CN107272662A - A kind of driving motor for electric automobile and controller calibration system and scaling method - Google Patents

Abstract

The invention discloses a driving motor and controller calibration system and calibration method for an electric vehicle, comprising: an AC dynamometer is coaxially connected with a calibrated driving motor, the driving motor is connected with the calibrated motor controller through a power line, The motor controller is connected to the battery simulator through the DC bus; the water cooling circulation system is connected to the driving motor and the motor controller through the cooling pipes, and the power analyzer is connected to the motor controller; the bench monitoring system is connected to the power analyzer, water cooling circulation system, The control cabinet of the dynamometer and the battery simulator are respectively connected; the beneficial effect of the invention is that it has the characteristics of optimizing the testing process, shortening the calibration period, and improving the comprehensive utilization rate of the calibration test bench. It is widely used in technology and research and development fields such as electric vehicle drive motor and controller manufacturing, matching optimization, etc., and has great promotion value.

Description

A calibration system and calibration method for a driving motor and a controller for an electric vehicle

technical field

The invention relates to a calibration system and calibration method for a driving motor and a controller for an electric vehicle.

Background technique

Electric vehicles have become an inevitable trend of future automobile development due to energy saving and environmental protection. Different from traditional fuel vehicles, the power system of electric vehicles is mainly a motor drive system powered by power batteries. The motor drive system mainly includes the drive motor and controller (including the motor inverter part). The performance of the motor drive system directly affects the power, economy and comfort of the vehicle. Therefore, the performance test and calibration of the drive motor and controller It occupies an important position in the development of the entire electric vehicle system.

Motor efficiency MAP diagram (also called contour map, cloud map) is a data curve generated during motor testing, mainly reflecting the distribution of motor efficiency at different speeds and torques. In the past, foreign motor manufacturers conducted many motor MAP tests, and the data sheets of imported motors basically included the tested motor efficiency MAP diagram. Before the vigorous promotion of electric vehicles in China, domestic drive motor manufacturers seldom provided the MAP diagram of the motor, and since the efficiency points of the drive motor at various speeds and torques must be measured with an electric dynamometer, the complete electric vehicle Manufacturer or enterprise testing is more troublesome. At present, there are many test instruments and equipment required for the matching test or calibration process of the electric vehicle drive motor and the controller. The test data is stored in different computers or software platforms, and is not completed under the same software and hardware system platform. Due to the influence of data transmission rate, transmission delay, electromagnetic interference and other factors, it is not only difficult to guarantee the measurement error caused by the poor time consistency of test data, but also the test data of different devices need to be saved separately, and then exported for manual processing, including unified data format, Calculation, drawing, etc., the processing process is cumbersome and takes a long time. In fact, in addition to the motor MAP diagram, the efficiency MAP of the motor controller (motor driver), especially the system efficiency MAP of the entire drive motor and controller, is also the focus of motor manufacturers, electric vehicle manufacturers or enterprises.

Contents of the invention

The object of the present invention is to solve the above-mentioned problems and provide a driving motor and controller calibration system and calibration method for electric vehicles. The calibration system integrates AC dynamometer, dynamometer control cabinet, bench monitoring system, power Analyzer, water cooling cycle system and battery simulator, etc., and transmit all test data to the unified monitoring system software for processing through CAN, TCP/IP and other different communication methods; the calibration system has a practical plan, easy to use, and functional Complete features; the measurement method has the characteristics of optimizing the test process and shortening the calibration cycle, and can improve the comprehensive utilization rate of the calibration test bench.

To achieve the above object, the specific scheme of the present invention is as follows:

A drive motor and controller calibration system for electric vehicles, including: AC dynamometer, dynamometer control cabinet, bench monitoring system, power analyzer, water cooling cycle system and battery simulator, etc.;

The AC dynamometer is coaxially connected with the calibrated driving motor, the driving motor is connected with the calibrated motor controller through the power line, and the motor controller is connected with the battery simulator through the DC bus; the water cooling circulation system is connected through the cooling pipe respectively connected to the driving motor and the motor controller, and the power analyzer is connected to the motor controller;

The bench monitoring system is connected to the power analyzer, the water cooling circulation system, the dynamometer control cabinet and the battery simulator respectively; the bench monitoring system receives the motor voltage and current signals collected by the power analyzer and the water cooling circulation system The output temperature, return temperature, refrigeration temperature, output pressure, return pressure, and output flow parameters of the cooling liquid are received. According to the received parameter information, control instructions are sent to the dynamometer control cabinet to control the AC dynamometer. output speed and torque, while monitoring the operation of the entire bench system.

