CN116300813A - Thermal management all-in-one controller test system - Google Patents
Thermal management all-in-one controller test system Download PDFInfo
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- CN116300813A CN116300813A CN202310256951.4A CN202310256951A CN116300813A CN 116300813 A CN116300813 A CN 116300813A CN 202310256951 A CN202310256951 A CN 202310256951A CN 116300813 A CN116300813 A CN 116300813A
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
- G05B23/0256—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults injecting test signals and analyzing monitored process response, e.g. injecting the test signal while interrupting the normal operation of the monitored system; superimposing the test signal onto a control signal during normal operation of the monitored system
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Abstract
The invention is suitable for the technical field of energy storage power stations, and provides a thermal management all-in-one controller testing system. The test system includes: the power supply module is respectively connected with the measured thermal management all-in-one controller and the industrial personal computer; the inversion load simulation module is respectively connected with the inversion module and the signal acquisition module in the measured thermal management all-in-one controller; the power distribution load simulation module is connected with the power distribution module in the measured thermal management all-in-one controller; the signal acquisition module is also connected between the power distribution module and the power distribution load simulation module and connected with the industrial personal computer; and the industrial personal computer is configured to control the starting operation of the measured thermal management integrated controller and acquire the operation state information of the measured thermal management integrated controller and the simulation output state information of the inversion load simulation module and the power distribution load simulation module. The invention can shorten the test time, improve the test efficiency and reduce the volume and cost of the test system.
Description
Technical Field
The invention belongs to the technical field of energy storage power stations, and particularly relates to a thermal management all-in-one controller testing system.
Background
As a core component in an energy storage power station, a battery is extremely sensitive to the ambient temperature, and the performance and the service life of the battery are affected by the excessively high ambient temperature caused by the battery charging and discharging process or the excessively low ambient temperature caused by seasonal reasons. Therefore, there is a need for thermal management of the batteries in an energy storage power station to bring the batteries to a suitable ambient temperature.
The rectification module, the inversion module, the direct current conversion module and the power distribution module can be integrated into a heat management all-in-one controller, so that the heat management all-in-one controller is utilized to control cooling or heating water of a compressor, an air conditioner or a heat pump system and the like, the temperature of a water path of the battery is controlled through the water temperature, and the battery is at a proper environment temperature. In order to ensure the functional performance of the thermal management integrated controller, it is necessary to perform a functional performance test before the thermal management integrated controller leaves the factory.
However, the current test system for the thermal management integrated controller includes various accessory devices, and the test system is large and complex, which is not beneficial to improving the test efficiency and has higher test cost.
Disclosure of Invention
In view of the above, the embodiment of the invention provides a testing system for a thermal management all-in-one controller, which solves the problems of complex testing system, low testing efficiency and high cost of the conventional thermal management all-in-one controller.
A first aspect of an embodiment of the present invention provides a thermal management all-in-one controller test system, including: the system comprises a power supply module, an inversion load simulation module, a power distribution load simulation module, a signal acquisition module and an industrial personal computer;
the power module is respectively connected with the measured thermal management all-in-one controller and the industrial personal computer and is configured to supply power to the measured thermal management all-in-one controller according to the control of the industrial personal computer;
the inversion load simulation module is respectively connected with the inversion module and the signal acquisition module in the measured thermal management all-in-one controller and is configured to simulate the actual load of the inversion module;
the power distribution load simulation module is connected with the power distribution module in the measured thermal management all-in-one controller and is configured to simulate the actual load of the power distribution module;
the signal acquisition module is also connected between the power distribution module and the power distribution load simulation module, is connected with the industrial personal computer, and is configured to acquire the simulation output state information of the inversion load simulation module and the power distribution load simulation module and send the simulation output state information to the industrial personal computer;
the industrial personal computer is configured to control the start-up operation of the tested thermal management integrated controller, and acquire the operation state information and the simulation output state information of the tested thermal management integrated controller so as to determine a test result based on the operation state information and the simulation output state information.
In one possible implementation manner, the inversion load simulation module includes: a drive motor and a load motor;
the three-phase input end of the driving motor is connected with the three-phase output end of the inversion module, and the output shaft of the driving motor is connected with the load motor through the signal acquisition module;
alternatively, the inversion load simulation module includes: the driving motor, the electromagnetic clutch and the friction disc;
the three-phase input end of the driving motor is connected with the three-phase output end of the inversion module, the output shaft of the driving motor is connected with the electromagnetic clutch through the signal acquisition module, and the electromagnetic clutch is connected with the friction disc.
In one possible implementation manner, the power distribution load simulation module includes: the power distribution circuit comprises a power distribution module, a plurality of paths of parallel circuits, a plurality of switching circuits and a plurality of switching circuits, wherein the power distribution circuit number of the power distribution module corresponds to that of the power distribution module one by one;
one end of each parallel circuit is connected with the corresponding power distribution module through the signal acquisition module, and the other end of each parallel circuit is grounded.
