CN114325192B - Pulse heating endurance test method for electric drive system - Google Patents
Pulse heating endurance test method for electric drive system Download PDFInfo
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- CN114325192B CN114325192B CN202111657924.5A CN202111657924A CN114325192B CN 114325192 B CN114325192 B CN 114325192B CN 202111657924 A CN202111657924 A CN 202111657924A CN 114325192 B CN114325192 B CN 114325192B
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- 238000013102 re-test Methods 0.000 claims abstract description 8
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Abstract
The invention provides a pulse heating endurance test method of an electric drive system, which comprises the following steps: step S1, building a test system; step S2, performing a endurance test initial test on the electric drive system to obtain an initial test result; step S3, standing the electric drive system for a first preset time; step S4, low-voltage power-on is performed on the electric drive system; step S5, high-voltage power is applied to the electric drive system, then an opening pulse heating instruction is sent out, and the battery simulator is heated; step S6, a torque mode instruction is sent; step S7, sending a Standby instruction; cycling N rounds of steps S4-S7; step S8, performing endurance test retest on the electric drive system, and verifying whether the state of the electric drive system is normal after N rounds of pulse heating based on the initial test result and the retest result; and S9, disassembling the electric drive system to form a disassembly report.
Description
Technical Field
The invention belongs to the field of new energy electric drive systems, and particularly relates to an electric drive pulse heating endurance test system and method.
Background
New energy automobiles start to enter a high-speed development stage, and batteries are used as energy sources of the electric automobiles and are the most central part of the electric automobiles, and lithium batteries are mainly adopted at present. However, the lithium ion battery has poor discharge performance at low temperature, so that in low-temperature occasions, the lithium ion battery needs to be lifted to a proper temperature to fully release energy, and the pulse heating technology is one of methods for solving the problem. The principle is that the battery releases pulse current through an electric drive system, and the pulse current reversely heats the battery. The pulse heating technology can rapidly raise the temperature of the battery and restore the performance of the battery.
For the current vehicles used by users, the service life requirement exists, and the pulse heating is used as a function on the electric vehicle, so that the service life requirement needs to be met, and therefore, a long-time endurance test is required to be carried out on the pulse heating technology. However, the lifetime of the current electric automobile is generally more than 24 ten thousand kilometers in 10 years, and if the pulse heating durability is verified according to the time, a great deal of time and effort are required, so that a method capable of verifying the pulse heating durability of an electric drive system is required, the pulse heating durability of the electric drive system can be verified, and the pulse heating durability test time can be shortened.
Disclosure of Invention
The embodiment of the invention provides a pulse endurance test method of an electric drive system, which can carry out endurance verification on the function of the electric drive system during pulse heating of a battery according to the service life requirement of an actual electric vehicle.
The technical scheme of the invention is as follows:
the invention provides a pulse heating endurance test method of an electric drive system, which comprises the following steps:
step S1, building a test system for performing pulse heating endurance test on an electric drive system;
step S2, before performing a pulse heating endurance test on the electric driving system, performing an endurance test initial test on the electric driving system by using a bench upper computer to obtain an initial test result;
step S3, after a preliminary test of a endurance test is carried out on the electric drive system, standing the electric drive system for a first preset time period, and then entering step S4;
step S4, the low-voltage power supply is used for applying low-voltage power to the electric drive system;
step S5, the upper computer of the bench controls the battery simulator to electrify the electric driving system at high voltage, controls an external load connected with the electric driving system to enter a working state through the electric driving system, and then sends an opening pulse heating instruction to a motor controller IPU in the electric driving system, so that the motor controller IPU heats the battery simulator within a second preset time length; outputting a stop pulse heating instruction by the upper computer after the second preset time length is reached;
step S6, the rack upper computer sends a torque mode instruction to a motor controller IPU in the electric drive system, so that the motor controller IPU in the electric drive system controls a motor to run for a third preset time period at a speed lower than a preset rotating speed; outputting a command for exiting the torque mode by the upper computer after the third preset time period arrives at the rear rack;
step S7, the bench upper computer sends a Standby instruction to a motor controller IPU of the electric drive system, so that the motor controller IPU in the electric drive system controls the electric drive system to enter a Standby state;
cycling through the N rounds of steps S4-S7, and stopping the test if the working parameters of the electric drive system exceed the corresponding preset working ranges and/or if the vibration quantity of the electric drive system exceeds the preset vibration quantity in the step S5;
s8, performing endurance test retest on the electric drive system by using the rack upper computer, and verifying whether the state of the electric drive system is normal after N rounds of pulse heating based on the initial test result and the retest result;
and S9, disassembling the electric drive system to form a disassembly report.
