CN107015091B - Endurance test device for vehicle-mounted DC/DC converter - Google Patents
Endurance test device for vehicle-mounted DC/DC converter Download PDFInfo
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- CN107015091B CN107015091B CN201710434296.1A CN201710434296A CN107015091B CN 107015091 B CN107015091 B CN 107015091B CN 201710434296 A CN201710434296 A CN 201710434296A CN 107015091 B CN107015091 B CN 107015091B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/005—Testing of electric installations on transport means
- G01R31/006—Testing of electric installations on transport means on road vehicles, e.g. automobiles or trucks
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/72—Electric energy management in electromobility
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Abstract
The invention provides a endurance test device of a vehicle-mounted DC/DC converter, which comprises: the high-voltage power conversion module is used for rectifying and converting high-voltage alternating current into high-voltage direct current and supplying the high-voltage direct current to two ends of the input sides of the N converters to be tested; wherein N is an integer greater than or equal to 2; an output side line for serially connecting the output sides of the N converters to be tested and outputting the N converters; an output electricity detection device for detecting the current and/or voltage output by the output side line; input electrical detection means for detecting a current and/or a voltage supplied to the converter under test; the controller is used for outputting PWM signals corresponding to the duty ratio according to the feedback of the output electric detection device and the input electric detection device, so that the converter to be tested works under the rated durable current; and the driver is used for respectively controlling the output power supply of each converter to be tested according to the PWM signals output by the controller.
Description
Technical Field
The invention relates to the field of vehicle-mounted converters, in particular to a endurance test device of a vehicle-mounted DC/DC converter.
Background
The vehicle-mounted DC/DC converter belongs to the technical field of automobile power electronics, and generally converts high-voltage direct current (200-720 VDC) nominally output by an electric automobile power battery into low-voltage direct current (12-48 VDC), and is widely used in secondary power supply modules of electric automobiles or hybrid electric vehicles (EV & HEV). The patent relates to a endurance test scheme of a vehicle-mounted DC/DC converter, which is mainly used in the research and development stage before batch production, and belongs to the technical field of automobile power electronic tests.
In the conventional endurance test, a single connection electronic load is generally used, which wastes energy and reduces the efficiency of the endurance test.
Moreover, the domestic DC/DC converter is mainly and intensively applied to the fields of computers, industrial instruments, aerospace, automatic control equipment and the like, and particularly the application of a 6-25W low-power industrial-level low-voltage converter is the most widely. After 2000, DC/DC converters have been mass-commercialized and power and switching frequencies have rapidly increased as IC microelectronics have advanced and PWM switching technologies have tended to mature. However, the endurance test technology of the vehicle-mounted DC/DC converter is still in the application stage of low-power low-voltage products in China, and the endurance test technology of high-power high-voltage, particularly high-current, is still blank and does not form products which can be practically applied in batch.
Disclosure of Invention
The invention aims to solve the technical problem of how to realize batch endurance test of the vehicle-mounted DC/DC converter.
In order to solve the technical problem, the invention provides a endurance test device of a vehicle-mounted DC/DC converter, which is characterized in that: comprising the following steps:
the high-voltage power conversion module is used for rectifying and converting high-voltage alternating current into high-voltage direct current and supplying the high-voltage direct current to two ends of the input sides of the N converters to be tested; wherein N is an integer greater than or equal to 2;
an output side line for serially connecting the output sides of the N converters to be tested and outputting the N converters;
an output electricity detection device for detecting the current and/or voltage output by the output side line;
input electrical detection means for detecting a current and/or a voltage supplied to the converter under test;
the controller is used for outputting PWM signals corresponding to the duty ratio according to the feedback of the output electric detection device and the input electric detection device, so that the converter to be tested works under the rated durable current;
and the driver is used for respectively controlling the output power supply of each converter to be tested according to the PWM signals output by the controller.
Optionally, the endurance test device of the vehicle-mounted DC/DC converter further includes N power switching devices, each of the power switching devices is connected to a first end of an output side of the converter to be tested, and the driver is further configured to control the N power switching devices respectively according to PWM signals output by the controller.
