CN113960400B - High-voltage testing system of new energy automobile - Google Patents
High-voltage testing system of new energy automobile Download PDFInfo
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- CN113960400B CN113960400B CN202111260748.1A CN202111260748A CN113960400B CN 113960400 B CN113960400 B CN 113960400B CN 202111260748 A CN202111260748 A CN 202111260748A CN 113960400 B CN113960400 B CN 113960400B
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- 238000012360 testing method Methods 0.000 title claims abstract description 131
- 238000004891 communication Methods 0.000 claims description 44
- 238000005259 measurement Methods 0.000 claims description 3
- 238000011990 functional testing Methods 0.000 claims description 2
- 230000006698 induction Effects 0.000 description 17
- 230000008859 change Effects 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
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- 229910052802 copper Inorganic materials 0.000 description 2
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- 238000005299 abrasion Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/005—Testing of electric installations on transport means
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R1/00—Details of instruments or arrangements of the types included in groups G01R5/00 - G01R13/00 and G01R31/00
- G01R1/02—General constructional details
- G01R1/04—Housings; Supporting members; Arrangements of terminals
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- Electric Propulsion And Braking For Vehicles (AREA)
- Charge And Discharge Circuits For Batteries Or The Like (AREA)
Abstract
The invention provides a high-voltage test system of a new energy automobile, which comprises a power supply; the high-voltage junction box is electrically connected with the power supply; the charge-discharge testing unit is electrically connected with the high-voltage junction box; the inductance cabinet is electrically connected with the high-voltage junction box; the motor testing unit is electrically connected with the inductance cabinet; the control unit is electrically connected with the power supply, the high-voltage junction box, the charging pile testing unit, the inductance cabinet and the motor testing unit; and the power domain controller is electrically connected with the main control unit. The high-voltage testing system of the new energy automobile provided by the invention can realize testing of high-voltage devices in different ranges.
Description
Technical Field
The invention relates to the technical field of vehicles, in particular to a high-voltage testing system of a new energy automobile.
Background
The power assembly system of the new energy automobile comprises a high-voltage battery pack, a driving part, a vehicle-mounted charger and a brake part, and all parts except the brake part of the power assembly system need to work in a high-voltage environment, so the power assembly system can be also called a high-voltage power assembly. At present, the high-voltage power assembly of the new energy automobile basically works under the voltage of 400V, and in order to increase the output of electric power, lighten a high-voltage cable in the whole automobile, shorten the charging time and increase the endurance mileage, the high-voltage power assembly of the energy automobile needs to be designed to work under the high-voltage of 800V.
After the design is finished, the high-voltage power assembly needs to be tested in a high-voltage testing environment of 800V, the existing 800V high-voltage testing environment can only test the high-voltage power assembly on the whole vehicle, and each subsystem or part of the high-voltage power assembly cannot be tested independently. The defects of testing the 800V high-voltage system on the whole vehicle are numerous, such as incapability of quickly finding out the root of the problem, incapability of quickly replacing hardware and wiring harnesses, incapability of quickly and iteratively upgrading tested parts, incapability of connecting high-precision measuring equipment due to narrow space in the vehicle, and the like.
Disclosure of Invention
In view of the above-mentioned shortcomings of the prior art, the present invention aims to provide a high-voltage testing system for a new energy automobile, which changes the connection loop between a tested piece and testing equipment by program-controlled switching of different high-voltage relays in a high-voltage junction box, so as to realize that after only one physical connection is performed between the tested piece and a main control unit, the switching of different high-voltage loops can be flexibly and safely selected according to different testing functions, so as to quickly find out the problem root in the high-voltage system of the new energy automobile, and the high-voltage wire harness does not need to be replaced or plugged.
To achieve the above and other related objects, the present invention provides a high voltage test system for a new energy automobile, comprising:
A power supply;
The high-voltage junction box is electrically connected with the power supply;
the charge-discharge testing unit is electrically connected with the high-voltage junction box;
The inductance cabinet is electrically connected with the high-voltage junction box;
The motor testing unit is electrically connected with the inductance cabinet;
The main control unit is electrically connected with the power supply, the high-voltage junction box, the charge and discharge testing unit, the inductance cabinet and the motor testing unit; and
And the power domain controller is electrically connected with the main control unit.
In one embodiment of the invention, the high voltage test system of the new energy automobile further comprises a plurality of wire harnesses, wherein the plurality of wire harnesses comprise a low voltage communication wire harness, a three-phase high voltage wire harness and a direct current high voltage wire harness.
In one embodiment of the present invention, the high voltage junction box includes a plurality of high voltage relays electrically connected to the tested piece.
In one embodiment of the present invention, the charge and discharge test unit includes:
The alternating-current charging pile simulator is electrically connected with the main control unit through a low-voltage communication wire harness;
And one end of the vehicle-mounted charger is electrically connected with the alternating current charging pile simulator through a three-phase high-voltage wire harness, and the other end of the vehicle-mounted charger is electrically connected with the high-voltage junction box through the direct current high-voltage wire harness.
