CN104236919B - Electric automobile multifunctional performance test-bed - Google Patents

Abstract

The invention provides a multifunctional performance test bench for an electric vehicle, which includes a test system, a system to be tested, a support structure of the bench, a control system, a data acquisition system and an electrical system; wherein the test system includes a dynamometer motor, a speed increasing Gearbox, first flange, torque sensor, second flange, bearing seat, third flange, and coupling, and the test shift actuator is integrated on the speed increaser; the system under test includes interconnection The gearbox and the motor under test are integrated with the gearshift actuator under test; the support structure of the bench includes the base, the support part of the test system and the support part of the system under test; the control system includes the dynamometer motor controller, the dynamometer control unit, motor controller under test and vehicle controller under test. All the tests on the electric vehicle test can be completed by using the test bench, and the test system and the system under test are installed in the support structure of the bench through sliders, which is convenient for installation and movement.

Description

Electric vehicle multifunctional performance test bench

technical field

The invention relates to the field of testing and testing of electric vehicles, in particular to a multifunctional performance test bench for electric vehicles.

Background technique

An electric vehicle refers to a vehicle powered by a vehicle-mounted power battery and driven by a motor. The performance of the motor, the performance of the motor controller and the matching between the two are directly related to the power and economy of the electric vehicle. Since the working range of the vehicle belongs to the surface working condition, the working range of the motor is very wide. Therefore, the output end of the motor is required to be equipped with a gearbox for deceleration and torque increase, which increases the application range of electric vehicles, so that the motor can always work at high efficiency. Area. The power performance test of the motor, the performance test of the motor controller, the matching performance test of the motor and the motor controller, the gear shift test test of the gearbox, the verification and calibration of the vehicle control strategy, and the power system test are all electric vehicles. Required experimental test content. Compared with traditional vehicles, electric vehicles can realize braking energy recovery and zero-speed start, so as to save energy and reduce environmental pollution. This performance should also be initially tested on the test bench, and then the actual vehicle test.

Traditional internal combustion engine vehicles also have corresponding test benches to test the dynamic performance of their power system components and assemblies, but all the tests cannot be completed on one test bench, and the test bench is bulky, which is not convenient for installation and Movement makes the experiment very complicated. Electric vehicles can complete the performance testing and matching of the power system assembly and various components on a test bench, and at the same time verify and calibrate the vehicle control strategy on this bench.

Contents of the invention

The technical problem to be solved by the present invention is to provide a multifunctional performance test bench for electric vehicles, in which all tests of electric vehicles can be completed, and it is easy to install and move.

The technical solution adopted by the present invention to solve the above technical problems is: a multifunctional performance test bench for electric vehicles, which is characterized in that it includes a test system, a system under test, a bench support structure, a control system, a data acquisition system and electrical systems; of which

The test system includes a dynamometer motor, a speed increaser, a first flange, a torque sensor, a second flange, a bearing housing, a third flange and a coupling coupled in sequence. The speed increaser is integrated with Test the gearshift actuator; the system under test includes the interconnected gearbox and the motor under test, and the gearshift actuator under test is integrated on the gearbox; the gearbox is connected with a coupling;

The support structure of the bench includes a base, the base is supported by liftable support pads, and the support part of the test system and the support part of the system under test are arranged on the base; the support part of the test system includes the support frame and the first support welding, and the bottom of the support frame The sliding block is slidingly connected to the base, and the support frame is used to support the dynamometer motor, speed increaser, first flange, torque sensor, second flange, bearing seat, and third flange connected in sequence from left to right Disc and coupling, the left bottom of the dynamometer motor is welded and fixed on the support frame through the first support, and a protective cover is provided outside the supporting part of the test system, only the right port of the coupling is exposed; the tested The support part of the system is set on the right side of the support part of the test system, including the lifting support block assembly and the second support welding, all of which are slidably connected to the base through the slider, and the sliding direction is consistent with the support frame;

The control system includes a dynamometer motor controller, a dynamometer control unit, a motor controller under test and a vehicle controller under test, wherein the dynamometer control unit controls the dynamometer motor through the dynamometer motor controller, and the vehicle controller under test through The motor controller under test controls the motor under test, the dynamometer control unit is also used to control the test shift actuator, and the vehicle controller under test is also used to control the gear shift actuator under test;

The data acquisition system is used to collect all the parameters required for the test and feed back to the corresponding part of the control system;

The electrical system is used to supply power to the above systems, including a low-voltage power supply circuit and a high-voltage power supply circuit.

According to the above solution, it also includes a host computer, which is respectively connected with the dynamometer control unit and the vehicle controller under test.

According to the above scheme, it also includes two sets of cooling systems, one set is used for the cooling of the test system, which is controlled by the dynamometer control unit, and the other set is used for the cooling of the system under test, which is controlled by the vehicle controller under test.

According to the above solution, the data acquisition system further includes a power analyzer, which is used to analyze the power output characteristics and matching of the motor under test, the controller of the motor under test and the gearbox.

According to the above scheme, the base is a rectangular box composed of a bottom plate, a backing plate, a horizontal liner and a vertical liner, wherein the backing plate is connected to the support pad, and the vertical liner is provided with a through hole, and the bottom plate A slot with a "convex" cross-section is provided, and the slot matches the slider.