Further, the dynamometer control cabinet receives the control signal of the bench monitoring system to control the rotation speed and torque of the AC dynamometer.

Further, the AC dynamometer is coaxially connected with the calibrated drive motor through the sequentially connected torque flange, transmission shaft and adapter, uses the torque flange to measure the torque and rotational speed of the calibrated drive motor, and transmits the measurement signal to power analyzer.

Further, upload the calibrated motor controller's input and output voltage, input and output current, motor speed and steering, motor torque, motor and controller temperature parameters to the bench monitoring system through CAN communication.

Further, the battery simulator simulates the external characteristic output of the voltage and current of the actual battery according to the load condition of the motor by loading the battery model.

Furthermore, the calibrated motor controller has a pre-charging circuit, and the power supply of the motor controller is connected in parallel with the storage battery.

Further, the drive motor and the AC dynamometer are fixed on the motor base and the dynamometer base respectively, and the motor base and the dynamometer base are fixed on a specific support platform; the AC dynamometer and the drive motor The room is equipped with a metal shield.

A calibration method for a drive motor and controller calibration system for an electric vehicle, comprising the following steps:

(1) System initialization, setting the cooling fluid temperature and outlet flow parameters of the water-cooling system required for calibration, and setting the basic parameters and safety protection limits of the battery simulator, AC dynamometer and the drive motor to be calibrated;

(2) Define the efficiencies of the drive motor in electric mode and power generation mode respectively, including: drive motor efficiency, motor controller efficiency and total efficiency of the motor system;

(3) According to the required calibration speed and torque range of the drive motor, calibration accuracy and test time limit requirements, design the given step size of the speed and torque during calibration;

(4) When the motor is unloaded, set a certain speed of the AC dynamometer, observe the motor operation and the torque of the bench, if the sound of the bench is abnormal or the torque is too large, it means that the motor is not installed or aligned well, and needs to be checked. readjust;

(5) The speed of the AC dynamometer is given according to the given step of the speed, which is recorded as the outer cycle of speed calibration; the torque of the driving motor is given according to the calibration step of the torque, which is recorded as the inner cycle of torque calibration;

(6) First, the speed calibration outer loop sets the speed of the dynamometer to 0, and the torque calibration inner loop sequentially sets the driving motor torque from 0Nm according to the step size until the maximum torque is set, and the inner loop test is completed once;

Then the speed calibration outer loop sets the next calibration speed of the dynamometer according to the step size, and the torque calibration inner loop sets the driving motor torque again until the speed calibration outer loop measures the maximum calibration speed, and the calibration process is completed;

(7) Read the measurement data of the power analyzer, torque flange, motor controller and water cooling system through the bench monitoring system, calculate the efficiency values of the drive motor, motor controller and motor system under different working conditions, and combine all The data of different test points are uniformly plotted in the computer, and then the efficiency MAP diagrams of the driving motor, motor controller and motor system are respectively obtained;

(8) According to the method of steps (4)-(7), the efficiency MAP diagrams of the driving motor and the controller under different test conditions are obtained.

Furthermore, if the actual output torque does not reach the target torque under a certain rotational speed condition, it is necessary to readjust the correspondence table between the dq axis current and the torque in the motor controller.

Beneficial effects of the present invention:

The drive motor and controller calibration system of the present invention integrates AC dynamometer, dynamometer control cabinet, bench monitoring system, power analyzer, water cooling cycle system and battery simulator, etc., and passes different test data through CAN , TCP/IP, IEEE1394 and other different communication methods are uniformly transmitted to the monitoring system software, which has the characteristics of practical scheme, convenient use and complete functions; the calibration method of the present invention avoids the need for separate data of different test equipment through system integration The cumbersome process of saving and manual processing, etc., processes the test data through the unified monitoring system software, thereby ensuring the consistency of the test data time, reducing the tedious data processing process, optimizing the test process, shortening the calibration period, and improving the calibration. Comprehensive utilization of the test bench. It is widely used in technology and research and development fields such as electric vehicle drive motor and controller manufacturing, matching optimization, etc., and has great promotion value.

Description of drawings

Fig. 1 is a schematic structural diagram of a calibration system for a driving motor and a controller for an electric vehicle according to the present invention.

detailed description:

The present invention is described in detail below in conjunction with accompanying drawing:

The invention discloses a driving motor and controller calibration system for electric vehicles, as shown in Figure 1, comprising: a calibrated driving motor and motor controller, an AC dynamometer, a battery simulator, a bench monitoring system, a water cooling Circulatory systems, power analyzers, dynamometer control cabinets, batteries, pre-charging circuits, motor bases, dynamometer bases, adapters, drive shafts, protective covers and torque flanges, etc.

