CN112014014B - Composite test system and method - Google Patents

Abstract

The embodiment of the invention provides a composite test system, which is switched between a first state for testing a first tested device and a second state for testing a second tested device; in the first state, the dynamometer is connected with the first tested device through the first output shaft of the speed changing device, and the data acquisition system acquires data acquired by the first torque sensing assembly; in the second state, the dynamometer is connected with the second tested device through the second output shaft of the speed changing device, and the data acquisition system acquires data acquired by the second torque sensing assembly. The composite test system can test the compatibility of the electric drive axle and the drive motor, and saves the test cost. The embodiment of the invention also provides a composite test method.

Description

Composite test system and method

Technical Field

The invention relates to the field of testing, in particular to a composite testing system and method.

Background

In the development process of products for driving an electric drive axle and a driving motor for an electric automobile, the performance of the electric drive axle and the performance of the driving motor for the electric automobile need to be tested. However, the difference between the operating characteristics of the electric drive axle and the driving motor is very large, and therefore, in the testing process, two testing benches are usually required to be prepared to respectively test the electric drive axle and the driving motor, which results in higher testing cost and larger occupied testing area.

Disclosure of Invention

The embodiment of the invention mainly aims to provide a composite test system and method, which can be used for carrying out compatibility test on an electric drive axle and a drive motor and saving test cost.

The embodiment of the invention provides a composite test system, which comprises: the system comprises a dynamometer, a speed change device and a data acquisition system, wherein the speed change device is connected with the dynamometer and comprises a first output shaft and a second output shaft which are respectively connected with first tested equipment and second tested equipment; a first torque sensing assembly is arranged on the first output shaft, and a second torque sensing assembly is arranged on the second output shaft; the speed ratio of one of the first output shaft and the second output shaft is a speed increasing ratio, and the other one of the first output shaft and the second output shaft is a speed reducing ratio;

the composite test system switches between a first state for testing the first tested device and a second state for testing the second tested device;

in the first state, the dynamometer is connected with the first tested device through the first output shaft of the speed changing device, and the data acquisition system acquires data acquired by the first torque sensing assembly; in the second state, the dynamometer is connected with the second tested device through the second output shaft of the speed changing device, and the data acquisition system acquires data acquired by the second torque sensing assembly.

The speed changing device comprises a gearbox, the first output shaft of the gearbox is connected with the first device to be tested, and the second output shaft of the gearbox is connected with the second device to be tested.

The transmission device further comprises a speed reducer, the dynamometer comprises a first dynamometer and a second dynamometer, the first dynamometer and the second dynamometer are respectively located on two opposite sides of the second tested device, the first dynamometer is connected with the transmission case, the second dynamometer is connected with the second tested device through the speed reducer, and a third torque sensing assembly is arranged on a connecting shaft of the second dynamometer and the second tested device.

The system comprises a first dynamometer and a second dynamometer, and further comprises a dynamometer control device connected with the first dynamometer and the second dynamometer respectively, wherein the dynamometer control device is used for controlling and setting a working starting state and corresponding working parameters of the first dynamometer and/or the second dynamometer respectively.

The device comprises a first tested device and a second tested device, and is characterized by further comprising a motor control device, wherein the motor control device is connected with the first tested device or the second tested device, and is used for controlling and setting the working starting state and the corresponding working parameters of the first tested device or the second tested device.

Each motor control device is connected with the first tested device or the second tested device through three-phase alternating current, and the system further comprises two alternating current sensing assemblies respectively arranged on at least two phases of the three-phase alternating current.

The dynamometer comprises a motor control device and a dynamometer control device, and is characterized by further comprising a direct current power supply device connected with the motor control device and the dynamometer control device respectively, wherein a direct current sensing assembly is arranged at the connecting end of the direct current power supply device and the motor control device.

The motor control device comprises a motor control device, a motor control device and a whole vehicle control device, wherein the whole vehicle control device is connected with the motor control device and used for controlling task switching of the motor control device.

The first moving device moves relative to a first output shaft of the speed changing device along a specified direction in the first state so as to adjust the position of the first device under test in the specified direction; in the second state, the second moving device moves relative to the second output shaft of the speed changing device along the designated direction so as to adjust the position of the second tested device in the designated direction.

The embodiment of the invention provides a composite test method adopting the composite test system according to any one of the embodiments of the invention, which comprises the following steps:

determining data acquired by a first torque sensor component in a first state that a dynamometer tests first tested equipment;

determining data acquired by the second torque sensing assembly in a second state that the dynamometer tests the second tested equipment;

and analyzing the data collected by the first torque sensing assembly and/or the second torque sensing assembly, and displaying the corresponding analysis result.

In the embodiment of the present invention, the composite test system can switch between a first state of testing the first device under test and a second state of testing the second device under test; in the first state, the dynamometer is connected with the first tested device through the first output shaft of the speed changing device, and data collected by the first torque sensing assembly is acquired; in the second state, the dynamometer is connected with the second tested device through the second output shaft of the speed changing device, and data collected by the second torque sensing assembly is acquired. Therefore, compatibility test can be performed on the first tested equipment and the second tested equipment with different performances, the test cost is saved, and the occupied area of a test system is reduced.

Drawings

Fig. 1 is a schematic structural diagram of a composite test system according to an embodiment of the present invention;

FIG. 2 is a schematic structural diagram of a composite test system according to another embodiment of the present invention;

FIG. 3 is a block diagram of a composite test rig as used to test a first device under test according to one embodiment of the present invention;

FIG. 4 is a block diagram of a composite test bench for testing a second device under test according to an embodiment of the present invention.

Detailed Description

The technical scheme of the invention is further elaborated by combining the drawings and the specific embodiments in the specification. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

In the description of the embodiments of the present invention, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the devices or elements referred to must have specific orientations, be constructed and operated in specific orientations, and thus, are not to be construed as limiting the present invention. In the description of the present invention, "a plurality" means two or more unless otherwise specified.