In one possible implementation manner, the signal acquisition module includes: the first signal acquisition unit and the second signal acquisition unit;
the first signal acquisition unit is respectively connected with the inversion load simulation module and the industrial personal computer;
the second signal acquisition unit is connected between the power distribution module and the power distribution load simulation module and is connected with the industrial personal computer.
In one possible implementation manner, the first signal acquisition unit includes: a rotational speed torque sensor and a rotational speed torque tester;
the rotating speed and torque sensor is respectively connected with the inversion load simulation module and the rotating speed and torque tester;
the rotating speed and torque tester is connected with the industrial personal computer.
In one possible implementation manner, the second signal acquisition unit includes: a voltage-current sensor;
the voltage and current sensor is connected between the power distribution module and the power distribution load simulation module, and is also connected with the industrial personal computer.
In one possible implementation, the thermal management all-in-one controller test system further includes: a fault injection module;
the fault injection module is respectively connected with the inversion load simulation module, the power distribution load simulation module and the industrial personal computer and is configured to simulate faults of actual loads of the inversion module and/or the power distribution module according to control of the industrial personal computer.
In one possible implementation manner, the fault injection module includes: the first fault injection units, a plurality of second open circuit fault injection units and a plurality of second short circuit fault injection units are in one-to-one correspondence with the number of power distribution paths of the power distribution module;
the first fault injection unit is connected between the inversion module and the inversion load simulation module, is connected with the industrial personal computer and is configured to simulate open-circuit and short-circuit faults of the actual load of the inversion module according to the control of the industrial personal computer;
each second open-circuit fault injection unit is connected in series between the signal acquisition module and the corresponding power distribution load simulation module and is configured to simulate an open-circuit fault of an actual load of the corresponding power distribution module according to the control of the industrial personal computer;
and each second short-circuit fault injection unit is connected at two ends of the corresponding power distribution load simulation module in parallel and is configured to simulate the short-circuit fault of the actual load of the corresponding power distribution module according to the control of the industrial personal computer.
In one possible implementation manner, the first fault injection unit includes: a three-phase open-circuit relay coil, a three-phase open-circuit relay normally-closed contact, a three-phase short-circuit relay coil, a three-phase short-circuit relay normally-open contact, a three-phase ground short-circuit relay coil and a three-phase ground short-circuit relay normally-open contact;
the three-phase open-circuit relay coil, the three-phase short-circuit relay coil and the three-phase ground short-circuit relay coil are all connected with the industrial personal computer;
one end of the normally-closed contact of the three-phase open-circuit relay is correspondingly connected with the three-phase output end of the inversion module, and the other end of the normally-closed contact of the three-phase open-circuit relay is respectively connected with the three-phase input end of the inversion load simulation module, one end of the normally-open contact of the three-phase short-circuit relay and one end of the normally-open contact of the three-phase short-circuit relay;
the other ends of the normally open contacts of the three-phase short-circuit relay are connected with each other;
and the other ends of the normally open contacts of the three-phase grounding short-circuit relay are connected with each other and then grounded.
In one possible implementation manner, each of the second open circuit fault injection units includes: an open-circuit fault relay coil and an open-circuit fault relay normally-closed contact;
the open-circuit fault relay coil is connected with the industrial personal computer, and the normally closed contact of the open-circuit fault relay is connected between the signal acquisition module and the corresponding power distribution load simulation module;
each of the second short fault injection units includes: a short-circuit fault relay coil and a normally open contact of the short-circuit fault relay;
the short-circuit fault relay coil is connected with the industrial personal computer, and the normally open contacts of the short-circuit fault relay are connected in parallel at two ends of the corresponding power distribution load simulation module.
Compared with the prior art, the embodiment of the invention has the beneficial effects that: according to the embodiment of the invention, the power supply module, the inversion load simulation module, the power distribution load simulation module, the signal acquisition module and the industrial personal computer can supply power for the all-in-one controller of the thermal management to be tested, and the actual load of the all-in-one controller of the thermal management to be tested is simulated based on the inversion load simulation module and the power distribution load simulation module, so that the all-in-one controller of the thermal management to be tested is controlled to start operation under the control of the industrial personal computer, the running state information of the all-in-one controller of the thermal management to be tested and the simulation output state information of the inversion load simulation module and the power distribution load simulation module are obtained, the functional performance test of the all-in-one controller of the thermal management to be tested can be performed under the condition that the actual application system of the all-in-one controller of the thermal management to be tested is not needed, and the all-in-one controller of the thermal management to be tested is decoupled through the inversion load simulation module and the power distribution load simulation module, so that the all-in-one controller of the thermal management to be tested can be independently simulated and tested, the working logic complexity of the test system of the all-in-one controller to be tested can be conveniently reduced, the test time is shortened, the test efficiency is improved, and the test system cost is reduced.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments or the description of the prior art will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a thermal management all-in-one controller test system according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a thermal management all-in-one controller according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a thermal management all-in-one controller test system according to another embodiment of the present invention;
FIG. 4 is a schematic diagram of a thermal management all-in-one controller test system according to another embodiment of the present invention.
