CN201193984Y - Hybrid powered automobile controller life test system - Google Patents
Hybrid powered automobile controller life test system Download PDFInfo
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- CN201193984Y CN201193984Y CNU2008201113948U CN200820111394U CN201193984Y CN 201193984 Y CN201193984 Y CN 201193984Y CN U2008201113948 U CNU2008201113948 U CN U2008201113948U CN 200820111394 U CN200820111394 U CN 200820111394U CN 201193984 Y CN201193984 Y CN 201193984Y
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Abstract
The utility model discloses a hybrid electric vehicle controller life test system, which comprises an electric mode test bench frame and an electric power generation mode test bench frame. the electric mode test bench frame consists of a BSG controller, a BSG motor, a BSG controller interface box, a programmable power supply and auxiliary capacitance box and mechanical loads; the electric power generation mode test bench frame consists of a BSG controller, a BSG motor, a BSG controller interface box, a speed adjusting motor and power resistor loads. The central controlling computer communicates with the BSG controller of the electric power generation mode test bench frame and the electric mode test bench frame through CAN bus, transmits control signals to implement the test instructions and test state feedbacks, monitors the system state during the testing process and acquires test results; the BSG controller is tested in the environment with high humidity, circular high and low temperature and fluctuating voltage in a wide range. Thus, by testing the BSG controller in a relatively short time, the potential working life of the BSG controller can be estimated out.
Description
Technical field
The utility model relates to the automobile controller test macro, particularly a kind of hybrid power automobile controller life-span test system.
Background technology
At present, cleaning vehicles efficient, energy-saving and environmental protection just become the automobile industry new development trend.For this reason, hybrid vehicle (Hybrid Electric Vehicle, abbreviation HEV) is because of it has the low emission advantage of electric motor car concurrently with the high-energy-density advantage of internal-combustion engines vehicle more and more receives publicity, and becomes one of new vehicle that the current stage researches and develops unexpectedly mutually.The a kind of of PHEV is weak degree hybrid power (BSG), the vehicle that engine is connected with startup/electric generator by belt, because its structure is simple relatively, and to the change minimum of former car, therefore the easiest realization.Its key component is that original simple generator is replaced with electronic motor with integrating generating, stops when realizing engine idle and the function of the engine that resets automatically, thereby reaches the purpose that reduces engine consumption.Therefore on weak degree PHEV, motor and hybrid controller performance will directly influence hybrid vehicle dynamic property and fuel economy.Need test the potential life-span of hybrid controller in design of Controller and production phase, like this can be before the controller entrucking, by analyzing its potential mission life to a spot of design of Controller checking and production checking, incipient fault and potential risk just can be found in early days, reduce the risk of PHEV operation.
The life test of controller belongs to very important in controller DV (design verification) test and PV (the producing checking) test.The accelerated aging test is a kind of controller life-span test method commonly used.The life-span test system of developing at PHEV both at home and abroad mainly concentrates on battery life test aspect at present, and the life test part manufacturer of controller finishes on laboratory vehicle by carrying.
Above-mentioned requirement to hybrid power automobile controller is the prior art technical issues that need to address.
The utility model content
Technical problem to be solved in the utility model provides a kind of hybrid power automobile controller life-span test system, pass through strict life testing method to reach in design of Controller and production phase, the potential life-span of hybrid controller is tested and verified, drop to the risk of hybrid controller product minimum.By the accelerated aging method of testing, with relatively the test duration of weak point is finished the potential life-span test of mixture control and the purpose of analyzing.
For solving the problems of the technologies described above, the technical solution of the utility model is a kind of hybrid power automobile controller life-span test system, it is characterized in that: be provided with BSG controller and BSG motor in the described controller life-span test system, BSG control unit interface case, programmable power supply and auxiliary electrical tank, electric model testboard bay that mechanical load is formed and BSG controller and BSG motor, BSG control unit interface case, buncher, the power generation mode testboard bay that the power resistive load is formed, central control computer carries out communication by BSG controller in CAN bus and described power generation mode testboard bay and the electric model testboard bay, transmit control signal and realize the transmission of test instruction and the feedback of test mode, and monitor system state and collecting test result in the test process; Described central control computer is electrically connected with programmable power supply and auxiliary electrical tank, mechanical load respectively, is electrically connected with environment storehouse controller, ac adjustable speed motor respectively by the RS-485 serial communication bus by the GBIB interface bus.