Preferably, the electric drive system in step S1 is an all-in-one electric drive system integrating a DCDC converter, a DCAC converter, a high voltage junction box, a motor controller IPU, a motor, and a decelerator, and step S1 includes:
simulating the real environment of the whole vehicle, and respectively connecting a rack upper computer with an acceleration sensor, an oscilloscope, a rack dynamometer, a battery simulator, an electric driving system and a cooling system through a signal wire harness; the electric driving system is connected with the battery simulator through a high-voltage wire harness, is connected with the bench dynamometer through a mechanical structure, is connected with a low-voltage power supply and an external load through a low-voltage wire harness, and is connected with the cooling system through a cooling loop.
Preferably, in step S2 and step S8, the content of the initial test for the endurance test and the content of the repeated test for the endurance test each include: carrying out peak external characteristic measurement, insulation resistance measurement and motor back electromotive force measurement on an electric drive system; wherein,,
the step of making off-peak characteristic measurements for the electric drive system includes:
the battery simulator is controlled by the bench upper computer to output the lowest working voltage, the highest working voltage and the rated working voltage of the electric driving system, and the peak external characteristics of the electric driving system under different working voltages are measured by the dynamometer;
the step of making insulation resistance measurements for the electric drive system includes:
measuring the insulation resistance of the motor controller IPU high-voltage input terminal of the electric drive system to the shell by using an insulation resistance tester and the insulation resistance of the DCAC converter output terminal of the electric drive system to the shell;
the step of measuring the back electromotive force of the motor for the electric drive system comprises:
firstly, disconnecting a three-phase copper bar of a motor controller in an electric drive system from a three-phase terminal of a motor, and connecting a high-voltage differential probe of an oscilloscope with a U-phase and a V-phase of the motor; the method comprises the steps that a signal is output by a rack upper computer, so that a rack dynamometer drags an electric driving system to operate to a preset rotating speed, and counter electromotive force of a U phase and a V phase of a motor under the preset rotating speed is measured by an oscilloscope; after the back electromotive force measurement is completed, connection between a motor controller three-phase copper bar and a motor three-phase terminal in an electric drive system is restored
Preferably, in step S2, the content of the endurance test initial test performed on the electric drive system by using the rack upper computer further includes:
the method comprises the steps that a pulse heating instruction is output to a motor controller IPU of an electric driving system through a rack upper computer, the motor controller IPU is enabled to start to heat a battery simulator in a pulse mode, an oscilloscope is used for measuring the current of a pulse heating direct-current end of the battery simulator, and an acceleration sensor is used for determining the vibration quantity of the electric driving system according to the vibration acceleration measured by the electric driving system in the pulse heating process; after the measurement is finished, the upper computer of the rack controls the motor controller IPU of the electric drive system to withdraw from pulse heating of the battery simulator.
Preferably, in step S4, after the low voltage power supply powers on the electric drive system, detecting whether the communication signals between the upper computer of the rack and the rack dynamometer, the electric drive system and the battery simulator are normal; and when the communication signals among the rack upper computer, the rack dynamometer, the electric drive system and the battery simulator are all normal, the step S5 is carried out again.