Detailed Description
In the following description, for purposes of explanation and not limitation, specific details are set forth such as the particular system architecture, techniques, etc., in order to provide a thorough understanding of the embodiments of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.
In order to illustrate the technical scheme of the invention, the following description is made by specific examples.
Referring to fig. 1, a thermal management all-in-one controller test system 100 provided in an embodiment of the present invention includes: the system comprises a power supply module 10, an inversion load simulation module 20, a power distribution load simulation module 30, a signal acquisition module 40 and an industrial personal computer 50.
The power module 10 is connected to the measured thermal management integrated controller 60 and the industrial personal computer 50, and is configured to supply power to the measured thermal management integrated controller 60 according to the control of the industrial personal computer 50.
The inversion load simulation module 20 is connected to the inversion module and the signal acquisition module 40 in the measured thermal management integrated controller 60, respectively, and is configured to simulate the actual load of the inversion module.
The power distribution load simulation module 30, which is connected to the power distribution module in the thermal management integrated controller under test 60, is configured to simulate the actual load of the power distribution module.
The signal acquisition module 40 is further connected between the power distribution module and the power distribution load simulation module 30, and is connected with the industrial personal computer 50, and is configured to acquire analog output state information of the inverter load simulation module 20 and the power distribution load simulation module 30 and send the analog output state information to the industrial personal computer 50.
The industrial personal computer 50 is configured to control the start-up operation of the thermal management integrated controller under test 60, and acquire the operation state information and the analog output state information of the thermal management integrated controller under test 60 to determine a test result based on the operation state information and the analog output state information.
The power module 10 may be a programmable high-voltage ac power supply, so that the high-voltage ac power required by the measured thermal management integrated controller is output under the control of the communication command of the industrial personal computer 50, and the industrial personal computer 50 may communicate with the power module 10 through RS 485. The signal acquisition module 40 can be powered by 220V alternating current commercial power, and the industrial personal computer 50 can communicate with the signal acquisition module 40 through RS 485.
For example, when the functional performance test is required for a certain heat management integrated controller 60, the relevant information of the heat management integrated controller 60 may be recorded in the industrial personal computer 50, and then the industrial personal computer 50 may send out a communication command to control the program-controlled high-voltage ac power supply to provide the high-voltage ac power for the heat management integrated controller 60. After the measured thermal management integrated controller 60 is powered on, a start operation command may be sent by the industrial personal computer 50, where the start operation command may be a command corresponding to the actual operation process of the measured thermal management integrated controller 60, for example, a command for controlling the measured thermal management integrated controller 60 to perform low-voltage dc output, or a command for controlling the measured thermal management integrated controller 60 to perform motor output. When the measured thermal management integrated controller 60 operates based on the corresponding start operation command, the operation state information of each module in the measured thermal management integrated controller 60 is output, so as to facilitate the judgment or control based on the operation state information in actual operation. Therefore, the detected thermal management integrated control 60 sends the operation state information output when operating based on the corresponding start operation command to the industrial personal computer 50, so as to determine whether to meet the actual use requirement based on the corresponding reference pre-stored in the industrial personal computer 50 or through manual judgment. The operation state information output when the measured thermal management integrated control 60 operates based on the corresponding start operation command CAN be sent to the industrial personal computer 50 through the CAN bus.
For example, the rectifier module of the thermal management all-in-one controller typically feeds back ac input voltage, internal bus voltage, substrate temperature, control supply voltage, and the like. The inverter module of the thermal management all-in-one controller generally feeds back direct current input voltage, motor rotation speed, output current, output power, IGBT temperature and the like. The DC-DC conversion module of the thermal management all-in-one controller generally feeds back a direct current input voltage, an output current, consumed power, and the like. The power distribution module of the thermal management all-in-one controller generally feeds back the distribution output state and fault state of each path, the NTC over-temperature protection temperature and the like. Based on the running state information fed back by each module of the tested thermal management all-in-one controller, whether the running state information is in a preset error range or a preset range can be determined, and whether the running state information fed back by the tested thermal management all-in-one controller meets the actual use requirement is tested. For example, whether the operating temperature of the IGBT meets the requirements is tested according to the temperature of the IGBT fed back by the measured thermal management integrated controller.
In addition, the on-load inverter load simulation module 20 and the power distribution load simulation module 30 may also be different in status when the thermal management integrated controller 60 is operated based on the corresponding start-up operation command. Therefore, the signal acquisition module 40 can acquire the analog output state information of the inversion load simulation module 20 and the power distribution load simulation module 30 and send the analog output state information to the industrial personal computer 50, so as to test whether the working state of the tested thermal management integrated control 60 meets the requirement through the preset reference value or the reference state in the industrial personal computer 50. For example, the signal acquisition module 40 acquires the rotation speed, torque and output power of the inversion load simulation module 20, so as to compare the rotation speed, torque and output power fed back by the inversion module in the integrated thermal management controller 60 to determine whether the corresponding error is within a set error range and whether the corresponding value is within a preset range. Or the current of the power distribution load simulation module 30 is collected based on the signal collection module 40, so as to judge whether the current is consistent with the working state of the system or not and accords with a preset value.
