CN116300813A - Thermal Management All-in-One Controller Test System - Google Patents

Abstract

The invention is applicable to the technical field of energy storage power stations, and provides a thermal management all-in-one controller testing system. The test system includes: a power module connected to the tested thermal management all-in-one controller and an industrial computer; an inverter load simulation connected to the tested thermal management all-in-one controller and the signal acquisition module respectively module; a power distribution load simulation module connected to the power distribution module in the tested thermal management all-in-one controller; a signal acquisition module connected between the power distribution module and the power distribution load simulation module, and connected to the industrial computer; And be configured to control the start-up operation of the thermal management all-in-one controller under test, and obtain the operating status information of the thermal management all-in-one controller under test and the analog output status information of the inverter load simulation module and the power distribution load simulation module industrial computer. The invention can shorten the test time, improve the test efficiency, and reduce the volume and cost of the test system.

Description

Thermal Management All-in-One Controller Test System

technical field

The invention belongs to the technical field of energy storage power stations, and in particular relates to a thermal management all-in-one controller testing system.

Background technique

As the core component of the energy storage power station, the battery is extremely sensitive to the ambient temperature, such as the high ambient temperature caused by the charging and discharging process of the battery or the low ambient temperature caused by seasonal reasons will affect the performance and life of the battery. Therefore, it is necessary to perform thermal management on the battery in the energy storage power station to keep the battery in a suitable ambient temperature.

Among them, the rectifier module, inverter module, DC conversion module and power distribution module can be integrated into a thermal management all-in-one controller, so that the thermal management all-in-one controller can be used to control compressors, air conditioners or heat pump systems to cool or heat water , to control the temperature of the battery water circuit through the water temperature, so that the battery is at a suitable ambient temperature. In order to ensure the functional performance of the thermal management all-in-one controller, it is necessary to conduct a functional performance test before the thermal management all-in-one controller leaves the factory.

However, the current thermal management all-in-one controller test system includes various auxiliary equipment, and the test system is large and complex, which is not conducive to the improvement of test efficiency, and the test cost is relatively high.

Contents of the invention

In view of this, an embodiment of the present invention provides a thermal management all-in-one controller testing system to solve the problems of complex testing systems, low testing efficiency, and high cost of the current thermal management all-in-one controller.

The first aspect of the embodiment of the present invention provides a thermal management all-in-one controller test system, including: a power supply module, an inverter load simulation module, a power distribution load simulation module, a signal acquisition module, and an industrial computer;

The power module is respectively connected to the measured thermal management all-in-one controller and the industrial computer, and is configured to supply power to the measured thermal management all-in-one controller according to the control of the industrial computer;

The inverter load simulation module is respectively connected to the inverter module in the measured thermal management all-in-one controller and the signal acquisition module, and is configured to simulate the actual load of the inverter module;

The power distribution load simulation module is connected to the power distribution module in the tested 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, and connected to the industrial computer, configured to collect the inverter load simulation module and the power distribution load The analog output state information of the analog module is sent to the industrial computer;

The industrial computer is configured to control the startup and operation of the tested thermal management all-in-one controller, and acquire the running status information and the analog output status information of the tested thermal management all-in-one controller, to A test result is determined based on the operating status information and the simulated output status information.

In a possible implementation manner, the inverter load simulation module includes: a drive motor and a load motor;

The three-phase input end of the driving motor is connected to the three-phase output end of the inverter module, and the output shaft of the driving motor is connected to the load motor through the signal acquisition module;

Alternatively, the inverter load simulation module includes: a drive motor, an electromagnetic clutch and a friction disc;

The three-phase input end of the drive motor is connected to the three-phase output end of the inverter module, the output shaft of the drive motor is connected to the electromagnetic clutch through the signal acquisition module, and the electromagnetic clutch is connected to the friction disc .

In a possible implementation manner, the power distribution load simulation module includes: multiple parallel circuits corresponding to the number of power distribution circuits of the power distribution module, and each parallel circuit is connected in parallel by a resistor and a capacitor constitute;

One end of each parallel circuit is connected to the corresponding power distribution module through the signal acquisition module, and the other end of each parallel circuit is grounded.

In a possible implementation manner, the signal acquisition module includes: a first signal acquisition unit and a second signal acquisition unit;

The first signal acquisition unit is respectively connected with the inverter load simulation module and the industrial 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 computer.

In a possible implementation manner, the first signal acquisition unit includes: a rotational speed torque sensor and a rotational speed torque tester;

The rotational speed torque sensor is respectively connected with the inverter load simulation module and the rotational speed torque tester;

The rotational speed torque tester is connected with the industrial computer.