Preferably, in step S5, after the rack upper computer controls the battery simulator to power up the electric drive system at high voltage, if the rack upper computer detects that: the rotor rotation signal, the random number, the bus voltage duty ratio, the basic frequency, the three-phase current value and the output voltage of the battery simulator of the electric drive system are all in the corresponding preset standard range, no fault code is generated in the communication signal output by the motor controller IPU of the electric drive system, the external load works normally with rated power, and the upper computer of the bench sends an opening pulse heating instruction to the motor controller IPU in the electric drive system;
after the battery simulator is started to be heated in a pulse mode, the upper computer of the rack detects three-phase current, rotor temperature, stator temperature, IGBT temperature, direct-current bus voltage, fault level and fault code of a motor output by the motor controller IPU, and when any signal of the three-phase current, rotor temperature, stator temperature, IGBT temperature, direct-current bus voltage, fault level and fault code of the motor output by the motor controller IPU shows that the working state of the electric drive system is faulty, the pulse heating endurance test is exited;
after the battery simulator is started to be heated in a pulse mode, the upper computer of the rack also measures the current of a pulse heating direct-current end of the battery simulator by using an oscilloscope, and determines the vibration quantity of the electric driving system by using the acceleration sensor to the vibration acceleration measured by the electric driving system in the pulse heating process; and comparing the measured pulse heating direct current end current with the pulse heating direct current end current obtained in the initial test in the step S2, and comparing the measured vibration quantity with the pulse heating direct current end current obtained in the initial test in the step S2 to determine whether the reason for the change of the pulse heating direct current end current and the vibration quantity is caused by the self reason of the electric drive system or the pulse heating of the battery simulator.
Preferably, before executing step S7, each time the mth cycle is entered, a back electromotive force measurement is performed on the U-phase and the V-phase of the motor at a predetermined rotation speed, and a pulse heating direct current measurement is performed on the battery simulator in a pulse heating environment; when the back electromotive force of the U phase and the V phase of the motor under the preset rotating speed and the pulse heating direct current end current of the battery simulator are both in the respective preset working ranges, executing the step S7; m is smaller than N.
Preferably, in step S7, after the electric drive system enters the standby state, the gantry upper computer determines whether the operation parameters of the electric drive system are within the corresponding predetermined operation ranges based on the CAN bus data output from the motor controller IPU of the electric drive system.
Preferably, in step S8, if the difference between the peak external characteristics of the electric drive system in the initial test result and the secondary test result is within a predetermined variation range, the insulation resistance of the high voltage input terminal of the motor controller IPU to the housing and the insulation resistance of the output terminal of the DCAC converter to the housing in the initial test result and the secondary test result are both within respective corresponding predetermined standard ranges, and the motor back electromotive force difference in the initial test result and the secondary test result is within a predetermined variation range, it is determined that the electric drive system supports N pulse heating endurance tests.
Preferably, in step S9, the disassembly report of the electric drive system is formed by disassembling the electric drive system to check whether the internal components of the electric drive system are damaged.
The beneficial effects of the invention are as follows:
according to the pulse heating endurance test of the electric drive system, the pulse heating endurance of the electric drive system can be verified according to the service life of the whole vehicle and the actual vehicle condition of a user, and compared with the whole vehicle verification, the pulse heating endurance test of the electric drive system can greatly shorten the test time, reduce the test resource investment, greatly improve the efficiency and reduce the test cost. Utilize rack host computer automatic control electric drive system, can realize the automatic control of electric drive system pulse heating endurance verification test, compare in manual operation, can reduce personnel's input and maloperation risk, improve experimental security and maneuverability, can accelerate the test progress of rack, reduce test cost.
Drawings
FIG. 1 is a block diagram of a pulse heating endurance test in an embodiment of the present invention;
FIG. 2 is a flow chart of a method according to an embodiment of the invention.
