CN117890752B - Evaluation method of resistive thermal effect of power device in ECU (electronic control Unit) - Google Patents
Evaluation method of resistive thermal effect of power device in ECU (electronic control Unit) Download PDFInfo
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Abstract
The invention discloses an evaluation method of a resistive thermal effect of a power device in an ECU (electronic control unit) controller, which relates to the technical field of automobile steering gears and is realized by utilizing a heating coefficient algorithm. The method can be used for calculating the heating coefficient of the component and detecting the heating of the resistive element of the controller through the output of the automatic regulating current and the acquisition of the temperature, can provide data basis for the design, the optimization and the device model selection of the PCB, also can realize the influence evaluation of the heating condition of the resistive element on the operation of the controller, and can provide support for the reliability of the product.
Description
Technical Field
The invention relates to the technical field of automobile steering gears, in particular to an evaluation method of resistive thermal effects of a power device in an ECU (electronic control unit).
Background
In the development process of the ECU controller, the PCB design of the hardware can use some pure resistive components, compared with other components, the components have larger heating value, the temperature of the controller is easy to rise, if the heat dissipation is not timely, or the design is unreasonable, certain potential safety hazards can be generated, and certain resistive components are greatly influenced by the temperature, and the performance deviation can be caused under the extreme environment temperature, so the heating condition of the pure resistive components also needs to be considered and evaluated, if the heating effect of the components is insufficient in advance, the problem is often exposed in the development process or the use process, and then the problem needs to be remedied, even the replacement or the redesign, but the mode is time-consuming and labor-consuming, the earlier development work is possibly influenced, even the rework is needed, and the development cost and the period are greatly influenced.
The current development process often relies on the following two methods to analyze the heat generation:
1. Technical parameters provided in the product selection table provided by the component manufacturer.
2. Based on the theoretical basis and experience of the developer.
The two methods are not intuitive for analysis of the heat effect, are suitable for qualitative analysis in a design stage, and the actual working environment and the operation working condition of the product are complex and various, and the two methods can be used as reference bases for the development process, so that the actual heat generation condition needs to consider various extreme conditions besides the conditions, a set of tool capable of quantitatively analyzing the heat generation condition and a measurement standard suitable for various working conditions are needed, so that the heat generation condition is measured, the heat effect of the controller is evaluated, and the stability and the reliability of the operation of the product are ensured;
To this end we provide a method of evaluating resistive thermal effects of power devices in an ECU controller to solve the above problems.
Disclosure of Invention
Aiming at the problems existing in the prior art, the invention provides an evaluation method of the resistive heating effect of the power device in the ECU controller, a tool for calculating the heating coefficient of the component and a detection standard of the resistive element of the controller can be realized through the output of the automatic regulating current and the acquisition of the temperature, the tool and the detection standard can provide data basis for the design, the optimization and the device model selection of the PCB, the evaluation of the influence of the heating condition of the resistive element on the operation of the controller is also realized, and the support is provided for the reliability of the product.