Optionally, the endurance test apparatus of the vehicle-mounted DC/DC converter further includes a capacitor and a load connected between the power switching device and the second end corresponding to the output side of the converter to be tested.
Optionally, the controller comprises a constant current loop adjustment module, a peak current control module and a periodic current limiting module;
the constant current loop adjustment module is used for adjusting the constant current loop based on feedback of the output electric detection device and/or the input electric detection device;
the peak current control module is used for carrying out peak current control based on the obtained input side current information of the converter to be tested;
the periodic current limiting module is used for limiting the current according to the period by period based on the obtained current information of the input side of the converter to be tested;
the input side current information is obtained according to the turn ratio of the output electric detection device and the converter to be tested.
Optionally, the controller further includes a short-circuit protection module, configured to perform short-circuit protection on the driver according to the obtained input side current information of the to-be-tested converter.
Optionally, the endurance test device of the vehicle-mounted DC/DC converter further includes an overcurrent protection device, configured to perform overcurrent protection on the driver according to feedback of the output electric detection device.
Optionally, the endurance test device of the vehicle-mounted DC/DC converter further includes a microprocessor, where the microprocessor is connected to the output electric detection device, the input electric detection device, and the enabling end of the controller, respectively.
Optionally, the microprocessor is configured to control the switching frequency of the controller through the controller enabling end, so as to realize control of constant voltage or constant current or constant power.
Optionally, the endurance test device of the vehicle-mounted DC/DC converter includes a high voltage region and a low voltage region, the high voltage region is at least provided with the high voltage power conversion module, and a circuit portion between the high voltage power conversion module and the converter to be tested, the low voltage region is at least provided with the output side circuit, and electrical isolation is performed between the high voltage region and the low voltage region.
Aiming at the actual requirements of endurance tests of a plurality of sets of vehicle-mounted DC/DC products under no-load conditions, the constant voltage and constant current control requirements of each product to be durable are considered, a high-low voltage isolation topological circuit with an input connected in parallel and an output connected in series is designed on hardware, meanwhile, energy consumption heating equipment such as an electronic load is eliminated, in a specific embodiment, a self-feedback and circulation regulation calibratable control scheme can be adopted, monitoring and diagnosis of a starting function are adopted, and designs such as operation protection under a rated durable working condition are adopted, so that the reliability, safety and energy-saving ideal effects of the durable process of the product are ensured.
Drawings
FIG. 1 is a functional block diagram of a endurance test apparatus for an in-vehicle DC/DC converter in an embodiment of the present disclosure;
FIG. 2 is a control schematic diagram of a endurance test apparatus of an in-vehicle DC/DC converter in an embodiment of the present disclosure;
FIG. 3 is a schematic diagram of a endurance test apparatus for an in-vehicle DC/DC converter in an embodiment of the present disclosure;
fig. 4 is a schematic diagram of a controller in an embodiment of the present disclosure.
Detailed Description
In order to introduce the apparatus provided by the present disclosure, the following description is first provided:
the existing DC/DC converter endurance technology is mainly applied to the industrial field and has the following defects:
1) Most existing durable circuit designs have low-voltage products in the low power range (< 1 kw) as the main durable target, while durable technologies for high-power high-voltage products (especially at the automobile level) have not yet matured and have not met the durable requirements at the automobile level. However, with the electric power steering EPS, the electric brake EPB, the electric air conditioner EHVAC, the start-stop ISG and other motor and electric equipment are gradually configured in the new energy automobile, and the power demand on the vehicle-mounted DC/DC is increasing.
2) The existing product is a non-intelligent control design, mainly adopts a single switching device to realize the pure hardware circuit designs such as the on-off function, the harmonic communication function such as PWM (pulse width modulation) and low-pass filtering, and the like, lacks the development and application of a software control strategy, and belongs to the technical and system scheme of the existing product.