Life-span test system in the utility model is according to the custom-designed cover life-span test system of the characteristic of Weak hybrid power controller.The condition of work that this life-span test system is simulated on true BSG (the belt drives startup electric generator) PHEV fully designs, test macro can analog controller operate outside condition allow controller be operated under power generation mode and the electric model, and the running status and the failure mode of tested controller are carried out record analysis.The hybrid controller life-span test system can be three parts according to structure: power generation mode testboard bay, electric model testboard bay and middle control computer and environment storehouse.Have 10 cover BSG controllers and receive life test simultaneously in test macro, wherein 5 cover BSG system works are under power generation mode, and 5 cover BSG controllers are operated under the electric model.In test process, this 10 cover BSG controller is placed in the environment storehouse, links to each other respectively with two stands by cable.Central control computer controls 5 cover BSG controllers respectively by cable and the power generation mode stand is operated under the power generation mode, other 5 cover BSG controllers and electric model stand are operated under the electric model, and the storehouse that controls environment is simultaneously carried out high low temperature temperature cycles and set abominable damp condition.
A kind of hybrid power automobile controller life-span test system, described programmable power supply links to each other with the input end of BSG motor by BSG control unit interface case, BSG controller successively with the auxiliary electrical tank, and the BSG motor output shaft is connected with mechanical load by belt pulley.
A kind of hybrid power automobile controller life-span test system, described mechanical load is made up of automatically controlled magnetic hysteresis brake, main shaft, joint flange, spindle pulley, and automatically controlled magnetic hysteresis brake is connected by joint flange and main shaft are coaxial; Spindle pulley is located on the position corresponding with the BSG motor pulley.
A kind of hybrid power automobile controller life-span test system, the speed ratio of described BSG motor and mechanical load is 1:1.
A kind of hybrid power automobile controller life-span test system, the BSG controller receives the measurement and control signal of central control computer power generation mode in the described power generation mode testboard bay by BSG control unit interface case; The BSG motor is electrically connected with the power resistive load by the BSG controller, and the BSG motor output shaft is connected with ac adjustable speed motor by belt pulley.
A kind of hybrid power automobile controller life-span test system, the speed ratio of described ac adjustable speed motor and BSG motor is 2.5:1.
A kind of hybrid power automobile controller life-span test system, the model of described central control computer are the Capax industrial computer.
A kind of method of testing of hybrid power automobile controller life-span test system, this method comprise routine step down;
A) step is set: be used for controller life-span test system mechanical load, ac adjustable speed motor, environment storehouse controller, programmable power supply and the initial operating mode of auxiliary electrical tank being set by central control computer;
B) setting up procedure: central control computer sends mechanical load, buncher enabling signal simultaneously, and controls the BSG machine operation under electric model by the BSG controller in the electric model testboard bay; Control the BSG machine operation under power generation mode by the BSG controller in the power generation mode testboard bay;
C) testing procedure 1; Central control computer is controlled tested BSG controller respectively according to the torque curve of pre-set ac adjustable speed motor rate curve and mechanical load and is operated under the power generation mode and under the electric model, and the load characteristic under two kinds of mode of operations, and the key property parameter of BSG controller and main failure mode in the monitoring test process (can not normal power generation under the power generation mode or different rotating speeds and loading condition under the generating voltage shakiness; Under the electric model, under different supply voltages, can not normally start by driven BSG motor; And any signal port afunction etc. in the test process).
D) testing procedure 2: the BSG controller in the central control computer control electric model testboard bay in BSG controller and the power generation mode testboard bay, by BSG control unit interface case import, the self-life test of output port, and write down the duty and the failure state of each BSG controller IO channel.Central control computer is by the cycle tests of storage in advance, and the input/output port of electric model, power generation mode and the controller of BSG controller is carried out life test.The BSG controller will be accepted the loop test of temperature/humidity/supply voltage of 1000 hours.