In order to achieve the above purpose, the method for evaluating the resistive thermal effect of the power device in the ECU is implemented by utilizing the algorithm of the heating coefficient, the temperature acquisition tool and the upper computer are used in the implementation process, the temperature acquisition tool acquires the temperature information of the component and transmits the result to the upper computer, the controller to be tested transmits the current information to the upper computer, the upper computer analyzes the current information, the received component current information and the temperature information are calculated by utilizing the algorithm of the heating coefficient to obtain the heating coefficient, and the analysis result is output in the form of a chart;
the calculation method of the heating coefficient comprises the following steps:
S1: setting a theoretical basis;
For pure resistive elements, the heat generation is known from the heat formula ；
Namely, when the basic parameters of the components are fixed, the quantity of the generated heat is in a quadratic function relationship with the current and in a linear function relationship with the time, the generated heat generates temperature rise, and the heat formula is referred, and the heat generation is assumed to be totally used for temperature rise, and the relation between the heat and the temperature is thatT, m is the mass of the object, c is the specific heat capacity,/>T is the temperature change, but in actual case, when the temperature is higher than the ambient temperature, the outward radiation is generated, namely heat dissipation, and the relation between the heat energy and the temperature is as follows: /(I)Where k is the heat transfer coefficient of the object, A is the object surface area,/>Is the temperature difference from the environment, t is the heat dissipation time, d is the thickness of the object, I is the current, and the unit is ampere; r represents resistance, and the unit is ohm;
according to the principle of energy conservation, the heat energy generated by the current flowing through the component is equal to the sum of the heat absorbed by heating and the heat emitted, namely And obtaining a differential equation through transformation: Then solving the differential equation to obtain the temperature/> The relationship with time t is as follows:
(formula 1);
s2: according to the theoretical basis in S1, the heating coefficient algorithm is developed by simplifying the formula 1 firstly, because Is the heating coefficient to be measured, and an unknown number/> isused as a wholeExpressed, let/>=/>At the same time, the testing process adopts the setting of the maximum value, the minimum value, the step length and the duration of the testing current, and the proper duration is set to ensure that the sampled temperature is stable, thus/>About 0, can be ignored, and thus the formula 1 can be obtained after transformation
(Formula 2);
Wherein the method comprises the steps of Is the heating coefficient,/>Is ambient temperature.
As a further optimization of the scheme, the temperature acquisition tool adopts an embedded system, a signal processing unit and a temperature sampling circuit are integrated in the embedded system, the input end of the temperature sampling circuit is connected with the output end of the thermocouple element, the temperature sampling circuit conveys a temperature sampling value of the thermocouple element to the temperature data processing module for processing and then feeds temperature information back to the signal processing unit, and the signal processing unit feeds temperature data back to the data analysis module through the communication unit after processing the temperature information in an uploading information format.
As a further optimization of the scheme, the upper computer comprises a data analysis module, the input end of the data analysis module is respectively connected with the output ends of the communication unit, the clock unit and the tester input module, the output end of the data analysis module is respectively connected with the input ends of the display and the heating coefficient information module, and the data analysis module is in bidirectional connection with the controller to be tested.
As a further optimization of the above scheme, the signal processing unit periodically reads temperature information at 1ms time intervals, transmits the temperature information to the upper computer software, records the current time and the current of the controller to be tested while receiving the temperature to form a group of sampling information, calculates a heat generation coefficient by adopting a heat generation coefficient algorithm according to the received sampling information, and displays the calculation result on a screen and simultaneously stores the calculation result in a computer.
As a further optimization of the scheme, the upper computer software sets the highest temperature limit value of each component, compares the temperature value read in real time with the temperature limit value, sends out a temperature over-high warning message of the corresponding component when detecting that the temperature of one component exceeds the temperature limit value, stops testing, and generates a current-heating coefficient chart when the testing is finished and the temperatures of all components do not exceed the limit value.
The evaluation method of the resistive thermal effect of the power device in the ECU controller has the following beneficial effects:
The evaluation method of the resistive heating effect of the power device in the ECU controller can realize the calculation of the heating coefficient of the component and the detection of the heating of the resistive element of the controller through the automatic adjustment of the output of the current and the acquisition of the temperature, can provide data basis for the design, the optimization and the device model selection of the PCB, also realize the evaluation of the influence of the heating condition of the resistive element on the operation of the controller, and provide support for the reliability of the product.
Specific embodiments of the invention have been disclosed in detail below with reference to the following description and drawings, indicating the manner in which the principles of the invention may be employed, it being understood that the embodiments of the invention are not limited in scope but are capable of numerous variations, modifications and equivalents within the spirit and scope of the appended claims.
Drawings
Fig. 1 is a flowchart of a method for evaluating resistive thermal effects of a power device in an ECU controller according to the invention.
