CN115343614A - New energy motor simulator power module temperature fault diagnosis system and method - Google Patents
New energy motor simulator power module temperature fault diagnosis system and method Download PDFInfo
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- 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
- G01R31/34—Testing dynamo-electric machines
- G01R31/343—Testing dynamo-electric machines in operation
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R21/00—Arrangements for measuring electric power or power factor
- G01R21/001—Measuring real or reactive component; Measuring apparent energy
- G01R21/003—Measuring reactive component
Abstract
A new energy motor simulator power module temperature fault diagnosis system and method relates to the technical field of motor simulator diagnosis, solves the problem that the existing power module temperature fault analysis and diagnosis is difficult, and can be applied to fault diagnosis of a motor simulator power module in a new energy inverter assembly development test. The system comprises a temperature sensor, a quick-insertion thermocouple extension line, a multi-path temperature acquisition module, an upper computer controller and an alarm information prompt module; temperature sensor locates heat exchanger's cooling outlet upper end, insert formula thermocouple extension line soon and draw forth from temperature sensor, insert multichannel temperature acquisition module, the host computer controller is used for gathering the rotational speed of rack, moment of torsion and motor simulator actual power data, and with data generation trend curve and the database of gathering, calculate and with actual temperature's contrast, produce power module running state analysis, and send running state to alarm information suggestion module, realize temperature fault diagnosis and suggestion.
Description
Technical Field
The invention relates to the technical field of motor simulator diagnosis, in particular to a new energy motor simulator power module temperature fault diagnosis technology.
Background
With the rapid development of new energy automobiles, the update iteration of the new energy test and verification rack is faster and faster. The new energy inverter assembly test bed is a bed frame capable of completing performance, reliability and functional safety test and evaluation of the inverter assembly and realizing functions of limit working condition strengthening examination, failure mode control strategy development and the like. The motor simulator is used as a part of the rack and has the function of simulating the power of the motor model on line to the actual motor consumption in the running test process of the motor inverter assembly. The power simulation part is composed of 16 power units, each power unit comprises 3 power modules, and each power module is mainly composed of a plurality of high-speed IGBTs. The high-speed IGBT is small in size, large in quantity and large in power consumption, heat dissipation with high heat flux density is needed in the operation control process, and generated heat is taken away in time through a radiator by cooling liquid.
In the test operation process, the motor simulator often generates abnormal operation temperature alarm, so that the long-time fault shutdown of the rack is caused. The original rack system only has the highest temperature protection of the motor simulator, the whole rack can be shut down as long as one power module gives an alarm, specific alarm indication is not provided, which module and unit are failed and are unclear, the trouble is cleared each time, a long time is needed for troubleshooting, the cost for directly replacing the power module of the motor simulator with the fault is extremely high, and the fault analysis and the maintenance diagnosis are very difficult. For this reason, no effective and convenient method exists at the present stage.
Disclosure of Invention
The invention provides a new energy motor simulator power module temperature fault diagnosis system, which aims to solve the problem that the existing power module temperature fault analysis and diagnosis are difficult.
The technical scheme of the invention is as follows:
a power module temperature fault diagnosis system of a new energy motor simulator comprises a power module circuit bottom plate, a plurality of high-speed IGBTs and a heat exchanger, wherein a cooling inlet and a cooling outlet are formed in the heat exchanger and used for a cooling medium to enter and exit, 3 power modules form power units, 16 power units form the motor simulator, and the system comprises a temperature sensor, a fast-plugging thermocouple extension line, a multi-path temperature acquisition module, an upper computer controller and an alarm information prompt module;
the temperature sensor is arranged at the upper end of a cooling outlet of the heat exchanger, the quick-insertion thermocouple extension line is led out from the temperature sensor and is connected with a plurality of temperature acquisition modules, the upper computer controller is used for acquiring the rotating speed, the torque and the actual power data of the motor simulator of the rack, and generating a trend curve and a database with the acquired data, calculating and comparing the trend curve and the database with the actual temperature, generating the analysis of the running state of the power module, and sending the running state to the alarm information prompt module to realize the diagnosis and prompt of temperature faults.
Preferably, the temperature sensor is a K-type thermocouple using a high-voltage insulating probe.
Preferably, the temperature sensor is fixed to the upper end of the cooling outlet of the heat exchanger using a thermally conductive adhesive.
Preferably, the cooling medium is propylene glycol thermostatted at 20 ℃.