In a possible implementation manner, the second signal acquisition unit includes: a voltage and current sensor;

The voltage and current sensor is connected between the power distribution module and the power distribution load simulation module, and the voltage and current sensor is also connected with the industrial computer.

In a possible implementation manner, the thermal management all-in-one controller testing system further includes: a fault injection module;

The fault injection module is respectively connected with the inverter load simulation module, the power distribution load simulation module and the industrial computer, and is configured to simulate the inverter module and/or the industrial computer according to the control of the industrial computer. failure of the actual load of the power distribution module described above.

In a possible implementation manner, the fault injection module includes: a first fault injection unit, a plurality of second open circuit fault injection units corresponding to the number of power distribution channels of the power distribution module and a plurality of a second short circuit fault injection unit;

The first fault injection unit is connected between the inverter module and the inverter load simulation module, and connected to the industrial computer, configured to simulate the inverter module according to the control of the industrial computer Open circuit and short circuit faults of the actual load;

Each of the second open-circuit fault injection units is connected in series between the signal acquisition module and the corresponding power distribution load simulation module, and is configured to simulate the corresponding power distribution module according to the control of the industrial computer open circuit fault of the actual load;

Each of the second short-circuit fault injection units is connected in parallel to both ends of the corresponding power distribution load simulation module, and is configured to simulate a short-circuit fault of the actual load of the corresponding power distribution module according to the control of the industrial computer .

In a 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 normally open contact, three Phase-to-ground short-circuit relay coil and three-phase-to-ground short-circuit relay normally open contacts;

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 to the industrial computer;

The normally closed contact of the three-phase open circuit relay has one end correspondingly connected to the three-phase output end of the inverter module, and the other end is respectively connected to the three-phase input end of the inverter load simulation module and the three-phase short-circuit relay normally One end of the open contact is connected to one end of the normally open contact of the three-phase-to-ground short-circuit relay;

The other ends of the normally open contacts of the three-phase short-circuit relay are connected to each other;

The other ends of the normally open contacts of the three-phase-to-ground short-circuit relay are connected to each other and then grounded.

In a possible implementation manner, each of the second open-circuit fault injection units includes: an open-circuit fault relay coil and a normally-closed contact of the open-circuit fault relay;

The coil of the open fault relay is connected to the industrial computer, and the normally closed contact of the open fault relay is connected between the signal acquisition module and the corresponding power distribution load simulation module;

Each of the second short-circuit fault injection units includes: a coil of a short-circuit fault relay and a normally open contact of the short-circuit fault relay;

The coil of the short-circuit fault relay is connected to the industrial computer, and the normally open contacts of the short-circuit fault relay are connected in parallel to both ends of the corresponding power distribution load simulation module.

Compared with the prior art, the embodiment of the present invention has the following beneficial effects: the embodiment of the present invention can manage the measured heat through the power supply module, the inverter load simulation module, the power distribution load simulation module, the signal acquisition module and the industrial computer. All-in-one control power supply, and simulate the actual load of the tested thermal management all-in-one controller based on the inverter load simulation module and power distribution load simulation module, so that under the control of the industrial computer, control the tested thermal management all-in-one control start the operation of the controller, and obtain the running status information of the thermal management all-in-one controller under test and the analog output status information of the inverter load simulation module and the power distribution load simulation module, so that the thermal management all-in-one controller under test can be used In the case of the actual application system, the functional performance test of the tested thermal management all-in-one controller is carried out, and the tested functions of the tested thermal management all-in-one controller are tested through the inverter load simulation module and the power distribution load simulation module. Decoupling, so that each module of the thermal management all-in-one controller under test can be individually simulated and tested, which is conducive to reducing the complexity of the working logic of the thermal management all-in-one controller test system, shortening the test time, and improving test efficiency. Reduce the size and cost of the test system.

Description of drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following will briefly introduce the accompanying drawings that need to be used in the descriptions of the embodiments or the prior art. Obviously, the accompanying drawings in the following description are only of the present invention. For some embodiments, those of ordinary skill in the art can also obtain other drawings based on these drawings without paying creative efforts.

Fig. 1 is a schematic structural diagram of a thermal management all-in-one controller testing system provided by an embodiment of the present invention;

Fig. 2 is a schematic structural diagram of a thermal management all-in-one controller provided by an embodiment of the present invention;

Fig. 3 is a schematic structural diagram of a thermal management all-in-one controller test system provided by another embodiment of the present invention;

Fig. 4 is a schematic structural diagram of a thermal management all-in-one controller testing system provided by another embodiment of the present invention.