The method of testing of hybrid power automobile controller life-span test system, the initial operating mode of described mechanical load is set the maximum load limit value that allows, the initial operating mode of ac adjustable speed motor is set maximum safe speed of rotation, overvoltage and overcurrent protection limit value, the initial operating mode of upper lower limit value, programmable power supply and auxiliary electrical tank of protection such as over-temperature protection restriction parameter, the initial operating mode design temperature of environment storehouse controller and humidity are set maximum output voltage and the maximum output current value that allows of allowing;
The method of testing of hybrid power automobile controller life-span test system, described cycle tests comprises temperature, humidity, power supply state control sequence, motor speed control sequence, load of electrical generation control sequence, controller supply voltage control sequence.
A kind of hybrid power automobile controller life-span test system and method for testing, owing to adopt above-mentioned structure and method of testing, adopt all devices in central control computer centralized control and the monitoring test, realize the transmission of test instruction and the feedback of test mode by CAN network and hybrid power control carrying out communication, all test instructions are assigned, system state monitoring and test result collection all have central control computer to finish in the test process.The BSG controller is placed in the environment of high humility and high low temperature temperature cycles and accepts life test, and the supply voltage of BSG controller also will carry out circular wave in a very wide scope.The BSG controller is carried out the continuous uninterrupted test, like this,, can estimate the potential mission life of BSG controller by to the test of a relative short period of BSG controller.
Description of drawings
Below in conjunction with the drawings and specific embodiments the utility model is described in further detail;
Fig. 1 is a kind of hybrid power automobile controller life-span test system structured flowchart of the utility model;
Fig. 2 is an electric model testboard bay structural representation shown in Figure 1;
Fig. 3 is a power generation mode testboard bay structural representation shown in Figure 1;
Fig. 4 is temperature, humidity, power supply state control sequence curve map;
Fig. 5 is a motor speed control sequence curve map;
Fig. 6 is a load of electrical generation control sequence curve map;
Fig. 7 is a controller supply voltage control sequence curve map;
In Fig. 1~Fig. 3,1, the electric model testboard bay; 2, power generation mode testboard bay; 3, central control computer; 4, BSG controller; 5, BSG control unit interface case; 6, BSG motor; 7, programmable power supply and auxiliary electrical tank; 8, mechanical load; 9, environment storehouse controller; 10, ac adjustable speed motor; 11, power resistive load; 12, CAN bus; 13, magnetic hysteresis brake; 14, joint flange; 15, main shaft; 16, belt pulley; 17, spindle pulley.
Embodiment
Contrast accompanying drawing below, by description to example, to embodiment of the present utility model, as the effect of the mutual alignment between each related control system and annexation, each system and principle of work, method of testing etc., be described in further detail, with help those skilled in the art to utility model of the present utility model conceive, technical scheme has more complete, accurate and deep understanding.
As shown in Figure 1, a kind of hybrid power automobile controller life-span test system, be provided with BSG controller 4 and BSG motor 6 in the described controller life-span test system, BSG control unit interface case 5, programmable power supply and auxiliary electrical tank 7, electric model testboard bay 1 that mechanical load 8 is formed and BSG controller 4 and BSG motor 6, BSG control unit interface case 5, ac adjustable speed motor 10, the power generation mode testboard bay 2 that power resistive load 11 is formed, the central control computer 3 of being furnished with data collecting card carries out communication by BSG controller 4 in CAN bus 12 and described power generation mode testboard bay 2 and the electric model testboard bay 1, transmit control signal and realize the transmission of test instruction and the feedback of test mode, and monitor system state and collecting test result in the test process; Described central control computer 3 is electrically connected with programmable power supply and auxiliary electrical tank 7, mechanical load 8 respectively, is electrically connected with environment storehouse controller 9, ac adjustable speed motor 10 respectively by the RS-485 serial communication bus by the GBIB interface bus.
A kind of structured flowchart of hybrid controller life-span test system and the annexation between the each several part have been described among Fig. 1.The hybrid controller life-span test system mainly is made up of three parts, electric model testboard bay 1, power generation mode testboard bay 2 and environment storehouse controller 9.Have 10 cover BSG controllers 4 and receive life test simultaneously in test macro, wherein 5 cover BSG system works are under power generation mode, and 5 cover BSG system works are under electric model.In test process, this 10 cover BSG controller 4 is placed in the environment storehouse, links to each other respectively with two stands by cable.Central control computer 3 controls 5 cover BSG controllers respectively by cable and power generation mode testboard bay 2 is operated under the power generation mode, other 5 cover BSG controllers and electric model testboard bays 1 are operated under the electric model, and the storehouse controller 9 that controls environment the simultaneously storehouse that controls environment is carried out high low temperature temperature cycles and set abominable damp condition.