The invention also provides a new energy motor simulator power module temperature fault diagnosis method, which is applied to the system and comprises the following steps:
s1, starting a rack, starting a cooling function of a motor simulator according to preset water temperature, and enabling each power unit of the motor simulator to be ready to enter a standby state;
s2, clicking a start button, and performing self-detection on the temperature of each channel;
s3, detecting a temperature transmission state: the upper computer controller judges whether the temperature is normal or not, if the temperature is within a reasonable range, the transmission is normal, and the next step is carried out; if the transmission is abnormal, the system alarms and enters an ending monitoring state;
s4, recording temperature data: generating a curve of the collected temperature and recording the curve in a database;
s5, starting the rack to normally operate: starting the rack to start a normal test, and transmitting the command rotating speed, the torque and the actual running power of the motor model to the upper computer controller;
s6, synchronous data calculation: the upper computer controller synchronizes all the acquired data for calculation, judges the states of all the power modules, generates a database and a trend graph, synchronously checks the running states of all the power units and clicks a state monitoring button of an interface;
s7, monitoring the running state of each power module: when the state of each unit is judged to be normal, the bench is prompted to enter normal operation, and the bench starts a normal test state; if the judgment result is abnormal, alarming information prompt is carried out, and the position of the fault power module is locked according to the alarming channel number;
s8, finishing monitoring: and clicking a closing button, stopping detecting various alarms of the system by the system, and then stopping various data records and trend chart updating.
Preferably, the step S2 specifically includes: multichannel temperature acquisition module converts the temperature data who gathers into 485 communication data based on the MODBUS agreement, and the host computer controller carries out self-checking to each passageway temperature of rack through the communication.
Preferably, the calculating of step S6 includes:
(1) Calculating ideal heat loss power P of power module 1 ：
Wherein, P S Calculating and solving the power input into the motor simulator according to the actually input rotating speed and torque of the rack; p E The actual power of the motor simulator is obtained; delta is the power coefficient of heat loss of the power part of the motor simulator, which is given by the equipment manufacturer; n is the number of power modules in the motor simulator;
(2) The theoretical temperature T at the cooling outlet end of the heat exchanger is calculated according to the following formula 1 ：
Wherein P2 is the actual heat loss power of the power module, P 1 ＝P 2 ；T 2 Constant value for cooling inlet temperature 20 ℃; r th The thermal resistance of the power module is obtained by inquiring a thermal resistance curve diagram of a radiator provided by a manufacturer.
Preferably, in step S6, the method for determining the state of each power module is:
bringing the theoretical temperature T of the outlet end of the heat exchanger 1 Comparing with the actual temperature T detected by the temperature sensor, and when T is less than T 1 When the power module works normally, all the power modules work normally; when T > T 1 When the heat of the power module is accumulated, the alarm system prompts that the state of the power module is abnormal and the power module needs to be cleaned, maintained or replaced in time.
The invention also provides a computer readable storage medium for storing a computer program for executing the new energy motor simulator power module temperature fault diagnosis method as described above.
The invention also provides electronic equipment which comprises a processor and a memory, wherein the processor and the memory finish mutual communication through a communication bus; a memory for storing a computer program; and the processor is used for realizing the temperature fault diagnosis method of the power module of the new energy motor simulator when executing the computer program stored in the memory.
Compared with the prior art, the invention solves the problem of difficult analysis and diagnosis of the temperature fault of the existing power module, and has the following specific beneficial effects:
1. the system and the method can be applied to fault diagnosis of the power module of the motor simulator in a new energy inverter assembly development test, can complete the function of synchronously acquiring the temperature of each power module in real time, and have the advantages of low system construction cost, simple operation and convenient debugging and maintenance; the real-time state analysis and calculation can be carried out, the hidden trouble of the power module can be predicted in advance, and the equipment safety is ensured.
2. The K-type thermocouple temperature sensor is arranged near a radiator cooling medium outlet of a power module in the power unit, the actual temperature of the power module radiator after heat exchange is collected in a centralized mode through a multi-channel thermometer, temperature change trend records are completed and a database is generated based on MODBUS protocol and upper computer communication, then the temperature data of each channel and synchronously collected real-time working condition data of a rack are analyzed and calculated in a coordinated mode, the fault and poor heat dissipation units of the motor simulator are locked according to operation results, finally, actual alarm state information is displayed for operators and maintenance personnel, and according to alarm prompt, the fault unit of the power module is directly positioned, rapid maintenance is achieved, and labor load of the maintenance personnel is effectively reduced.
Drawings
Fig. 1 is a schematic diagram of a power module in embodiment 1;
fig. 2 is a schematic diagram of a new energy motor simulator power module temperature fault diagnosis system according to embodiment 1;
fig. 3 is a schematic flowchart of a method for diagnosing a temperature fault of a power module of a new energy motor simulator according to embodiment 5.