Detailed ways

In the following description, specific details such as specific system structures and technologies are presented for the purpose of illustration rather than limitation, so as to thoroughly understand the embodiments of the present invention. It will be apparent, however, to one skilled in the art that the invention may be practiced in other embodiments without 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 solutions of the present invention, specific examples are used below to illustrate.

Referring to FIG. 1 , a thermal management all-in-one controller test system 100 provided by an embodiment of the present invention includes: a power supply module 10 , an inverter load simulation module 20 , a power distribution load simulation module 30 , a signal acquisition module 40 and an industrial computer 50 .

Wherein, the power module 10 is respectively connected with the tested thermal management all-in-one controller 60 and the industrial computer 50 , and is configured to supply power to the tested thermal management all-in-one controller 60 according to the control of the industrial computer 50 .

The inverter load simulation module 20 is respectively connected with the inverter module and the signal acquisition module 40 in the thermal management all-in-one controller 60 under test, and is configured to simulate the actual load of the inverter module.

The power distribution load simulation module 30 is connected to the power distribution module in the thermal management all-in-one controller 60 under test, and is configured to simulate the actual load of the power distribution module.

The signal acquisition module 40 is also connected between the power distribution module and the power distribution load simulation module 30, and is connected with the industrial computer 50, and is configured to collect the analog output status information of the inverter load simulation module 20 and the power distribution load simulation module 30 And send to the industrial computer 50.

The industrial computer 50 is configured to control the start-up operation of the tested thermal management all-in-one controller 60, and obtain the running state information and analog output state information of the tested thermal management all-in-one controller 60, to Analog output status information determines test results.

Wherein, the power supply module 10 can be a program-controlled high-voltage AC power supply, so as to output the high-voltage AC power required by the thermal management all-in-one controller under test under the control of the communication command of the industrial computer 50, and the industrial computer 50 can communicate with the power supply module 10 through RS485 . The signal acquisition module 40 can be powered by 220V AC mains, and the industrial computer 50 can communicate with the signal acquisition module 40 through RS485.

Exemplarily, when it is necessary to perform a functional performance test on a certain thermal management all-in-one controller 60 under test, the relevant information of the tested thermal management all-in-one controller 60 can be entered in the industrial computer 50 first, and then the industrial control The computer 50 can issue a communication command to control the programmable high-voltage AC power supply to provide high-voltage AC power supply to the thermal management all-in-one controller 60 under test. After the tested thermal management all-in-one controller 60 is powered on, the industrial computer 50 can issue a start-up operation command, and the start-up operation command can be a corresponding command during the actual operation of the measured thermal management all-in-one controller 60 For example, a command to control the tested thermal management all-in-one controller 60 to perform low-voltage DC output, or a command to control the tested thermal management all-in-one controller 60 to perform motor output. When the tested thermal management all-in-one controller 60 runs based on the corresponding start-up command, it will output the running state information of each module in the tested thermal management all-in-one controller 60, so that the actual running can be based on these running states information for judgment or control. Therefore, the tested thermal management all-in-one control 60 is sent to the industrial computer 50 based on the running state information output when the corresponding start-up command runs, to determine whether it meets the actual use based on the corresponding reference prestored in the industrial computer 50 or through human judgment. need. Wherein, the running status information output by the tested thermal management all-in-one control 60 based on the corresponding start running command can be sent to the industrial computer 50 through the CAN bus.

For example, the rectifier module of a thermal management all-in-one controller usually feeds back AC input voltage, internal bus voltage, substrate temperature, control power supply voltage, etc. The inverter module of the thermal management all-in-one controller usually feeds back the DC input voltage, motor speed, output current, output power, IGBT temperature, etc. The DC-DC conversion module of the thermal management all-in-one controller usually feeds back the DC input voltage, output current, power consumption, etc. The power distribution module of the thermal management all-in-one controller usually feeds back the output status and fault status of each power distribution channel, NTC over-temperature protection temperature, etc. Based on the operating status information fed back by each module of the tested thermal management all-in-one controller, it can be determined whether it is within the preset error range or within the preset range, and then test the operation of the tested thermal management all-in-one controller feedback Whether the status information meets the actual use requirements. For example, test whether the IGBT operating temperature meets the requirements based on the IGBT temperature fed back by the tested thermal management all-in-one controller.