3) In order to avoid electric energy waste caused by using an electronic load as much as possible, a design scheme of connecting energy recovery in parallel in a series/parallel mode is an energy-saving test technology, but the energy recovery efficiency is a technical key for testing the adaptability of the power class and the number of products and avoiding circuit repeated design and the convenience of actual operation. For example: in the past, serial-parallel connection modes of different power levels or different numbers of products need to be repeatedly calculated to form an arrangement scheme, so that the universality is poor, and particularly, when the serial connection mode or the parallel connection mode cannot realize energy recovery grid connection, an electronic load or a voltage regulating module is also required to be independently added to realize voltage regulating grid connection.
4) The detection and control of the existing durable products still stay in the scheme design stage, and the self-diagnosis function is not realized on the actual product design, namely the realization of control functions such as further comparison, feedback, pulse width modulation and the like;
5) The starting function of the existing durable product to be durable product is not synchronously coupled to the whole machine control system, and is often divided into two steps to be executed and the voltage and rectifying modules are manually regulated, so that the energy saving is achieved to the greatest extent, and the energy recovery efficiency cannot be accurately regulated.
Therefore, in consideration of the actual demands of DC/DC converter products with different power levels and different durable numbers, the intelligent control design scheme of the present disclosure is adopted and applied in the endurance test of the actual products, in order to further enhance the reliability of the endurance bench control loop and the self-diagnosis and accurate regulation and control of the power circuit, improve the energy recovery efficiency and operability, and widen the endurance test bench adaptation power level range and the consideration of the quantity and cost optimization.
The embodiment provides a endurance test device for a vehicle-mounted DC/DC converter, which can be used for batch endurance technology of vehicle-mounted high-power DC/DC converter products exceeding 1kW and above, and can also be used for product endurance tests of high-voltage conversion and concentration of 300V or above of output of a vehicle-mounted power battery pack. The durable current 100A is used for verifying the reliability in product research and development, checking the reliability index of the product and making the product have bad cycle times.
Comprising the following steps:
the high-voltage power conversion module is used for rectifying and converting high-voltage alternating current into high-voltage direct current and supplying the high-voltage direct current to two ends of the input sides of the N converters to be tested; wherein N is an integer greater than or equal to 2;
an output side line for serially connecting the output sides of the N converters to be tested and outputting the N converters;
an output electrical detection device for detecting the current and/or voltage output by the output-side line, in the illustrated embodiment, comprises:
an output voltage detection device for detecting the voltage output by the output side line;
input electrical detection means for detecting the current and/or voltage supplied to the converter to be tested; in the illustrated embodiment, in particular, input voltage detection means are included for detecting the voltage supplied to the converter under test;
the controller outputs PWM signals corresponding to the duty ratio according to the feedback of the output electric detection device and the input electric detection device, so that the converter to be tested works under rated durable current;
and the driver is used for controlling the output power supply of each converter to be tested according to the PWM signals output by the controller. It can be seen that the present invention employs a separate control for each test product based on the large endurance current.
In one embodiment, the endurance test apparatus for the vehicle-mounted DC/DC converter is characterized in that: the power switching device is connected to a first end of an output side of the converter to be tested, and the driver is further used for respectively controlling the N power switching devices according to PWM signals output by the controller. The power switch device can adopt an IGBT device, and is a device resistant to high voltage and high current.
In one embodiment, the endurance test device of the vehicle-mounted DC/DC converter further includes a capacitor and a load connected between the power switch device and the second end corresponding to the output side of the converter to be tested, and the design ensures accuracy of constant control of output voltage and current. The load and the capacitor are added at the output end of each set, the capacitor is provided with stored energy, large current impact is buffered, the load regulates output voltage and current, and the output current control is more accurate and stable by combining the load with the current. The voltage detection is added between the added load and the capacitor to monitor and adjust the output voltage to ensure the constant value of the input voltage, namely, the output voltage exceeds the rated output voltage, and the charging mode is switched to the discharging mode to realize energy recovery.