Referring to Fig. 2, programmable power supply links to each other with the input end of BSG motor 6 by BSG control unit interface case 5, BSG controller 4 successively with auxiliary electrical tank 7, and BSG motor 6 output shafts are connected with mechanical load 8 by belt pulley 16.Described mechanical load 8 is made up of automatically controlled magnetic hysteresis brake 13, main shaft 15 joint flanges 14, spindle pulley 17, and automatically controlled magnetic hysteresis brake 13 is by joint flange 14 and 15 coaxial connections of main shaft; Spindle pulley 17 is located on the position corresponding with BSG motor pulley 16.In the electric model stand, 5 cover BSG motors are coupled by a main shaft and a magnetic hysteresis brake.Engine loading characteristic when magnetic hysteresis brake can be exported certain resistive torque simulate BSG motor when starting/idling on PHEV.On 1 of electric model test board, connect by interface box between the BSG controller and between the BSG motor; 5 cover BSG systems carry out the electric model test one by one.During certain every the BSG electric motor starting of resistive torque simulation of central control computer control magnetic hysteresis brake output/engine loading during engine idle.(auxiliary electrical tank 7 mainly is the capacitance characteristic of simulated automotive accumulator for programmable power supply and auxiliary electrical tank, being exactly in addition that buffering causes the supply voltage decay because of electric current is excessive when BSG motor 6 starts) accumulator is that the BSG controller is DC bus powered by interface box on the simulation car, BSG controller 4 drives the BSG motor rotations, and the BSG motor consumes by the mechanical energy of a spindle coupled when automatically controlled magnetic hysteresis brake is gone up motor rotation.The electric model stand is realized the condition of work of simulation BSG controller electric model.Central control computer 3 is finished the life test of BSG controller 4 input/output port jointly and test result is fed back to central control computer 3 with BSG control unit interface case 5 by CAN bus 12 controller BSG controllers 4 and carries out test result analysis.
Referring to Fig. 3, BSG controller 4 receives the measurement and control signal of central control computer 3 power generation modes in the power generation mode testboard bay 2 by BSG control unit interface case 5; BSG motor 6 is electrically connected with power resistive load 11 by BSG controller 4, and BSG motor 6 output shafts are connected with ac adjustable speed motor 10 by belt pulley.Ac adjustable speed motor 10 is 2.5:1 with the speed ratio of BSG motor 6.
Power generation mode testboard bay 2 will provide the peripheral condition of test and simulate electric load characteristic on the car for the test of BSG controller power generation mode.In the power generation mode testboard bay 2, a 7.5KW speed-regulating AC machine 10 drags 5 BSG motor rotation generatings simultaneously, these 5 BSG motors are connected by cable with 5 BSG controllers that are operated under the power generation mode in the environment storehouse respectively, through becoming direct current after 4 rectifications of BSG controller, the direct current of the DC side output of each BSG controller 4 consumes by the controlled power resistive load that is installed on the power generation mode testboard bay 2 respectively respectively.Central control computer 3 will select be connected to the power resistor size of each BSG controller DC side by BSG control unit interface case 5, control each be operated under the power generation mode the electrical load characteristic of BSG controller dc bus.At test process, the velocity of rotation of central control computer 3 control speed-regulating AC machines 1 changes the velocity of rotation of BSG motor 6, controls the resistance of the power resistor of every cover BSG system matches simultaneously and simulates the load characteristic of BSG controller power generation mode output.Power generation mode testboard bay 2 can be simulated in different engine speed and the power generation mode functional test to the BSG controller of different onboard electrical load characteristic.In to the test of BSG control carrying out power generation mode, central control computer 3 is finished the life test of BSG controller 4 input/output port jointly and test result is fed back to central control computer 3 with BSG control unit interface case 5 by CAN bus 12 controller BSG controllers 4 and carries out test result analysis.