After acquiring the operation state information and the analog output state information of the thermal management integrated controller 60, the industrial personal computer 50 records the corresponding information as a test record, and marks that the test passes when each phase of information meets the preset requirement. If a certain item of information does not meet the preset requirement, the measured thermal management integrated controller 60 also feeds back a fault code to the industrial personal computer 50, wherein the fault code is a code table coded by each module in the measured thermal management integrated controller 60, and after receiving the fault code, the industrial personal computer 50 marks that the test of the corresponding measured thermal management integrated controller fails.
Optionally, the industrial personal computer 50 may perform a system self-test after the measured thermal management integrated controller 60 is powered on, so as to determine whether the program controlled high voltage ac power supply is normal according to the result of the program controlled power self-test, determine whether the signal acquisition module 40 is normal according to whether the signal acquired by the signal acquisition module 40 after the system is powered on is within a reasonable range, and determine whether the fault injection module 70 is normal according to whether each relay of the fault injection module 70 acts. And then, the operator information can be input into the industrial personal computer 50, the ID information of the measured thermal management all-in-one controller is input through the code scanning gun, and the hardware and version software information of each module in the measured thermal management all-in-one controller is read and compared with the standard. After the work is done, a starting operation command is sent to the all-in-one controller for the measured thermal management to start operation according to the command requirement.
When the measured heat management all-in-one controller is controlled to start operation, the measured heat management all-in-one controller can be controlled to perform low-voltage direct current output, then the measured heat management all-in-one controller is controlled to perform motor output, and the rotating speed of a given motor is stepped until the preset highest rotating speed is reached; and then when the tested heat management integrated controller carries out low-voltage direct current output and the motor output reaches a preset maximum rotating speed, the system power factor of the tested heat management integrated controller is read through program-controlled high-voltage alternating current voltage.
After the test of the tested heat management all-in-one controller is completed, the tested heat management all-in-one controller can be powered down, and then the next heat management all-in-one controller is waited for testing.
In practical application, as shown in fig. 2, the thermal management all-in-one controller of the energy storage power station converts the on-site alternating current into direct current through the rectifying module, and sends the converted direct current to the inversion module in one way, so as to obtain the alternating current required by the motor of the compressor or the air conditioner through inversion of the inversion module, and sends the direct current to the DC-DC conversion module in the other way, so as to obtain the low-voltage direct current required by the power distribution module (namely the PDU module in fig. 2) through the DC-DC conversion module, and then distributes the low-voltage direct current through the power distribution module, for example, outputs 8 paths of low-voltage direct current power distribution through the power distribution module, and respectively sends the low-voltage direct current to a water pump of a water path of a battery, various fans corresponding to the compressor or the air conditioner, various electromagnetic valves used for performing thermal management on the battery in the energy storage power station, and the like. If the practical application system of the heat management all-in-one controller is built for testing whether the functional performance of the heat management all-in-one controller is qualified, not only the practical load directly controlled by the heat management all-in-one controller is needed to be equipped, but also various accessory devices corresponding to the practical load are also needed to be equipped, so that the test system of the heat management all-in-one controller is huge and complex, the improvement of the test efficiency is not facilitated, and the test cost is higher.
Therefore, in this embodiment, the actual load of the inverter module in the thermal management all-in-one controller is simulated by the inverter load simulation module 20, and the actual load of the power distribution module in the thermal management all-in-one controller is simulated by the power distribution load simulation module 30, so that the actual application system of the thermal management all-in-one controller is not needed, and each function to be tested of the thermal management all-in-one controller is decoupled, so that each module of the thermal management all-in-one controller is simulated and tested independently. Therefore, the complexity of the test system of the heat management all-in-one controller can be reduced, the volume of the test system is reduced, the test cost is reduced, and the working logic complexity of the test system of the heat management all-in-one controller can be reduced, so that the test efficiency is improved.
Optionally, referring to fig. 3, the inverting load simulation module 20 includes: a drive motor 21 and a load motor 22.
The three-phase input end of the driving motor 21 is connected with the three-phase output end of the inversion module, and the output shaft of the driving motor 21 is connected with the load motor 22 through the signal acquisition module 40.
Alternatively, the inverting load simulation module 20 includes: a drive motor 21, an electromagnetic clutch 23 and a friction disk 24.
The three-phase input end of the driving motor 21 is connected with the three-phase output end of the inversion module, the output shaft of the driving motor 21 is connected with the electromagnetic clutch 23 through the signal acquisition module 40, and the electromagnetic clutch 23 is connected with the friction disc 24.