In one embodiment of the present invention, the charge and discharge test unit further includes:
the high-voltage battery pack is electrically connected with the high-voltage junction box through the direct-current high-voltage wire harness;
The direct current charging pile simulator is electrically connected with the main control unit through the low-voltage communication wire harness and is electrically connected with the high-voltage battery pack through the direct current high-voltage wire harness.
In one embodiment of the invention, the motor test unit includes:
the inductance cabinet is electrically connected with the main control unit through the low-voltage communication wire harness;
And the motor controller is electrically connected with the inductance cabinet through the direct-current high-voltage wire harness and is electrically connected with the main control unit through the low-voltage communication wire harness.
In one embodiment of the invention, the motor test unit further comprises:
The first motor is electrically connected with the motor controller through the low-voltage communication wire harness;
the second motor is electrically connected with the main control unit through the low-voltage communication wire harness and is electrically connected with the inductance cabinet through the direct-current high-voltage wire harness;
The dynamometer machine bench is electrically connected with the main control unit, the motor controller and the second motor through low-voltage communication wiring harnesses.
In one embodiment of the invention, the power domain controller is further electrically connected to the motor controller, the first motor, and the high voltage battery pack.
In one embodiment of the present invention, the high-voltage battery pack is further electrically connected to the motor controller, the second motor, and the vehicle-mounted charger.
In one embodiment of the invention, the dynamometer bench pair drags the first motor or the second motor.
As described above, the high-voltage testing system for the new energy automobile is characterized in that a plurality of tested pieces are connected through the plurality of wire harnesses, the electrical and communication connection between the tested pieces is realized, the tested pieces are connected through the plurality of high-voltage relays in the high-voltage junction box, the single or partial system is tested, the connection mode of the high-voltage wire harnesses is not required to be changed, the tested pieces are not required to be completely separated from the high-voltage environment, and the high voltage is ensured not to damage the tested pieces. And the charge and discharge testing unit and the single machine testing unit are connected with the main control unit, so that the charge and discharge of the whole vehicle and the running test are realized. According to the invention, after the tested piece is in one-time physical connection with the main control unit, the main control system is used for controlling the on-off of different relays in the high-voltage junction box, so that different testing ranges can be flexibly and safely selected, the problem root in the high-voltage system of the new energy automobile can be rapidly found out, and the high-voltage wire bundles are not required to be replaced and pulled out, so that the wire bundles are not required to be replaced when the high-voltage elements with different testing purposes are tested, and the problems of connector aging and insulation caused by the fact that the high-voltage wire bundles of the tested piece are pulled out are avoided.
Drawings
Fig. 1 is a schematic diagram of a high-voltage test system of a new energy automobile according to the present invention.
Fig. 2 shows a schematic view of a high voltage distribution box according to the present invention.
Fig. 3 is a schematic diagram showing a connection between the first to sixth high-voltage relays and the tested member in the present invention.
Fig. 4 is a schematic diagram showing another connection between the first to sixth high-voltage relays and the test piece in the present invention.
Detailed Description
Other advantages and effects of the present invention will become apparent to those skilled in the art from the following disclosure, which describes the embodiments of the present invention with reference to specific examples. The invention may be practiced or carried out in other embodiments that depart from the specific details, and the details of the present description may be modified or varied from the spirit and scope of the present invention.
Referring to fig. 1, the voltage of the high voltage system is raised (for example, the voltage is raised to 800V or above) to realize the fast charging of the electric automobile, and the current transmitted on the high voltage wire harness is reduced by the improvement of the voltage class on the premise of the same electric power, so that the sectional area of the high voltage wire harness is reduced, the weight of the wire harness is reduced, and the installation space is saved. However, a new testing environment is needed for testing the high-voltage power assembly, namely a high-voltage power assembly system test bed, in which a plurality of tested pieces and testing devices suitable for high voltage can be connected, and the high-voltage system test bed has higher requirements on the insulating and pressure-resisting capacities of the testing devices and the tested pieces. And when testing the high-voltage power system assembly or parts thereof, the high-voltage wire harness needs to be frequently pulled out and plugged, which can lead to ageing and abrasion of the wire harness and connectors and affect the insulation capability of the whole laboratory.
Referring to fig. 1, in an embodiment of the invention, the high voltage testing system of the new energy automobile includes a main control unit 1000, a power source 100, a high voltage junction box 200, a charge and discharge testing unit 300, an inductance cabinet 400, a motor testing unit 500 and a power domain controller 600. The power supply 100 provides power for the high-voltage test system of the new energy automobile, the high-voltage junction box 200 is electrically connected with the power supply 100, and the connected tested pieces can be freely switched through the high-voltage junction box 200. The charge and discharge testing unit 300 is electrically connected to the high voltage junction box 200, and can perform charge and discharge testing on the vehicle electrical components in the charge and discharge testing unit 300 through the high voltage junction box 200. The induction cabinet 400 is electrically connected to the high-voltage junction box 200, and monitors the voltage/current in the high-voltage test system of the new energy automobile. The motor testing unit 500 is electrically connected to the induction cabinet 400, and the motor testing unit 500 performs a driving test. The main control unit 1000 is electrically connected to the power supply 100, the high-voltage distribution box 200, the charge/discharge testing unit 300, the inductance cabinet 400, the motor testing unit 500, and the power domain controller 600 is electrically connected to the main control unit 1000. By controlling the high-voltage junction box 200, the main control unit 1000 can test vehicle electrical elements in different ranges and for different purposes.
