CN210038541U - Function test system of motor controller PCBA board - Google Patents

Abstract

The utility model relates to the field of motor controller test systems, in particular to a function test system of a motor controller PCBA board, and a function test system of the motor controller PCBA board, comprising a motor controller PCBA board, a tool, a function test adapter board, Loading module, relay module, program-controlled power supply, signal generator, CAN card, desktop multimeter, switching power supply and test host computer, the function test system of the motor controller PCBA board of the utility model, based on the resolver module simulates the motor to generate resolver signals , through the control of the relay, the functional test of the resolver demodulation module of the motor controller PCBA board is realized; by adding the real-time state readback function of the loading module, the number of state switching times of each channel of the loading module is counted in real time, and the The monitoring of the health status of the relay is conducive to timely finding and solving the problem of test failure caused by the frequent switching of the relay to reach its life, and improves the test efficiency and the stability of the test system.

Description

A functional test system for motor controller PCBA board

technical field

The utility model relates to the field of motor controller test systems, in particular to a function test system of a motor controller PCBA board.

Background technique

In order to ensure that the mass-produced motor controller PCBA board meets the preset functional requirements, it is necessary to perform a function test (Function Test, FCT), that is, load appropriate excitations on the motor controller PCBA board, and check the circuit of the motor controller PCBA board. On and off, measure whether the response of the output terminal meets the requirements.

In the existing test system, there are multimeters with relay modules and perfect measurement and display functions. Several relays are switched and controlled by the data collector to build different test environments. A test system for functional testing of motor controller PCBA boards. However, the existing test system has the following shortcomings: because the relay has a certain mechanical life and electrical life, in many tests, the frequent switching of the relay on the test adapter board makes it reach its life, the relay is abnormal, resulting in the test The system is unstable and the test fails. The test system is simpler and the test function is simpler. Part of the preset functional requirements of the mass-produced motor controller PCBA board cannot be verified, and some defective motor controller PCBA boards with phenomena such as lack of soldering, virtual soldering, and short circuit have not been screened out, which increases the rework and rework rate, and the subsequent The intervention of test equipment and methods not only reduces the test efficiency, but also increases the test cost.

In conclusion, it is necessary to improve the test system.

SUMMARY OF THE INVENTION

In view of the above-mentioned problems, an object of the present invention is to provide a functional testing system of a motor controller PCBA board, which expands the testing function on the basis of the existing functional testing and ensures the mass-produced motor controller PCBA to a large extent. The preset functional requirements of the board have been verified, which improves the accuracy of the test, and can monitor the health status of each relay, which is conducive to timely discovery and resolution of the problem of test failure caused by the frequent switching of the relay to reach its life, and improves the test Efficiency and test system stability.

The purpose of this utility model is to realize through the following technical solutions:

A functional test system for a motor controller PCBA board, comprising a motor controller PCBA board, the functional test system further includes tooling, a functional test adapter board, a loading module, a relay module, a program-controlled power supply, a signal generator, a CAN card, Desktop multimeter, switching power supply and test host computer, among which,

The functional test adapter board includes connectors, resolver modules, and DIP switches;

The connectors include C1, C2, C3, C4, C5, C6, C7, C8 and C9;

The connector C3 includes C30, C31 and C32, wherein, C30 and C31 are the connectors of the motor controller PCBA board, C32 is the connector of the tooling, and C31 is also connected with the IGBT replacement module;

Connector C4 is a DB9-type CAN connector, which is connected to the test host computer, and is connected to the motor controller PCBA board through connector C30;

The resolver module simulates a motor to generate a resolver signal, which is used to detect whether the resolver demodulation module on the motor controller PCBA board is abnormal; the resolver module includes two AD633R multipliers, two multipliers lead The pins Y1 and Y2 receive the excitation signals EXCP and EXCN respectively; the pins X1 and X2 of one multiplier are fixedly connected to 2.5V and 0V, and the pins X1 and X2 of the other multiplier are controlled by the relay to be connected to 2.5V and 0V or 0V and 2.5V, the switching control is realized by a double-pole double-throw relay; after the multiplication operation by the multiplier, the pin W outputs the resolver signals SINP and COSP respectively, which are loaded to the motor controller PCBA board through the connector C30; the signals SINN and COSN is connected to 2.5V, and is also loaded to the motor controller PCBA board through connector C30;

The pins on one side of the button on of the DIP switch are sequentially connected with the digital input channel of the loading module WP8024;

The loading module includes one WP8024 and a plurality of WP8027, and the communication end of the loading module is connected with the test host computer, wherein,