Detailed Description
Embodiments of the present invention and the actual operation of the gantry automatic control pulse heating function on and off will be described with reference to the schematic design drawings. Since the core technical points of the present invention need to be protected, the illustrated embodiments are only a part of the content of the present invention, but all fall within the scope of the protection of the present invention.
The embodiment of the invention provides an electric drive pulse heating endurance test system and method, which are used for verifying the durability of electric drive pulse heating based on the service life of a whole vehicle.
Referring to fig. 2, the method in the embodiment of the invention comprises the following steps:
step S1, a test system for performing pulse heating endurance test on the electric drive system is built.
In this embodiment, referring to fig. 1, a module or a device related to the test system includes: the system comprises a bench upper computer, an acceleration sensor, a bench dynamometer, a battery simulator, an adjustable low-voltage power supply, a cooling system, an oscilloscope, an insulation resistance tester and an external load. When the test system is built, the following steps are needed: simulating the real environment of the whole vehicle, and respectively connecting a rack upper computer with an acceleration sensor, an oscilloscope, a rack dynamometer, a battery simulator, an electric driving system and a cooling system through a signal wire harness; the electric driving system is connected with the battery simulator through a high-voltage wire harness, is connected with the bench dynamometer through a mechanical structure, is connected with a low-voltage power supply and a load through a low-voltage wire harness, and is connected with the cooling system through a cooling loop.
After step S1 is completed, an initial test is required to be performed on the electric drive system, that is, step S2 is performed, before a pulse heating endurance test is performed on the electric drive system, an endurance test initial test is performed on the electric drive system by using a rack upper computer, and an initial test result is obtained.
The test items for performing the endurance test initial test on the electric drive system by using the bench upper computer comprise: and (3) carrying out peak external characteristic generation, insulation resistance test, motor back electromotive force test, pulse heating direct current end current and vibration quantity test and the like on the electric drive system. Wherein, the peak external characteristic result, the insulation resistance result and the motor back electromotive force result of the electric drive system together form the initial test result in the embodiment. The pulse heating direct current end current and the vibration quantity are designed for determining the reason of the end current and the vibration quantity of the electric drive system.
Off-peak characteristics for an electric drive system: the battery simulator is controlled by the upper computer of the bench to output the lowest working voltage, the highest working voltage and the rated working voltage of the electric drive system, and the peak external characteristics of the electric drive system under different working voltages are measured by the dynamometer.
The contents of insulation resistance testing of an electric drive system include: the insulation resistance of the motor controller IPU high-voltage input terminal of the electric drive system to the shell is measured by using an insulation resistance tester, and the insulation resistance of the DCAC converter output terminal of the electric drive system to the shell is measured by using the insulation resistance tester.
The content of measuring the back electromotive force of the motor of the electric drive system comprises: during testing, the three-phase copper bar of the motor controller is manually disconnected from the three-phase terminals of the motor, the high-voltage differential probe of the oscilloscope is respectively connected with the U phase and the V phase of the motor, signals are output through the upper computer of the rack, the power measuring machine of the rack drags the electric drive system to a certain rotating speed (preset rotating speed), and counter electromotive force of the U phase and the V phase of the motor under the preset rotating speed is recorded by the oscilloscope. And after the test is finished, manually recovering the connection between the three-phase copper bars of the motor controller and the three-phase terminals of the motor.
The step of measuring the current and vibration quantity of the pulse heating direct current end comprises the following steps:
the pulse heating instruction is output to the motor controller IPU of the electric drive system through the rack upper computer, so that the motor controller IPU is started to perform pulse heating on the battery simulator, an oscilloscope is used for measuring the pulse heating direct current end current of the battery simulator, and the vibration quantity of the electric drive system assembly in the pulse heating process is measured.
The above preliminary test items are only needed by the examples, and the actual preliminary test items can be adjusted according to the requirements of the electric drive system.
The step S3 is as follows: after an initial endurance test is performed on the electric drive system, the electric drive system is allowed to stand for a first predetermined period of time (t 1 hours).