Bench monitoring system, including monitoring system software, communication interface, input display device, etc., input display device includes display, operation control panel, emergency stop control switch, keyboard, mouse and other operating equipment, etc.; bench monitoring system and motor controller , AC dynamometer, battery simulator, and water cooling cycle system are connected; the bench monitoring system sends control and receives feedback signals to realize the whole process monitoring of the bench.

The AC dynamometer is connected with the dynamometer control cabinet. The dynamometer control cabinet receives the control signal from the bench monitoring system to control the output speed and torque of the dynamometer; the AC dynamometer passes through the torque flange, transmission shaft and adapter It is coaxially connected with the drive motor to be calibrated, and the torque and speed of the drive motor are measured by using the torque flange, and the measurement signal is transmitted to the power analyzer.

The drive motor is connected to the motor controller through the power line, and the motor controller is connected to the battery simulator through the DC bus; the motor controller is connected to the bench monitoring system, and the input and output voltage, input and output current, and motor Parameters such as speed and steering, motor torque, motor and controller temperature are transmitted to the bench monitoring system.

The battery simulator can simulate the external characteristic output of the voltage and current of the actual battery according to the load condition of the motor by loading the battery model.

The power analyzer is connected with the DC bus of the motor controller, the three-phase power line, and the three-phase current sensor; the power analyzer transmits the collected motor voltage, current and other signals to the bench monitoring system through TCP/IP communication.

The water-cooled cycle machine is connected with the drive motor and the motor controller through the cooling pipe to realize the water-cooled cycle; the water-cooled cycle machine communicates the output liquid temperature, return liquid temperature, cooling temperature, output liquid pressure, return Parameters such as hydraulic pressure and output flow are transmitted to the bench monitoring system.

The driving motor and the AC dynamometer are respectively fixed on the motor base and the dynamometer base, and the motor base and the dynamometer base are fixed on a specific supporting platform. A metal protective cover is arranged between the AC dynamometer and the drive motor.

The motor controller has a pre-charging circuit to prevent the impact of high-current startup. At the same time, the power supply of the motor controller is connected to the battery in parallel to prevent the controller from accidentally losing power.

On the other hand, the present invention discloses a method for calibrating driving motors and controllers for electric vehicles, which mainly includes various safety checks before calibration, such as whether each power supply of the bench is normal, whether the motor protective cover is firm, etc.; starting the bench After monitoring the system, load the system configuration file to observe whether there is a warning or error message; start the motor water cooling circulation system, set the coolant temperature required for calibration; start and set the battery simulator, AC dynamometer and the drive motor to be calibrated Basic parameters and safety protection limits; start the system operation, start the calibration test, observe the operation of the entire bench system through the bench monitoring system, and do a good job of saving the parameters required for the calibration of the drive motor and controller; after the calibration task is completed, Save and read test data, shut down system equipment in order, organize test data and write calibration reports.

The calibration method of the present invention mainly includes motor efficiency calibration, controller efficiency calibration and system efficiency calibration. Calibration is to obtain the efficiency MAP map (also called contour map, cloud map) of the motor and the controller through the motor bench test, which reflects the efficiency distribution of the motor or controller or the entire system at different speeds and torques. A data graph. The specific calibration method is as follows:

(1) Before calibration, it is necessary to obtain the basic design parameters or range of the calibrated motor, such as motor type, motor phase number, bus voltage, rated power, rated speed, peak power, peak torque, peak speed, etc.

(2) Complete the initialization of the system, set the coolant temperature required for calibration, and set the basic parameters and safety protection limits of the battery simulator, AC dynamometer and the drive motor to be calibrated;

(3) Define the efficiency of the drive motor in electric mode and power generation mode respectively, including: the efficiency of the drive motor, the efficiency of the motor controller and the total efficiency of the motor system, for example, in the electric mode, the drive motor, controller (inverter) and the total efficiency of the system are ETA1, ETA2 and ETA3 respectively, then:

ETA1=Pm/ΣPA, ETA2=ΣPA/Pdc, ETA3=Pm/Pdc(1)

Among them, Pm is the output mechanical power of the motor, ΣPA is the input electric power of the three-phase AC power of the motor, and Pdc is the input electric power of the DC bus of the motor controller;

Correspondingly, in the power generation mode, the total efficiency of the motor, controller, and motor system corresponds to ETA4, ETA5, and ETA6 respectively, then:

ETA4=ΣPA/Pm, ETA5=Pdc/ΣPA, ETA6=Pdc/Pm(2)

During the calibration process, through the test of the motor output power by the dynamometer, and the parameter measurement of the input and output current and voltage of the motor and the controller by the power analyzer, the motor, controller and motor system can be calibrated under different working conditions. efficiency value.