According to the above scheme, the lifting support block assembly is composed of an upper fixing ring, a screw rod, a supporting slider, a left side wall, a lower fixing ring, a bottom block, an upper cover, a right side wall and a supporting column;

The bottom block, the left side wall, the right side wall and the upper cover form a frame structure; the lower fixing ring is fixed on the bottom block, the upper fixing ring is fixed on the upper cover, the two ends of the screw are respectively limited by the upper and lower fixing rings, and There is a section on the top of the screw rod exposed outside the upper cover and fixed with an adjusting nut; the supporting slider is sleeved on the screw rod and connected with the screw rod through threads, the fixed slider is fixed with the supporting slider by bolts, and the supporting column is set between the fixed slider and the supporting Between the sliders, the two ends of the supporting column are respectively fixed on the bottom block and the upper cover, and the supporting slider and the fixed slider are correspondingly provided with through-holes with variable diameters for fixing the parts under test, which are used to connect with the parts under test; The bottom block is slidably connected with the bottom plate through the slide block.

The beneficial effects of the present invention are:

1. This test bench can be used to complete all the tests of the electric vehicle test, and the test system and the system under test are installed in the support structure of the bench through the slider, which is easy to install and move; since any part of the system under test is It is detachable, so this test bench can not only test the whole system under test, but also test any part of the system under test, and can also carry out matching tests and efficiency tests between components of the electric vehicle power system. Evaluate the performance of the system.

2. The test bench can also be equipped with a host computer, and a road load simulation module can be embedded in the host computer to simulate real-time road loads, test the working performance of the electric vehicle power system under different working conditions and verify the vehicle control strategy.

Description of drawings

Fig. 1 is the electric system circuit connection schematic diagram of an embodiment of the present invention;

FIG. 2 is a schematic diagram of a signal transmission connection according to an embodiment of the present invention;

3 is a schematic diagram of a connection structure of mechanical components according to an embodiment of the present invention;

Fig. 4 is a schematic diagram of the structure of the slider in the mechanical structure of an embodiment of the present invention;

Fig. 5 is a detailed schematic diagram of the base in Fig. 3 according to an embodiment of the present invention;

Fig. 6 is a detailed schematic diagram of the lifting support block assembly in Fig. 3 according to an embodiment of the present invention;

Fig. 7 is another detailed schematic diagram of the lifting support block assembly in Fig. 3 according to an embodiment of the present invention;

Fig. 8 is a schematic diagram of a test principle diagram when performing a working condition simulation test according to an embodiment of the present invention;

Fig. 9 is a schematic diagram of a test principle when performing a performance test in an embodiment of the present invention;

Fig. 10 is a schematic diagram of another test principle when performing a performance test test according to an embodiment of the present invention;

Fig. 11 is a start-up flowchart of an embodiment of the present invention.

1-Dynamometer motor; 2-Gear increaser; 3-Test shift actuator; 4-Torque sensor; Box; 9-motor under test; 10-cooling system under test; 11-motor controller under test; 12-high voltage signal acquisition module; 13-inverter; 14-DC/DC converter; 15-24V battery; 16-high-voltage power distribution system; 17-dynamometer control unit; 18-tested vehicle controller; 19-dynamometer motor controller; 20-dynamometer cooling system; 21-host computer; 22-power analyzer; 23 -accelerator pedal; 24-the first support welding; 25-the lower cover of the first protective cover; 26-the three-phase line of the dynamometer motor; 27-the upper cover of the first protective cover; 28-the first connection end face; 29-the second Connection end face; 30-bracket; 31-first flange; 32-second flange; 33-upper connecting plate; 34-bearing seat; 35-third flange; 36-second protective cover upper cover ; 37-the third connection end face; 38-the fourth connection end face; 39--the three-phase line of the motor under test; 40-the second support welding; 41-lifting support block assembly; 42-the second protective cover lower cover; 43-through viewing hole; 44-lower connecting plate; 45-groove vertical plate; 46-connecting plate; 47-vertical plate; 48-bottom plate; 49-base; 53-backing plate; 54-horizontal lining; 55-grooving; 56-upper fixing ring; 57-screw; 58-support slider; 59-left side wall; 60-lower fixing ring; 62-adjusting nut; 63-top cover; 64-right side wall; 65-support column; 66-fixed slider; 67-dynamometer motor controller temperature sensor; 68-dynamometer motor temperature sensor; 70-gearbox speed sensor; 71-tested motor temperature sensor; 72-tested motor controller temperature sensor; 73-tested motor speed sensor; 74-dynamometer motor speed sensor; 75-dynamometer motor Controller current sensor; 76-resistance torque analog module; 77-vehicle speed conversion unit; 78-gear ratio; 79-gear ratio; 80-three-phase AC current sensor; 81-three-phase AC voltage sensor; 82-DC bus Voltage sensor; 83-DC bus current sensor.

detailed description

In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only for explaining the present invention, and are not intended to limit the present invention.

The present invention provides an electric vehicle multifunctional performance test bench as shown in Figures 1, 2 and 3, including a testing system, a system to be tested, a supporting structure of the bench, a control system, a data acquisition system and an electrical system.