The method of testing of hybrid power automobile controller life-span test system; This method comprises routine step down; A) step is set: be used for controller life-span test system mechanical load 8, ac adjustable speed motor 10, environment storehouse controller 9, programmable power supply and auxiliary electrical tank 7 initial operating modes being set by central control computer 3; Mechanical load 8 initial operating modes; set the maximum load limit value that allows; ac adjustable speed motor 10 initial operating modes; set maximum safe speed of rotation; overvoltage and overcurrent protection limit value; protection such as over-temperature protection restriction parameter, environment storehouse controller 9 initial operating modes, the upper lower limit value of design temperature and humidity, programmable power supply and auxiliary electrical tank 7 initial operating modes are set maximum output voltage and the maximum output current value that allows of allowing.B) setting up procedure: central control computer 3 sends mechanical load 8, ac adjustable speed motor 10 enabling signals simultaneously, and is operated under the electric model by the 4 control BSG motors 6 of the BSG controller in the electric model testboard bay 1; Be operated under the power generation mode by the 4 control BSG motors 6 of the BSG controller in the power generation mode testboard bay 2; C) testing procedure 1; Central control computer 3 is controlled tested BSG controller 4 respectively according to the torque curve of pre-set buncher rate curve and mechanical load 8 and is operated under the power generation mode and under the electric model, and the load characteristic under two kinds of mode of operations, and the key property parameter of BSG controller 4 and main failure mode in the monitoring test process (can not normal power generation under the power generation mode or different rotating speeds and loading condition under the generating voltage shakiness; Under the electric model, under different supply voltages, can not normally start by driven BSG motor; And any signal port afunction etc. in the test process). D) testing procedure 2: the BSG controller 4 in the central control computer 3 control electric model testboard bays 1 in BSG controller 4 and the power generation mode testboard bay 2, by BSG control unit interface case 5 import, the self-life test of output port, and write down the duty and the failure state of each BSG controller 4 IO channel.Referring to Fig. 4, Fig. 5, Fig. 6, Fig. 7, the cycle tests of central control computer by storing in advance, described cycle tests comprises temperature, humidity, power supply state control sequence, the motor speed control sequence, the load of electrical generation control sequence, controller supply voltage control sequence is carried out life test to the input/output port of electric model, power generation mode and the controller of BSG controller 4.BSG controller 4 will be accepted the loop test of temperature/humidity/supply voltage of 1000 hours.
Hybrid controller life-span test system in the utility model, adopt all devices in central control computer centralized control and the monitoring test, realize the transmission of test instruction and the feedback of test mode by CAN network and hybrid power control carrying out communication, all test instructions are assigned, system state monitoring and test result collection all have central control computer to finish in the test process.Simulate the PHEV service condition fully.
In conjunction with the accompanying drawings the utility model has been carried out exemplary description above; obviously the utility model specific implementation is not subjected to the restriction of aforesaid way; as long as adopted the improvement of the various unsubstantialities that method of the present utility model design and technical scheme carry out; or design of the present utility model and technical scheme are directly applied to other occasion without improving, all within the protection domain of utility model.
Claims (7)
1. hybrid power automobile controller life-span test system, it is characterized in that: be provided with BSG controller (4) and BSG motor (6) in the described controller life-span test system, BSG control unit interface case (5), programmable power supply and auxiliary electrical tank (7), electric model testboard bay (1) that mechanical load (8) is formed and BSG controller (4) and BSG motor (6), BSG control unit interface case (5), ac adjustable speed motor (10), the power generation mode testboard bay (2) that power resistive load (11) is formed, central control computer (3) carries out communication by CAN bus (12) and described power generation mode testboard bay (2) and the middle BSG controller (4) of electric model testboard bay (1), transmit control signal and realize the transmission of test instruction and the feedback of test mode, and monitor system state and collecting test result in the test process; Described central control computer (3) is electrically connected with programmable power supply and auxiliary electrical tank (7), mechanical load (8) respectively, is electrically connected with environment storehouse controller (9), ac adjustable speed motor (10) respectively by the RS-485 serial communication bus by the GBIB interface bus.
2. a kind of hybrid power automobile controller life-span test system according to claim 1, it is characterized in that: described programmable power supply links to each other with the input end of BSG motor (6) by BSG control unit interface case (5), BSG controller (4) successively with auxiliary electrical tank (7), and BSG motor (6) output shaft is connected with mechanical load (8) by belt pulley (16).