The WP8027 digital output channel is connected to the connector C7 on the functional test adapter board, and is connected to the input drive end of the relay module through the connector C8;

The WP8024 digital input channel and relay output channel are directly connected to the tooling with the connector C32 through the connector C7 on the functional test adapter board;

The relay module includes a plurality of relays, the input driving end of which is connected to the connector C8 on the functional test adapter board, and the output signal end is connected to the connector C9 on the functional test adapter board, and the connector C9 is respectively connected with the connectors C1 and C3. , C5, C6 and the output voltage 3.3/5V module are connected;

The program-controlled power supply is connected to the connector C1 on the function test adapter board, and the output voltage is controlled by the test host computer, and the voltage signal sequentially supplies power to the motor controller PCBA board through the connectors C1, C9 and C30;

The switching power supply is connected to the connector C2 on the functional test adapter board, and directly or indirectly supplies power to the equipment used for functional testing such as relay modules, DCDC modules and IGBT replacement modules;

The desktop multimeter is connected to the connector C5 on the functional test adapter board, and the connector C5 is connected to C9. Under the control of the test host computer, the voltage and current values of each test point connected to the desktop multimeter are measured;

The signal generator is connected to connector C6 on the functional test adapter board;

The CAN card is connected to the connector C4 on the functional test adapter board, and then connected to the motor controller PCBA board through the connector C30 to realize the communication between the test host computer and the microcontroller on the motor controller PCBA board;

Test that the host computer is connected to the program-controlled power supply, desktop multimeter, signal generator, loading module and CAN card;

The tooling includes a number of buttons and indicator lights, which are connected to the digital input channel and relay output channel of the loading module WP8024 through the connector C32, respectively.

The function test adapter board also includes an output voltage 3.3/5V module.

The functional test adapter board also includes a DCDC module.

The functional test adapter board also includes an IGBT replacement module, which is used to replace the real three-phase bridge IGBT module inside the motor controller, and is connected to the motor controller PCBA board through the connector C31 on the functional test adapter board. connect.

The WP8024 digital input channel is also connected with the DIP switch.

The program-controlled power supply adopts GWPSP-405 programmable switching DC power supply, and the output voltage is controlled to be 13V by default.

The CAN card adopts Kvaser Leaf Light V2 CAN analyzer.

The signal generator adopts GWAFG-2000 series signal generator.

The beneficial effects of the present utility model are:

1. Compared with the existing test system, the function test system of the motor controller PCBA board of the present utility model and the test method thereof, by adding the real-time state readback function of the signal input and output channels of the loading module, the real-time statistics of the loading module The number of state switching times of each signal input and output channel is the number of times of use of each relay controlled by the loading module, so as to monitor the health status of each relay. It is beneficial to discover and solve the problem of test failure caused by the frequent switching of relays to reach the service life in time, and improves the test efficiency and the stability of the test system.

2. Compared with the existing test system, the function test method and system of the motor controller PCBA board of the present invention has a large expansion of the test function, including simulating a motor based on a resolver module to generate a resolver signal, and by loading The module controls the relay switching, realizes the functional test of the resolver demodulation module of the motor controller PCBA board, and ensures that the preset functional requirements of the mass-produced motor controller PCBA board are verified to a large extent, improving the test accuracy and avoiding Unnecessary rework tests, while avoiding the intervention of subsequent test equipment and methods, improve test efficiency and reduce test costs.

Description of drawings

Fig. 1 is the functional test system structure schematic diagram of the motor controller PCBA board of the utility model;

Fig. 2 is the pin diagram of connectors C1-C6 in the embodiment of the utility model;

Fig. 3 is the pin diagram of the connector C7 in the embodiment of the utility model;

4A and 4B are pin diagrams of connectors C8 and C9 in an embodiment of the present invention;

FIG. 5 is a schematic circuit diagram of a resolver module in an embodiment of the present invention.

Detailed ways

The specific embodiments of the present utility model will be described in further detail below with reference to the accompanying drawings and embodiments.

A functional test system of a motor controller PCBA board, the functional test is used to check the continuity of the circuit of the motor controller PCBA board, and to measure whether the electrical waveform of each network node of the motor controller conforms to expectations.

As shown in Figure 1, a functional test system of a motor controller PCBA board includes a motor controller PCBA board, tooling, a functional test adapter board, a loading module, a relay module, a program-controlled power supply, a signal generator, a CAN card, and a desktop multimeter. , switching power supply and test host computer, among which,

The functional test adapter board includes connectors, resolver modules, output voltage 3.3/5V modules, DIP switches, DCDC modules and IGBT replacement modules, among which,

The functional test adapter board is used to connect the motor controller PCBA board, desktop multimeter, signal generator and other equipment together to ensure normal communication between the devices.