The test system includes a dynamometer motor 1, a speed increaser 2, a first flange 31, a torque sensor 4, a second flange 32, a bearing seat 34, a third flange 35 and a coupling that are connected in sequence 5. The test shift actuator 3 is integrated on the speed increaser 2; the system under test includes the interconnected gearbox 8 and the motor 9 under test, and the gearbox 8 is integrated with the tested shift actuator 7; the output of the gearbox 8 The shaft end is directly connected with the coupling 5. Both the test shift actuator 3 and the tested shift actuator 7 adopt pneumatic shift, and the air pressure is provided by the air pump 6 .

The stand support structure comprises a base 49, the base 49 is supported by a liftable support block 50, and the base 49 is provided with a test system support part and a system under test support part; wherein the test system support part includes a support frame and a first support welding 24. The bottom of the support frame is slidably connected with the base 49 through the slider 51, the left bottom of the dynamometer motor 1 is fixed on the support frame through the first support welding 24, and a first protective cover is provided outside the support part of the test system. The protective cover is composed of the first protective cover upper cover 27 and the first protective cover lower cover 25, and only the right port of the coupling 5 is exposed; the supporting part of the system under test is arranged on the right side of the supporting part of the testing system, including a lifting support block The assembly 41 and the second support welding 40 are all slidably connected to the base 49 through the slider 51, and the sliding direction is consistent with the support frame. The base 49 is a rectangular box made of a base plate 48, a backing plate 53, a horizontal liner 54 and a vertical liner 52, wherein the backing plate 53 is connected to the support block 50, and the vertical liner 52 has a through hole 43, The bottom plate 48 is provided with a slot 55 with a “convex” cross-section, and the slot 55 is matched with the slider 51 . The lifting support block assembly 41 is composed of an upper fixing ring 56, a screw rod 57, a supporting slider 58, a left side wall 59, a lower fixing ring 60, a bottom block 61, an upper cover 63, a right side wall 64 and a supporting column 65. Wherein bottom block 61, left side wall 59, right side wall 64 and loam cake 63 form a frame structure; Lower fixed ring 60 is fixed on the bottom block 61, and upper fixed ring 56 is fixed on the loam cake 63, and screw rod 57 two The ends are respectively limited by the upper fixing ring 56 and the lower fixing ring 60, and a section of the top of the screw rod 57 is exposed outside the upper cover 63 and is fixed with an adjusting nut 62; connection, the fixed slider 66 is fixed with the support slider 58 by bolts, the support column 65 is arranged between the fixed slider 66 and the support slider 58, and the two ends of the support column 65 are respectively fixed on the bottom block 61 and the upper cover 63, supporting The sliding block 58 and the fixed sliding block 66 are correspondingly provided with a through hole of variable diameter for fixing the tested gearbox 8 for connecting with the tested gearbox 8 ; the bottom block 61 is slidably connected with the bottom plate 48 through the slider 51 .

The control system includes a dynamometer motor controller 19, a dynamometer control unit (ECU) 17, a tested motor controller 11 and a tested vehicle controller (VCU) 18, wherein the dynamometer control unit 17 passes the dynamometer motor controller 19 Control the dynamometer motor 1, the tested vehicle controller 18 controls the tested motor 9 through the tested motor controller 11, the dynamometer control unit 17 is also used to control the test shift actuator 3, and the tested vehicle controller 18 also It is used to control the shift actuator 7 under test.

The data acquisition system is used to collect all the parameters required for the test and feed back to the corresponding part of the control system;

The electrical system is used to supply power to the above systems, including a high-voltage power supply circuit and a low-voltage power supply circuit.

As shown in FIG. 1 , it is a schematic diagram of electrical system circuit connection in the electric vehicle multifunctional performance test bench of the embodiment of the present invention. In the high-voltage power supply circuit, the inverter (power supply) 13 inverts the three-phase alternating current (380VAC) in the grid into a stable high-voltage DC power, and supplies the DC power to the motor controller 11 under test through the high-voltage power distribution system 16. The dynamometer controller 19 and the DC/DC converter 14 can also invert the power generated by the dynamometer motor 1 and the motor under test 9 in the power generation state into 380VAC and feed it back to the power grid, so as to realize the recovery of the braking energy of the motor under test 9 Performance test; inverter (power supply) is connected with 13 high-voltage power distribution system 16; high-voltage power distribution system 16 supplies DC high-voltage power to the dynamometer controller 19, and the dynamometer controller 19 inverts the DC high-voltage power into The three-phase AC power supply dynamometer motor 1 drives electric energy, and can also invert the three-phase AC power generated by the dynamometer motor 1 in the power generation state into direct current, which is fed back to the high-voltage power distribution system 16; the high-voltage power distribution system 16 converts the DC high-voltage The electricity is supplied to the dynamometer motor controller 19 through the high-voltage electrical signal acquisition module 12, and the dynamometer motor controller 19 inverts the DC high-voltage power into a three-phase alternating current and supplies the measured motor 9 through the high-voltage electrical signal acquisition module 12. When the measuring motor 9 is in the power generation state, the three-phase AC power generated is inverted into DC and fed back to the high-voltage power distribution system 16; the high-voltage electrical signal acquisition module 12 is equipped with a three-phase AC current sensor 80, a three-phase AC voltage sensor 81, and a DC bus The voltage sensor 82 and the DC bus current sensor 83 measure the DC voltage and DC current input to the dynamometer motor controller 11 and the three-phase AC voltage and three-phase AC current input to the motor 9 under test; the high-voltage power distribution system 16 converts the DC high-voltage Electricity is supplied to the DC/DC converter 14 .