Detailed Description
In order to make the technical solutions of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings of the specification of the present invention, and it should be noted that the following embodiments are only used for better understanding of the technical solutions of the present invention, and should not be construed as limiting the present invention.
Example 1.
The embodiment provides a temperature fault diagnosis system for a power module of a new energy motor simulator, wherein the power module is shown in figure 1 in a composition structure, the power module comprises a power module circuit bottom plate, a plurality of high-speed IGBTs and a heat exchanger, a cooling inlet and a cooling outlet are formed in the heat exchanger and used for a cooling medium to enter and exit, 3 power modules form power units, 16 power units form a motor simulator, and the system comprises a temperature sensor, a fast-plugging thermocouple extension line, a multi-path temperature acquisition module, an upper computer controller and an alarm information prompt module;
the temperature sensor is arranged at the upper end of a cooling outlet of the heat exchanger, the quick-insertion thermocouple extension line is led out from the temperature sensor and is connected with a plurality of temperature acquisition modules, the upper computer controller is used for acquiring the rotating speed, the torque and the actual power data of the motor simulator of the rack, and generating a trend curve and a database with the acquired data, calculating and comparing the trend curve and the database with the actual temperature, generating the analysis of the running state of the power module, and sending the running state to the alarm information prompt module to realize the diagnosis and prompt of temperature faults.
The structural schematic diagram of the power module temperature fault diagnosis system is shown in fig. 2, the power module temperature fault diagnosis system can be applied to fault diagnosis of a motor simulator power module in a new energy inverter assembly development test, the system provided by the embodiment can complete the function of synchronously acquiring the temperature of each power module in real time, and the system is low in construction cost, simple to operate and convenient to debug and maintain; the real-time state analysis and calculation can be carried out, the hidden trouble of the power module can be predicted in advance, and the equipment safety is ensured.
Example 2.
This example is a further illustration of example 1, wherein the temperature sensor is a K-type thermocouple using a high voltage insulating probe.
Example 3.
This example is further illustrative of example 1, in which the temperature sensor is fixed to the upper end of the cooling outlet of the heat exchanger using a thermally conductive adhesive.
Example 4.
This example is a further illustration of example 1, wherein the cooling medium is propylene glycol thermostated at 20 ℃.
Example 5.
The present embodiment is a new energy motor simulator power module temperature fault diagnosis method, a flow chart of the method is shown in fig. 3, and the system according to any one of embodiments 1 to 4 is applied, where the method includes the following steps:
s1, starting a rack, starting a cooling function of a motor simulator according to preset water temperature, and enabling each power unit of the motor simulator to be ready to enter a standby state;
s2, clicking a start button, and performing self-detection on the temperature of each channel;
s3, temperature transmission state detection: the upper computer controller judges whether the temperature is normal or not, if the temperature is within a reasonable range, the transmission is normal, and the next step is carried out; if the transmission is abnormal, the system alarms and enters an ending monitoring state;
s4, recording temperature data: generating a curve of the collected temperature and recording the curve in a database;
s5, starting the rack to normally operate: starting the rack to start a normal test, and transmitting the command rotating speed, the torque and the actual running power of the motor model to the upper computer controller;
s6, synchronous data calculation: the upper computer controller synchronizes all the acquired data for calculation, judges the state of each power module, generates a database and a trend chart, synchronously checks the running state of each power unit, and clicks a state monitoring button of an interface;
s7, monitoring the running state of each power module: when the state of each unit is judged to be normal, the bench is prompted to enter normal operation, and the bench starts a normal test state; if the judgment result is abnormal, alarming information prompt is carried out, and the position of the fault power module is locked according to the alarming channel number;
s8, finishing monitoring: and clicking a closing button, stopping detecting various alarms of the system by the system, and then stopping various data records and trend chart updating.
In the embodiment, the K-type thermocouple temperature sensor is arranged near the outlet of a cooling medium of a radiator of a power module in a power unit, the actual temperature of the heat exchange of the power module radiator is collected in a centralized manner through a multi-channel thermometer, the temperature change trend record is completed and a database is generated, the temperature data of each channel are analyzed and calculated in a coordinated manner with the synchronously collected real-time working condition data of a rack respectively, the fault and poor heat dissipation unit of the motor simulator is locked according to the operation result, finally, the actual alarm state information is displayed for an operator and maintenance personnel, the fault unit of the power module is directly positioned according to the alarm prompt, rapid maintenance is realized, and the labor load of the maintenance personnel is effectively reduced.