In addition, when the thermal management all-in-one controller 60 under test operates based on the corresponding start-up command, the state of the loaded inverter load simulation module 20 and power distribution load simulation module 30 will also be different. Therefore, the analog output state information of the inverter load simulation module 20 and the power distribution load simulation module 30 can be collected based on the signal acquisition module 40 and sent to the industrial computer 50, so as to be tested by the preset reference value or reference state in the industrial computer 50. Whether the working status of the thermal measurement management all-in-one control 60 meets the requirements. For example, based on the signal acquisition module 40, the rotational speed, torque, and output power of the inverter load simulation module 20 are collected to compare with the rotational speed, torque, and output power fed back by the inverter module in the thermal management all-in-one controller 60 under test. , to determine whether the corresponding error is within the set error range, and whether the corresponding value is within the preset range. Or collect the current of the power distribution load simulation module 30 based on the signal collection module 40, so as to determine whether it is consistent with the system working state and conforms to the preset value.

Wherein, after the industrial computer 50 obtains the running state information and the analog output state information of the thermal management all-in-one controller 60 under test, it records the corresponding information as a test record, and when the information of each phase meets the preset requirements, it is marked as The test passes. If a certain piece of information does not meet the preset requirements, the tested thermal management all-in-one controller 60 will also feed back a fault code to the industrial computer 50, and the fault code is compiled for each module in the tested thermal management all-in-one controller 60 Code meter, after receiving the fault code, the industrial computer 50 marks that the test of the corresponding thermal management all-in-one controller under test has failed.

Optionally, after the tested thermal management all-in-one controller 60 is powered on, the industrial computer 50 can perform a system self-check first, so as to determine whether the program-controlled high-voltage AC power supply is normal according to the self-check result of the program-controlled power supply. Whether the signal after the system is powered on is within a reasonable range determines whether the signal acquisition module 40 is normal, and determines whether the function of the fault injection module 70 is normal according to whether each relay of the fault injection module 70 operates. Then the operator information can be entered into the industrial computer 50, and the ID information of the tested thermal management all-in-one controller can be entered through the code scanning gun, and the hardware and version software of each module in the tested thermal management all-in-one controller can be read information and compare it to the standard. After completing these tasks, send the start-up command to the thermal management all-in-one controller under test to make it start up and run according to the command requirements.

Among them, when controlling the tested thermal management all-in-one controller to start operation, the tested thermal management all-in-one controller can be controlled to output low-voltage DC, and then the tested thermal management all-in-one controller can be controlled to output the motor. And stepping the given motor speed until it reaches the preset maximum speed; then when the measured thermal management all-in-one controller is outputting low-voltage DC and the motor output reaches the preset maximum speed, read the measured heat through the program-controlled high-voltage AC voltage Manage system power factor for all-in-one controllers.

After the tested thermal management all-in-one controller is tested, the tested thermal management all-in-one controller can be powered off, and then wait for the next thermal management all-in-one controller to be tested.

As shown in Figure 2, in practical applications, the thermal management all-in-one controller of the energy storage power station converts the on-site AC power into DC power through the rectification module, and sends the converted DC power to the inverter module all the way to invert the inverter module. Obtain the AC power required by the compressor or the motor of the air conditioner, and give the DC-DC conversion module another way to obtain the low-voltage direct current required by the power distribution module (ie, the PDU module in Figure 2) through the DC-DC conversion module, and then Distribute the low-voltage DC power through the power distribution module, for example, output 8 low-voltage DC power distribution through the power distribution module, and respectively supply the water pumps, compressors or fans corresponding to the air conditioners in the battery waterway, as well as heat management for the batteries in the energy storage power station Various solenoid valves used, etc. If the actual application system of the thermal management all-in-one controller is built in order to test whether the functional performance of the thermal management all-in-one controller is qualified, not only the actual load directly controlled by the thermal management all-in-one controller is required, but also the corresponding actual load. Various ancillary equipment of the load, resulting in a large and complex test system for the thermal management all-in-one controller, which is not conducive to the improvement of test efficiency, and the test cost is relatively high.

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 control is simulated by the power distribution load simulation module 30, Therefore, the actual application system of the thermal management all-in-one controller is not required, and each function to be tested of the thermal management all-in-one controller is decoupled, so as to separately simulate and test each module of the thermal management all-in-one controller. Therefore, the complexity of the test system of the thermal management all-in-one controller can be reduced to reduce the volume of the test system and the test cost, and the complexity of the working logic of the test system of the thermal management all-in-one controller can be reduced to improve Test efficiency.

Optionally, referring to FIG. 3 , the inverter load simulation module 20 includes: a drive motor 21 and a load motor 22 .

The three-phase input end of the drive motor 21 is connected to the three-phase output end of the inverter module, and the output shaft of the drive motor 21 is connected to the load motor 22 through the signal acquisition module 40 .

Alternatively, the inverter load simulation module 20 includes: a driving motor 21 , an electromagnetic clutch 23 and a friction disc 24 .