Referring to fig. 1, in an embodiment of the present invention, the high voltage testing system of the new energy automobile further includes a plurality of harnesses, where the plurality of harnesses includes a low voltage communication harness 710, a direct current high voltage harness 720 and a three phase high voltage harness 730, each tested piece is connected to the main control unit 1000 through the plurality of harnesses, and in order to match with a high voltage testing platform, the high voltage is, for example, 800V, 900V and 1000V, and is not limited thereto, when the harnesses and the terminals are selected, the insulating harnesses are selected according to the requirement of the high voltage, and insulation detection is not required to be performed even if the insulating harnesses are replaced, so that a great amount of testing time is saved. The dc high-voltage harness 720 is, for example, a national standard dc charging gun, and the three-phase high-voltage harness 730 is, for example, a national standard ac charging gun, but is not limited thereto.
Referring to fig. 1, in one embodiment of the present invention, a power source 100 is connected to a main control unit 1000 through a low voltage communication harness 710 and connected to a high voltage distribution box 200 through a dc high voltage harness 720. The power supply 100 outputs a direct current voltage and a direct current, and monitors a voltage and a current in a high voltage environment of a power domain and has an insulation detection function and a high voltage fault injection capability.
Referring to fig. 1 and 2, in an embodiment of the invention, the high voltage junction box 200 is electrically connected to the power source 100 through a dc high voltage harness 720, connected to the main control unit 1000 through a low voltage communication harness 710, and connected to the charging and discharging unit 300 and the inductor cabinet 400 through the dc high voltage harness 720. The high-voltage junction box 200 adopts a standard cabinet closed structure outside, and internal high-voltage components are arranged in layers up and down, for example, a vehicle-mounted charger 320, a tested motor 523, a direct-current charging pile 340 and a battery pack 330, but not limited to the above. The high voltage junction box 200 mainly includes a first high voltage relay K1, a second high voltage relay K2, a third high voltage relay K3, a fourth high voltage relay K4, a fifth high voltage relay K5, and a sixth high voltage relay K6, a first input/output terminal 810, a second input/output terminal 820, a third input/output terminal 830, a fourth input/output terminal 840, and a fifth input/output terminal 850, an internal power supply 861, and a control area network (Controller Area Netwoek, CAN) communication module 862. The first to sixth high-voltage relays K1 to K6 control the connection state of the measured object and the measuring device, and the first input/output terminal 810, the second input/output terminal 820, the third input/output terminal 830, the fourth input/output terminal 840 and the fifth input/output terminal 850 are connected by aviation plug and socket, i.e. the connection is performed by aviation plug and socket, and the copper bar inside the copper bar is required to bear voltage, for example, 1000V, and the current is, for example, 1000A. The main control unit 1000 controls states of the first high-voltage relay K1 to the sixth high-voltage relay K6 in the high-voltage junction box 200 through a CAN network communication mode of the CAN communication module 862, so as to change a testing range and test different high-voltage components. The CAN communication module 862 receives an instruction of the main control unit 1000 and feeds back various states of the current first to sixth high-voltage relays K1 to K6, wherein the response time of the main control unit 1000 to control the instruction of the CAN communication module 862 is, for example, less than 10ms. The high-voltage junction box 200 is further provided with a plurality of indicator lamps (not shown in the figure), and the indicator lamps are respectively and electrically connected to the first to sixth high-voltage relays K1 to K6 to respectively display the working states of the first to sixth high-voltage relays K1 to K6, and the internal power supply 861 supplies power to the first to sixth high-voltage relays K1 to K6 and the indicator lamps.
Referring to fig. 2, in an embodiment of the invention, one end of the third high voltage relay K3 is electrically connected to the first input/output terminal 810, and is electrically connected to the vehicle-mounted charger 320 through the first input/output terminal 810, and the third high voltage relay K3 is electrically connected to the third input/output terminal 830, and is electrically connected to the high voltage battery pack 330 through the third input/output terminal 830. One end of the first high-voltage relay K1 is electrically connected to the vehicle-mounted charger 320, the other end of the first high-voltage relay K1 is electrically connected to the second high-voltage relay K2, and when the second high-voltage relay K2 is closed, the first high-voltage relay K1 is electrically connected to the power supply 100. One end of the fifth high-voltage relay K5 is electrically connected to the second input/output terminal 820, and is electrically connected to the dc charging pile simulator 340 through the second input/output terminal 820, and the other end of the high-voltage relay K5 is electrically connected to the fourth input/output terminal 840, and is electrically connected to the power supply 100 through the fourth input/output terminal 840. One end of the second high-voltage relay K2 is electrically connected to the first high-voltage relay K1, and the other end of the second high-voltage relay K2 is electrically connected to the power supply 100. One end of the fourth high-voltage relay K4 is electrically connected to the third high-voltage relay K3, and the other end of the fourth high-voltage relay K4 is electrically connected to the fifth high-voltage relay K5. One end of the sixth high-voltage relay K6 is electrically connected to the fifth input/output terminal 850, and is electrically connected to the tested motor 523 through the fifth input/output terminal 850, and the other end of the sixth high-voltage relay K6 is electrically connected to the power supply 100. The main control unit 1000 can safely and flexibly select different testing ranges by controlling the high-voltage junction box 200, freely switch the connection mode of the tested piece, and does not need to replace and plug the high-voltage wire harness.