In the description of the present application, it is to be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in this application will be understood to be a specific case for those of ordinary skill in the art.

As shown in fig. 1, a schematic structural diagram of a composite test system provided in an embodiment of the present invention is shown, where the composite test system includes: the system comprises a dynamometer 101, a speed change device 102 and a data acquisition system 107, wherein the speed change device 102 is connected with the dynamometer 101 and comprises a first output shaft and a second output shaft which are respectively connected with a first tested device 103 and a second tested device 104; a first torque sensing assembly 105 is arranged on the first output shaft, and a second torque sensing assembly 106 is arranged on the second output shaft; the speed ratio of one of the first output shaft and the second output shaft is a speed increasing ratio, and the other one of the first output shaft and the second output shaft is a speed reducing ratio; the composite test system switches between a first state for testing the first device under test 103 and a second state for testing the second device under test 104; in the first state, the dynamometer 101 is connected to the first device under test 103 via the first output shaft of the transmission 102, and the data acquisition system 107 acquires data acquired by the first torque sensing assembly 105; in the second state, the dynamometer 101 is connected to the second device under test 104 via the second output shaft of the transmission 102, and the data acquisition system 107 acquires data acquired by the second torque sensing assembly 106.

The dynamometer 101 is mainly used for testing the rotation speed, the torque, and the like of the first device under test 103 and the second device under test 104, and may be a hydraulic dynamometer, an eddy current dynamometer, an electric dynamometer, and the like. The speed changing device 102 is used for respectively matching the output rotating speed and the torque of the first tested device 103 and the dynamometer 101, and the output rotating speed and the torque of the second tested device 104 and the dynamometer 101. The first torque sensing component 105 may be a first torque sensor for detecting the actual rotational speed and the actual torque of the first device under test 103, and the second torque sensing component 106 may be a second torque sensor for detecting the actual rotational speed and the actual torque of the second device under test 104. The first torque sensor and the second torque sensor may have the same property, for example, both may be sensors compatible with two ranges, for example, the first torque sensor may include a first large torque sensor and a first small torque sensor, the first large torque sensor is used for measuring the rotating speed and the torque of the first device under test under high power, and the first small torque sensor is used for measuring the rotating speed and the torque of the first device under test under low power; similarly, the second torque sensor may include a second large torque sensor and a second small torque sensor, the second large torque sensor is used for measuring the rotating speed and the torque of the second device under test under high power, and the second small torque sensor is used for measuring the rotating speed and the torque of the second device under test under low power.

The switching of the composite test system between the first state of testing the first device under test 103 and the second state of testing the second device under test 104 may mean that a tester may control the composite test system to switch back and forth between the first state of testing the first device under test 103 and the second state of testing the second device under test 104 according to a test requirement.

Wherein, in the first state, the dynamometer 101 is connected to the first device under test 103 via the first output shaft of the transmission 102, and the data acquisition system 107 may acquire the data acquired by the first torque sensing assembly 105 by: in a first state that the first device under test 103 needs to be tested, the dynamometer 101 is connected to the first device under test 103 via the first output shaft of the speed changing device 102, and when the first device under test 103 is in a power generation mode, the dynamometer 101 is in a power-driven mode and is used for consuming energy transmitted by the first device under test 103; when the first device under test 103 is in motoring mode, the dynamometer 101 is in generating mode, transferring consumable energy to the first device under test 103. The data acquisition system 107 is connected to the first torque sensing component 105, and is configured to acquire an actual rotational speed and an actual torque of the first device under test 103 acquired by the first torque sensing component 105, where the data acquisition system 107 includes a power analyzer, and the power analyzer may analyze the actual rotational speed and the actual torque of the first device under test 103, store an analysis result, and send the analysis result to an upper computer connected to the data acquisition system 107 for display.

Wherein, in the second state, the dynamometer 101 is connected to the second device under test 104 via the second output shaft of the transmission 102, and the data collected by the data collecting system 107 through the second torque sensing assembly 106 may be: in a second state that the second device under test 104 needs to be tested, the dynamometer 101 is connected with the second device under test 104 via the second output shaft of the transmission 102, and when the second device under test 104 is in a power generation mode, the dynamometer 101 is in an electric mode for consuming energy transmitted by the second device under test 104; when the second device under test 104 is in motoring mode, the dynamometer 101 is in generating mode, transferring consumable energy to the second device under test 104. The data acquisition system 107 is further connected to the second torque sensing assembly 106, and is configured to acquire the actual rotation speed and the actual torque of the second device under test 104 acquired by the second torque sensing assembly 106, analyze the actual rotation speed and the actual torque of the second device under test 104 by the power analyzer, and store and send an analysis result to an upper computer for display.

It should be noted that the power analyzer in the data acquisition system 107 may analyze the actual rotational speed and the actual torque of the first device under test 103 acquired by the first torque sensing assembly 105 alone, or may analyze the actual rotational speed and the actual torque of the second device under test 104 acquired by the second torque sensing assembly 106 together. For example, after acquiring the actual rotational speed and the actual torque of the first device under test 103 acquired by the first torque sensing assembly 105, the data acquisition system 107 stores the actual rotational speed and the actual torque of the first device under test 103, and then after acquiring the actual rotational speed and the actual torque of the second device under test 104 acquired by the data 106 of the second torque sensing assembly, the power analyzer analyzes the stored actual rotational speed and the actual torque of the first device under test 103 and the actual rotational speed and the actual torque of the second device under test 104 together, and correspondingly stores and sends the analysis result to the upper computer for corresponding display.