Because the vehicle-mounted DC/DC converter needs to be configured with design indexes of different vehicle types, different power grade differences are formed, and meanwhile, the cost advantage of simultaneous durability of a plurality of DC/DC converter products is considered, the scheme designs that the input voltage and the output voltage and the current are adjustable, so that the vehicle-mounted DC/DC converter can adapt to the multiple-aspect requirement of simultaneous durability of different power grades and different numbers of DC/DC products. As such, the present embodiment incorporates a controller, a detection device, a driver, and the like.
In the embodiment illustrated in fig. 1, the output current detecting device, the output voltage detecting device, the input voltage detecting device, the controller, the driver, the overcurrent protection device, etc. may be provided in the low-voltage starting distribution box, and the control system illustrated in fig. 2 includes the output current detecting device, the output voltage detecting device, the input voltage detecting device, the controller, the driver, the overcurrent protection device, etc.
In one implementation, the controller comprises a constant current loop adjustment module, a peak current control module and a periodic current limiting module;
the constant current loop adjustment module performs constant current loop adjustment based on feedback of the output electric detection device and/or the input electric detection device, and in a specific embodiment, performs constant current loop adjustment based on feedback of the output current detection device; the second subtracter is respectively input with an output current set value and an output current detection value, wherein the output current detection value can be a direct measurement value or a conversion value; and the output side of the second subtracter outputs an output current error signal of the output current set value and the output current detection value, and the output current error signal is controlled according to the output current error, so that constant current loop control can be realized. In the embodiment illustrated in fig. 4, the output current error may be output to a minimum circuit.
The peak current control module is used for controlling peak current based on the obtained current information of the input side of the converter to be tested; in one embodiment, the peak current control module may include a third subtractor, where one input end of the third subtractor inputs the input current detection value, the other input end inputs the output value of the minimum value circuit, the minimum value circuit inputs the output voltage error and the output current error respectively, a smaller error of the two is taken as an input of the third subtractor, and the third subtractor determines the peak current according to the input current detection value and the smaller error, and then outputs the peak current to perform corresponding control. Because the output of the constant-current loop can also reflect whether the output current is constant or not, the constant-current loop control and the peak current control are realized together; in other alternative embodiments, the constant current loop adjustment module may also be controlled by a separate output.
The periodic current limiting module limits the current according to the period by period based on the obtained current information of the input side of the converter to be tested. In one embodiment, the control circuit comprises a second comparator, wherein the input side of the second comparator is respectively input with an input current detection value and a cycle-by-cycle current limit value, and the comparison between the input current detection value and the cycle-by-cycle current limit value is performed to output according to the comparison result, so that the control can be realized.
The constant current loop adjustment module, the peak current control module and the periodic current limiting module can respectively perform input and output, in the embodiment illustrated in fig. 4, the constant current loop adjustment module, the peak current control module and the periodic current limiting module are combined together and input to the logic block for judgment output, and the constant current loop adjustment module and the peak current control module generate corresponding PWM signals according to the output of the second comparator and the third subtracter and output the PWM signals to the driver.
The input side current information is obtained according to the output electric detection device and/or the input electric detection device, wherein in one implementation mode, because the number of turns of the source end and the secondary end of the converter is determined, the electric parameters of the two ends can be converted through the ratio of the turns of the source end and the secondary end of the converter, and can also be converted through the relation between voltage and current.
In one embodiment, the endurance test device of the vehicle-mounted DC/DC converter further includes a short-circuit protection module, and short-circuit protection is implemented according to the obtained input side current information of the converter to be tested. In a specific embodiment, the circuit may include a second comparator, where the second comparator inputs a current detection value and a current protection set value, and the second comparator compares the current detection value with the current protection set value, and outputs and controls the driver according to a comparison result, so as to implement short-circuit protection.