The three-phase input end of the drive motor 21 is connected to the three-phase output end of the inverter module, the output shaft of the drive motor 21 is connected to the electromagnetic clutch 23 through the signal acquisition module 40 , and the electromagnetic clutch 23 is connected to the friction disc 24 .

In this embodiment, the actual motor load characteristics of the tested thermal management all-in-one controller 60 are simulated by driving the motor 21 and the load motor 22, or driving the motor 21, the electromagnetic clutch 23 and the friction disc 24, so as to test the tested thermal management Whether the AC power obtained by the rectifier module and the inverter module of the all-in-one controller 60 has sufficient load capacity.

Wherein, when the inverter load simulation module 20 is constituted by the driving motor 21, the electromagnetic clutch 23 and the friction disc 24, the industrial computer 50 can apply a load to the electromagnetic clutch 23 to control the inverter module to work under the rated output.

Optionally, the power distribution load simulation module 30 includes: multiple parallel circuits 31 corresponding to the number of power distribution channels of the power distribution module, and each parallel circuit is composed of a resistor 311 and a capacitor 312 connected in parallel.

Wherein, one end of each parallel circuit 31 is connected to the corresponding power distribution module through the signal acquisition module 40 , and the other end of each parallel circuit 31 is grounded.

In this embodiment, considering thermal management, the power distribution module of the all-in-one controller usually has multiple loads, and each load has a capacitive characteristic. Therefore, the parallel circuit 31 based on the parallel connection of the resistor 311 and the capacitor 312 simulates the load of each power distribution module, thereby simulating the characteristics that the actual load of the power distribution module has an inrush current at the moment of starting and then operates at the rated current. To test whether the DC power obtained by the rectification module, DC-DC conversion module and power distribution module of the thermal management all-in-one controller 60 under test has sufficient load capacity. For example, test whether a certain channel of the power distribution module has the load capacity of 24V/20A.

Wherein, the resistance value of the resistor and the capacitance value of the capacitor in the corresponding parallel circuit can be adjusted according to the loading requirements of each channel of the power distribution module. This embodiment does not limit the resistance value of the resistor and the capacitance value of the capacitor in each parallel circuit.

Optionally, referring to FIG. 3 , the signal acquisition module 40 includes: a first signal acquisition unit 41 and a second signal acquisition unit 42 .

Wherein, the first signal acquisition unit 41 is respectively connected with the inverter load simulation module 20 and the industrial computer 50 . 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 computer 50 .

Optionally, the first signal acquisition unit 41 includes: a rotational speed torque sensor 411 and a rotational speed torque tester 412 .

Wherein, the rotational speed torque sensor 411 is respectively connected with the inverter load simulation module 20 and the rotational speed torque tester 412 . The rotational speed torque tester 412 is connected with the industrial computer 50 .

As shown in Figure 3, that is, the rotational speed torque sensor 411 is connected between the output shaft of the drive motor 21 and the load motor 22, or between the output shaft of the drive motor 21 and the electromagnetic clutch 23, the rotational speed torque sensor 411 is also It communicates with the rotational speed torque tester 412 ; the rotational speed torque tester 412 is connected with the industrial computer 50 .

In this embodiment, by adding a speed torque sensor 411 between the output shaft of the drive motor 21 and the load motor 22, or adding a speed torque sensor 411 between the output shaft of the drive motor 21 and the electromagnetic clutch 23, the drive can be monitored. Data such as the real-time rotating speed of motor 21, torque, and the real-time output power of driving motor 21 is calculated according to the real-time rotating speed that speed torque sensor 411 gathers by rotating speed torque tester 412, torque, to provide the real-time rotating speed of driving motor 21, Data such as torque and output power are sent to the industrial computer 50 so as to obtain test results related to the inverter module of the tested thermal management all-in-one controller 60 based on the industrial computer 50 .

Optionally, the second signal acquisition unit 42 includes: a voltage and current sensor 421 .

Wherein, 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 to the industrial computer 50 .

As shown in FIG. 3 , that is, the voltage and current sensor 421 is connected between each parallel circuit 31 and the corresponding power distribution module, and the voltage and current sensor 421 is also connected to the industrial computer 50 .

In this embodiment, by adding a voltage and current sensor 421 between each parallel circuit 31 and the corresponding power distribution module, the output voltage and output current of each circuit of the power distribution module can be monitored, so that the tested thermal management all-in-one The controller 60 is related to the working state of the power distribution module.

Optionally, referring to FIG. 4 , the thermal management all-in-one controller testing system 100 further includes: a fault injection module 70 .

Wherein, the fault injection module 70 is respectively connected with the inverter load simulation module 20, the power distribution load simulation module 30 and the industrial computer 50, and is configured to simulate the actual load of the inverter module and/or the power distribution module according to the control of the industrial computer 50 failure.