In the low-voltage power supply circuit, the DC/DC converter 14 converts the DC high-voltage 600VDC into 27VDC to charge the 24V battery 15, and the 24V battery 15 supplies the low-voltage power to the high-voltage power distribution system 16. The high-voltage power distribution system 16 has a low-voltage distribution system. The electrical part is supplied to the tested motor controller 11, the dynamometer motor controller 19, the tested vehicle controller 18, the dynamometer control unit 17, the tested cooling system 10, and the dynamometer cooling system 20 through the high-voltage power distribution system 16. low voltage electricity.

In this embodiment, preferably, the test bench further includes a host computer 21, which is respectively connected to the dynamometer control unit 17 and the vehicle controller 18 under test.

In this embodiment, preferably, the test bench also includes 2 sets of cooling systems (10, 20), 1 set is used for the cooling of the test system, controlled by the dynamometer control unit 17, and the other 1 set is used for the cooling of the system under test. It is controlled by the vehicle controller 18 under test. Both the test system and the system under test require a cooling system. In the test system, the dynamometer motor 1 and the dynamometer motor controller 19 adopt the same water cooling cycle and share the dynamometer cooling system 20; in the system under test, the tested motor 9 and the tested motor controller 11 adopt the same water cooling cycle and share the Measure the cooling system 10. The cooling methods are all water-cooled; each cooling system includes a cooling water pump and a cooling fan; the dynamometer cooling system 20 is controlled by the dynamometer control unit 17 through the temperature of the dynamometer motor stator and the temperature of the dynamometer motor controller. The cooling system 10 under test is opened and closed by the vehicle controller 18 under test through the stator temperature of the drive motor and the temperature of the drive motor controller; both sets of cooling systems can be directly controlled to open and close by manually inputting commands from the host computer.

In this embodiment, preferably, the data acquisition system further includes a power analyzer 22 for analyzing power output characteristics and matching of the tested motor 9 , the tested motor controller 11 and the gearbox 8 .

As shown in FIG. 2 , various electrical components in the electric vehicle multifunctional performance test bench according to the embodiment of the present invention include transmission of various signals. In the test system, the dynamometer control unit 17 is connected to the dynamometer motor controller 19 through a CAN line, and the two also perform signal interaction through hard wires, and the dynamometer control unit 17 can control the dynamometer motor controller by sending commands 19; The dynamometer motor controller 19 controls the dynamometer motor 1, and the dynamometer motor 1 feeds back the output value of the control variable to the dynamometer motor controller 19; the dynamometer motor speed sensor 74 and the speed increaser are installed at the speed increaser 2 shaft end The rotational speed sensor 69 feeds back the rotational speed of the dynamometer motor 1 and the output rotational speed of the shaft end of the speed increaser 2 to the dynamometer motor controller 19; the torque sensor 4 feeds back the real-time torque output by the shaft end of the speed increaser 2 to the dynamometer motor controller 19. Realize torque closed-loop control; the test gearshift actuator 3 feeds back the current gear position to the dynamometer control unit 17, and the dynamometer control unit 17 provides analog electricity for the test gearshift actuator 3, and simultaneously controls the test gearshift actuator 3 Shifting action; the high-voltage power distribution system 16 feeds back corresponding acquisition signals to the dynamometer control unit 17, and the dynamometer control unit 17 controls the opening and closing of the corresponding high-voltage DC contactor and low-voltage contactor; the dynamometer control unit 17 controls the The temperature of the dynamometer motor controller 19 and the stator temperature feedback value of the dynamometer motor 1 measured by the dynamometer temperature sensor 67 and the dynamometer motor temperature sensor 68 are used to control the disconnection of the dynamometer cooling system 20 . In the system under test, the vehicle controller 18 under test is connected to the motor controller 11 under test through a CAN line, and the two are also transmitted through hard wires for signal interaction. The vehicle controller 18 under test can be controlled by sending commands. The motor controller under test 11; the motor controller under test 11 controls the motor under test 9, and the motor under test 9 feeds back the output value of the control variable to the motor controller under test 11; the shaft end of the gearbox 8 is equipped with a speed sensor 73 of the motor under test and the gearbox speed sensor 70, respectively feed back the speed of the motor 9 under test and the output speed of the shaft end of the gearbox 8 to the motor controller 11 under test; the shift actuator 7 under test feeds back the current gear position to the vehicle control 18, the tested vehicle controller 18 provides simulated power for the tested gear shift actuator 7, and simultaneously controls the shifting action of the tested gear shift actuator 7; the high-voltage power distribution system 16 feeds back to the tested vehicle controller 18 According to the corresponding acquisition signal, the measured vehicle controller 18 controls the opening and closing of the corresponding high-voltage DC contactor and low-voltage contactor; The temperature of the measured motor controller 11 and the stator temperature feedback value of the measured motor 9 are used to control the disconnection of the measured cooling system 10; the accelerator pedal 23 inputs the accelerator pedal command into the measured vehicle controller 18, which is used to simulate the actual Car accelerator pedal 23 commands; there is signal interaction transmission between the high-voltage electrical signal acquisition module 12 and the measured vehicle controller 18, and the high-voltage electrical signal acquisition module 12 provides the collected analog signal to the measured vehicle controller 18, and the tested The vehicle controller 18 provides analog power to the high-voltage electrical signal acquisition module 12; the high-voltage electrical signal acquisition module 12 feeds back the collected analog signal to the power analyzer 22, and the power analyzer 22 also receives the measured torque and the measured torque from the torque sensor 4 at the same time. The rotational speed signals fed back by the vehicle controller 18 are measured, and these collected signals are used to analyze the power output characteristics and matching of the motor 9 under test, the motor controller 11 under test, and the gearbox 8 . The dynamometer control unit 17 and the vehicle controller under test 18 are connected to the upper computer (PC) 21 through CAN, and at the same time, signals are transmitted interactively. And the control, data collection, storage and recording of the tested vehicle controller 18. Signal transmission can be realized between the power analyzer 22 and the host computer (PC) 21 .