Specifically, prior to testing, the electric drive system needs to be sufficiently immersed in the test environment to bring the test conditions of the electric drive system closer to the surrounding environment. The first predetermined time period t1 may thus be based on the actual situation, in order to achieve the effect time.
Step S4, the low-voltage power supply is used for low-voltage power on the electric drive system.
In step S4, it is required to detect whether the communication signals between the upper computer of the rack and the rack power measuring machine, the electric driving system and the battery simulator are normal, wherein whether the communication signals are normal refers to whether the signals transmitted between the devices are transmitted according to the design standard.
Specifically, in the step S4, after the low voltage is applied, if the communication signals between the rack upper computer and the rack dynamometer, the electric drive system and the battery simulator are all normal, the next test is performed; if any signal is abnormal, the low voltage signal is checked, and the problem is found and solved.
And S5, the upper computer of the rack controls the battery simulator to electrify the electric driving system at high voltage, the external load works at rated power under the control of the electric driving system, the upper computer of the rack sends a pulse heating instruction to start a motor controller IPU of the electric driving system, the motor controller IPU starts to pulse heat the battery simulator, after a second preset time (t 2 minutes) of working time, the motor controller IPU closes the external load, and the upper computer of the rack sends a pulse heating instruction to close the motor controller IPU.
Specifically, after the battery simulator is powered on the electric drive system at high voltage, whether the condition of the rack meets the pulse heating requirement is required to be judged (specifically, the upper computer of the rack is used for detecting that the rotor rotation signal, the random number, the bus voltage duty ratio, the basic frequency, the three-phase current value and the output voltage of the battery simulator of the electric drive system are all in the corresponding preset standard range, no fault code is generated in the communication signal output by the motor controller IPU of the electric drive system, and after the external load works normally at rated power, a pulse heating instruction is sent to the motor controller IPU in the electric drive system again), the signals in the example are only referenced, and the signals can be actually adjusted according to the upper computer of the rack and the electric drive system.
After the battery simulator is started to be heated in a pulse mode, the upper computer of the rack detects three-phase current, rotor temperature, stator temperature, IGBT temperature, direct-current bus voltage, fault level and fault code of a motor output by the motor controller IPU, and when any signal of the three-phase current, rotor temperature, stator temperature, IGBT temperature, direct-current bus voltage, fault level and fault code of the motor output by the motor controller IPU shows that the working state of the electric drive system is faulty, the pulse heating endurance test is exited. The external load is an actual car scene of a simulated user, and can be adjusted, increased or reduced according to the actual pulse heating test. The second predetermined time period t2 is determined according to the specific situation and the specific requirement.
After the battery simulator is started to be heated in a pulse mode, the upper computer of the rack also measures the current of a pulse heating direct-current end of the battery simulator by using an oscilloscope, and determines the vibration quantity of the electric driving system by using the acceleration sensor to the vibration acceleration measured by the electric driving system in the pulse heating process; and comparing the measured pulse heating direct current end current with the pulse heating direct current end current obtained in the initial test in the step S2, and comparing the measured vibration quantity with the pulse heating direct current end current obtained in the initial test in the step S2 to determine whether the reason for the change of the pulse heating direct current end current and the vibration quantity is caused by the self reason of the electric drive system or the pulse heating of the battery simulator.
Step S6, the upper computer of the rack sends a motor controller IPU entering the torque mode command electric drive system, the motor controller IPU controls the motor to work for a third preset time (t 3 minutes) at a preset rotating speed (recommended not higher than 100 r/min), and the upper computer of the rack sends a torque control mode command ending to the motor controller IPU.
Specifically, the step mainly simulates the actual vehicle condition of a user after the pulse heating of the user is completed, and agitates the oil lubrication gear and the bearing of the speed reducer. Therefore, the preset rotating speed and the third preset time t3 in the example can be adjusted according to actual conditions and specific requirements.