In this embodiment, considering the practical application system based on the thermal management all-in-one controller, it is difficult to test some fault conditions of the thermal management all-in-one controller, the fault injection module 70 is designed to pass the fault injection module 70 covers items that cannot be tested by the actual application system, so as to realize a comprehensive test of the functional performance of each function of the thermal management all-in-one controller.

Wherein, the fault injection module 70 can be powered by AC mains 220V, and the fault injection module 70 can be connected with the industrial computer 50 through the CAN bus.

Optionally, continue to refer to FIG. 4 , the fault injection module 70 includes: a first fault injection unit 71, and a plurality of second open-circuit fault injection units 72 and a plurality of first fault injection units corresponding to the number of power distribution channels of the power distribution module. Two short circuit fault injection unit 73 .

Wherein, the first fault injection unit 71 is connected between the inverter module and the inverter load simulation module 20, and is connected with the industrial computer 50, and is configured to simulate the open circuit and the actual load of the inverter module according to the control of the industrial computer 50. Short circuit fault.

Each second open-circuit fault injection unit 72 is connected in series between the signal acquisition module 40 and the corresponding power distribution load simulation module 30, and is configured to simulate the open-circuit fault of the actual load of the corresponding power distribution module according to the control of the industrial computer 50 .

Each second short-circuit fault injection unit 73 is connected in parallel to both ends of the corresponding power distribution load simulation module 30 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 computer 50 .

Specifically, the first fault injection unit 71 can 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 the short-circuit fault of the three-phase line of the actual motor of the inverter module, thereby testing The output short-circuit protection function of the inverter module, or simulate the open-circuit fault of a certain phase of the actual motor of the inverter module, so as to test the phase loss protection function of the inverter module.

Each second open-circuit fault injection unit 72 can be connected between the corresponding voltage and current sensor 421 and the parallel circuit 31 to simulate the output load open-circuit fault of the power distribution module, so as to test the output open-circuit protection function of the power distribution module.

Each second short-circuit fault injection unit 73 can be connected in parallel to both ends of the parallel circuit 31 to simulate the output load short-circuit fault of the power distribution module, so as to test the output overcurrent protection function of the power distribution module.

Optionally, the first fault injection unit 71 includes: three-phase open relay coils, three-phase open relay normally closed contacts J1, J2, J3, three-phase short-circuit relay coils, three-phase short-circuit relay normally open contacts J4, J5 , J6, three-phase-to-ground short-circuit relay coil and three-phase-to-ground short-circuit relay normally open contacts J7, J8, J9.

Wherein, the three-phase open-circuit relay coils, the three-phase short-circuit relay coils and the three-phase ground short-circuit relay coils are all connected to the industrial computer 50 .

Three-phase open circuit relay normally closed contacts J1, J2, J3, one end is connected to the three-phase output end of the inverter module correspondingly, and the other end is respectively connected to the three-phase input end of the inverter load simulation module 20 and the three-phase short-circuit relay normally open contact One end of points J4, J5, J6 is connected with one end of normally open contacts J7, J8, J9 of the three-phase-to-ground short-circuit relay.

The other ends of the normally open contacts J4, J5, and J6 of the three-phase short-circuit relay are connected to each other.

The other ends of the normally open contacts J7, J8, and J9 of the three-phase-to-ground short-circuit relay are connected to each other and grounded.

In this embodiment, the coil of the three-phase open circuit relay and the normally closed contacts J1, J2, and J3 of the three-phase open circuit relay form a three-phase open circuit relay, and the normally closed contacts J1, J2, and J3 of the three-phase open circuit relay are closed under normal conditions. When it is necessary to simulate an open-circuit fault of a certain phase of the actual motor of the inverter module, the corresponding phase open-circuit relay coil is controlled to be energized or de-energized through the industrial computer 50, and then the normally closed contacts J1/J2/J3 of the corresponding phase open-circuit relay are disconnected, In this way, the simulation of an open-circuit fault of a certain phase of the actual motor of the inverter module is realized.

The three-phase short-circuit relay coil and the three-phase short-circuit relay normally open contacts J4, J5, J6 form a three-phase short-circuit relay. The three-phase short-circuit relay normally open contacts J4, J5, and J6 are disconnected under normal conditions. When the three-phase line of the actual motor of the module is short-circuited, the coil of the three-phase short-circuit relay is controlled to be energized or de-energized through the industrial computer 50, and then the normally open contacts J4, J5, and J6 of the three-phase short-circuit relay are closed, thereby realizing the inverter module The simulation of the three-phase line short-circuit fault of the real motor.