The preferred structure of the bench support structure in the electric vehicle multifunctional performance test bench of the embodiment of the present invention is shown in Figure 3, including a base 49, the base 49 is supported by a liftable support pad 50, and the base 49 is provided with a dynamometer motor The supporting part and the supporting part of the motor under test; where

The supporting part of the dynamometer motor includes a support frame and a first support weld 24, the bottom of the support frame is slidably connected with the base 49 through a slider 51, and the support frame is used to support the dynamometer motor 1 and the speed increaser 2 connected in sequence from left to right , the first flange 31, the torque sensor 4, the second flange 32, the bearing seat 34, the third flange 35 and the coupling 5, the left bottom of the dynamometer motor 1 is welded through the first support The joint 24 is fixed on the supporting frame, and the supporting part of the dynamometer motor is equipped with a protective cover, only the right port of the coupling is exposed;

The supporting part of the motor under test is arranged on the right side of the supporting part of the dynamometer motor, including the lifting support block assembly 41 and the second support welding 40, which are all slidably connected to the base 49 through the slider 51, and the sliding direction is consistent with the support frame.

In this embodiment, preferably, the support frame includes a bracket 30, an upper connecting plate 33, a lower connecting plate 44, a grooved vertical plate 45, a vertical plate 47 and a connecting plate 46, and the vertical plate 47 is fixed on the base by bolts and sliders 51 49, connecting plate 46 is fixed on the vertical plate 47 by bolts, and the first support welding 24 and support 30 are all fixed on the connecting plate 46 by bolts; three identical grooved vertical plates 45 are fixed by bolts and slide blocks 51 On the base 49, the lower connecting plate 44 is fixed on the groove-shaped vertical plate 45 by bolts, and the upper connecting plate 33 is connected with the lower connecting plate 44 by bolts; The second connection end surface 29 is integrated together, the output shaft end of the speed increaser 2 is connected with the torque sensor 4 through the first flange 31, and the other end of the torque sensor 4 is connected with the bearing seat 34 through the second flange 32, and the bearing seat 34 and the coupling 5 are connected through the third flange 35; the other end of the coupling 5 is connected with the gearbox 8; the gearbox 8 and the motor 9 are connected through the third connecting end face 37 It is integrated with the fourth connection end surface 38; the tail of the dynamometer motor 1 is fixed and supported by the first support welding 24, and the two sides of the speed increaser 2 are fixed and supported by the bracket 30, which ensures that the dynamometer motor 1 and the speed increaser 2 are both The person is installed securely; the torque sensor 4 and the bearing seat 34 are all fixed on the upper connecting plate 33 by bolts; the whole dynamometer motor supporting part is covered by the first protective cover lower cover 25, and the upper cover and the first protective cover upper cover 27 Cooperate, the whole dynamometer motor supporting part and dynamometer motor etc. are covered inside, only the other end of the coupling 5 is exposed, which improves the safety performance of the bench, the first protective cover lower cover 25 and the first protective cover The periphery of loam cake 27 is provided with cooling devices, such as cooling fins and cooling holes.

In this embodiment, preferably, both sides of the gearbox 8 are fixed on the lifting support block assembly 41 through the fixed slider 66; the tail of the motor 9 under test is fixed and supported by the second support welding 40, and the second support welding 40 It is fixed on the bottom plate 48 by a slider 51 . The shift actuator 3 of the speed increaser 2 is integrated at the upper end of the speed increaser 2 , and the shift actuator 8 of the gearbox 8 is integrated at the upper end of the transmission 2 . The system under test and the test system are connected by the second protective cover lower cover 42 to cover both sides through the coupling part of the disturbance coupling 5, and the upper cover cooperates with the second protective cover upper cover 36 to improve the safety performance of the stand.