Step S7, the upper computer of the rack sends a Stanby instruction to the motor controller IPU of the electric drive system, so that the electric drive system enters a Stanby mode, and the running time is a fourth preset time t4;
and (4) circularly performing the steps S4-S7 until the cycle reaches N times (such as 800 times, and the service life can be adjusted according to the actual requirement of the whole vehicle), and ending the test. In any of the steps S4 to S7, if the operating parameter of the electric drive system exceeds the corresponding predetermined operating range, and/or if the vibration amount of the electric drive system exceeds the predetermined vibration amount in the step S5, the test is stopped.
In step S7, after the electric drive system enters the standby state, the gantry upper computer determines whether the operating parameters of the electric drive system are located in the corresponding predetermined operating ranges based on the CAN bus data output from the motor controller IPU of the electric drive system. The following judgment is specifically needed:
judging whether the motor state is normal or not based on the back electromotive force of the motor V phase and the motor U phase, and whether the motor state can support continuous test or not;
judging whether the corresponding relation between the three-phase current of the motor and the pulse heating direct current end current obtained in the step S5 is normal or not, and whether the continuous test can be supported or not;
judging whether the motor is over-temperature or not based on the temperature of the rotor, and whether the motor can support continuous test or not;
judging whether the motor is over-heated or not based on the temperature of the stator, and whether the motor can support continuous test or not;
judging whether the motor controller is over-heated or not based on the IGBT temperature, and whether the motor controller can support continuous test or not;
judging whether the battery voltage is normal or not based on the direct current bus voltage, and whether the continuous test can be supported or not;
judging a fault grade based on the fault grade;
and judging the fault reason based on the fault code.
When these signals are in normal state, it is indicated that the working parameters of the electric drive system are in normal state, and the state of the electric drive system is normal.
Specifically, the fourth predetermined period t4 is a period of time that simulates a user standing the vehicle, and the retarder oil deposits and the retarder bottom, and is therefore adjustable according to the test requirements.
In which, each time the test is performed for M cycles (M may be 50 times, 100 times, etc.), a motor back electromotive force measurement and a pulse heating dc bus current measurement need to be performed in step S5, mainly for checking and identifying the conditions of the electric drive system and the pulse heating function, the risk is identified in advance, so as to determine whether the cause of the change of the current and the vibration quantity of the pulse heating dc terminal is caused by the self cause of the electric drive system or the pulse heating of the battery simulator.
And S8, performing pulse heating retest on the sample, wherein the specific test content of the retest is the same as that of the step S2. In particular, it is desirable to verify that the electric drive system is functioning properly and that the durability of the pulse heating affects proper use of the electric drive system.
In step S8, if the peak external characteristic variation difference of the electric drive system in the initial test result and the repeated test result is within the predetermined variation range, the insulation resistance of the motor controller IPU high voltage input terminal to the housing and the insulation resistance of the DCAC converter output terminal to the housing in the initial test result and the repeated test result are both within the respective corresponding preset standard ranges, and the motor back electromotive force difference in the initial test result and the repeated test result is within the predetermined variation range, it is determined that the electric drive system supports N pulse heating endurance tests.
And S9, disassembling the sample to form a disassembly report. In particular, disassembly is to check whether the internal components are damaged.
The embodiment of the invention provides the method, which can verify the pulse heating durability of the electric drive system based on the service life condition of the whole vehicle, can greatly shorten the pulse heating durability test time of the electric drive system and reduce the manpower and capital investment.