Detailed Description
The present invention will be further described in detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the detailed description and specific examples, while indicating the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs, and the terms used herein in this description are for the purpose of describing particular embodiments only and are not intended to limit the invention to any and all combinations of one or more of the associated listed items;
Referring to fig. 1 of the specification, the present invention provides a technical solution: the invention relates to a method for evaluating resistive thermal effect of a power device in an ECU (electronic control unit) controller, which is a set of system for evaluating the thermal effect of the device based on temperature, time, current and other data.
The temperature acquisition tool has higher requirements on tailorability and real-time performance, so an embedded system is adopted, a signal processing unit (MCU controller), a temperature sampling circuit, a plurality of thermocouple elements (thermocouple 1, thermocouple 2, thermocouple 3. Thermocouple N) required according to design requirements, a peripheral basic power supply circuit, a clock oscillation circuit, a switching circuit and the like are integrated in the system, the input end of the temperature sampling circuit is connected with the output end of the thermocouple element, the temperature sampling circuit transmits a temperature sampling value of the thermocouple element to a temperature data processing module for processing and then feeds temperature information back to the signal processing unit, and the signal processing unit feeds temperature data back to a data analysis module through a communication unit after processing the temperature information in an uploading information format; the upper computer comprises a data analysis module, the input end of the data analysis module is respectively connected with the output ends of the communication unit, the clock unit and the tester input module, the output end of the data analysis module is respectively connected with the input ends of the display and the heating coefficient information module, and the data analysis module is in bidirectional connection with the controller to be tested.
The MCU controller collects temperature information through the thermocouple element, periodically reads the temperature information at 1ms time intervals, transmits the temperature information to the upper computer software, and records the current time and the current of the controller to be tested to form a group of sampling information when the upper computer software receives the temperature; and calculating a heating coefficient by adopting a heating coefficient algorithm according to the received sampling information, displaying the calculation result on a screen and simultaneously storing the calculation result in a computer.
The upper computer software needs to set the highest temperature limit value of each component, the software compares the temperature value read in real time with the temperature limit value, when detecting that the temperature of one component exceeds the temperature limit value, the software sends out a temperature over-high warning message of the corresponding component and stops testing, when the testing is finished, the temperature of all components does not exceed the limit value, and a current-heating coefficient chart is generated. The system adjusts the output signal by setting the current adjusting step length, duration, initial value (minimum value) and final value (maximum value), thereby achieving the purpose of controlling current output, and the controller uses the current sampling value to carry out feedback adjustment.
Theoretical basis:
For pure resistive elements, the heat generation is known from the heat formula (Joule law formula, Q represents heat generated by current, the unit is Joule, I represents current, the unit is ampere, R represents resistor, the unit is ohm, t represents time, the unit is seconds) that is, when the basic parameters of the components are fixed, the quantity of the generated heat is in a quadratic function relationship with the current, the quantity of the generated heat is in a linear function relationship with the time, the generated heat generates temperature rise, and referring to the heat formula, the relation between the generated heat and the temperature is/>, assuming that the generated heat is used for temperature rise completelyM is the mass of the object, c is the specific heat capacity,/>The temperature is changed, but when the temperature is higher than the ambient temperature, outward radiation is generated, namely heat is dissipated, and the relation between the amount of heat energy and the temperature is as follows: Where k is the heat transfer coefficient of the object, A is the object surface area,/> The temperature difference with the environment is t is the heat dissipation time, d is the thickness of the object, so that the heat energy generated by the current flowing through the component can be obtained according to the principle of energy conservation to be equal to the sum of the heat absorbed by heating and the heat emitted, namely/>The differential equation can be obtained through transformation: /(I)Then solving the differential equation to obtain the temperature/>The relationship with time t is as follows:
(1)
Assuming that multiple testing processes are performed on the same component, each testing process is guaranteed to be long enough to stabilize the temperature, thenWill approach 0,/>, if the ambient temperature remains constantIs also constant, so that the temperature value will depend on the magnitude of the current during different tests, so one can take/>As the heat generation coefficient of the element, the resistance value of the resistive element is affected by temperature, and therefore the heat generation coefficient is also affected by the ambient temperature and the heat generation condition of the element to change.
