. A road simulation test method of a power battery pack is characterized in that during test, the power battery pack to be tested is fixed on a six-degree-of-freedom platform, road vibration is simulated by the six-degree-of-freedom platform, and performance test is carried out on the power battery pack;
before testing, firstly obtaining vibration data of a power battery pack under the working condition of a real vehicle road, installing the power battery pack with the same model on the real vehicle, arranging at least three-way acceleration sensors on the power battery pack, and obtaining and calculating displacement and corner data of the power battery pack under the working condition of the real vehicle road in real time; during testing, the displacement and the corner data of the power battery pack under the actual vehicle road working condition are used as control parameters to be input into a control system of the six-degree-of-freedom platform, the six-degree-of-freedom platform is controlled to change the pose, and the actual vehicle road working condition of the power battery pack is simulated;
the six-degree-of-freedom platform is a serial six-degree-of-freedom platform and comprises a static platform and a movable platform, wherein a connection part is connected between the movable platform and the static platformThree groups of vertical driving mechanisms and three groups of horizontal driving mechanisms; the vertical driving mechanism is an actuator which is vertically arranged, two ends of the actuator are respectively hinged to the movable platform and the static platform, and the vertical driving mechanism is respectively a first actuator A1B1, a second actuator A2B2 and a third actuator A3B 3; each group of transverse driving mechanisms comprises an actuator vertically hinged on the static platform, a connecting rod transversely hinged on the dynamic platform and a triangular rotating block hinged between the actuator and the connecting rod, and the three groups of transverse driving mechanisms respectively correspond to a third actuator B4E4, a first connecting rod A4D1, a first rotating block C1D1E1, a fifth actuator B5E5, a second connecting rod A5D2, a second rotating block C2D2E2, a sixth actuator B6E6, a second connecting rod A6D3 and a second rotating block C3D3E 3; wherein A1-A6 are hinge points on the movable platform; B1-B6 are hinge points on the static platform; C1-C3, D1-D3 and E1-E3 are hinge points on the rotating block; the displacement of the power battery pack in X, Y, Z three directions under the actual road working condition is a1，a2，a3(ii) a The rotating angles of the power battery pack around the Z axis, the Y axis and the X axis are respectively a under the working condition of a real vehicle road4，a5，a6(ii) a During specific control, the elongation of the actuator of the six-degree-of-freedom platform is as follows:
Δl1＝l1-l0
Δl2＝l2-l0
Δl3＝l3-l0
Δl4＝l4-l0
Δl5＝l5-l0
Δl6＝l6-l0
in the formula I0Is the original length of the actuator; l1～l6The lengths of the first actuator to the sixth actuator after the actuators are extended are respectively set;
wherein l1～l3Calculated using the following formula:
wherein i is 1 to 3, Hix、Hiy、HizCoordinates of a hinge point on the movable platform in the x direction, the y direction and the z direction in the static coordinate system are respectively; b isix、Biy、BizCoordinates of a hinge point on the static platform in the three directions of x, y and z in the static coordinate system are respectively; o isx、Oy、OzCoordinates of an origin on the movable platform in the x direction, the y direction and the z direction in the static coordinate system are respectively;
l4～l6calculated using the following formula:
wherein E1, E2, E3; b4, B5 and B6 are vectors formed by coordinates of each hinge point in the x direction, the y direction and the z direction in a static coordinate system respectively, T is a transformation matrix, and specifically comprises the following steps:
wherein sna ═ sina, csa ═ cosa;
five acceleration measuring points are arranged on the power battery pack: m1, M2, M3, M4, M5; then, the displacement of the measuring points M1-M4 is selected and averaged to calculate the displacement a1，a2，a3；
The displacements of the measuring points M1-M5 relative to the centroid of the battery pack are respectively L1～L5Point M1The displacement amounts of the acceleration of M5 in the X, Y, Z direction after twice integral conversion are X1～X5，Y1～Y5And Z1～Z5The rotation angles of the measuring points M1 and M3 around the x axis are respectively a41、a43The rotation angles of the measuring points M2 and M4 around the y axis are respectively a52、a54The rotation angles of the measuring points M1-M5 around the z axis are a61～a65；
Wherein:
then according to
Calculating the rotating angles a of the power battery pack around the Z axis, the Y axis and the X axis under the working condition of the real vehicle road4，a5，a6。
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