In the composite test system provided in the embodiment of the present invention, the first state of testing the first device under test 103 and the second state of testing the second device under test 104 are switched; in the first state, the dynamometer 101 is connected with the first device under test 103 through the first output shaft of the transmission 102, and acquires data acquired by the first torque sensing assembly 105; in the second state, the dynamometer 101 is connected with the second device under test 104 through the second output shaft of the transmission 102, and acquires data acquired by the second torque sensing assembly 106, so that compatibility tests on the first device under test 103 and the second device under test 104 with different characteristics can be met in the same test system, the test cost is saved, and the occupied area of the test system is reduced.

In an alternative specific embodiment, the transmission 102 comprises a gearbox, the first output shaft of the gearbox is connected to the first device under test 103, and the second output shaft of the gearbox is connected to the second device under test 104.

Here, the first device under test 103 may be a driving motor, and the driving motor and the dynamometer 101 both have two operation modes, i.e. when the driving motor is in the power generation mode, the dynamometer 101 is in the power generation mode for consuming the energy transmitted by the driving motor; when the driving motor is in motoring mode, the dynamometer 101 is in generating mode, transmitting consumable energy to the first device under test 103. In the process of testing the reliability performance of the driving motor of the electric automobile by using the composite testing system, the testing of the driving motor is biased to high rotating speed and small torque testing, the rotating speed requirement is generally 9000 rpm-15000 rpm, and the torque requirement is generally 200 Nm-2000 Nm, so that the speed ratio of the first output shaft of the gearbox is set to be a speed increasing ratio for increasing the output rotating speed of the dynamometer 101, wherein the first output shaft of the gearbox can be provided with one or more speed increasing gears with different speed ratios. For example, the output rotation speed of the dynamometer 101 is 2000rpm, the output rotation speed of the driving motor is 10000rpm, then, the speed increasing ratio of the first output shaft of the gearbox is increased by 5 times, or the output rotation speed of the dynamometer 101 is 2000rpm, the output rotation speed of the other driving motor is 12000rpm, then, the speed increasing ratio of the first output shaft of the gearbox is increased by 6 times, so that the gearbox can match the output rotation speed of the driving motor with the output rotation speed of the dynamometer 101. Wherein, the driving motor can be a motor system of an electric automobile. Correspondingly, the second output shaft of the gearbox is a reduction ratio and is used for reducing the output rotating speed of the dynamometer 101, so that the output rotating speed of the second tested device 104 is matched with the output rotating speed of the dynamometer 101.

It should be noted that, if the test peak torque of the driving motor is Tmmax, the test peak rotational speed is nmmax, and the test peak power Pmmax, the test peak torque of the second device under test 104 is Tamax, the test peak rotational speed is namax, and the test peak power Pamax, the speed ratio of the first output shaft of the speed changing device 102 is i1 (speed increasing ratio), and the speed ratio of the second output shaft is i2 (speed reducing ratio), the rated torque Tcn, the peak rotational speed ncmax, and the rated power Pcn selected by the dynamometer 101 are:

Tcn＝max(Tmmax*i1，Tamax/i2)

ncmax＝max(nmmax/i1，namax*i2)

Pcn＝max(Pmmax，Pamax)

the rated rotation speed ncn of the dynamometer 101 is:

ncn＝9550*Pcn/Tcn

in the model selection process of the dynamometer 101, in order to avoid the weak magnetic magnification of the dynamometer 101 being too high, the relationship between the peak rotational speed and the rated rotational speed of the dynamometer 101 is generally required to be: ncmax is less than or equal to 3 × ncn. During testing using the dynamometer 101, the peak torque and the peak power of the first device under test 103 or the second device under test 104 are generally satisfied with the rated torque and the rated power. For two speed ratios of the gearbox, the value of i2/i1 is controlled within 20, otherwise the gearbox cannot be machined or the machining cost is too high.

According to the composite test system provided by the embodiment of the invention, the first output shaft of the gearbox is connected with the first tested equipment, and the speed ratio of the first output shaft of the gearbox is set as the speed increasing ratio, so that the composite test system can meet the test requirements of various drive motors with different requirements on relevant parameters such as rotating speed, torque and the like, and has wider applicability.

In another optional specific embodiment, the transmission 102 further includes a speed reducer, the dynamometer 101 includes a first dynamometer and a second dynamometer, the first dynamometer and the second dynamometer are respectively located at two opposite sides of the second device under test 104, wherein the first dynamometer is connected to the transmission, the second dynamometer is connected to the second device under test 104 through the speed reducer, and a third torque sensing assembly is disposed on a connecting shaft of the second dynamometer and the second device under test 104.