In this embodiment, the actual motor load characteristics of the tested thermal management integrated controller 60 are simulated by the driving motor 21 and the load motor 22, or the driving motor 21, the electromagnetic clutch 23 and the friction disc 24, so as to test whether the ac power obtained by the rectifying module and the inverting module of the tested thermal management integrated controller 60 has enough load capacity.
When the inverter load simulation module 20 is formed by the driving motor 21, the electromagnetic clutch 23 and the friction disc 24, the industrial personal computer 50 can apply load to the electromagnetic clutch 23 to control the inverter module to work at rated output.
Optionally, the power distribution load simulation module 30 includes: the multi-path parallel circuits 31 which are in one-to-one correspondence with the number of power distribution paths of the power distribution module are formed by connecting a resistor 311 and a capacitor 312 in parallel.
One end of each parallel circuit 31 is connected to a corresponding power distribution module through a signal acquisition module 40, and the other end of each parallel circuit 31 is grounded.
In this embodiment, the power distribution module of the all-in-one controller is typically provided with multiple load paths, and each load path has a capacitive characteristic. The parallel circuit 31 formed by parallel connection of the resistor 311 and the capacitor 312 simulates each load of the power distribution module, so that the actual load of the power distribution module has the characteristics of having the surge current at the moment of starting and then operating at the rated current. To test whether the direct current obtained through the rectification module, the DC-DC direct current conversion module and the power distribution module of the tested thermal management integrated controller 60 has sufficient load capacity. For example, to test whether a certain way of the power distribution module has 24V/20A of load capacity.
The resistance value of the resistor and the capacitance value of the capacitor in the corresponding parallel circuit can be adjusted according to the load requirement of each path of the power distribution module, and the resistance value of the resistor and the capacitance value of the capacitor in each path of the parallel circuit are not limited in this embodiment.
Optionally, referring to fig. 3, the signal acquisition module 40 includes: a first signal acquisition unit 41 and a second signal acquisition unit 42.
The first signal acquisition unit 41 is connected with the inversion load simulation module 20 and the industrial personal computer 50 respectively. The second signal acquisition unit 42 is connected between the power distribution module and the power distribution load simulation module 30, and is connected with the industrial personal computer 50.
Optionally, the first signal acquisition unit 41 includes: a rotational speed torque sensor 411 and a rotational speed torque tester 412.
The rotational speed and torque sensor 411 is connected to the inversion load simulation module 20 and the rotational speed and torque tester 412, respectively. The rotational speed and torque tester 412 is connected with the industrial personal computer 50.
As shown in fig. 3, that is, the rotational speed torque sensor 411 is connected between the output shaft of the driving motor 21 and the load motor 22, or between the output shaft of the driving motor 21 and the electromagnetic clutch 23, the rotational speed torque sensor 411 is also connected in communication with the rotational speed torque tester 412; the rotational speed and torque tester 412 is connected with the industrial personal computer 50.
In this embodiment, by adding the rotational speed and torque sensor 411 between the output shaft of the driving motor 21 and the load motor 22, or adding the rotational speed and torque sensor 411 between the output shaft of the driving motor 21 and the electromagnetic clutch 23, the real-time rotational speed and torque of the driving motor 21 can be monitored, and the real-time output power of the driving motor 21 can be calculated by the rotational speed and torque tester 412 according to the real-time rotational speed and torque collected by the rotational speed and torque sensor 411, so as to provide the real-time rotational speed, torque, output power and other data of the driving motor 21 to the industrial personal computer 50, so as to obtain the test result of the measured thermal management all-in-one controller 60 on the inverter module based on the industrial personal computer 50.
Optionally, the second signal acquisition unit 42 includes: a voltage current sensor 421.
The voltage and current sensor 421 is connected between the power distribution module and the power distribution load simulation module 30, and the voltage and current sensor 421 is also connected with the industrial personal computer 50.
As shown in fig. 3, that is, a voltage-current sensor 421 is connected between each parallel circuit 31 and the corresponding power distribution module, and the voltage-current sensor 421 is also connected to the industrial personal computer 50.
In this embodiment, by adding the voltage and current sensor 421 between each parallel circuit 31 and the corresponding power distribution module, the output voltage and output current of each power distribution module can be monitored, so that the operating state of the thermal management integrated controller 60 under test about the power distribution module can be tested.
Optionally, referring to fig. 4, the thermal management all-in-one controller test system 100 further includes: fault injection module 70.
The fault injection module 70 is connected to the inverter load simulation module 20, the power distribution load simulation module 30, and the industrial personal computer 50, and is configured to simulate a fault of an actual load of the inverter module and/or the power distribution module according to control of the industrial personal computer 50.
In this embodiment, considering the problem that it is difficult to test some fault conditions of the thermal management integrated controller based on the actual application system of the thermal management integrated controller, the fault injection module 70 is designed to cover the items that cannot be tested by the actual application system through the fault injection module 70, so as to realize the comprehensive test of the functional performance of each function of the thermal management integrated controller.