In this embodiment, the base 49, as shown in Figure 5, is a rectangular box made of a bottom plate 48, a backing plate 53, a horizontal liner 54 and a vertical liner 52, wherein the backing plate 53 is connected to the supporting pad 50 connection, the longitudinal liner 52 is provided with a through hole 43, and the bottom plate 48 is provided with a slot 55 with a "convex" cross section, and the slot 55 is matched with the slider 51 (as shown in Figure 4). In this embodiment, the longitudinal liner 52 and the horizontal liner 54 are fixed around the bottom plate 48 by welding, and the longitudinal liner 52 has a through hole 43 at the place where the support block 50 is installed, which is used to adjust the height of the support block 50 to ensure that the test bench The overall level of the frame; the backing plate 53 is fixed under the longitudinal liner 52 and the horizontal liner 54 by welding, and the backing plate 53 has a circular hole at the place where the support pad 50 is installed; the bottom plate 48 has equidistant "convex" shaped The slot 55, the slider 51 is located in the slot 55, so the lateral distance can be changed by selecting different slots 55, the axial distance can be directly adjusted by the installation position of the slider 51, the adjustable axial distance is continuously variable, And the adjustable range is relatively large; the base plate 48 and the slot 55 are coated with lubricating oil, so that the installation is quick and easy to move.

In this embodiment, the lifting support block assembly 41 is shown in Figure 6 and Figure 7, and the described lifting support block assembly is composed of an upper fixing ring 56, a screw rod 57, a supporting slider 58, a left side wall 59, and a lower fixing ring 60, bottom block 61, loam cake 63, right side wall 64, support column 65 form. Wherein the bottom block 61, the left side wall 59, the right side wall 64 and the upper cover 63 form a frame structure; the lower fixing ring 60 is fixed on the bottom block 61, the upper fixing ring 56 is fixed on the upper cover 63, and the two ends of the screw rod 57 Respectively through the upper and lower fixing rings 56, 60 limit, and the top of the screw rod 57 has a section exposed outside the upper cover 63 and is fixed with an adjusting nut 62; the support slider 58 is sleeved on the screw rod 57 and connected with the screw rod 57 through threads, the fixed slider Block 66 is fixed with support slide block 58 by bolt, and support column 65 is arranged between fixed slide block 66 and support slide block 58, and support column 65 two ends are respectively fixed on bottom block 61 and loam cake 63, support slide block 58 and support slide block 58. The fixed slider 66 is correspondingly provided with a through hole of variable diameter for fixing the component under test, and is used for connecting with the component under test; the bottom block 61 is slidably connected with the bottom plate 48 through the slider 51 .

When the lifting support block assembly is installed on the bottom plate 48, firstly the slide block 51 drives the bottom block 61 to slide. Preferably, a long through hole perpendicular to the "convex" shaped slot 55 can also be set on the bottom block 51, so that the lifting support block assembly can slide in both horizontal and vertical directions. When sliding to a fixed position, bolts are used to to fix it.

During use, turn the adjusting nut 62 to make the screw rod 57 rotate, thereby driving the support slider 58 to move up and down, and the fixed slider 66 connected with the support slider 58 also moves up and down, finally making the tested gearbox 8 also move up and down, supporting The adjustable height of slide block 58 is equal to the tapping length of screw rod 57, and its adjustable height is relatively large. The support column 65 is disposed between the support slider 58 and the fixed slider 66 , so that the support slider 58 and the fixed slider 66 always face to the fixed side, and will not rotate with the screw rod 57 .

As shown in FIG. 8 , it is a schematic diagram of a test principle diagram when the electric vehicle multifunctional performance test bench of the embodiment of the present invention performs working condition simulation. This test schematic diagram is mainly used to simulate real-time road loads, test the working performance of the power system of electric vehicles under different working conditions and verify the control strategy of the whole vehicle. State of the powertrain under starting conditions. The dynamometer motor controller current sensor 75 measures the input DC current of the dynamometer motor controller 19, and feeds back the test value to the dynamometer control unit 17; the dynamometer motor controller temperature sensor 67 and the dynamometer motor temperature sensor 68 respectively measure the dynamometer motor The controller 19 and the temperature of the stator of the dynamometer motor 1 feed back the tested analog quantity to the dynamometer control unit 17; the speed sensor 69 of the speed increaser and the speed sensor 74 of the dynamometer motor measure the output speed of the shaft end of the speed increaser 2 and the speed of the test motor respectively. The rotor speed of the dynamometer 1 is fed back to the dynamometer control unit 17, and the test shift actuator 3 feeds back the real-time gear ratio 78 to the dynamometer control unit 17. At this time, the dynamometer control unit 17 can realize the test The gear shifting control of the gear shifting actuator 3 can also be completed by manual gear shifting during the test process to complete the gear change of the speed increaser 2; the resistance torque simulation module 76 and the vehicle speed conversion unit 77 are located in the dynamometer control unit 17, through The upper computer (PC) 21 is implanted and called; the vehicle speed conversion unit 77 is a single-valued function of the output speed of the 2 shaft ends of the speed increaser, and the resistance torque simulation module 76 is a function of the gear ratio 78, the gear ratio 79, and the real-time vehicle speed. The torque sensor 4 is used to feedback whether the output torque of the shaft end of the speed increaser 2 reaches the torque demanded by the resistance torque simulation module 76 to realize internal torque closed-loop control. The transmission speed sensor 70 and the measured motor speed sensor 73 respectively measure the shaft end speed of the gearbox 8 and the rotor speed of the measured motor 9, and feed back to the measured vehicle controller 18, and the measured gear shift actuator 7 sets the real-time gear position Ratio feedback to the tested vehicle controller 18, the tested vehicle controller 18 can be used to verify the automatic gear shifting of the gearbox 8 in the shift strategy or test process at this time; the tested motor temperature sensor 71 and the tested motor control The temperature sensor 72 measures the temperature of the stator of the motor 9 under test and the temperature of the motor controller 11 under test respectively, and feeds back its value to the vehicle controller 18 under test; The torque sensor 4 collects signals and rotational speed signals to analyze the data during the test; the upper computer (PC) 21 can make the bench run according to the predetermined working conditions by implanting the corresponding working condition data, so as to simulate the actual vehicle running. The working performance and matching status of each component of the electric vehicle power system can also be implanted into the vehicle control strategy through the host computer (PC) 21 to complete the verification of the vehicle control strategy. In this test mode, the closed-loop control of the speed of the test system and the system under test is realized through the resistance torque simulation module 76, and the two are coupled together through the functional relationship of the speed.