Here, the second device under test 104 may be an electric drive axle including a centralized electric drive axle, a wheel-rim electric drive axle, and a hub electric drive axle. Since the test of the electric drive axle is biased to the low-rotation-speed and high-torque test, the rotation speed requirement is about 1000rpm generally, and the torque requirement is 4000Nm to 20000Nm generally, the speed ratio of the second output shaft of the gearbox is set as a reduction ratio for reducing the output rotation speed of the dynamometer 101. In the process of testing the wheel-side electric drive axle or the hub-type electric drive axle by the dynamometer 101, because the wheel-side electric drive axle or the hub-type electric drive axle is a dual-motor electric drive axle, two dynamometers are required to respectively test dual motors of the wheel-side electric drive axle, so that the dynamometers comprise a first dynamometer and a second dynamometer, the first dynamometer and the second dynamometer are respectively positioned at two opposite sides of the wheel-side electric drive axle or the hub-type electric drive axle, wherein the first dynamometer is connected with the gearbox and is connected with the wheel-side electric drive axle or the hub-type electric drive axle through a second output shaft of the gearbox, the second dynamometer is connected with the wheel-side electric drive axle or the hub-type electric drive axle through the speed reducer, and thus, the output rotating speeds of the first dynamometer and the second dynamometer are reduced, the testing requirements of low rotating speed and large torque of the wheel-side electric drive axle or the hub-type electric drive axle are met. The first dynamometer and the second dynamometer have the same property, the property of the second output shaft of the gearbox is the same as the property of the speed reducer, and the second output shaft of the gearbox and the speed reducer can be provided with one or more speed reduction gears with different speed ratios. For example, the output rotation speeds of the first dynamometer and the second dynamometer are both 2000rpm, and the output rotation speeds of the double motors of the wheel-side electric drive bridge or the hub-type electric drive bridge are both 1000rpm, then the reduction ratio of the second output shaft of the gearbox is reduced by 2 times, and the reduction ratio of the output shaft of the speed reducer is reduced by 2 times; or the output rotating speeds of the first dynamometer and the second dynamometer are both 2000rpm, and the output rotating speeds of the wheel-side electric drive bridge or the hub-type electric drive bridge are 1000rpm and 800rpm respectively, so that the reduction ratio of the second output shaft of the gearbox is reduced by 2.5 times, and the reduction ratio of the output shaft of the speed reducer is reduced by 2 times; therefore, the gearbox and the speed reducer can enable the output rotating speed of the wheel-side electric drive axle or the hub-type electric drive axle to be matched with the output rotating speed of the first dynamometer and the output rotating speed of the second dynamometer respectively. The second torque sensing assembly 105 is configured to detect an actual rotational speed and an actual torque of a motor connected to a transmission in the wheel-side electric drive axle or the hub-side electric drive axle, and the third torque sensing assembly is configured to detect an actual rotational speed and an actual torque of another motor connected to a speed reducer in the wheel-side electric drive axle or the hub-side electric drive axle. The third torque sensor may have the same properties as the first torque sensor 105 and the second torque sensor 106. And meanwhile, the data acquisition system 107 in the composite test system is also connected with the third torque sensing assembly and used for acquiring the actual rotating speed and the actual torque of the other motor in the wheel-side electric drive bridge, which are acquired by the third torque sensing assembly, analyzing the actual rotating speed and the actual torque of the other motor in the wheel-side electric drive bridge through the power analyzer, and storing and sending the analysis result to the upper computer for displaying.

In the composite test system provided by the embodiment of the invention, the first dynamometer is respectively connected with the second tested equipment 104 through the second output shaft of the gearbox and the second dynamometer through the speed reducer, so that the double motors of the wheel-side electric drive axle or the hub-type electric drive axle can be respectively and independently tested, and the test requirements of the electric drive axle with various requirements on related parameters such as different rotating speeds, torques and the like can be met.

In another embodiment, the composite test system further comprises dynamometer control devices respectively connected with the first dynamometer and the second dynamometer, wherein the dynamometer control devices are used for respectively controlling and setting the working starting state and the corresponding working parameters of the first dynamometer and/or the second dynamometer.

The dynamometer control device may be a dynamometer controller, and the dynamometer controller may be connected to the dynamometer 101 and configured to control a start state of the dynamometer 101.

Here, the dynamometer controller may also be a dynamometer dual-motor controller for separately controlling the first dynamometer and the second dynamometer; or the dynamometer controller comprises a first dynamometer controller and a second dynamometer controller, and the first dynamometer controller and the second dynamometer controller are used for controlling the first dynamometer and the second dynamometer respectively. The dynamometer control device is used for respectively controlling and setting the working starting state and the corresponding working parameters of the first dynamometer and/or the second dynamometer, and the working starting state and the corresponding working parameters may be as follows: when the first dynamometer is only needed to be started for testing, the first dynamometer controller controls and sets a working starting state of the first dynamometer and corresponding working parameters in the working starting state; when the second dynamometer is only needed to be started for testing, the second dynamometer controller controls and sets a working starting state of the second dynamometer and corresponding working parameters in the working starting state; when the first dynamometer and the second dynamometer are required to be started simultaneously for testing, the first dynamometer controller controls and sets the work starting state of the first dynamometer and the corresponding working parameters in the work starting state, and the second dynamometer controller controls and sets the work starting state of the second dynamometer and the corresponding working parameters in the work starting state. The work starting state comprises a working state of switching from a closing state to a starting state, maintaining forward rotation or reverse rotation, switching from the starting state to the closing state and the like. The working parameters comprise parameters such as the rotating speed and the torque of the dynamometer.

According to the composite test system provided by the embodiment of the invention, the dynamometer control device is used for respectively and independently controlling the first dynamometer and the second dynamometer, so that the first dynamometer and the second dynamometer can work according to respective parameter requirements without mutual influence.

In another embodiment, the composite test system further includes a motor control device, where the motor control device is connected to the first device under test 103 or the second device under test 104, and the motor control device is configured to control and set a working start state and corresponding working parameters of the first device under test 103 or the second device under test 104.

Here, the motor control device may be a motor controller, and the connection of the motor control device with the first device under test 103 or the second device under test 104 may mean that the motor controller is connected with a driving motor or an electric drive axle. When the motor controller is connected with the driving motor, the number of the motor controllers is one; when the motor controller is connected with a centralized electric drive axle, the number of the motor controllers is one, and when the motor controller is connected with a wheel-side electric drive axle or a wheel-hub electric drive axle, the number of the motor controllers is two. The motor control device is configured to control and set the working start state and the corresponding working parameters of the first device under test 103 or the second device under test 104, which may be: the first tested equipment is a driving motor, and when the driving motor needs to be tested, the motor controller is used for controlling and setting the working starting state and the corresponding working parameters of the driving motor; the second tested equipment is a centralized electric drive axle or a hub type electric drive axle or a wheel-side electric drive axle, and when the centralized electric drive axle needs to be tested, the motor controller is used for controlling and setting the working starting state and the corresponding working parameters of the centralized electric drive axle; when the wheel-side electric drive axle or the hub-type electric drive axle needs to be tested, the two motor controllers are adopted to respectively and independently control and set the working starting state and the corresponding working parameters of the wheel-side electric drive axle or the hub-type electric drive axle. The work starting state comprises a work state which is switched from a closing state to a starting state, a work state which keeps forward rotation or reverse rotation, a work state which is switched from the starting state to the closing state and the like. The working parameters comprise parameters such as the rotating speed and the torque of the driving motor or the driving bridge.