As shown in Figures 2, 3, 4A and 4B, the connectors include C1, C2, C3, C4, C5, C6, C7, C8 and C9.

The connector C3 includes C30, C31 and C32, wherein, C30 and C31 are the connectors of the motor controller PCBA board, C32 is the connector of the tooling, and C31 is also connected with the IGBT replacement module.

Connector C4 is a DB9 type CAN connector, which is connected to the test host computer, and is connected to the motor controller PCBA board through the connector C30 to ensure the network communication between the test host computer and the motor controller PCBA board.

As shown in FIG. 5 , the resolver module simulates a motor to generate a resolver signal, which is used to detect whether the resolver demodulation module on the PCBA board of the motor controller is abnormal. The resolver module includes two AD633R multipliers, and the pins Y1 and Y2 of the two multipliers receive the excitation signals EXCP and EXCN respectively; the pins X1 and X2 of one multiplier are fixedly connected to 2.5V and 0V, and the other The pins X1 and X2 of the multiplier are connected to 2.5V and 0V or 0V and 2.5V by the relay control, and the switching control is realized by a double-pole double-throw relay; after the multiplication operation of the multiplier, the pin W outputs the resolver signal respectively SINP and COSP are loaded to the motor controller PCBA board through the connector C30; the signals SINN and COSN are connected to 2.5V and are also loaded to the motor controller PCBA board through the connector C30.

The pins on the key on side of the DIP switch are sequentially connected with the digital input channel of the loading module WP8024. When debugging the function test system, the DIP switch provides signal input for the loading module WP8024 to start the test, which is used to replace the tool button signal input during the actual test.

The DCDC module includes two voltage conversion modules, which respectively provide 48V, 15V and 2.5V voltage inputs for the IGBT replacement module and the resolver module.

The IGBT replacement module is used to replace the real three-phase bridge IGBT module inside the motor controller, and is connected to the motor controller PCBA board through the connector C31 on the functional test adapter board, and the switching power supply is connected to the DCDC module to generate a 48V power supply. For three-phase bridge bus voltage simulation.

The output voltage 3.3/5V module is used to realize pull-up and pull-down of signals, and input of a given voltage.

The loading module includes one WP8024 and a plurality of WP8027, and the communication end of the loading module is connected with the test host computer, wherein,

The WP8027 digital output channel is connected to the connector C7 on the function test adapter board, and is connected to the input drive end of the relay module through the connector C8.

The WP8024 digital input channel and relay output channel are directly connected to the tooling with the connector C32 through the connector C7 on the function test adapter board. For the convenience of debugging, the WP8024 digital input channel is also connected with the DIP switch.

The loading module WP8027 makes corresponding switching actions to control the relay according to the command of the test host computer, loads the corresponding switching value, voltage and resistance type signal to the PCBA board of the motor controller, and obtains the environment of the signal measured by the desktop multimeter, so that the desktop multimeter In working state or in non-working state. The loading module WP8024 displays the reserved action and test status of the functional test system on the tooling by receiving the command of the test host computer or the action signal of the tooling button.

The relay module includes a plurality of relays, the input driving end of which is connected to the connector C8 on the functional test adapter board, and the output signal end is connected to the connector C9 on the functional test adapter board, and the connector C9 is respectively connected with the connectors C1 and C3. , C5, C6 and the output voltage 3.3/5V module are connected.

The program-controlled power supply is connected to the connector C1 on the function test adapter board, and the output voltage is controlled by the test host computer. The voltage signal sequentially supplies power to the motor controller PCBA board through the connectors C1, C9 and C30.

The switching power supply is connected to the connector C2 on the functional test adapter board, and directly or indirectly supplies power to the equipment used for functional testing such as relay modules, DCDC modules and IGBT replacement modules. The output voltage of the switching power supply is 12V.

The desktop multimeter is connected to the connector C5 on the functional test adapter board, and the connector C5 is connected to C9. Under the control of the test host computer, the voltage and current values of each test point connected to the desktop multimeter are measured.

The signal generator is connected to the connector C6 on the functional test adapter board, and is controlled by the test host computer to generate a specific waveform to make the motor controller PCBA board enter the test mode.

The CAN card is connected to the connector C4 on the functional test adapter board, and then connected to the motor controller PCBA board through the connector C30 to realize the communication between the test host computer and the microcontroller on the motor controller PCBA board.