Therefore, the nominal commercial power alternating current in the embodiment is converted into 400VDC from 380VAC through rectification and is chopped through a full bridge switch, and the periodic current limiting module is added on the basis of the peak current control module and the constant current loop adjusting module, the module limits the current of the full bridge input side of DC/DC one by one, once overcurrent occurs, the PWM duty ratio is immediately limited, so that the output current is limited, the DC/DC converter keeps working in the nominal durable current mode, the reliability of the system is ensured, the functional requirement of the whole vehicle on DC/DC is met, in addition, the output power of the DC/DC converter is directly fed back to the input end without using an electronic load, the voltage and the current fluctuation of the input end and the AC/DC direct current power supply end can be caused, and the constant voltage, constant current and constant power stable operation can be achieved by controlling the switching frequency through the microprocessor by detecting the current and the change of the current and the voltage of the input end.
According to the embodiment, the short-circuit protection module of the durable control circuit is added on the basis of the peak current control module and the constant current loop-based adjustment module, and the protection response speed is still insufficient to protect durable products from being damaged under the condition of no-load starting. Therefore, a path of high-speed overcurrent protection circuit is additionally added, namely, the current of the full-bridge output side of the durable circuit is detected, the high-speed overcurrent protection is realized through a hardware comparator, and once the short-circuit overcurrent occurs, the control circuit is directly closed and the fault is reported, namely, the following steps are realized:
in one embodiment, the endurance test device of the vehicle-mounted DC/DC converter further includes an overcurrent protection device, and the overcurrent protection device performs overcurrent protection on the driver according to feedback of the output current detection device.
In one embodiment, the endurance test device of the vehicle-mounted DC/DC converter further includes a microprocessor, where the microprocessor is connected to the output current detection device, the output voltage detection device, the input voltage detection device, and the enable end of the controller, respectively.
In one embodiment, the microprocessor also controls the switching frequency of the controller through the controller enabling end, so as to realize the control of constant voltage or constant current or constant power. Therefore, the microprocessor controls the switching frequency to achieve constant voltage, constant current and constant power stable operation.
In one embodiment, the endurance test apparatus of the vehicle DC/DC converter further includes a first diode and a second diode, an input side of the first diode is connected to the high voltage power conversion module, an output side of the first diode is supplied to the converter under test, an output side line is output to an input side of the second diode, and an output side of the second diode is connected between the output side of the first diode and the converter under test. The coupling control function of the high-voltage direct current power supply end and the electric energy recovery end of the DC/DC product can be realized.
In one embodiment, the endurance test device of the vehicle-mounted DC/DC converter includes a high voltage region and a low voltage region, the high voltage region is at least provided with the high voltage power conversion module, and a circuit portion between the high voltage power conversion module and the converter to be tested, the low voltage region is at least provided with the output side line, and electrical isolation is performed between the high voltage region and the low voltage region.
Specific alternative embodiments of the present disclosure may have the following effects:
1) The bridge topology circuit and the constant current control strategy under the high-reliability current protection mode are adopted, meanwhile, various overcurrent or overvoltage working conditions are considered for self-checking, protection, fault alarming and rapid automatic recovery design are carried out, and the method comprises the following steps: overload, overvoltage, undervoltage, short circuit, overtemperature and other working conditions;
2) In the implementation, the ground wire of the endurance test device is strictly and relatively separated, and the high-voltage and low-voltage functional areas are subjected to electric isolation design, so that the mutual inductance and self-inductance anti-interference performance of the endurance bench is effectively ensured;
3) The power supply control circuit software, namely adding coupling control between power supplies, comprises: feedback, filtering, constant voltage or constant current;
4) The fault logic diagnosis function is used for setting current, voltage and a measured piece sensor;
5) An operation mode determination circuit includes: switching constant voltage, constant current or constant power operation modes;
6) The endurance test device is provided with an auxiliary control system, so that serial-parallel coupling starting of the product to be durable is realized;
7) Compared with the design scheme of the traditional open-loop durable system, the energy recovery of the closed loop is realized by the current loop, the grid-connected voltage can be configured and adjusted in real time according to different power grades and the quantity of products to be durable, and the energy recovery efficiency is kept above 90%.