According to the composite test system provided by the embodiment of the invention, the motor control device is used for controlling the working starting state of the driving motor or the electric drive axle, so that the driving motor or the electric drive axle can be tested according to different working parameters, and the reliability degree of the driving motor or the electric drive axle can be further determined.

In another embodiment, each of the motor control devices is connected to the first device under test 103 or the second device under test 104 through three-phase alternating current, and the system further includes two alternating current sensing assemblies respectively disposed on at least two phases of the three-phase alternating current.

Here, each of the motor control apparatuses is connected to the first device under test 103 or the second device under test 104 through a three-phase alternating current, and the system further includes two ac sensing components respectively disposed on at least two phases of the three-phase alternating current, which may specifically be: when the first device under test 103 needs to be tested, the motor controller provides three-phase alternating current to the first device under test 103, and tests any two phases of the three-phase alternating current through two alternating current sensing components, where the alternating current sensing components may be alternating current sensors. For example, the three-phase alternating current provided by the motor controller to the driving motor is respectively U/V/W, and the two alternating current sensors can be arranged to test U/V two-phase or V/W two-phase or U/W two-phase. Alternatively, when the second device under test 104 needs to be tested, the motor controller provides three-phase alternating current to the second device under test 104, and tests any two phases of the three-phase alternating current through two alternating current sensing components, where the alternating current sensing components may be alternating current sensors. For example, the three-phase alternating currents respectively provided by the two motor controllers for the wheel-side electric drive axle are both U/V/W, and the two alternating current sensors corresponding to any one of the motor controllers can test U/V two-phase or V/W two-phase or U/W two-phase.

In addition, the data acquisition system 107 in the composite test system is further connected with the two alternating current sensing assemblies, when any two-phase alternating current in the two alternating current sensing assemblies is detected, the data acquisition system 107 acquires the values of the two alternating current sensing assemblies, and the undetected one-phase alternating current is calculated by a power analyzer in the data acquisition system 107. For example, the three-phase alternating current provided by the motor controller to the driving motor is U/V/W respectively, and when the two alternating current sensors detect the values of the U/V two-phase alternating current therein, the power analyzer in the data acquisition system 107 calculates the values of the remaining W-phase alternating current according to the phase angle relationship between the three-phase alternating current; then, the power analyzer stores the detected value of the U/V two-phase alternating current and the calculated value of the W-phase alternating current, and sends the values to an upper computer connected to the data acquisition system 107 for display.

According to the composite test system provided by the embodiment of the invention, the three-phase alternating current provided by the motor controller for the driving motor or the electric drive bridge can be obtained by arranging the two alternating current sensing assemblies, so that the test cost is saved, and the test system is simplified.

In another embodiment, the composite test system further includes a dc power supply device respectively connected to the motor control devices, wherein a dc sensing component is disposed at a connection end of the dc power supply device and the motor control devices.

Here, the dc power supply device is configured to provide dc power to the motor control device, and the dc power supply device may be a power battery. Because the motor control device has a bidirectional DC/AC inversion function, after the motor control device receives the direct current of the direct current power supply device, the motor control device converts the direct current into three-phase alternating current, so that the motor controller provides the three-phase alternating current for the driving motor or the electric drive bridge. It should be noted that, when the dc power supply device does not include a power battery, the dc power supply device may also be a dc power supply amplification device that is provided with a dc power supply by the first dynamometer control device and/or the second dynamometer control device, and specifically may be: the first dynamometer control device and/or the second dynamometer control device are connected with a power supply grid through a boost isolation device, the boost isolation device boosts 380V AC provided by the power supply grid to 690V AC and outputs the AC to the first dynamometer control device and/or the second dynamometer control device, then the first dynamometer control device and/or the second dynamometer control device converts the 690V AC into DC and sends the DC to a direct current power supply device, and the direct current power supply device amplifies the converted DC and supplies power to a motor control device. The direct current sensing component can be a direct current sensor and is used for detecting direct current and direct current voltage output to the motor control device by the direct current power supply device.

In addition, the data acquisition system 107 in the composite test system is also connected with the direct current sensing assembly, and after the direct current sensing assembly detects the direct current and the direct current voltage output to the motor control device by the direct current power supply device, the data acquisition system 107 acquires numerical values of the direct current and the direct current voltage, analyzes and stores the numerical values by a power analyzer in the data acquisition system, and then sends the numerical values to an upper computer for displaying.

The composite test system provided by the embodiment of the invention is used for testing the performance of the driving motor and the electric drive bridge by arranging the direct current sensing assembly to detect the actual direct current and the actual direct current voltage provided by the direct current power supply device for the motor control device.

In another embodiment, the composite test system further comprises a vehicle control device connected with the motor control device, wherein the vehicle control device is used for controlling task switching of the motor control device.

Here, the vehicle control device may be configured to send a task to the motor control device and control the motor control device to perform task switching, and the vehicle control device may be a vehicle control device. Wherein, the whole vehicle control device is used for controlling the task switching of the motor control device can comprise: the vehicle control unit receives a control instruction sent by the upper computer, and performs task switching on the motor controller according to the control instruction, where the task switching may be to request the motor controller to switch a working mode of the driving motor, for example, to request the motor controller to switch a power generation mode of the driving motor to an electric mode.

The composite test system provided by the embodiment of the invention controls the motor control device by arranging the vehicle control device, and is beneficial to realizing joint debugging among the direct-current power supply device, the tested equipment and the vehicle control device.