The three-phase ground short-circuit relay coil and the three-phase ground short-circuit relay normally open contacts J7, J8, and J9 form a three-phase ground short-circuit relay. The three-phase ground short-circuit relay normally open contacts J7, J8, and J9 are disconnected under normal conditions. When it is necessary to simulate the three-phase line-to-ground short-circuit fault of the actual motor of the inverter module, the coil of the three-phase-to-ground short-circuit relay is controlled to be energized or de-energized through the industrial computer 50, so that the normally open contacts J7, J8, J9 is closed, thereby realizing the simulation of the three-phase line-to-ground short circuit fault of the actual motor of the inverter module.

Wherein, after the short circuit or open circuit fault simulation of the actual motor of the inverter module is carried out in the above manner, the inverter module feeds back the short circuit or open circuit fault to the industrial computer, and after the measured thermal management all-in-one controller 60 is powered on again Run it again to verify that the corresponding functions are intact.

Optionally, each second open-circuit fault injection unit 72 includes: an open-circuit fault relay coil and an open-circuit fault relay normally-closed contact J10.

Wherein, the coil of the open fault relay is connected to the industrial computer 50 , and the normally closed contact J10 of the open fault relay is connected between the signal acquisition module 40 and the corresponding power distribution load simulation module 30 .

Each second short-circuit fault injection unit 73 includes: a coil of a short-circuit fault relay and a normally open contact J11 of the short-circuit fault relay.

Wherein, the coil of the short-circuit fault relay is connected to the industrial computer 50 , and the normally open contact J11 of the short-circuit fault relay is connected in parallel to both ends of the corresponding power distribution load simulation module 30 .

In this embodiment, each open-circuit fault relay coil and open-circuit fault relay normally closed contact J10 form an open-circuit fault relay, and the normally-closed contact J10 of the open-circuit fault relay is closed under normal conditions. At this time, the industrial computer 50 controls the corresponding open-circuit fault relay coil to be energized or de-energized, and then the normally closed contact J10 of the corresponding open-circuit fault relay is disconnected, thereby realizing the simulation of the output load open-circuit fault of the power distribution module.

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 disconnected under normal conditions. The machine 50 controls the coil of the corresponding short-circuit fault relay to be energized or de-energized, and then closes the normally open contact J11 of the corresponding short-circuit fault relay, thereby realizing the simulation of the short-circuit fault of the output load of the power distribution module.

Wherein, after the output load short-circuit or open-circuit fault simulation of the power distribution module is performed in the above-mentioned manner, the power distribution module feeds back the short-circuit or open-circuit fault to the industrial computer, and re-energizes the tested thermal management all-in-one controller 60 again. Run to verify that the corresponding functions are intact.

Optionally, continue to refer to FIG. 4 , the fault injection module 70 further includes an electromechanical valve 74, and the electromechanical valve 74 is installed on the output shaft of the drive motor 21 to lock the output shaft of the drive motor 21 when power is applied. , so as to simulate the stalling fault of the driving motor, so as to realize the test of the motor stalling protection of the inverter module of the thermal management all-in-one controller under test.

Optionally, based on the thermal management all-in-one controller test system provided in this embodiment, fault simulations such as overvoltage and undervoltage can also be performed to test and verify the corresponding functions of the thermal management all-in-one controller under test.

The thermal management all-in-one controller test system provided in this embodiment can test the protection performance of the thermal management all-in-one controller by adding a fault injection module, and enhance the reliability of the thermal management all-in-one controller, and this embodiment provides The thermal management all-in-one controller system of the company has achieved very good results in the production of thermal management all-in-one controllers by virtue of the advantages of simple system, small size, low cost, high testing efficiency and more comprehensive testing.

The above-described embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: it can still carry out the foregoing embodiments Modifications to the technical solutions recorded in the examples, or equivalent replacement of some of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention, and should be included in within the protection scope of the present invention.