The fault injection module 70 may be powered by 220V ac mains, and the fault injection module 70 may be connected to the industrial personal computer 50 through a CAN bus.
Optionally, with continued reference to fig. 4, the fault injection module 70 includes: the first fault injection unit 71, and a plurality of second open fault injection units 72 and a plurality of second short fault injection units 73, which are in one-to-one correspondence with the number of power distribution paths of the power distribution module.
The first fault injection unit 71 is connected between the inverter module and the inverter load simulation module 20, and is connected to the industrial personal computer 50, and is configured to simulate open and short faults of an actual load of the inverter module according to control of the industrial personal computer 50.
Each of the second open-circuit fault injection units 72, which are connected in series between the signal acquisition module 40 and the corresponding power distribution load simulation module 30, is configured to simulate an open-circuit fault of an actual load of the corresponding power distribution module according to the control of the industrial personal computer 50.
Each of the second short-circuit fault injection units 73 is connected in parallel to both ends of the corresponding power distribution load simulation module 30 and configured to simulate a short-circuit fault of an actual load of the corresponding power distribution module according to the control of the industrial personal computer 50.
Specifically, the first fault injection unit 71 may be connected between the three-phase output terminal of the inverter module and the three-phase input terminal of the driving motor 21, so as to simulate a three-phase line short-circuit fault of an actual motor of the inverter module, thereby testing an output short-circuit protection function of the inverter module, or simulate an open-circuit fault of a certain phase of the actual motor of the inverter module, thereby testing a phase-loss protection function of the inverter module.
Each of the second open fault injection units 72 may be connected between the corresponding voltage-current sensor 421 and the parallel circuit 31 to simulate an output load open fault of the power distribution module, thereby testing an output open protection function of the power distribution module.
Each of the second short fault injection units 73 may be connected in parallel at both ends of the parallel circuit 31 to simulate an output load short fault of the power distribution module, thereby testing an output overcurrent protection function of the power distribution module.
Optionally, the first fault injection unit 71 includes: three-phase open-circuit relay coil, three-phase open-circuit relay normally closed contacts J1, J2, J3, three-phase short-circuit relay coil, three-phase short-circuit relay normally open contacts J4, J5, J6, three-phase short-circuit relay coil and three-phase short-circuit relay normally open contacts J7, J8, J9.
Wherein, the three-phase open-circuit relay coil, the three-phase short-circuit relay coil and the three-phase to-ground short-circuit relay coil are all connected with the industrial personal computer 50.
One end of the normally closed contacts J1, J2 and J3 of the three-phase open-circuit relay is correspondingly connected with the three-phase output end of the inversion module, and the other end of the normally closed contacts is respectively connected with the three-phase input end of the inversion load simulation module 20, one ends of normally open contacts J4, J5 and J6 of the three-phase short-circuit relay and one ends of normally open contacts J7, J8 and J9 of the three-phase short-circuit relay.
The other ends of the normally open contacts J4, J5 and J6 of the three-phase short-circuit relay are connected with each other.
The other ends of the normally open contacts J7, J8 and J9 of the three-phase grounding short-circuit relay are connected with each other and then grounded.
In this embodiment, the three-phase open-circuit relay coil and the three-phase open-circuit relay normally-closed contacts J1, J2, J3 form a three-phase open-circuit relay, the three-phase open-circuit relay normally-closed contacts J1, J2, J3 are closed in a normal state, when a certain phase of the actual motor of the inverter module needs to be simulated for an open-circuit fault, the corresponding phase open-circuit relay coil is controlled to be powered on or powered off by the industrial personal computer 50, so that the corresponding phase open-circuit relay normally-closed contacts J1/J2/J3 are disconnected, and the simulation of the certain phase open-circuit fault of the actual motor of the inverter module is realized.
The three-phase short-circuit relay coil and the normally open contacts J4, J5 and J6 of the three-phase short-circuit relay form a three-phase short-circuit relay, the normally open contacts J4, J5 and J6 of the three-phase short-circuit relay are opened in a normal state, when a three-phase line short-circuit fault of an actual motor of an inversion module needs to be simulated, the industrial personal computer 50 is used for controlling the three-phase short-circuit relay coil to obtain or lose electricity, and then the normally open contacts J4, J5 and J6 of the three-phase short-circuit relay are closed, so that the simulation of the three-phase line short-circuit fault of the actual motor of the inversion module is realized.
The three-phase grounding short-circuit relay coil and the three-phase grounding short-circuit relay normally open contacts J7, J8 and J9 form a three-phase grounding short-circuit relay, the three-phase grounding short-circuit relay normally open contacts J7, J8 and J9 are opened in a normal state, when a three-phase line grounding short-circuit fault of an actual motor of an inverter module needs to be simulated, the three-phase grounding short-circuit relay coil is controlled to be powered on or powered off through the industrial personal computer 50, and then the three-phase grounding short-circuit relay normally open contacts J7, J8 and J9 are closed, so that simulation of the three-phase line grounding short-circuit fault of the actual motor of the inverter module is realized.