The structural schematic diagram of the composite test system provided by the embodiment of the present invention is described in detail below by taking the first device under test 103 as a driving motor in a motor system of an electric vehicle and the second device under test 104 as a wheel-side electric drive axle as an example.

Referring to fig. 2, the first device under test 103 is a driving motor 11, the second device under test 104 is a wheel-rim electric drive axle 17, the dynamometer includes a first dynamometer 4 and a second dynamometer 20, the first dynamometer 4 and the second dynamometer 20 are respectively located at two opposite sides of the wheel-rim electric drive axle 17, the first dynamometer 4 is respectively connected to a first dynamometer controller 201 and a transmission case 5, and the second dynamometer 20 is respectively connected to a second dynamometer controller 202 and a speed reducer 21; the gearbox 5 comprises a first output shaft and a second output shaft, the first output shaft is connected with the driving motor 11, the second output shaft is connected with the wheel-side electric drive axle 17, the first output shaft is provided with a first torque sensor 8, the second output shaft is provided with a second torque sensor 14, and a connecting shaft between the second dynamometer 20 and the wheel-side electric drive axle 17 is provided with a third torque sensor 24.

The composite test system further includes two motor controllers, which are respectively a first motor controller 203 and a second motor controller 204. When the driving motor 11 is tested, the first motor controller 203 or the second motor controller 204 is connected with the driving motor 11 through three-phase alternating current; wherein, at least two phases of the three-phase alternating current are provided with alternating current sensors 205; when the wheel-side electric drive axle 17 is tested, the first motor controller 203 and the second motor controller 204 are respectively connected with the wheel-side electric drive axle 17 through three-phase alternating current, wherein at least two phases of the three-phase alternating current are provided with alternating current sensors 205.

The composite test system further comprises a power battery 206, wherein the power battery 206 is respectively connected with the first motor controller 203 and the second motor controller 204, and the connection ends of the first motor controller 203, the second motor controller 204 and the power battery 206 are respectively provided with a direct current sensor 207.

The composite testing system further comprises a data collection system 107, and the data collection system 107 is respectively connected with the first torque sensor 8, the second torque sensor 14, the third torque sensor 24, the alternating current sensor 205 and the direct current sensor 207.

The hybrid test system further comprises a vehicle controller 208, and the vehicle controller 208 is connected with the first motor controller 203 and the second motor controller 204 respectively.

The composite test system further comprises a power supply grid 209 of 380V AC, the power supply grid 209 is connected with a boosting isolation device 211, the boosting isolation device 211 is connected with the first dynamometer controller 201 and the second dynamometer controller 202, and alternating current power supplies are respectively provided for the first dynamometer controller 201 and the second dynamometer controller 202.

The composite test system further comprises an upper computer 212, wherein the upper computer 212 is respectively connected with the first dynamometer motor control 201, the second dynamometer motor controller 202, the whole vehicle controller 208 and the data acquisition system 107, and is used for displaying data acquired by the data acquisition system 107, issuing control instructions to the first dynamometer motor control 201, the second dynamometer motor controller 202 and the whole vehicle controller 208 and the like.

Wherein the composite test system further comprises a cooling system 210, the cooling system 210 being configured to provide cooling to the drive motor 11 and the wheel-side electric transaxle 17.

When the composite test system provided by the embodiment of the invention needs to test the motor system, at least the following functions can be realized: the method comprises the following steps of (1) motor system no-load loss, a steady-state short-circuit current limit value, a steady-state short-circuit current tolerance, a motor flow resistance test, the highest working rotating speed, locked-rotor torque and current, peak torque and peak power, continuous torque and continuous power, torque rotating speed characteristics and efficiency, a temperature rise rate under the condition of peak power, a temperature rise under the continuous torque and power, feed and power assisting characteristics, a voltage closed-loop control function, motor system high-voltage power supply working range verification, power-limited maximum output torque and power, torque control precision, rotating speed control precision, torque feedback deviation, rotating speed feedback deviation, voltage feedback deviation, current feedback deviation, torque response speed, rotating speed response speed, zero torque control precision and motor system reliability; when the electric drive axle needs to be tested, the following functions can be realized: the method comprises an electric drive axle system efficiency test, an electric drive axle single-side fault simulation test, a temperature rise test, a running-in test and a reliability test.

Wherein, vehicle control unit can realize following function: the method comprises the following steps of working condition simulation tests (uniform speed, climbing, descending, acceleration working conditions and the like), automatic defined working condition simulation, three-electrical-system (VCU, battery system and motor system) matching tests, whole vehicle economy simulation tests, whole vehicle control strategy tests, whole vehicle part fault simulation tests, differential simulation function control and split road surface function simulation tests.

In another optional specific embodiment, the composite test system further comprises a supporting frame, the supporting frame comprises a first moving device for supporting the first device under test 103 and at least one second moving device for supporting the second device under test 104, respectively, and in the first state, the first moving device moves along a specified direction relative to the first output shaft of the speed changing device 102 to adjust the position of the first device under test in the specified direction; in the second state, the second moving device moves in a specified direction relative to the second output shaft of the transmission 102 to adjust the position of the second device under test 104 in the specified direction.

Here, referring to fig. 3 and fig. 4, the first moving device may be the first moving tooling 10, and the second moving device includes two second moving tooling 16, where the two second moving tooling 16 are respectively located at two opposite sides of the second device under test 104. In the first state, the first moving device moves along a specified direction relative to the first output shaft of the speed changing device to adjust the position of the first device under test 103 in the specified direction may specifically be: when the driving motor needs to be tested, the first movable tool 10 moves relative to the first output shaft of the gearbox 5 along the Z-axis direction so as to adjust the position of the driving motor in the height direction, and the driving motor can be accurately connected with the first output shaft of the gearbox 5. In the second state, the second moving device moves along a specified direction relative to the second output shaft of the speed changing device 102 to adjust the position of the second device under test 104 in the specified direction may specifically be: when the electric drive axle needs to be tested, the two second movable tools 16 simultaneously move along the Z-axis direction relative to the second output shaft of the gearbox 5 so as to adjust the position of the electric drive axle in the height direction, and ensure that the electric drive axle can be accurately connected with the second output shaft of the gearbox 5.