(4) According to the required calibration speed and torque range of the driving motor, calibration accuracy and test time limit, etc., reasonably design the given step size of the speed and torque during calibration. If the step size is too large, it will affect the calibration accuracy. A step size that is too small will result in a long test time. For example, assuming that the given steps of speed and torque during calibration are 100r/min and 20Nm respectively, then during the test, the speed will be given as 0, 100r/min, 200r/min, 300r/min...or 0, -100r/min, -200r/min, -300r/min..., the torque will be given as 0, 20Nm, 40Nm, 60Nm... or 0, -20Nm, -40Nm, -60Nm... but the given should not exceed the motor design The maximum speed and maximum torque.

(5) Calibration test process: first set the parameters such as the cooling liquid temperature and the liquid flow rate of the water-cooling system required for calibration; since the dynamometer and the driving motor are mechanically connected by a coupling, the centering of the motor shaft has a greater impact on the test results Large, at the beginning, you can set a certain speed of the dynamometer under the condition of no load on the motor, such as 500r/min, 1000r/min, etc., and observe the operation of the motor and the torque of the bench. If the sound of the bench is abnormal or the torque is too large , indicating that the installation or alignment of the motor is not good, and it needs to be readjusted; the speed of the AC dynamometer is given according to the calibrated speed step (denoted as the outer cycle of speed calibration), and the torque of the drive motor is calibrated according to the torque step (denoted as is the inner loop of torque calibration), firstly, the outer loop of speed calibration sets the speed of the dynamometer to 0, and the inner loop of torque calibration sets the torque of the drive motor sequentially starting from 0Nm according to the step size, until the maximum torque is set, the inner loop The loop test is completed once; then the outer loop of speed calibration specifies the next calibration speed of the dynamometer according to the step length, and the inner loop of torque calibration specifies the torque of the drive motor again until the maximum calibration speed is measured by the outer loop of speed calibration, and the calibration The process is complete.

Pay attention to the motor power limit during the calibration process, the speed calibration outer loop and the torque calibration inner loop are not all given to the maximum calibration value. During the test, read the measurement data of the power analyzer, torque flange, motor controller and water cooling system through the bench monitoring system, and record the speed and torque of the drive motor at this time, as well as the DC bus voltage at the input end of the controller, DC Various parameters such as bus current, three-phase current at the output end, three-phase voltage, motor temperature, controller temperature, liquid outlet temperature, liquid return temperature, cooling temperature, liquid outlet pressure, liquid return pressure, and liquid outlet flow of the water cooling system are calculated. Calculate the efficiency values of the driving motor, motor controller and motor system under different working conditions, draw the data of all different test points in the computer, and then obtain the efficiency MAP diagram of the driving motor, controller and system respectively;

(5) According to the test method described in (4), the efficiency MAP diagram of the drive motor and controller under different test conditions can be obtained, such as the power supply voltage is lower than the rated bus voltage (power battery undervoltage), and the MAP diagram under different water cooling temperatures Efficiency MAP etc.

Although the specific implementation of the present invention has been described above in conjunction with the accompanying drawings, it does not limit the protection scope of the present invention. Those skilled in the art should understand that on the basis of the technical solution of the present invention, those skilled in the art do not need to pay creative work Various modifications or variations that can be made are still within the protection scope of the present invention.

Claims (9)

1. a kind of driving motor for electric automobile and controller calibration system, it is characterized in that, including：Ac dynamometer, dynamometer machine Switch board, stand monitoring system, power analyzer, water-cooling circulating system and battery simulator；

The ac dynamometer and the motor being calibrated are coaxially connected, and motor passes through power line and the motor being calibrated Controller is connected, and electric machine controller is connected by dc bus with battery simulator；The water-cooling circulating system passes through cooling tube Road is respectively connected with motor and electric machine controller, and the power analyzer is connected with electric machine controller；

The stand monitoring system connects respectively with power analyzer, water-cooling circulating system, Dynamometer Control cabinet and battery simulator Connect；Electric moter voltage, current signal and the water-cooling circulating system that the stand monitoring system receiving power analyzer is collected are adopted The coolant collected goes out liquid temperature degree, returns liquid temperature degree, cryogenic temperature, fluid pressure, return hydraulic coupling, goes out flow quantity parameter, according to The parameter information received sends control instruction to Dynamometer Control cabinet, controls the output speed and moment of torsion of ac dynamometer, together When monitor the operation of whole platform system.