After the simulation of the short circuit or open circuit fault of the actual motor of the inverter module is performed in the above manner, the inverter module feeds back the short circuit or open circuit fault to the industrial personal computer, and after the measured thermal management all-in-one controller 60 is powered on again, the inverter module operates again to verify that the corresponding function is good.
Optionally, each second open-circuit fault injection unit 72 includes: an open fault relay coil and an open fault relay normally closed contact J10.
The open-circuit fault relay coil is connected with the industrial personal computer 50, and the normally closed contact J10 of the open-circuit fault relay is connected between the signal acquisition module 40 and the corresponding power distribution load simulation module 30.
Each of the second short fault injection units 73 includes: a short-circuit fault relay coil and a short-circuit fault relay normally open contact J11.
The short-circuit fault relay coil is connected with the industrial personal computer 50, and normally open contacts J11 of the short-circuit fault relay are connected in parallel at two ends of the corresponding power distribution load simulation module 30.
In this embodiment, each open-circuit fault relay coil and the open-circuit fault relay normally-closed contact J10 form an open-circuit fault relay, the open-circuit fault relay normally-closed contact J10 is closed in a normal state, and when an output load of the power distribution module needs to be simulated for open-circuit fault, the corresponding open-circuit fault relay coil is controlled to be powered on or powered off by the industrial personal computer 50, so that the corresponding open-circuit fault relay normally-closed contact J10 is disconnected, and thus the simulation of the output load open-circuit fault of the power distribution module is realized.
Each short-circuit fault relay coil and the normally-closed contact J11 of the short-circuit fault relay form a short-circuit fault relay, the normally-open contact J11 of the short-circuit fault relay is opened in a normal state, when the output load short-circuit fault of the power distribution module needs to be simulated, the corresponding short-circuit fault relay coil is controlled to be powered on or powered off through the industrial personal computer 50, and then the normally-open contact J11 of the corresponding short-circuit fault relay is closed, so that the simulation of the output load short-circuit fault of the power distribution module is realized.
After the output load short circuit or open circuit fault simulation of the power distribution module is performed in the above manner, the power distribution module feeds back the short circuit or open circuit fault to the industrial personal computer, and after the measured thermal management integrated controller 60 is powered on again, the power distribution module operates again to verify that the corresponding function is good.
Optionally, with continued reference to fig. 4, the fault injection module 70 further includes an electrically-controlled mechanical valve 74, where the electrically-controlled mechanical valve 74 is mounted on an output shaft of the driving motor 21 to lock the output shaft of the driving motor 21 when powered, so as to simulate a locked-rotor fault of the driving motor, thereby implementing a test of motor locked-rotor protection of the inverter module of the tested thermal management all-in-one controller.
Optionally, based on the thermal management integrated controller testing system provided in this embodiment, fault simulation such as overvoltage and undervoltage may be performed, so as to test and verify the corresponding function of the thermal management integrated controller under test.
The heat management all-in-one controller test system provided by the embodiment can test the protection performance of the heat management all-in-one controller by adding the fault injection module, and the reliability of the heat management all-in-one controller is enhanced.
The above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention, and are intended to be included in the scope of the present invention.
Claims (10)
1. A thermal management all-in-one controller test system, comprising: the system comprises a power supply module, an inversion load simulation module, a power distribution load simulation module, a signal acquisition module and an industrial personal computer;
the power module is respectively connected with the measured thermal management all-in-one controller and the industrial personal computer and is configured to supply power to the measured thermal management all-in-one controller according to the control of the industrial personal computer;
the inversion load simulation module is respectively connected with the inversion module and the signal acquisition module in the measured thermal management all-in-one controller and is configured to simulate the actual load of the inversion module;
the power distribution load simulation module is connected with the power distribution module in the measured thermal management all-in-one controller and is configured to simulate the actual load of the power distribution module;
the signal acquisition module is also connected between the power distribution module and the power distribution load simulation module, is connected with the industrial personal computer, and is configured to acquire the simulation output state information of the inversion load simulation module and the power distribution load simulation module and send the simulation output state information to the industrial personal computer;
the industrial personal computer is configured to control the start-up operation of the tested thermal management integrated controller, and acquire the operation state information and the simulation output state information of the tested thermal management integrated controller so as to determine a test result based on the operation state information and the simulation output state information.
2. The thermal management all-in-one controller test system of claim 1, wherein the inverter load simulation module comprises: a drive motor and a load motor;
the three-phase input end of the driving motor is connected with the three-phase output end of the inversion module, and the output shaft of the driving motor is connected with the load motor through the signal acquisition module;
alternatively, the inversion load simulation module includes: the driving motor, the electromagnetic clutch and the friction disc;
the three-phase input end of the driving motor is connected with the three-phase output end of the inversion module, the output shaft of the driving motor is connected with the electromagnetic clutch through the signal acquisition module, and the electromagnetic clutch is connected with the friction disc.