As shown in FIG. 9 , it is a schematic diagram of a test principle when performing a performance test on the electric vehicle multifunctional performance test bench of the embodiment of the present invention. In this test state, the dynamometer motor 1 is in the torque control mode, and has been in the power generation state during the test; the tested motor 9 is in the speed control mode, and has been in the driving state during the test. This test principle is mainly used to test the performance test of a single drive motor (such as: run-in test, no-load test, temperature rise test, MAP test test, maximum operating speed test, overspeed test, steady state and dynamic performance test under speed control mode , durability test), efficiency test and output characteristic test of motor controller, matching test between motor controller and motor, verification of automatic transmission shift control strategy, matching and performance verification test of electric vehicle power system, etc. The test system part feeds back the real-time speed-up 2 shaft end torque to the dynamometer control unit 17 through the torque sensor 4 to realize closed-loop torque control, so that the output torque is equal to the target torque given by the host computer (PC) 21; 3. Both automatic gear shifting can be realized through the dynamometer control unit 17, and manual gear shifting can also be adopted. The tested system feeds back the rotor speed of the tested motor 9 to the measured vehicle controller 18 through the tested motor speed sensor 73, so as to realize the closed-loop control of the speed, so that the output speed is equal to the given target speed of the upper computer (PC) 21; The gear shift actuator 7 realizes automatic gear shift through the vehicle controller 18 under test, which can be used to initially verify the gear shift control strategy. In the test, the signal collection, testing and data collection, analysis and storage of each sensor are the same as those shown in Figure 8.

As shown in FIG. 10 , it is a schematic diagram of another test principle when performing a performance test on the electric vehicle multifunctional performance test bench of the embodiment of the present invention. In this test state, the dynamometer motor 1 is in the speed control mode and is always in the driving state during the test; the tested motor 9 is in the torque control mode and is in the power generation state during the test. This test principle is mainly used to test the braking energy feedback test of a single drive motor and the steady-state and dynamic performance tests in torque mode. It can also test the overall performance of the electric vehicle power system in these two states of the drive motor. The part of the system under test feeds back the real-time speed-up 2 shaft end torque to the measured vehicle controller 18 through the torque sensor 4, so as to realize closed-loop control of the torque, so that the output torque is equal to the given target torque of the upper computer (PC) 21; The actuator 7 realizes automatic gear shifting through the vehicle controller 18 under test. The test system feeds back the rotor speed of the dynamometer motor 1 to the dynamometer control unit 17 through the dynamometer motor speed sensor 74 to realize the closed-loop control of the speed so that the output speed is equal to the given target speed of the host computer (PC) 21; the shift actuator 3 Both automatic gear shifting can be realized through the dynamometer control unit 17, and manual gear shifting can also be achieved. In the test, the signal collection, testing and data collection, analysis and storage of each sensor are the same as those shown in Figure 8.

As shown in FIG. 11 , the start-up flow chart of the electric vehicle multifunctional performance test bench according to the embodiment of the present invention. When the bench is started, the high-voltage power is first connected, and then the low-voltage power is connected. After that, it enters the leakage detection state. If the leakage current is greater than the specified value, the start-up ends and the high voltage power is forcibly cut off; if the leakage current is less than the specified value, it enters the pre-charging stage. During pre-charging, if the voltage difference between the two ends of the main contactor is greater than 20V, the pre-charging fails, and the pre-charging continues; if the voltage difference between the two ends of the main contactor is less than 20V, the pre-charging is completed, and the high-voltage power of each circuit is connected. The test bench enters the standby operation state.