3. a kind of hybrid power automobile controller life-span test system according to claim 1 and 2, it is characterized in that: described mechanical load (8) by automatically controlled magnetic hysteresis brake (13), main shaft (15) joint flange (14), spindle pulley (17) formed, automatically controlled magnetic hysteresis brake (13) is by joint flange (14) and coaxial connection of main shaft (15); Spindle pulley (17) is located on the position corresponding with BSG motor pulley (16).
4. a kind of hybrid power automobile controller life-span test system according to claim 1 and 2 is characterized in that: described BSG motor (6) is 1:1 with the speed ratio of mechanical load (8).
5. a kind of hybrid power automobile controller life-span test system according to claim 1 is characterized in that: BSG controller (4) receives the measurement and control signal of central control computer (3) power generation mode in the described power generation mode testboard bay (2) by BSG control unit interface case (5); BSG motor (6) is electrically connected with power resistive load (11) by BSG controller (4), and BSG motor (6) output shaft is connected with ac adjustable speed motor (10) by belt pulley.
6. a kind of hybrid power automobile controller life-span test system according to claim 5 is characterized in that: described ac adjustable speed motor (10) is 2.5:1 with the speed ratio of BSG motor (6).
7. a kind of hybrid power automobile controller life-span test system according to claim 1 is characterized in that: the model of described central control computer (3) is the Capax industrial computer.
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2010034240A1 (en) * | 2008-09-29 | 2010-04-01 | 奇瑞汽车股份有限公司 | Lifetime test system for hybrid electric vehicle controllers |
CN101261190B (en) * | 2007-12-27 | 2010-12-22 | 奇瑞汽车股份有限公司 | Hybrid power automobile controller life-span test system and test method |
CN102023636A (en) * | 2010-12-03 | 2011-04-20 | 浙江理工大学 | Accelerated life testing method of machine tool numerical control system |
WO2012089857A1 (en) | 2010-12-30 | 2012-07-05 | Fundacion Tecnalia Research & Innovation | System for testing and evaluating the behaviour and energy efficiency of the drive system of a hybrid-electric motor vehicle |
CN106596127A (en) * | 2016-12-13 | 2017-04-26 | 安徽江淮汽车集团股份有限公司 | Endurance test method for hybrid electric vehicle drive module assembly |
CN114993541A (en) * | 2022-05-27 | 2022-09-02 | 中国第一汽车股份有限公司 | Method and system for testing starting static friction torque of 48V system |
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2008
- 2008-04-18 CN CNU2008201113948U patent/CN201193984Y/en not_active Expired - Fee Related
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
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CN101261190B (en) * | 2007-12-27 | 2010-12-22 | 奇瑞汽车股份有限公司 | Hybrid power automobile controller life-span test system and test method |
WO2010034240A1 (en) * | 2008-09-29 | 2010-04-01 | 奇瑞汽车股份有限公司 | Lifetime test system for hybrid electric vehicle controllers |
CN102023636A (en) * | 2010-12-03 | 2011-04-20 | 浙江理工大学 | Accelerated life testing method of machine tool numerical control system |
CN102023636B (en) * | 2010-12-03 | 2012-07-25 | 浙江理工大学 | Accelerated life testing method of machine tool numerical control system |
WO2012089857A1 (en) | 2010-12-30 | 2012-07-05 | Fundacion Tecnalia Research & Innovation | System for testing and evaluating the behaviour and energy efficiency of the drive system of a hybrid-electric motor vehicle |
CN106596127A (en) * | 2016-12-13 | 2017-04-26 | 安徽江淮汽车集团股份有限公司 | Endurance test method for hybrid electric vehicle drive module assembly |
CN106596127B (en) * | 2016-12-13 | 2018-11-16 | 安徽江淮汽车集团股份有限公司 | The endurance test method of hybrid vehicle drive module assembly |
CN114993541A (en) * | 2022-05-27 | 2022-09-02 | 中国第一汽车股份有限公司 | Method and system for testing starting static friction torque of 48V system |
CN114993541B (en) * | 2022-05-27 | 2023-09-22 | 中国第一汽车股份有限公司 | Method and system for testing starting static friction torque of 48V system |
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