Claims (10)
1. A method of pulse heating durability testing an electric drive system, comprising:
step S1, building a test system for performing pulse heating endurance test on an electric drive system;
step S2, before performing a pulse heating endurance test on the electric driving system, performing an endurance test initial test on the electric driving system by using a bench upper computer to obtain an initial test result;
step S3, after a preliminary test of a endurance test is carried out on the electric drive system, standing the electric drive system for a first preset time period, and then entering step S4;
step S4, the low-voltage power supply is used for applying low-voltage power to the electric drive system;
step S5, the upper computer of the bench controls the battery simulator to electrify the electric driving system at high voltage, controls an external load connected with the electric driving system to enter a working state through the electric driving system, and then sends an opening pulse heating instruction to a motor controller IPU in the electric driving system, so that the motor controller IPU heats the battery simulator within a second preset time length; outputting a stop pulse heating instruction by the upper computer after the second preset time length is reached;
step S6, the rack upper computer sends a torque mode instruction to a motor controller IPU in the electric drive system, so that the motor controller IPU in the electric drive system controls a motor to run for a third preset time period at a speed lower than a preset rotating speed; outputting a command for exiting the torque mode by the upper computer after the third preset time period arrives at the rear rack;
step S7, the bench upper computer sends a Standby instruction to a motor controller IPU of the electric drive system, so that the motor controller IPU in the electric drive system controls the electric drive system to enter a Standby state;
cycling through the N rounds of steps S4-S7, and stopping the test if the working parameters of the electric drive system exceed the corresponding preset working ranges and/or if the vibration quantity of the electric drive system exceeds the preset vibration quantity in the step S5;
s8, performing endurance test retest on the electric drive system by using the rack upper computer, and verifying whether the state of the electric drive system is normal after N rounds of pulse heating based on the initial test result and the retest result;
and S9, disassembling the electric drive system to form a disassembly report.
2. The method of claim 1, wherein the electric drive system in step S1 is an integrated DCDC converter, a DCAC converter, a high voltage junction box, a motor controller IPU, a motor, and a decelerator electric drive system, and step S1 includes:
simulating the real environment of the whole vehicle, and respectively connecting a rack upper computer with an acceleration sensor, an oscilloscope, a rack dynamometer, a battery simulator, an electric driving system and a cooling system through a signal wire harness; the electric driving system is connected with the battery simulator through a high-voltage wire harness, is connected with the bench dynamometer through a mechanical structure, is connected with a low-voltage power supply and an external load through a low-voltage wire harness, and is connected with the cooling system through a cooling loop.
3. The method of claim 1, wherein in step S2 and step S8, the content of the initial endurance test and the content of the repeated endurance test include: carrying out peak external characteristic measurement, insulation resistance measurement and motor back electromotive force measurement on an electric drive system; wherein,,
the step of making off-peak characteristic measurements for the electric drive system includes:
the battery simulator is controlled by the bench upper computer to output the lowest working voltage, the highest working voltage and the rated working voltage of the electric driving system, and the peak external characteristics of the electric driving system under different working voltages are measured by the dynamometer;
the step of making insulation resistance measurements for the electric drive system includes:
measuring the insulation resistance of the motor controller IPU high-voltage input terminal of the electric drive system to the shell by using an insulation resistance tester and the insulation resistance of the DCAC converter output terminal of the electric drive system to the shell;
the step of measuring the back electromotive force of the motor for the electric drive system comprises:
firstly, disconnecting a three-phase copper bar of a motor controller in an electric drive system from a three-phase terminal of a motor, and connecting a high-voltage differential probe of an oscilloscope with a U-phase and a V-phase of the motor; the method comprises the steps that a signal is output by a rack upper computer, so that a rack dynamometer drags an electric driving system to operate to a preset rotating speed, and counter electromotive force of a U phase and a V phase of a motor under the preset rotating speed is measured by an oscilloscope; and after the back electromotive force measurement is completed, the connection between the three-phase copper bar of the motor controller in the electric drive system and the three-phase terminal of the motor is restored.
4. The method of claim 3, wherein in step S2, performing, with the rack host computer, the endurance test on the electric drive system further includes:
the method comprises the steps that a pulse heating instruction is output to a motor controller IPU of an electric driving system through a rack upper computer, the motor controller IPU is enabled to start to heat a battery simulator in a pulse mode, an oscilloscope is used for measuring the current of a pulse heating direct-current end of the battery simulator, and an acceleration sensor is used for determining the vibration quantity of the electric driving system according to the vibration acceleration measured by the electric driving system in the pulse heating process; after the measurement is finished, the upper computer of the rack controls the motor controller IPU of the electric drive system to withdraw from pulse heating of the battery simulator.