Referring to fig. 1, in one embodiment of the present invention, the charge/discharge testing unit 300 is electrically connected to the high voltage distribution box 200 through a dc high voltage harness 720. The charge and discharge test unit 300 includes an ac charge stake simulator 310, an on-board charger 320, a high-voltage battery pack 330, and a dc charge stake simulator 340. The ac charging pile simulator 310 is electrically connected to the main control unit 1000 through the low-voltage communication harness 710, is electrically connected to the main control unit 1000 through the connection to the high-voltage battery pack 330, and the ac charging pile simulator 310 is electrically connected to the vehicle-mounted charger 320 through the three-phase high-voltage harness 730. The ac charging pile simulator 310 monitors the input/output voltage/current of the vehicle-mounted charger 320, has a high-low voltage function of simulating ac charging piles, a power grid fault injection function and a charging gun resistance simulator function, and supports charging standards of china, the united states, europe and japan.
Referring to fig. 1, in an embodiment of the invention, the vehicle-mounted charger 320 is electrically connected to the main control unit 1000 through the low voltage communication harness 710, and the vehicle-mounted charger 320 is electrically connected to the power domain controller 600 and the high voltage battery pack 330 through the electrical connection with the main control unit 1000. The vehicle-mounted charger 320 is electrically connected to the ac charging pile simulator 310 through a three-phase high-voltage harness 730, and is electrically connected to the high-voltage junction box 200 through a dc high-voltage harness 720. The vehicle-mounted charger 320 receives the three-phase high voltage output from the ac charging pile simulator 310, converts the three-phase ac high voltage into dc high voltage through an internal conversion circuit, and charges the high-voltage battery pack 300.
Referring to fig. 1, in an embodiment of the invention, the dc charging pile simulator 340 is electrically connected to the main control unit 1000 and the high-voltage battery pack 330 through the low-voltage communication harness 710, and is electrically connected to the high-voltage junction box 200 through the dc high-voltage harness 720. The dc charging pile simulator 340 may detect various charging parameters in the dc charging process, and has a standard test function, an interoperability test function, and a communication consistency test function for simulating the dc charging pile, and is not limited thereto. In an embodiment, the dc charging stake simulator 340 supports the charging standards of china, the united states, europe, and japan.
Referring to fig. 1, in an embodiment of the invention, the high-voltage battery pack 330 is electrically connected to the main control unit 100 through the low-voltage communication harness 710, and the high-voltage battery pack 330 is electrically connected to the power domain controller 600, the motor controller 510, the dynamometer stand 530, and the vehicle-mounted charger 320 through the electrical connection with the main control unit 100. The high voltage battery pack 330 is electrically connected to the high voltage junction box 200 through a dc high voltage harness 720. The high voltage battery pack 330 provides high voltage to the power domain and receives the voltage/current output by the ac charging pile and the dc charging pile for charging. In the charge and discharge test of the high-voltage battery pack 330, the high-voltage battery pack 330 may be a real one or an analog one. When the high-voltage battery pack 330 is subjected to charge and discharge testing, different high-voltage loops are switched by controlling the high-voltage junction box 200 according to different testing requirements, so that the testing purpose is achieved.
Referring to fig. 1, in an embodiment of the invention, the induction cabinet 400 is electrically connected to the high-voltage junction box 200 through a dc high-voltage wire harness, is electrically connected to the main control unit 1000 through a low-voltage communication wire harness 710, and is electrically connected to the main control unit 1000, and the induction cabinet 400 is electrically connected to the dynamometer stand 540. The induction cabinet 400 detects the voltage and current of the dc high voltage harness 720 between the high voltage distribution box 200 and the motor controller 510, and simultaneously monitors the three-phase ac voltage and current of the motor controller 510 and the first motor 520, and monitors the voltage and current of the dc high voltage harness 720 between the high voltage distribution box 200 and the second motor 530.
Referring to fig. 1, in an embodiment of the invention, a motor testing unit 500 is electrically connected to an inductance cabinet 400, and the motor testing unit 500 includes a motor controller 510, a first motor 520, a second motor 530, and a dynamometer bench 540. The motor controller 510 is electrically connected to the main control unit 1000 and the first motor 520 through the low voltage communication harness 710. The motor controller 510 is electrically connected to the main control unit 1000 and also electrically connected to the power domain controller 600. The motor controller 510 receives the dc high voltage output from the induction cabinet 400 through the dc high voltage harness 720. The motor controller 510 internally includes an inverter circuit through which the dc high voltage received from the induction cabinet 400 is inverted into three-phase high voltage, and the three-phase high voltage is input to the induction cabinet 400, and the induction cabinet 400 transmits the received three-phase high voltage to the first motor 520. The motor controller 510 is electrically connected to the induction cabinet 400 through the three-phase high voltage wire harness 730, and inputs the converted three-phase high voltage power to the induction cabinet 400. The motor controller 510 feeds back the data of the first motor 520 to the power domain controller 600, receives the command of the power domain controller 600, and drives the first motor 520 to output torque, and the dynamometer bench 540 receives the command output rotation speed of the power domain controller 600 and converts the direct-current high voltage sent by the induction cabinet 400 into three-phase voltage.