Heating coefficient algorithm:
According to the theoretical basis above, the algorithm is developed by first simplifying equation 1 because Is the heating coefficient to be measured, and an unknown number/>Expressed, let/>; The test process adopts the setting of the maximum value, the minimum value, the step length and the duration of the test current, and the setting of the proper duration ensures that the sampled temperature is stable, thus/>About 0, can be ignored, and can be obtained by transforming the original formula
(2)
Wherein the method comprises the steps ofIs the heating coefficient,/>Is ambient temperature.
After the collection tool stably operates, firstly recording the uploaded ambient temperatureThe current value of the first frame of uploading data is rounded to an integer value to be used as the current value of the first sampling sample to be stored and used as a reference value, then whether the current of each frame of data after the data is changed is judged according to the set step length (not less than 1A) and the reference value, if the change amount of the current relative to the reference value is smaller than the/>, of the step lengthAnd (C) continuing to wait for the next frame data to judge when the step size is larger than or equal to the step size if the change amount is larger than or equal to the step sizeAnd when the current is changed, recording the temperature of the current element as the temperature of the first sample, rounding the current value to an integer value to serve as the current value of the second sample, storing the current value, updating the current value to a reference value, continuing to judge, recording the temperature of the current element again as the temperature of the second sample if the current is changed, continuing to repeat the steps to finish the third, fourth and later sampling until the current reaches the maximum value, and stopping sampling.
After the sampling is completed, calculating the samples, and calculating the current according to the temperature value and the current value of each sample and the ambient temperatureValues.
The invention is mainly used for testing the PCBA board of the ECU controller, and evaluating the heating value of the resistive element related to the motor control part under different working conditions in normal environment and extreme environment.
Firstly, connecting a to-be-tested controller with a power supply and a control motor, blocking the motor, connecting the to-be-tested controller to an upper computer through a can bus, fixing a thermocouple of a temperature acquisition tool to a to-be-tested component, putting the to-be-tested controller into a high-low temperature box with adjustable temperature after preparation work is finished, opening the power supply, setting the maximum current of a sample, the minimum current, the current adjustment step length, the maximum temperature and the duration of each current by using upper computer software after the controller normally operates, wherein the duration of the current is generally set to be large, and the temperature stability is ensured; the highest temperature is set to ensure that the test can be stopped in time when the highest temperature is reached, so as to prevent irreversible damage to the element; the maximum working current of the sample maximum current is selected by referring to the design principle, and can be properly increased under the condition that the controller is not damaged. After the operation is finished, the test is started, the upper computer after starting sends a current value instruction according to the step length from the minimum value according to the set current information and the time length, the controller to be tested adjusts after receiving the instruction, when the temperature is detected to be higher than the set highest temperature in the test process, the upper computer gives an alarm and stops the test, if the maximum current is reached, the alarm is not received, the test is finished, and a heating coefficient result is generated.
The operation is repeated by regulating the temperature of the temperature control environment of the high-low temperature box to obtain a plurality of groups of data to be summarized, the low temperature is selected to be-40 ℃ to-10 ℃ under the extreme environment according to the standard requirement, the high temperature is selected to be 70 ℃ to 115 ℃ to be tested, and then the summarized information is checked against a heating coefficient reference table (a table I and a table II), and the heating coefficient under unit resistance is given by the heating coefficient reference table, so that the operation result is firstly converted according to the resistance of the element, and when the result exceeds the data provided by the reference table, the heating condition of the element is considered to not meet the requirement, and the selection is recommended again.
List one heating coefficient reference list one
Reference meter two for heat coefficient
It should be understood that the invention is not limited to the preferred embodiments, but is intended to cover modifications, equivalents, or alternatives falling within the spirit and principles of the invention.