5. The method according to claim 1, wherein in step S4, after the low voltage power is applied to the electric drive system, it is detected whether the communication signals between the upper computer of the rack and the power measuring machine of the rack, the electric drive system and the battery simulator are normal; and when the communication signals among the rack upper computer, the rack dynamometer, the electric drive system and the battery simulator are all normal, the step S5 is carried out again.
6. The method according to claim 1, wherein in step S5, after the rack upper computer controls the battery simulator to power up the electric drive system at high voltage, if the rack upper computer detects: the rotor rotation signal, the random number, the bus voltage duty ratio, the basic frequency, the three-phase current value and the output voltage of the battery simulator of the electric drive system are all in the corresponding preset standard range, no fault code is generated in the communication signal output by the motor controller IPU of the electric drive system, the external load works normally with rated power, and the upper computer of the bench sends an opening pulse heating instruction to the motor controller IPU in the electric drive system;
after the battery simulator is started to be heated in a pulse mode, the upper computer of the rack detects three-phase current, rotor temperature, stator temperature, IGBT temperature, direct-current bus voltage, fault level and fault code of a motor output by the motor controller IPU, and when any signal of the three-phase current, rotor temperature, stator temperature, IGBT temperature, direct-current bus voltage, fault level and fault code of the motor output by the motor controller IPU shows that the working state of the electric drive system is faulty, the pulse heating endurance test is exited;
after the battery simulator is started to be heated in a pulse mode, the upper computer of the rack also measures the current of a pulse heating direct-current end of the battery simulator by using an oscilloscope, and determines the vibration quantity of the electric driving system by using the acceleration sensor to the vibration acceleration measured by the electric driving system in the pulse heating process; and comparing the measured pulse heating direct current end current with the pulse heating direct current end current obtained in the initial test in the step S2, and comparing the measured vibration quantity with the pulse heating direct current end current obtained in the initial test in the step S2 to determine whether the reason for the change of the pulse heating direct current end current and the vibration quantity is caused by the self reason of the electric drive system or the pulse heating of the battery simulator.
7. The pulse heating endurance test method of the electric drive system according to claim 1, wherein, before executing step S7, the U-phase and the V-phase of the motor are measured once for counter electromotive force at a predetermined rotation speed and the battery simulator is measured once for pulse heating direct current terminal in a pulse heating environment every time the mth cycle is entered; when the back electromotive force of the U phase and the V phase of the motor under the preset rotating speed and the pulse heating direct current end current of the battery simulator are both in the respective preset working ranges, executing the step S7; m is smaller than N.
8. The pulse heating endurance test method of the electric drive system according to claim 1, wherein in step S7, after the electric drive system enters a standby state, the gantry upper computer judges whether an operation parameter of the electric drive system is within a corresponding predetermined operation range based on CAN bus data outputted from a motor controller IPU of the electric drive system.
9. The pulse heating endurance test method of the electric drive system according to claim 1, wherein in step S8, if the peak external characteristic variation difference of the electric drive system in the initial test result and the repeated test result is within a predetermined variation range, the insulation resistance of the motor controller IPU high voltage input terminal to the housing and the insulation resistance of the DCAC converter output terminal to the housing in the initial test result and the repeated test result are both within respective corresponding preset standard ranges, and the motor back electromotive force difference in the initial test result and the repeated test result is within a predetermined variation range, it is determined that the electric drive system supports N pulse heating endurance tests.
10. The method according to claim 1, wherein in step S9, the disassembly report of the electric drive system is formed by disassembling the electric drive system to check whether the internal components of the electric drive system are damaged.
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