Referring to fig. 1 and 2, in an embodiment of the present invention, a first motor 520 is electrically connected to a motor controller 510 through a low-voltage communication harness 710, and is connected to a dynamometer stand 540 through a special fixture, where the fixture is a device for implementing the opposite dragging of the first motor 520 and the dynamometer stand 540, and the dynamometer stand 540 can be caused to opposite drag the first motor 520 through the special fixture. The first motor 520 receives instructions of the motor controller 510 and executes the instructions. Wherein there is no integrated controller in the first motor 520, the first motor 520 may be matched with the motor controller 510 to form a two-in-one motor, i.e. the combined motor 512, to perform the first motor 520 test.
Referring to fig. 1 to 3, in an embodiment of the invention, the second motor 530 is electrically connected to the main control unit 1000 through the low voltage communication harness 710, and the second motor 530 is electrically connected to the power domain controller 600 through the main control unit 1000. The second motor 530 is electrically connected to the dynamometer stand 540 through the low-voltage communication harness 710, and the second motor 530 is further connected to the dynamometer stand 540 through a special tool, so that the dynamometer stand 540 drags the second motor 530. The second motor 530 is electrically connected to the induction cabinet 400 through a dc high voltage harness 720. The power domain controller 600 issues a control instruction to the dynamometer stand 540 through the main control unit 1000, so that the dynamometer stand 540 outputs a rotating speed, the second motor 530 indirectly outputs a torque due to the fact that the dynamometer stand 540 drags the second motor 530, and the power domain controller 600 receives data fed back by the dynamometer stand 540 and the second motor 530 in real time. Meanwhile, the main control unit 1000 controls the switching high-voltage loop of the high-voltage junction box 200, so that the power domain controller 600 outputs high voltage by controlling the high-voltage battery pack 330, the high voltage is transmitted to the second motor 530 through the high-voltage junction box 200 and the inductance cabinet 400, and the inductance cabinet 400 monitors high-voltage parameters in the testing process in real time and feeds back the high-voltage parameters to the main control unit 1000, for example, voltage and current transmitted by the direct-current high-voltage wire harness 720. The tested motor 523 includes a first motor 520, a combined motor 512 and a second motor 530, and the second motor 530 is internally provided with an integrated controller and a speed reducer.
Referring to fig. 1, in one embodiment of the present invention, the dynamometer stand 540 is electrically connected to the motor controller 510, the second motor 530 and the main control unit 1000 through the low voltage wire harness 710, and is electrically connected to the induction cabinet 400, the first motor 520 and the vehicle-mounted charger 320 through the low voltage wire harness 710, and the dynamometer stand 540 is in communication connection with the motor controller 510 through the low voltage wire harness 710 to perform a local series of motor tests. The dynamometer rack 540 comprises a dynamometer motor, the dynamometer rack 540 controls the rotation speed of the dynamometer, the dynamometer motor controls the rotation speed of the first motor 520 or the second motor 530 respectively through special tools, and the dynamometer rack 540 controls the rotation speed of the first motor 520 and the second motor 530 respectively indirectly. The dynamometer bench 540 also monitors other data of the first motor 520 and the second motor 530, such as monitoring vibration amplitudes of the first motor 520 and the second motor 530, calculating efficiency of the motor under test. The rotation speeds of the first motor 520 and the second motor 530 are controlled through the dynamometer bench 540, and the power domain controller 600 controls the torque of the first motor 520 and the torque of the second motor 530, so that the measurement accuracy is improved, and the measurement data is more accurate.
Referring to fig. 1, in one embodiment of the present invention, all components of a high-voltage power assembly are connected to a high-voltage system test stand, a main control system of the high-voltage system test stand is a main control unit 1000, the main control unit 1000 simulates control signals of electrical components, and performs an automatic procedure, and collects data of equipment and a tested piece. The power domain controller 600 is electrically connected to the main control unit 1000 through a low voltage communication line 710, and is electrically connected to the motor controller 510, the first motor 520, and the high voltage battery pack 330 through connection with the main control unit 1000. The power domain controller 600 controls the charge and discharge and driving functions of the vehicle, interacts data with other controllers of the whole vehicle, performs data acquisition by means of various sensors, performs data exchange by means of a wire harness, judges the state of the vehicle and the intention of a driver, and finally performs specific functions by means of an actuator.
Referring to fig. 1, in one embodiment of the present invention, the tested components are, for example, a power source 100, an ac charging pile simulator 310, a vehicle charging pile 320, a high-voltage battery pack 330, a dc charging pile simulator 340, an inductance cabinet 400, a motor controller 510, a first motor 520, a second motor 530, a dynamometer stand 540, and a power domain controller 600, and these high-voltage components may be used as the tested components individually for testing different purposes. The tested piece can be, for example, a combination of a plurality of high-voltage elements for testing different purposes, and is not limited to this. Such as, but not limited to, ac charging stake simulators 310, dc charging stake simulators 340, and power sources 100.