In summary, the present disclosure is directed to the actual requirements of endurance test under the no-load condition of multiple sets of vehicle-mounted DC/DC products, and considers the constant voltage and constant current control requirements of each product to be durable, and designs the high and low voltage isolation topology circuit in an input parallel output series connection mode on hardware, and meanwhile, eliminates the energy consumption heating devices such as electronic loads.
Claims (7)
1. A endurance test device of a vehicle-mounted DC/DC converter is characterized in that: comprising the following steps:
the high-voltage power conversion module is used for rectifying and converting high-voltage alternating current into high-voltage direct current and supplying the high-voltage direct current to two ends of the input sides of the N converters to be tested; wherein N is an integer greater than or equal to 2;
an output side line for serially connecting the output sides of the N converters to be tested and outputting the N converters;
an output electricity detection device for detecting the current and/or voltage output by the output side line;
input electrical detection means for detecting a current and/or a voltage supplied to the converter under test;
the controller is used for outputting PWM signals corresponding to the duty ratio according to the feedback of the output electric detection device and the input electric detection device, so that the converter to be tested works under the rated durable current;
the driver is used for respectively controlling the output power supply of each converter to be tested according to the PWM signals output by the controller;
the controller comprises a constant current loop adjusting module, a peak current control module and a periodic current limiting module;
the constant current loop adjustment module is used for adjusting the constant current loop based on feedback of the output electric detection device and/or the input electric detection device;
the peak current control module is used for carrying out peak current control based on the obtained input side current information of the converter to be tested;
the periodic current limiting module is used for limiting the current according to the period by period based on the obtained current information of the input side of the converter to be tested;
the input side current information is obtained according to the turn ratio of the output electric detection device and the converter to be tested;
and the overcurrent protection device is used for carrying out overcurrent protection on the driver according to the feedback of the output electric detection device.
2. The endurance test apparatus of the in-vehicle DC/DC converter according to claim 1, wherein: the power switching device is connected to a first end of an output side of the converter to be tested, and the driver is further used for respectively controlling the N power switching devices according to PWM signals output by the controller.
3. The endurance test apparatus of the in-vehicle DC/DC converter according to claim 2, wherein: and a capacitor and a load connected between the power switching device and a second end of the output side of the corresponding converter to be tested.
4. The endurance test apparatus of the in-vehicle DC/DC converter according to claim 1, wherein: the controller also comprises a short-circuit protection module which is used for carrying out short-circuit protection on the driver according to the obtained input side current information of the to-be-tested converter.
5. The endurance test apparatus of the in-vehicle DC/DC converter according to claim 1, wherein: the intelligent controller also comprises a microprocessor which is respectively connected with the output electric detection device, the input electric detection device and the enabling end of the controller.
6. The endurance test apparatus for an in-vehicle DC/DC converter as claimed in claim 5, wherein: and the microprocessor is used for controlling the switching frequency of the controller through the controller enabling end so as to realize the control of constant voltage or constant current or constant power.
7. The endurance test apparatus of the in-vehicle DC/DC converter according to claim 1, wherein: the high-voltage power conversion device comprises a high-voltage area and a low-voltage area, wherein the high-voltage area is at least provided with a high-voltage power conversion module and a circuit part between the high-voltage power conversion module and a converter to be tested, the low-voltage area is at least provided with an output side circuit, and the high-voltage area and the low-voltage area are electrically isolated.
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| CN107490742A (en) * | 2017-09-25 | 2017-12-19 | 安徽合力股份有限公司 | A kind of electri forklift DC DC experimental rigs and endurance test method |
| CN110196371B (en) * | 2019-06-28 | 2021-02-23 | 潍柴动力股份有限公司 | Test System for DC-DC Converters |
| CN114002520A (en) * | 2021-06-23 | 2022-02-01 | 浙江万向马瑞利减震器有限公司 | An Automatically Controlled Electronically Controlled Shock Absorber Current Drive Test Device |
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