Claims (10)

1. A thermal management all-in-one controller test system, is characterized in that, comprises: power supply module, inverter load simulation module, power distribution load simulation module, signal acquisition module and industrial computer; The power module is respectively connected to the measured thermal management all-in-one controller and the industrial computer, and is configured to supply power to the measured thermal management all-in-one controller according to the control of the industrial computer; The inverter load simulation module is respectively connected to the inverter module in the measured thermal management all-in-one controller and the signal acquisition module, and is configured to simulate the actual load of the inverter module; The power distribution load simulation module is connected to the power distribution module in the tested 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, and connected to the industrial computer, configured to collect the inverter load simulation module and the power distribution load The analog output state information of the analog module is sent to the industrial computer; The industrial computer is configured to control the startup and operation of the tested thermal management all-in-one controller, and acquire the running status information and the analog output status information of the tested thermal management all-in-one controller, to A test result is determined based on the operating status information and the simulated output status information. 2. The thermal management all-in-one controller test system according to claim 1, wherein the inverter load simulation module includes: a drive motor and a load motor; The three-phase input end of the driving motor is connected to the three-phase output end of the inverter module, and the output shaft of the driving motor is connected to the load motor through the signal acquisition module; Alternatively, the inverter load simulation module includes: a drive motor, an electromagnetic clutch and a friction disc; The three-phase input end of the drive motor is connected to the three-phase output end of the inverter module, the output shaft of the drive motor is connected to the electromagnetic clutch through the signal acquisition module, and the electromagnetic clutch is connected to the friction disc . 3. The thermal management all-in-one controller test system according to claim 1, wherein the power distribution load simulation module includes: a multi-channel corresponding to the number of power distribution channels of the power distribution module Parallel circuits, each of which is composed of resistors and capacitors connected in parallel; One end of each parallel circuit is connected to 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 according to claim 1, wherein the signal acquisition module comprises: a first signal acquisition unit and a second signal acquisition unit; The first signal acquisition unit is respectively connected with the inverter load simulation module and the industrial 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 computer. 5. The thermal management all-in-one controller testing system according to claim 4, wherein the first signal acquisition unit comprises: a rotational speed torque sensor and a rotational speed torque tester; The rotational speed torque sensor is respectively connected with the inverter load simulation module and the rotational speed torque tester; The rotational speed torque tester is connected with the industrial computer. 6. The thermal management all-in-one controller testing system according to claim 4, wherein the second signal acquisition unit comprises: a voltage and current sensor; The voltage and current sensor is connected between the power distribution module and the power distribution load simulation module, and the voltage and current sensor is also connected with the industrial computer. 7. The thermal management all-in-one controller test system according to any one of claims 1-6, further comprising: a fault injection module; The fault injection module is respectively connected with the inverter load simulation module, the power distribution load simulation module and the industrial computer, and is configured to simulate the inverter module and/or the industrial computer according to the control of the industrial computer. failure of the actual load of the power distribution module described above. 8. The thermal management all-in-one controller testing system according to claim 7, wherein the fault injection module includes: a first fault injection unit, and a a corresponding plurality of second open-circuit fault injection units and a plurality of second short-circuit fault injection units; The first fault injection unit is connected between the inverter module and the inverter load simulation module, and connected to the industrial computer, configured to simulate the inverter module according to the control of the industrial computer Open circuit and short circuit faults of the actual load; Each of the second open-circuit fault injection units is connected in series between the signal acquisition module and the corresponding power distribution load simulation module, and is configured to simulate the corresponding power distribution module according to the control of the industrial computer open circuit fault of the actual load; Each of the second short-circuit fault injection units is connected in parallel to both ends of the corresponding power distribution load simulation module, and is configured to simulate a short-circuit fault of the actual load of the corresponding power distribution module according to the control of the industrial computer . 9. The thermal management all-in-one controller test system according to claim 8, wherein the first fault injection unit includes: a three-phase open relay coil, a three-phase open relay normally closed contact, a three-phase Short-circuit relay coils, three-phase short-circuit relay normally open contacts, three-phase ground short-circuit relay coils and three-phase ground short-circuit relay normally open contacts; 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 to the industrial computer; The normally closed contact of the three-phase open circuit relay has one end correspondingly connected to the three-phase output end of the inverter module, and the other end is respectively connected to the three-phase input end of the inverter load simulation module and the three-phase short-circuit relay normally One end of the open contact is connected to one end of the normally open contact of the three-phase-to-ground short-circuit relay; The other ends of the normally open contacts of the three-phase short-circuit relay are connected to each other; The other ends of the normally open contacts of the three-phase-to-ground short-circuit relay are connected to each other and then grounded. 10. The thermal management all-in-one controller testing system according to claim 8, wherein each of the second open-circuit fault injection units comprises: an open-circuit fault relay coil and an open-circuit fault relay normally closed contact; The coil of the open fault relay is connected to the industrial computer, and the normally closed contact of the open fault relay is connected between the signal acquisition module and the corresponding power distribution load simulation module; Each of the second short-circuit fault injection units includes: a coil of a short-circuit fault relay and a normally open contact of the short-circuit fault relay; The coil of the short-circuit fault relay is connected to the industrial computer, and the normally open contacts of the short-circuit fault relay are connected in parallel to both ends of the corresponding power distribution load simulation module.

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