According to the monitoring and diagnosing method, when the rack runs, real-time calculation can be carried out according to actual running conditions, finally, maintenance of the pre-measured point of the high-speed IGBT or the power module can be completed in advance according to temperature trend analysis, and the function of effective maintenance of the motor simulator can be achieved according to alarm prompt information.
Example 6.
This embodiment is a further example of embodiment 5, and the step S2 specifically includes: multichannel temperature acquisition module converts the temperature data who gathers into 485 communication data based on the MODBUS agreement, and the host computer controller carries out self-checking to each passageway temperature of rack through the communication.
Example 7.
This embodiment is a further illustration of embodiment 5, and the calculating in step S6 includes:
(1) Calculating ideal heat loss power P of power module 1 ：
Wherein, P S For power input to the motor simulator, according toCalculating and solving the actual input rotating speed and torque of the rack; p E Actual power of the motor simulator; delta is the heat loss power coefficient of the power part of the motor simulator, which is given by the equipment manufacturer; n is the number of power modules in the motor simulator;
(2) The theoretical temperature T at the cooling outlet end of the heat exchanger is calculated according to the following formula 1 ：
Wherein P2 is the actual heat loss power of the power module, P 1 ＝P 2 ；T 2 Constant value for cooling inlet temperature 20 ℃; r th The thermal resistance of the power module is obtained by inquiring a thermal resistance curve diagram of a radiator provided by a manufacturer.
Example 8.
This embodiment is a further example of embodiment 7, and the method for determining the state of each power module in step S6 includes:
bringing the theoretical temperature T of the outlet end of the heat exchanger 1 Comparing with the actual temperature T detected by the temperature sensor, and when T is less than T 1 When the power module works normally, all the power modules work normally; when T > T 1 When the heat of the power module is accumulated, the alarm system prompts that the state of the power module is abnormal and the power module needs to be cleaned, maintained or replaced in time.
Example 9.
The present embodiment provides a computer-readable storage medium for storing a computer program for executing the new energy motor simulator power module temperature fault diagnosis method according to any one of embodiments 5 to 8.
Example 10.
The embodiment provides an electronic device, which comprises a processor and a memory, wherein the processor and the memory complete mutual communication through a communication bus; a memory for storing a computer program; a processor configured to implement the method for diagnosing a temperature fault of a power module of a new energy motor simulator as described in any one of embodiments 5 to 8 when executing the computer program stored in the memory.
Claims (10)
1. A new energy motor simulator power module temperature fault diagnosis system is disclosed, wherein a power module comprises a power module circuit bottom plate, a plurality of high-speed IGBTs and a heat exchanger, the heat exchanger is provided with a cooling inlet and a cooling outlet for a cooling medium to enter and exit, 3 power modules form power units, and 16 power units form a motor simulator;
the temperature sensor is arranged at the upper end of a cooling outlet of the heat exchanger, the quick-insertion thermocouple extension line is led out from the temperature sensor and is connected with a plurality of temperature acquisition modules, the upper computer controller is used for acquiring the rotating speed, the torque and the actual power data of the motor simulator of the rack, and generating a trend curve and a database with the acquired data, calculating and comparing the trend curve and the database with the actual temperature, generating the analysis of the running state of the power module, and sending the running state to the alarm information prompt module to realize the diagnosis and prompt of temperature faults.
2. The new energy motor simulator power module temperature fault diagnostic system of claim 1, wherein the temperature sensor is a type K thermocouple employing a high voltage insulation probe.
3. The new energy motor simulator power module temperature fault diagnostic system of claim 1, wherein the temperature sensor is fixed to the upper end of the cooling outlet of the heat exchanger using a heat conductive glue.
4. The new energy motor simulator power module temperature fault diagnostic system of claim 1, wherein the cooling medium is propylene glycol thermostatted at 20 ℃.
5. A new energy motor simulator power module temperature fault diagnosis method, characterized in that the system according to any one of claims 1-4 is applied, the method comprises the following steps:
s1, starting a rack, starting a cooling function of a motor simulator according to preset water temperature, and enabling each power unit of the motor simulator to be ready to enter a standby state;
s2, clicking a start button, and performing self-detection on the temperature of each channel;
s3, temperature transmission state detection: the upper computer controller judges whether the temperature is normal or not, if the temperature is within a reasonable range, the transmission is normal, and the next step is carried out; if the transmission is abnormal, the system alarms and enters an ending monitoring state;
s4, recording temperature data: generating a curve of the collected temperature and recording the curve in a database;
s5, starting the rack to normally operate: starting the rack to start a normal test, and transmitting the command rotating speed, the torque and the actual running power of the motor model to the upper computer controller;
s6, synchronous data calculation: the upper computer controller synchronizes all the acquired data for calculation, judges the states of all the power modules, generates a database and a trend graph, synchronously checks the running states of all the power units and clicks a state monitoring button of an interface;
s7, monitoring the running state of each power module: when the state of each unit is judged to be normal, the bench is prompted to enter normal operation, and the bench starts a normal test state; if the judgment result is abnormal, alarming information prompt is carried out, and the position of the fault power module is locked according to the alarming channel number;
s8, finishing monitoring: and clicking a closing button, stopping detecting various alarms of the system by the system, and then stopping various data records and trend chart updating.