The invention integrates all the basic performance tests required by the power system of the electric vehicle, and can perform separate performance tests on the components of the power system (the motor under test, the controller of the motor under test, the gearbox, and the controller of the whole vehicle under test) Tests can also be performed on the entire power system assembly, including run-in tests of a single drive motor, no-load tests, temperature rise tests, MAP test tests, maximum operating speed tests, overspeed tests, and regenerative energy feedback Test, dynamic performance test, steady-state performance test, durability test, efficiency test of motor controller, output characteristic test, performance matching test between motor controller and motor, shift control strategy verification test of automatic transmission, automatic Transmission shift efficiency, temperature rise, noise test, power system assembly matching test, efficiency test and matching efficiency test between various components. In addition to the basic performance test, this test bench can also implant a road load simulation module in the ECU through the host computer to simulate the vehicle road driving resistance moment in real time, which is used to verify the control strategy and power of the vehicle under different working conditions. The operating performance status of the system assembly. The test bench test system comes with a speed increaser (its specific system structure and performance are similar to the patent CN200910061844.6, the difference is that the patent CN200910061844.6 is directly used for the power system of the vehicle, while this system is used for testing) to increase The adaptability range of the speed and torque of the test object is widened; the two modes of test bench wire control and CAN control coexist, which broadens the adaptability and reliability; the self-contained inverter has a large instantaneous discharge power, making the The bench can run for a long time; the overall installation of the test bench is simple, the site requirements are low, and the installation of the tested components is also convenient and simple.

The above embodiments are only used to illustrate the calculation ideas and characteristics of the present invention, and its purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. The protection scope of the present invention is not limited to the above embodiments. Therefore, all equivalent changes or modifications based on the principles and design ideas disclosed in the present invention are within the protection scope of the present invention.

Claims (6)

1. An electric vehicle multifunctional performance test bench is characterized in that: it includes a test system, a system under test, a stand support structure, a control system, a data acquisition system and an electrical system; wherein The test system includes a dynamometer motor, a speed increaser, a first flange, a torque sensor, a second flange, a bearing housing, a third flange and a coupling coupled in sequence. The speed increaser is integrated with Test the gearshift actuator; the system under test includes the interconnected gearbox and the motor under test, and the gearshift actuator under test is integrated on the gearbox; the gearbox is connected with a coupling; The support structure of the bench includes a base, the base is supported by liftable support pads, and the support part of the test system and the support part of the system under test are arranged on the base; the support part of the test system includes the support frame and the first support welding, and the bottom of the support frame The sliding block is slidingly connected to the base, and the support frame is used to support the dynamometer motor, speed increaser, first flange, torque sensor, second flange, bearing seat, and third flange connected in sequence from left to right Disc and coupling, the left bottom of the dynamometer motor is welded and fixed on the support frame through the first support, and a protective cover is provided outside the supporting part of the test system, only the right port of the coupling is exposed; the tested The support part of the system is set on the right side of the support part of the test system, including the lifting support block assembly and the second support welding, all of which are slidably connected to the base through the slider, and the sliding direction is consistent with the support frame; The control system includes a dynamometer motor controller, a dynamometer control unit, a motor controller under test and a vehicle controller under test, wherein the dynamometer control unit controls the dynamometer motor through the dynamometer motor controller, and the vehicle controller under test through The motor controller under test controls the motor under test, the dynamometer control unit is also used to control the test shift actuator, and the vehicle controller under test is also used to control the gear shift actuator under test; The data acquisition system is used to collect all the parameters required for the test and feed back to the corresponding part of the control system; The electrical system is used to supply power to the above systems, including a low-voltage power supply circuit and a high-voltage power supply circuit. 2. The electric vehicle multifunctional performance test bench according to claim 1, characterized in that: it also includes a host computer, which is respectively connected with the dynamometer control unit and the vehicle controller under test. 3. The electric vehicle multifunctional performance test bench according to claim 1, characterized in that: it also includes 2 sets of cooling systems, one set is used for the cooling of the test system, controlled by the dynamometer control unit, and the other set is used for the cooling of the test system. The cooling of the system under test is controlled by the vehicle controller under test. 4. The electric vehicle multifunctional performance test bench according to claim 1, characterized in that: the data acquisition system also includes a power analyzer, which is used to test the motor under test, the motor controller under test and the gearbox The power output characteristics and matching are analyzed. 5. The electric vehicle multifunctional performance test bench according to claim 1, characterized in that: the base is a rectangular box composed of a bottom plate, a backing plate, a horizontal liner and a vertical liner, wherein the backing plate and the The above-mentioned supporting pads are connected, the longitudinal lining is provided with a through hole, and the bottom plate is provided with a slot with a "convex" cross-section, which matches the slide block. 6. The electric vehicle multifunctional performance test bench according to claim 1, characterized in that: the lifting support block assembly is composed of an upper fixing ring, a screw rod, a supporting slider, a left side wall, a lower fixing ring, a bottom block, upper cover, right side wall and support column; The bottom block, the left side wall, the right side wall and the upper cover form a frame structure; the lower fixing ring is fixed on the bottom block, the upper fixing ring is fixed on the upper cover, the two ends of the screw are respectively limited by the upper and lower fixing rings, and There is a section on the top of the screw rod exposed outside the upper cover and fixed with an adjusting nut; the supporting slider is sleeved on the screw rod and connected with the screw rod through threads, the fixed slider is fixed with the supporting slider by bolts, and the supporting column is set between the fixed slider and the supporting Between the sliders, the two ends of the supporting column are respectively fixed on the bottom block and the upper cover, and the supporting slider and the fixed slider are correspondingly provided with through-holes with variable diameters for fixing the parts under test, which are used to connect with the parts under test; The bottom block is slidably connected with the bottom plate through the slide block.