Referring to fig. 1, in some embodiments, in order to avoid frequent replacement and plugging of the high-voltage wire harness, the main control unit 1000 of the present invention can freely switch the testing range by controlling the high-voltage junction box 200, connect all the parts of each high-voltage power assembly at one time by the high-voltage wire harness, and execute different functional tests on the premise of not changing the wire harness, so as to quickly find out the problem root in the high-voltage system of the new energy automobile. In the present invention, the default state of the high-voltage junction box 200 is the first high-voltage relay K1 to the sixth high-voltage relay K6 are the off state.
Referring to fig. 1 and 2, in one embodiment of the present invention, when only the ac charging test is performed on the high voltage battery pack 330, the main control unit 1000 simulates the control of the power domain controller 600 on the ac charging test of the whole vehicle, the main control unit 1000 controls the high voltage junction box 200, and the third high voltage relay K3 is closed by opening the first high voltage relay K1, the second high voltage relay K2, the fourth high voltage relay K4, the fifth high voltage relay K5, and the sixth high voltage relay K6 in the high voltage junction box 200, so that the vehicle-mounted charger 320 and the high voltage battery pack 300 are electrically connected, the vehicle-mounted charger 320 charges the high voltage battery pack 300, and the ac charging test is performed on the high voltage battery pack 330 through the ac charging pile simulator 310, without changing the high and low voltage wiring harness.
Referring to fig. 1 and 2, in an embodiment of the present invention, when only the dc charging test is performed on the high-voltage battery pack 330, the main control unit 1000 simulates the control of the power domain controller 600 on the dc charging test of the whole vehicle, the main control unit 1000 controls the high-voltage junction box 200, the first to fourth high-voltage relays K1 to K4 and the sixth high-voltage relay K6 in the high-voltage junction box 200 are disconnected through the main control unit 1000, the fifth high-voltage relay K5 is closed, the power supply 100 is electrically connected to the dc charging pile simulator 340, and the power supply 100 is used as the dc source of the dc charging pile simulator 300, so that the dc charging pile simulator 340 performs the dc charging test on the high-voltage battery pack 330 without changing the high-voltage and low-voltage harnesses.
Referring to fig. 1 and 2, in one embodiment of the present invention, when the power domain controller 600 and the high-voltage battery pack 330 are subjected to the integrated ac charging test, the main control unit 100 controls the high-voltage junction box 200 to disconnect the first high-voltage relay K1, the second high-voltage relay K2, the fourth high-voltage relay K4, the fifth high-voltage relay K5, and the sixth high-voltage relay K6 in the high-voltage junction box 200, close the high-voltage relay K3, electrically connect the vehicle-mounted charger 320 and the high-voltage battery pack 300, charge the vehicle-mounted charger 320 to the high-voltage battery pack 300, and perform the ac charging test on the high-voltage battery pack 330 through the ac charging pile simulator 310, which does not need to change the high-low voltage harness.
Referring to fig. 1 and 2, in one embodiment of the present invention, when V2X (Vehicle to X) is performed on the whole vehicle, for example, when the power domain controller 600 and the high-voltage battery pack 330 are subjected to an integrated AC discharge test, the main control unit 100 controls the high-voltage junction box 200 to disconnect the first high-voltage relay K1, the second high-voltage relay K2, the fourth high-voltage relay K4, the fifth high-voltage relay K5, and the sixth high-voltage relay K6 in the high-voltage junction box 200, and close the third high-voltage relay K3, so that the vehicle-mounted charger 320 and the high-voltage battery pack 300 are electrically connected, the vehicle-mounted charger 320 performs the discharge test, and the high-voltage battery pack 300 performs the AC discharge test on a program-controlled AC load (not shown in the figure) through the vehicle-mounted charger 320, without changing the high-low voltage harness.
Referring to fig. 1 and 2, in an embodiment of the present invention, when the power domain controller 600 and the high-voltage battery pack 330 are subjected to the integrated dc charging test, the main control unit 1000 controls the high-voltage junction box 200, and the first high-voltage relay K1 to the fourth high-voltage relay K4 and the sixth high-voltage relay K6 in the high-voltage junction box 200 are opened, so that the fifth high-voltage relay K5 is closed, the power source 100 is electrically connected to the dc charging pile simulator 340, and the power source 100 is used as a dc source of the dc charging pile simulator 300, so that the dc charging pile simulator 340 performs the dc charging test on the high-voltage battery pack 330 without changing the high-voltage and low-voltage wire harness.
Referring to fig. 1 and 2, in an embodiment of the present invention, when the power domain controller 600 and the vehicle-mounted charger 320 are subjected to the integrated ac charging test, the main control unit 1000 simulates the communication logic of the high-voltage battery pack 330, the main control unit 1000 controls the high-voltage junction box 200, so that the third to sixth high-voltage relays K3 to K6 in the high-voltage junction box 200 are opened, the first and second high-voltage relays K1 and K2 are closed, the vehicle-mounted charger 320 is connected to the power supply 100, the power supply 100 simulates the high-voltage battery pack 330 to receive the voltage/current, and the integrated ac charging test is performed by the ac charging pile simulator 310 without changing the high-voltage and low-voltage wire harness.