The test host computer is connected to the program-controlled power supply, desktop multimeter, signal generator, loading module and CAN card through hardware interfaces such as RS232 and RS485.

The tooling includes a number of buttons and indicator lights, which are connected to the digital input channel and relay output channel of the load module WP8024 through the connector C32, respectively, which are related to the start-up test and display the test status of the functional test system, including the start and end of the test. , the test is in progress.

Preferably, the relay module adopts a plurality of 16-channel relay modules, that is, one relay module includes 16 relays.

Preferably, the program-controlled power supply adopts GWPSP-405 programmable switching DC power supply, and the output voltage is controlled to be 13V by default.

Preferably, the CAN card adopts a Kvaser Leaf Light V2 CAN analyzer.

Preferably, the signal generator adopts GWAFG-2000 series signal generator.

Preferably, the specific waveform frequency of the motor controller PCBA board entering the test mode is 1.7(+/-0.1)kHz, and the duty cycle is 37%(+/-1%);

Preferably, the desktop multimeter adopts an Agilent 33401A digital multimeter.

Preferably, the microcontroller is an Infineon-AURIX-TC277 microcontroller.

Preferably, the test host computer uses the software LabVIEW to make the test interface, which mainly has the following functions:

1. Start the test, run the functional test system test program, control the input and output of the functional test system, and suspend or terminate the test;

2. Monitor the signal input and output channel status of the loading module in real time;

3. Real-time display of the operation information of the functional test system;

4. Based on the readback function of the signal input and output channel status of the loading module, the status switching times of each signal input and output channel of the loading module are counted in real time, thereby realizing the monitoring of the health status of each relay.

A test method for a function test system of a motor controller PCBA board of the utility model comprises the following steps:

1. Connect the device and initialize the device;

2. Test the specific waveform output from the control signal generator of the host computer, and load it to the motor controller PCBA board through connectors C6, C9 and C30. If the motor controller PCBA board checks that the loaded waveform is consistent with the set waveform, the motor control The PCBA board enters the test mode; otherwise, the test fails and the test is terminated.

3. Start the test, press the tooling start test button or start the test through the test host computer.

4. The test host computer sends out the test file instructions in sequence, controls the input and output of the functional test system, builds and tests various functional test environments. At the same time, record the feedback value of the desktop multimeter and the single-chip microcomputer on the PCBA board of the motor controller to the test host computer in the test file, and compare the feedback value with the theoretical value: if the feedback value is consistent with the theoretical value or within the specified range of the theoretical value within, the test result of this item is recorded as passed, otherwise it is recorded as failed.

Preferably, in step 4, the functional test also includes the test of the resolver demodulation module of the motor controller PCBA board, including the following steps:

4.1. Test the host computer through the connectors C4 and C30 to send the read resolver value command to the single-chip microcomputer of the motor controller PCBA board in the form of CAN messages. The single-chip microcomputer outputs the excitation source signals EXCP and EXCN, and inputs the signals to The resolver module of the functional test adapter board, the resolver output signal is loaded to the motor controller PCBA board by the connector C30, and the output resolver value is calculated by the resolver demodulation module of the motor controller PCBA board, and finally connected by the single chip microcomputer. The device C4 feeds back the output resolver value to the test host computer;

4.2. Record the test host computer and compare the resolver value with the theoretical value. If the resolver value is consistent with the theoretical value or within the specified range of the theoretical value, the test result of this item is recorded as passed, otherwise it is recorded as failed.

Preferably, the microcontroller is an Infineon-AURIX-TC277 microcontroller.

5. If the test result of each item in the test file is passed, the motor controller PCBA board is qualified, otherwise, the motor controller PCBA board is unqualified; continue to wait for the test to be started again.

6. During the test, the test host computer monitors the signal input and output channel status of each loading module in real time, and counts the state switching times of the loading module WP8024 digital input, relay output channel and WP8027 digital output channel in real time, which is the loading module control The usage times of each relay is displayed on the test interface in real time.

Compare the use times of each relay with the service life of the relays. When the use times of at least one relay is greater than or equal to the service life, it will prompt that the relay controlled by a certain channel of the load module of a certain address has reached the service life and terminates. test, otherwise continue with the test.

The embodiments of the present invention are described above in detail, but the invention of the present invention is not limited to the above-mentioned embodiments. Any equivalent modifications or substitutions and improvements made on the premise of the spirit and principle of the present invention are included within the scope defined by the claims of the present application.