6. The method for diagnosing the temperature fault of the power module of the new energy motor simulator according to claim 5, wherein the step S2 is specifically as follows: multichannel temperature acquisition module converts the temperature data who gathers into 485 communication data based on the MODBUS agreement, and the host computer controller carries out self-checking to each passageway temperature of rack through the communication.
7. The new energy motor simulator power module temperature fault diagnosis method of claim 5, wherein the calculating of step S6 comprises:
(1) Calculating ideal heat loss power P of power module 1 ：
Wherein, P S Calculating and solving the power input to the motor simulator according to the actual input rotating speed and torque of the rack; p E The actual power of the motor simulator is obtained; delta is the heat loss power coefficient of the power part of the motor simulator, which is given by the equipment manufacturer; n is the number of power modules in the motor simulator;
(2) The theoretical temperature T at the cooling outlet end of the heat exchanger is calculated according to the following formula 1 ：
Wherein P2 is the actual heat loss power of the power module, P 1 ＝P 2 ；T 2 Constant value for cooling inlet temperature 20 ℃; r th The thermal resistance of the power module is obtained by inquiring a thermal resistance curve diagram of a radiator provided by a manufacturer.
8. The method for diagnosing the temperature fault of the power module of the new energy motor simulator according to claim 7, wherein the method for judging the state of each power module in the step S6 is as follows:
bringing the theoretical temperature T of the outlet end of the heat exchanger 1 Comparing with the actual temperature T detected by the temperature sensor, and when T is less than T 1 When the power module works normally, all the power modules work normally; when T > T 1 When the heat of the power module is accumulated, the alarm system prompts the workThe rate module is abnormal in state and needs to be cleaned, maintained or replaced in time.
9. A computer-readable storage medium for storing a computer program for executing the new energy motor simulator power module temperature fault diagnosis method according to any one of claims 5 to 8.
10. An electronic device, comprising a processor and a memory, wherein the processor and the memory communicate with each other via a communication bus; a memory for storing a computer program; a processor for implementing the new energy motor simulator power module temperature fault diagnosis method according to any one of claims 5 to 8 when executing the computer program stored on the memory.
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|---|---|---|---|---|
| DE102011121832A1 (en) * | 2010-12-21 | 2012-06-21 | Sumitomo Heavy Industries, Ltd. | Inverter device for driving motor e.g. servomotor, has control unit that performs operating condition setting process around carrier frequency of pulse width modulation signal based on temperature information of semiconductor device |
| CN106199253A (en) * | 2016-06-29 | 2016-12-07 | 武汉广源动力科技有限公司 | A kind of high voltage transducer power unit remote fault diagnosis method |
| US20210034129A1 (en) * | 2019-08-02 | 2021-02-04 | Schneider Electric Industries Sas | Detection of a failure of a power module based on operating conditions |
| CN114275007A (en) * | 2022-01-21 | 2022-04-05 | 中国铁道科学研究院集团有限公司 | Fault determination device and method based on rail vehicle power module |
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- 2022-07-11 CN CN202210808913.0A patent/CN115343614A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102011121832A1 (en) * | 2010-12-21 | 2012-06-21 | Sumitomo Heavy Industries, Ltd. | Inverter device for driving motor e.g. servomotor, has control unit that performs operating condition setting process around carrier frequency of pulse width modulation signal based on temperature information of semiconductor device |
| CN106199253A (en) * | 2016-06-29 | 2016-12-07 | 武汉广源动力科技有限公司 | A kind of high voltage transducer power unit remote fault diagnosis method |
| US20210034129A1 (en) * | 2019-08-02 | 2021-02-04 | Schneider Electric Industries Sas | Detection of a failure of a power module based on operating conditions |
| CN114275007A (en) * | 2022-01-21 | 2022-04-05 | 中国铁道科学研究院集团有限公司 | Fault determination device and method based on rail vehicle power module |
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