Referring to fig. 1 and 4, in an embodiment of the present invention, when the combined motor 512 is tested for driving, the main control unit 1000 simulates the control of the power domain controller 600 for driving the whole vehicle and simulates the communication logic of the high voltage battery pack 330, the main control unit 1000 controls the high voltage junction box 200 to open the first high voltage relay K1 to the fifth high voltage relay K5 and close the sixth high voltage relay K6 in the high voltage junction box 200. The motor controller 510, the inductance cabinet 400 and the power supply 1000 are electrically connected, and the power supply 100 simulates the high voltage battery pack 330 to output direct current high voltage/current for running test of the motor controller 510 and the first motor 520, and the high voltage and low voltage wire harness is not required to be changed.
Referring to fig. 1 and 3, in an embodiment of the present invention, when the second motor 530 is tested for driving, the main control unit 1000 simulates the control of the power domain controller 600 for driving the whole vehicle and simulates the communication logic of the high voltage battery pack 330, the main control unit 1000 controls the high voltage junction box 200 to open the first high voltage relay K1 to the fifth high voltage relay K5 and close the sixth high voltage relay K6 in the high voltage junction box 200. The second motor 530, the induction cabinet 400 and the power supply 1000 are electrically connected, and the power supply 100 simulates the output of the high voltage battery pack 330 to perform the running test without changing the high voltage and low voltage wiring harness.
Referring to fig. 1 and 4, in an embodiment of the present invention, when the integrated driving test is performed on the combined motor 512 and the high-voltage battery pack 330, the main control unit 1000 simulates the control signal of the power domain controller 600, and the main control unit 1000 controls the high-voltage junction box 200 to open the first to third high-voltage relays K1 to K3 and the fifth high-voltage relay K5 and close the fourth and sixth high-voltage relays K4 and K6 in the high-voltage junction box 200. The motor controller 510, the induction cabinet 400 and the high-voltage battery pack 330 are electrically connected to perform an integrated driving test of the motor controller 510, the first motor 520 and the high-voltage battery pack 330, which does not require to change high-low voltage wiring harnesses.
Referring to fig. 1 and 3, in an embodiment of the present invention, when the integrated driving test is performed on the second motor 530 and the high voltage battery pack 330, the main control unit 1000 simulates the driving test control of the power domain controller 600 on the whole vehicle, and the main control unit 1000 controls the high voltage junction box 200 such that the first to third high voltage relays K1 to K3 and the fifth high voltage relay K5 in the high voltage junction box 200 are opened, and the fourth and sixth high voltage relays K4 and K6 are closed. The second motor 530, the induction cabinet 400 and the high-voltage battery pack 330 are electrically connected to perform an integrated driving test of the second motor 530 and the high-voltage battery pack 330, which does not require to change high-low voltage wiring harnesses.
Referring to fig. 1 and 2, in one embodiment of the present invention, when performing a power domain system test on the power domain controller 600, the second motor 530, the vehicle-mounted charger 320 and the high-voltage battery pack 330, the main control unit 1000 is electrically connected to the power domain controller 600, the second motor 530, the vehicle-mounted charger 320 and the high-voltage battery pack 330 through the low-voltage communication harness 710, and the main control unit 1000 controls the high-voltage junction box 200 such that the first high-voltage relay K1, the second high-voltage relay K2 and the high-voltage relay K5 in the high-voltage junction box 200 are opened, and the third high-voltage relay K3, the fourth high-voltage relay K4 and the sixth high-voltage relay K6 are closed. The second motor 530, the vehicle-mounted charger 320 and the high-voltage battery pack 330 are connected through the high-voltage wire harness, and the power domain controller 600, the second motor 530, the vehicle-mounted charger 320 and the high-voltage battery pack 330 are subjected to power domain system test without changing the high-voltage wire harness and the low-voltage wire harness.
Referring to fig. 1 to 4, in an embodiment of the present invention, when performing a power domain system test on the power domain controller 600, the combined motor 512, the vehicle-mounted charger 320 and the high-voltage battery pack 330, the main control unit 1000 is electrically connected to the power domain controller 600, the first motor 520, the motor controller 510, the vehicle-mounted charger 320 and the high-voltage battery pack 330 through the low-voltage communication harness 710, and the main control unit 1000 controls the high-voltage junction box 200 such that the first high-voltage relay K1, the second high-voltage relay K2 and the fifth high-voltage relay K5 in the high-voltage junction box 200 are opened, and the third high-voltage relay K3, the fourth high-voltage relay K4 and the sixth high-voltage relay K6 are closed. The first motor 520, the motor controller 510, the vehicle-mounted charger 320 and the high-voltage battery pack 330 are connected through the high-voltage wire harness to perform the power domain system test of the power domain controller 600, the first motor 520, the motor controller 510, the vehicle-mounted charger 320 and the high-voltage battery pack 330, and the high-voltage wire harness is not required to be changed.