Claims (8)

1. a functional test system of a motor controller PCBA board, comprising a motor controller PCBA board, is characterized in that: The functional test system also includes tooling, functional test adapter board, loading module, relay module, program-controlled power supply, signal generator, CAN card, desktop multimeter, switching power supply and test host computer, wherein, The functional test adapter board includes connectors, resolver modules, and DIP switches; The connectors include C1, C2, C3, C4, C5, C6, C7, C8 and C9; The connector C3 includes C30, C31 and C32, wherein, C30 and C31 are the connectors of the motor controller PCBA board, C32 is the connector of the tooling, and C31 is also connected with the IGBT replacement module; Connector C4 is a DB9-type CAN connector, which is connected to the test host computer, and is connected to the motor controller PCBA board through connector C30; The resolver module simulates a motor to generate a resolver signal, which is used to detect whether the resolver demodulation module on the PCBA board of the motor controller is abnormal; the resolver module includes two AD633R multipliers, two multiplier leads The pins Y1 and Y2 receive the excitation signals EXCP and EXCN respectively; the pins X1 and X2 of one multiplier are fixedly connected to 2.5V and 0V, and the pins X1 and X2 of the other multiplier are controlled by the relay to be connected to 2.5V and 0V or 0V and 2.5V, the switching control is realized by a double-pole double-throw relay; after the multiplication operation by the multiplier, the pin W outputs the resolver signals SINP and COSP respectively, which are loaded to the motor controller PCBA board through the connector C30; the signals SINN and COSN is connected to 2.5V, and is also loaded to the motor controller PCBA board through connector C30; The pins on one side of the button on of the DIP switch are sequentially connected with the digital input channel of the loading module WP8024; The loading module includes one WP8024 and a plurality of WP8027, and the communication end of the loading module is connected with the test host computer, wherein, The WP8027 digital output channel is connected to the connector C7 on the functional test adapter board, and is connected to the input drive end of the relay module through the connector C8; The WP8024 digital input channel and relay output channel are directly connected to the tooling with the connector C32 through the connector C7 on the functional test adapter board; The relay module includes a plurality of relays, the input driving end of which is connected to the connector C8 on the functional test adapter board, and the output signal end is connected to the connector C9 on the functional test adapter board, and the connector C9 is respectively connected with the connectors C1 and C3. , C5, C6 and the output voltage 3.3/5V module are connected; The program-controlled power supply is connected to the connector C1 on the function test adapter board, and the output voltage is controlled by the test host computer, and the voltage signal sequentially supplies power to the motor controller PCBA board through the connectors C1, C9 and C30; The switching power supply is connected to the connector C2 on the functional test adapter board, and directly or indirectly supplies power to the equipment used for functional testing such as relay modules, DCDC modules and IGBT replacement modules; The desktop multimeter is connected to the connector C5 on the functional test adapter board, and the connector C5 is connected to C9. Under the control of the test host computer, the voltage and current values of each test point connected to the desktop multimeter are measured; The signal generator is connected to connector C6 on the functional test adapter board; The CAN card is connected to the connector C4 on the functional test adapter board, and then connected to the motor controller PCBA board through the connector C30 to realize the communication between the test host computer and the microcontroller on the motor controller PCBA board; Test that the host computer is connected to the program-controlled power supply, desktop multimeter, signal generator, loading module and CAN card; The tooling includes a number of buttons and indicator lights, which are connected to the digital input channel and relay output channel of the loading module WP8024 through the connector C32, respectively. 2 . The functional testing system of the motor controller PCBA board according to claim 1 , wherein the functional testing adapter board further comprises an output voltage 3.3/5V module. 3 . 3 . The functional testing system of the motor controller PCBA board according to claim 1 , wherein the functional testing adapter board further comprises a DCDC module. 4 . 4. the function test system of the motor controller PCBA board as claimed in claim 1, is characterized in that: the function test adapter plate also comprises IGBT substitute module, and described IGBT substitute module is used to substitute the real three inside the motor controller. The phase bridge IGBT module is connected to the motor controller PCBA board through the connector C31 on the functional test adapter board. 5. The functional testing system of the motor controller PCBA board as claimed in claim 1, wherein the WP8024 digital input channel is also connected with the DIP switch. 6. The functional testing system of the motor controller PCBA board according to claim 1, wherein the program-controlled power supply adopts GWPSP-405 programmable switching DC power supply, and the output voltage is controlled to be 13V by default. 7. The functional testing system of the motor controller PCBA board as claimed in claim 1, wherein the CAN card adopts a Kvaser Leaf Light V2CAN analyzer. 8. The functional testing system of the motor controller PCBA board according to claim 1, wherein the signal generator adopts the GWAFG-2000 series signal generator.

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