2. a kind of driving motor for electric automobile as claimed in claim 1 and controller calibration system, it is characterized in that, it is described to survey Work(machine switch board receives the control signal of stand monitoring system, controls the rotating speed and moment of torsion of ac dynamometer.

3. a kind of driving motor for electric automobile as claimed in claim 1 and controller calibration system, it is characterized in that, it is described to hand over Flow dynamometer machine coaxially connected with being calibrated motor by moment of torsion flange, power transmission shaft and the adapter being sequentially connected, utilize Moment of torsion flange measurement is calibrated the moment of torsion and rotating speed of motor, and measurement signal is transferred into power analyzer.

4. a kind of driving motor for electric automobile as claimed in claim 1 and controller calibration system, it is characterized in that, pass through CAN communication turns the input and output voltage for the electric machine controller being calibrated, input and output electric current, motor speed and steering, motor Square, motor and controller temperature parameter, are uploaded to stand monitoring system.

5. a kind of driving motor for electric automobile as claimed in claim 1 and controller calibration system, it is characterized in that, the electricity Pond simulator is simulated the voltage of actual battery, the external characteristics of electric current by load cell model, according to motor load situation and exported.

6. a kind of driving motor for electric automobile as claimed in claim 1 and controller calibration system, it is characterized in that, it is calibrated Electric machine controller there is pre-charge circuit, the power supply multiple-connected battery of electric machine controller is powered.

7. a kind of driving motor for electric automobile as claimed in claim 1 and controller calibration system, it is characterized in that, it is described to drive Dynamic motor and ac dynamometer are individually fixed on motor base and measurement of power machine base, and motor base is fixed with measurement of power machine base In in specific support platform；It is furnished with shelter-clad between the ac dynamometer and motor.

8. the scaling method of a kind of driving motor for electric automobile as claimed in claim 1 and controller calibration system, it is special Levying is, comprises the following steps：

(1) system initialization, the water-cooling system coolant temperature needed for setting demarcation is simulated with flow quantity parameter, setting battery is gone out Device, ac dynamometer and the basic parameter and safeguard protection limit value for being calibrated motor；

(2) efficiency of the motor under electric model and power generation mode is defined respectively, including：Motor efficiency, motor control Device efficiency and electric system gross efficiency processed；

(3) rotating speed and torque range, stated accuracy and the testing time limitation demarcated according to needed for motor require that design is marked Fixed step size is given in timing rotating speed and torque；

(4) in the case of empty load of motor, the certain rotating speed of ac dynamometer is given, observation motor operation situation and stand moment of torsion are big It is small, if stand cacophonia or torque are excessive, illustrate that motor is installed or Disalignment is, it is necessary to readjust；

(5) ac dynamometer rotating speed is given to fixed step size by rotating speed, is designated as rotating speed demarcation outer circulation；By the demarcation step-length of torque Given motor torque, is designated as torque demarcation interior circulation；

(6) it is 0 that rotating speed demarcation outer circulation, which gives dynamometer machine rotating speed, first, torque demarcate interior circulation by step-length since 0Nm successively Given motor torque, until giving torque capacity, interior circulation has been tested one time；

Then rotating speed demarcation outer circulation gives the next rated engine speed of dynamometer machine by step-length, and torque demarcation interior circulation gives driving again Motor torque one time, until rotating speed demarcates the rated engine speed that outer circulation measures maximum, calibration process is completed；

(7) the measurement number of stand monitoring system readout power analyzer, moment of torsion flange, electric machine controller and water-cooling system is passed through According to the efficiency value of motor, electric machine controller and electric system under different operating modes being calculated, by all different test points Data unify mapping in a computer, and then respectively obtain the efficiency MAP of motor, electric machine controller and electric system；

(8) according to the method for step (4)-(7), the motor and controller efficiency MAP under different test conditions are obtained.

9. the scaling method of a kind of driving motor for electric automobile as claimed in claim 8 and controller calibration system, it is special Levying is, if under certain speed conditions, reality output torque does not reach target torque, it is necessary to readjust dq in electric machine controller Shaft current and level of torque mapping table.