Referring to fig. 1 and 2, in an embodiment of the present invention, when only the vehicle-mounted charger 320 is tested individually, the main control unit 1000 simulates the control of the power domain controller 600 on the vehicle-mounted charger 320, the main control unit 1000 controls the high voltage junction box 200, disconnects the first to sixth high voltage relays K1 to K6 in the high voltage junction box 200, protects other tested parts and testing equipment, and uses the ac charging pile simulator 310 to test the vehicle-mounted charger 320 without changing the high and low voltage wiring harnesses.
Referring to fig. 1 and 2, in an embodiment of the present invention, when performing an ac charging test on the high-voltage battery pack 330 and the vehicle-mounted charger 320, the main control unit 1000 simulates a control signal of the power domain controller 600, and the main control unit 1000 controls the high-voltage junction box 200 to open the first high-voltage relay K1, the second high-voltage relay K2 and the fourth high-voltage relay K4 to the sixth high-voltage relay K6 in the high-voltage junction box 200, and close the high-voltage relay K3. The high-voltage battery pack 330 is electrically connected to the vehicle-mounted charger 320, and an ac charging test is performed by an ac charging stake simulator without changing the high-voltage and low-voltage wiring harness.
The above embodiments are merely illustrative of the principles of the present invention and its effectiveness, and are not intended to limit the invention. Modifications and variations may be made to the above-described embodiments by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is intended that all equivalent modifications and variations of the invention be covered by the claims, which are within the ordinary skill of the art, be within the spirit and scope of the present disclosure.
Claims (7)
1. The utility model provides a new energy automobile's high pressure test system which characterized in that includes:
A power supply;
the high-voltage junction box is electrically connected with the power supply and comprises a plurality of high-voltage relays which are respectively and electrically connected with corresponding tested pieces;
the charge-discharge testing unit is electrically connected with the high-voltage junction box;
The inductance cabinet is electrically connected with the high-voltage junction box;
The motor testing unit is electrically connected with the inductance cabinet;
The main control unit is electrically connected with the power supply, the high-voltage branch box, the charge-discharge testing unit, the inductance cabinet and the motor testing unit, and is in communication connection with the high-voltage branch box so as to control the high-voltage branch box to switch the testing range of the tested piece; and
The power domain controller is electrically connected with the main control unit;
The high-voltage testing system further comprises a plurality of wire harnesses, wherein the plurality of wire harnesses comprise a low-voltage communication wire harness, a three-phase high-voltage wire harness and a direct-current high-voltage wire harness, and each tested piece is electrically connected with the main control unit through the plurality of wire harnesses respectively so as to execute different functional tests on the tested piece;
the charge and discharge test unit includes:
The high-voltage battery pack is electrically connected with the main control unit through the low-voltage communication wire harness and is also electrically connected with the high-voltage branch box through the direct-current high-voltage wire harness so as to control the high-voltage branch box to switch different high-voltage loops according to different test requirements;
The motor test unit further includes:
The first motor is electrically connected with the motor controller through the low-voltage communication wire harness;
the second motor is electrically connected with the main control unit through the low-voltage communication wire harness and is electrically connected with the inductance cabinet through the direct-current high-voltage wire harness;
The dynamometer rack is electrically connected with the main control unit, the motor controller and the second motor through a low-voltage communication wire harness, so that the rotating speed and the torque of the first motor and the second motor are controlled, and the measurement accuracy is improved.
2. The high-voltage testing system of a new energy automobile according to claim 1, wherein the charge and discharge testing unit comprises:
the alternating-current charging pile simulator is electrically connected with the main control unit through the low-voltage communication wire harness;
And one end of the vehicle-mounted charger is electrically connected with the alternating current charging pile simulator through the three-phase high-voltage wire harness, and the other end of the vehicle-mounted charger is electrically connected with the high-voltage junction box through the direct current high-voltage wire harness.
3. The high-voltage testing system of a new energy automobile according to claim 2, wherein the charge-discharge testing unit further comprises:
The direct current charging pile simulator is electrically connected with the main control unit through the low-voltage communication wire harness and is electrically connected with the high-voltage battery pack through the direct current high-voltage wire harness.
4. The high voltage testing system of a new energy automobile according to claim 1, wherein the motor testing unit comprises:
the inductance cabinet is electrically connected with the main control unit through the low-voltage communication wire harness;
And the motor controller is electrically connected with the inductance cabinet through the direct-current high-voltage wire harness and is electrically connected with the main control unit through the low-voltage communication wire harness.
5. The high voltage testing system of a new energy vehicle of claim 1, wherein the power domain controller is further electrically connected to the motor controller, the first motor and the high voltage battery pack.
6. The high voltage testing system of the new energy vehicle of claim 2, wherein the high voltage battery pack is further electrically connected to the motor controller, the second motor and the vehicle-mounted charger.
7. The high voltage testing system of a new energy vehicle of claim 1, wherein the dynamometer bench pair drags the first motor or the second motor.
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| CN210742701U (en) * | 2019-12-21 | 2020-06-12 | 郑州意昂新能源汽车科技有限公司 | Three-station rack joint debugging simulation test system |
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