In addition, the compound test system further comprises a first dynamometer base 3 supporting the first dynamometer 4 and the gearbox 5, and a second dynamometer base 19 supporting the second dynamometer 20 and the speed reducer 21, and further comprises a first supporting base 1 supporting the first dynamometer base 3, a second supporting base 2 supporting the first device under test 103 or the second device under test 104, and a third supporting base 18 supporting the second dynamometer base 19. The first dynamometer base 3 and the first support base 1 can relatively move along an X axis, the second dynamometer base 19 and the second support base 18 can relatively move along the X axis, and the relative movement along the X axis can be mutually moving along the left-right direction, so as to adjust the horizontal distance between the first dynamometer 4 and/or the second dynamometer 20 and the first tested device 103 and/or the second tested device 104. The first supporting base 1, the second supporting base 2, and the third supporting base 18 are detachably connected, and the first supporting base 1, the second supporting base 2, and the third supporting base 18 can relatively move along the Y axis, where the relative movement along the Y axis can be a relative movement along the front-back direction, so as to adjust the position of the first device under test 103 and/or the second device under test 104 in the front-back direction, and ensure that the first device under test 103 is accurately connected with the first output shaft of the transmission case 5 and/or the second device under test 104 is accurately connected with the second output shaft of the transmission case 5.

In the composite test system provided in the embodiment of the present invention, the movement of the first device under test 103 relative to the first output shaft of the speed changing device 102 is adjusted by the first moving device, so as to ensure that the first device under test 103 can be accurately connected to the first output shaft of the speed changing device 102; the second movement device is arranged to adjust the motion of the second device under test 104 relative to the second output shaft of the speed changing device 102, so that the second device under test 104 can be accurately connected to the second output shaft of the speed changing device 102. In this way, the reliability test of the first device under test 103 or the second device under test 104 by the composite test system can be successfully completed.

For convenience of understanding, the composite test system provided in the embodiment of the present invention is further described below by taking the composite test system as a composite test bench, the first device under test as a wheel hub driving motor, and the second device under test as a wheel-side electric drive axle.

Referring to fig. 3 again, a structural diagram of the composite test bench for testing the hub driving motor according to the embodiment of the present invention is shown. Wherein the composite test bench comprises a support base comprising a first support base 1, a second support base 2, the first support base 1 is provided with a first dynamometer base 3, the first support base 1 and the first dynamometer base 3 can move relatively along the X axis, the first dynamometer base 3 is provided with a first dynamometer 4, a gear box 5 and a first torque sensor bracket 7, a first torque sensor 8 is arranged on the first torque sensor bracket 7, the first dynamometer 4 is connected with the gearbox 5 through a coupling 6, a first output shaft of the gearbox 5 and the first torque sensor 8 are also connected by a coupling 6, and a transmission shaft support 9 is further arranged at the coupling 6 between the first output shaft of the gearbox 5 and the first torque sensor 8. The second support base 2 is provided with a first movable tool 10, and the first movable tool 10 is provided with a driving motor 11. The first movable tool 10 is connected with the first torque sensor 8 through a connecting end surface 26.

Referring to fig. 4 again, a structural diagram of the composite test bench for testing the wheel-side electric drive axle according to the embodiment of the present invention is shown. Wherein, the composite test bench comprises a supporting base, the supporting base comprises a first supporting base 1 and a second supporting base 2, the first supporting base 1 is provided with a first dynamometer base 3, the first supporting base 1 and the first dynamometer base 3 can mutually move along the X axis, the first dynamometer base 3 is provided with a first dynamometer 4, a gear box 5, a second large torque sensor bracket 12 and a second small torque sensor bracket 13, the second large torque sensor bracket 12 is provided with a second large torque sensor 14, the second small torque sensor bracket 13 is provided with a second small torque sensor 15, the first dynamometer 4 is connected with the gear box 5 through a coupler 6, a second output shaft of the gear box 5 is connected with the second large torque sensor 14 through a coupler 6, a transmission support 9 is further arranged at the position of the coupling 6 between the second large torque sensor 14 and the second small torque sensor 15. Two second movable tools 16 are installed on the second supporting base 2, and the two second movable tools 16 respectively support two ends of the wheel-side electric drive axle 17. The composite test bench further comprises a third support pedestal 18, a second dynamometer pedestal 19 is arranged on the third support pedestal 18, the third supporting base 18 and the second dynamometer base 19 can move relatively along the X-axis, the second dynamometer base 19 is provided with a second dynamometer 20, a speed reducer 21, a third large torque sensor bracket 22 and a third small torque sensor bracket 23, a third large torque sensor 24 is mounted on the third large torque sensor bracket 22, a third small torque sensor 25 is mounted on the third small torque sensor bracket 23, the second dynamometer 20 is connected with a speed reducer 21 through a coupling 6, the speed reducer 21 is also connected with the third large torque sensor 4 through the coupling 6, a transmission shaft support 9 is further arranged at the coupling 6 between the third large torque sensor 14 and the third small torque sensor 15. One of the second movable tools is connected with the second small torque sensor through a connecting end surface 26, and the other of the second movable tools is connected with the third small torque sensor through a connecting end surface 26.

The composite test system provided by the embodiment of the invention can carry out compatibility test on the first tested equipment and the second tested equipment with different performances, thereby saving the test cost and reducing the occupied area of the test system.