3. The thermal management all-in-one controller test system of claim 1, wherein the power distribution load simulation module comprises: the power distribution circuit comprises a power distribution module, a plurality of paths of parallel circuits, a plurality of switching circuits and a plurality of switching circuits, wherein the power distribution circuit number of the power distribution module corresponds to that of the power distribution module one by one;
one end of each parallel circuit is connected with the corresponding power distribution module through the signal acquisition module, and the other end of each parallel circuit is grounded.
4. The thermal management all-in-one controller test system of claim 1, wherein the signal acquisition module comprises: the first signal acquisition unit and the second signal acquisition unit;
the first signal acquisition unit is respectively connected with the inversion load simulation module and the industrial personal computer;
the second signal acquisition unit is connected between the power distribution module and the power distribution load simulation module and is connected with the industrial personal computer.
5. The thermal management all-in-one controller test system of claim 4, wherein the first signal acquisition unit comprises: a rotational speed torque sensor and a rotational speed torque tester;
the rotating speed and torque sensor is respectively connected with the inversion load simulation module and the rotating speed and torque tester;
the rotating speed and torque tester is connected with the industrial personal computer.
6. The thermal management all-in-one controller test system of claim 4, wherein the second signal acquisition unit comprises: a voltage-current sensor;
the voltage and current sensor is connected between the power distribution module and the power distribution load simulation module, and is also connected with the industrial personal computer.
7. The thermal management all-in-one controller test system of any one of claims 1-6, further comprising: a fault injection module;
the fault injection module is respectively connected with the inversion load simulation module, the power distribution load simulation module and the industrial personal computer and is configured to simulate faults of actual loads of the inversion module and/or the power distribution module according to control of the industrial personal computer.
8. The thermal management all-in-one controller test system of claim 7, wherein the fault injection module comprises: the first fault injection units, a plurality of second open circuit fault injection units and a plurality of second short circuit fault injection units are in one-to-one correspondence with the number of power distribution paths of the power distribution module;
the first fault injection unit is connected between the inversion module and the inversion load simulation module, is connected with the industrial personal computer and is configured to simulate open-circuit and short-circuit faults of the actual load of the inversion module according to the control of the industrial personal computer;
each second open-circuit fault injection unit is connected in series between the signal acquisition module and the corresponding power distribution load simulation module and is configured to simulate an open-circuit fault of an actual load of the corresponding power distribution module according to the control of the industrial personal computer;
and each second short-circuit fault injection unit is connected at two ends of the corresponding power distribution load simulation module in parallel and is configured to simulate the short-circuit fault of the actual load of the corresponding power distribution module according to the control of the industrial personal computer.
9. The thermal management all-in-one controller test system of claim 8, wherein the first fault injection unit comprises: a three-phase open-circuit relay coil, a three-phase open-circuit relay normally-closed contact, a three-phase short-circuit relay coil, a three-phase short-circuit relay normally-open contact, a three-phase ground short-circuit relay coil and a three-phase ground short-circuit relay normally-open contact;
the three-phase open-circuit relay coil, the three-phase short-circuit relay coil and the three-phase ground short-circuit relay coil are all connected with the industrial personal computer;
one end of the normally-closed contact of the three-phase open-circuit relay is correspondingly connected with the three-phase output end of the inversion module, and the other end of the normally-closed contact of the three-phase open-circuit relay is respectively connected with the three-phase input end of the inversion load simulation module, one end of the normally-open contact of the three-phase short-circuit relay and one end of the normally-open contact of the three-phase short-circuit relay;
the other ends of the normally open contacts of the three-phase short-circuit relay are connected with each other;
and the other ends of the normally open contacts of the three-phase grounding short-circuit relay are connected with each other and then grounded.
10. The thermal management all-in-one controller test system of claim 8, wherein each of the second open fault injection units comprises: an open-circuit fault relay coil and an open-circuit fault relay normally-closed contact;
the open-circuit fault relay coil is connected with the industrial personal computer, and the normally closed contact of the open-circuit fault relay is connected between the signal acquisition module and the corresponding power distribution load simulation module;
each of the second short fault injection units includes: a short-circuit fault relay coil and a normally open contact of the short-circuit fault relay;
the short-circuit fault relay coil is connected with the industrial personal computer, and the normally open contacts of the short-circuit fault relay are connected in parallel at two ends of the corresponding power distribution load simulation module.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310256951.4A CN116300813A (en) | 2023-03-16 | 2023-03-16 | Thermal management all-in-one controller test system |
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| CN202310256951.4A CN116300813A (en) | 2023-03-16 | 2023-03-16 | Thermal management all-in-one controller test system |
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| CN202310256951.4A Pending CN116300813A (en) | 2023-03-16 | 2023-03-16 | Thermal management all-in-one controller test system |
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