Claims (3)
- The method is characterized in that an algorithm of a heating coefficient is utilized to realize evaluation, a temperature acquisition tool and an upper computer are used in the implementation process, the temperature acquisition tool acquires temperature information of components and the components and transmits the result to the upper computer, a to-be-tested controller transmits current information to the upper computer, the upper computer analyzes the current information, the received component current information and the received temperature information are calculated by utilizing the heating coefficient algorithm to obtain the heating coefficient, and an analysis result is output in a chart form;The algorithm of the heating coefficient comprises the following steps:S1: setting a theoretical basis;For pure resistive elements, the heat generation is known from the heat formula ；When the basic parameters of the components are fixed, the quantity of the generated heat and the current are in a quadratic function relationship and a primary function relationship with time, the generated heat generates temperature rise, and the heat formula is referred, and the heat quantity is assumed to be used for temperature rise, and the relation between the heat and the temperature is thatT, m is the mass of the object, c is the specific heat capacity,/>T is the temperature change, but in the actual situation, heat dissipation is generated when the temperature is higher than the ambient temperature, and the relation between the heat energy dissipation and the temperature is as follows: /(I)Where k is the heat transfer coefficient of the object, A is the object surface area,/>Is the temperature difference from the environment, t is the heat dissipation time, d is the thickness of the object, I is the current, and the unit is ampere; r represents resistance, and the unit is ohm;According to the principle of energy conservation, the heat energy generated by the current flowing through the components is equal to the sum of the heat absorbed by heating and the heat emitted by the components, And obtaining a differential equation through transformation: /(I)Then solving the differential equation to obtain the temperature/>The relationship with time t is as follows:(formula 1);S2: according to the theoretical basis in S1, the heating coefficient algorithm is developed, the formula 1 is simplified, Is the heating coefficient to be measured, and an unknown number/> isused as a wholeExpressed, let/>=/>At the same time, the testing process adopts the setting of the maximum value, the minimum value, the step length and the duration of the testing current, the setting of the proper duration ensures that the sampled temperature is stable,About 0, neglect, transform formula 1 to obtain(Formula 2);Wherein the method comprises the steps of Is the heating coefficient,/>Is ambient temperature;The temperature acquisition tool adopts an embedded system, a signal processing unit and a temperature sampling circuit are integrated in the embedded system, the input end of the temperature sampling circuit is connected with the output end of the thermocouple element, the temperature sampling circuit conveys a temperature sampling value of the thermocouple element to the temperature data processing module for processing and then feeds temperature information back to the signal processing unit, and the signal processing unit processes the temperature information in an uploading information format and then feeds temperature data back to the data analysis module through the communication unit;the signal processing unit periodically reads temperature information at 1ms time intervals, the temperature information is transmitted to the upper computer software, the upper computer software records the current time and the current of the controller to be tested to form a group of sampling information while receiving the temperature, the heating coefficient is calculated by adopting a heating coefficient algorithm according to the received sampling information, and the calculation result is displayed on a screen and stored in the computer.
- 2. The method for evaluating resistive thermal effects of power devices in an ECU controller according to claim 1, wherein: the upper computer comprises a data analysis module, the input end of the data analysis module is respectively connected with the output ends of the communication unit, the clock unit and the tester input module, the output end of the data analysis module is respectively connected with the input ends of the display and the heating coefficient information module, and the data analysis module is in bidirectional connection with the controller to be tested.
- 3. The method for evaluating resistive thermal effects of power devices in an ECU controller according to claim 1, wherein: the upper computer software sets the highest temperature limit value of each component, compares the temperature value read in real time with the temperature limit value, sends out a temperature over-high warning message of a corresponding component when detecting that the temperature of a certain component exceeds the temperature limit value, and stops the test, and generates a current-heating coefficient chart when the test is finished and the temperature of all components does not exceed the limit value.
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