The embodiment of the present invention further provides a composite test method using the composite test system according to any one of the embodiments of the present invention, including:

determining data acquired by a first torque sensor component in a first state that a dynamometer carries out testing on first tested equipment;

determining data acquired by the second torque sensing assembly in a second state that the dynamometer tests the second tested equipment;

and analyzing the data collected by the first torque sensing assembly and/or the second torque sensing assembly, and displaying the corresponding analysis result.

The determining that the dynamometer performs a test on the first device under test in the first state may specifically be: a tester connects a first dynamometer controller in the composite test system with a power supply grid through a boosting isolation device, connects a first motor controller or a second motor controller with a battery, sets relevant parameters corresponding to the test on an upper computer and starts the test. Then, the upper computer sends the set related parameters to the vehicle control unit, and the vehicle control unit determines that the data acquired by the first torque sensing assembly is acquired by the data acquisition system in a first state that the dynamometer tests the motor, wherein the data comprises the rotating speed and the torque of first tested equipment, and the first tested equipment can be a driving motor;

the determining that the dynamometer performs a test on the second device under test in the second state may specifically acquire data collected by the second torque sensing component: a tester connects a first dynamometer controller and/or a second dynamometer controller in the composite test system with a power supply grid through a boost isolation device, connects the first motor controller and/or the second motor controller with a power battery, sets relevant parameters corresponding to the test on an upper computer and starts the test. Then, the vehicle control unit in the composite test system determines that the dynamometer carries out test on the electric drive axle in a first state, and the data acquisition system acquires data acquired by the second torque sensing assembly, wherein the data comprises the rotating speed and the torque of second tested equipment.

The analyzing the data collected by the first torque sensing assembly or the second torque sensing assembly and displaying the corresponding analysis result may be: when the data acquisition system acquires the data of the first torque sensing assembly, the data acquisition system analyzes the data and sends a corresponding analysis result to the upper computer, and the upper computer displays the data so that a tester can know the actual rotating speed and the actual torque of the first tested equipment. When the data acquisition system acquires data of the second torque sensing assembly, the data acquisition system analyzes the data and sends a corresponding analysis result to the upper computer, and the upper computer displays the data so that a tester can know the actual rotating speed and the actual torque of the second tested equipment, wherein the second tested equipment can be a driving bridge.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention.

Claims (8)

1. A composite test system, comprising: the system comprises a dynamometer, a speed change device and a data acquisition system, wherein the speed change device is connected with the dynamometer and comprises a first output shaft and a second output shaft which are respectively connected with first tested equipment and second tested equipment; a first torque sensing assembly is arranged on the first output shaft, and a second torque sensing assembly is arranged on the second output shaft; the speed ratio of one of the first output shaft and the second output shaft is a speed increasing ratio, and the other one of the first output shaft and the second output shaft is a speed reducing ratio;

the speed increasing ratio is used for increasing the output rotating speed of the dynamometer;

the reduction ratio is used for reducing the output rotating speed of the dynamometer;

the composite test system is switched between a first state and a second state, wherein the first state is a state for testing the first tested equipment, and the second state is a state for testing the second tested equipment;

in the first state, the dynamometer is connected with the first tested device through the first output shaft of the speed changing device, and the data acquisition system acquires data acquired by the first torque sensing assembly; in the second state, the dynamometer is connected with the second tested device through the second output shaft of the speed changing device, and the data acquisition system acquires data acquired by the second torque sensing assembly, wherein the speed changing device comprises a gearbox, the first output shaft of the gearbox is connected with the first tested device, and the second output shaft of the gearbox is connected with the second tested device;

the composite test system further comprises a support frame, wherein the support frame comprises a first moving device and at least one second moving device, the first moving device is used for supporting the first tested device and the second moving device is used for supporting the second tested device respectively, and in the first state, the first moving device moves relative to the first output shaft of the speed changing device along a specified direction so as to adjust the position of the first tested device in the specified direction; in the second state, the second moving device moves relative to the second output shaft of the speed changing device along a specified direction so as to adjust the position of the second device to be tested in the specified direction.

2. The compound testing system of claim 1, wherein the speed changing device further comprises a speed reducer, the dynamometers comprise a first dynamometer and a second dynamometer, the first dynamometer and the second dynamometer are respectively located on two opposite sides of the second tested device, the first dynamometer is connected with the gearbox, the second dynamometer is connected with the second tested device through the speed reducer, and a third torque sensing assembly is arranged on a connecting shaft of the second dynamometer and the second tested device.

3. The composite test system of claim 2 further comprising dynamometer control means coupled to the first dynamometer and the second dynamometer, respectively, wherein the dynamometer control means is configured to control setting of a work start state and corresponding work parameters of the first dynamometer and/or the second dynamometer, respectively.

4. The composite test system according to claim 2, further comprising a motor control device, wherein the motor control device is connected to the first device under test or the second device under test, and the motor control device is configured to control and set the working start state and the corresponding working parameters of the first device under test or the second device under test.

5. The composite test system as defined in claim 4, wherein each of the motor control devices is connected to the first device under test or the second device under test via a three-phase alternating current, the system further comprising two alternating current sensing assemblies respectively disposed on at least two phases of the three-phase alternating current.

6. The composite test system as claimed in claim 4, further comprising a dc power supply device connected to the motor control device, wherein a dc sensing component is disposed on a connection end of the dc power supply device and the motor control device.

7. The composite test system of claim 4, further comprising a vehicle control device connected to the motor control device, wherein the vehicle control device is configured to control task switching of the motor control device.

8. A composite test method using the composite test system as claimed in any one of claims 1 to 7, comprising:

determining data acquired by a first torque sensor component in a first state that a dynamometer tests first tested equipment;

determining data acquired by the second torque sensing assembly in a second state that the dynamometer tests the second tested equipment;

and analyzing the data collected by the first torque sensing assembly and/or the second torque sensing assembly, and displaying the corresponding analysis result.

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