Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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AT4000—New Energy Vehicle Electric Drive Assembly Performance Test System

Case Presentation

  AT4000—New Energy Vehicle Electric Drive Assembly Performance Test System—Product Background

  Overview:

  New energy vehicle electric drive assemblies are increasingly widely used in passenger vehicles in the automotive industry. The product development and factory inspection of electric drive assemblies must ensure product performance and product quality (motors, controllers, gearboxes). It is particularly important to conduct rigorous testing on the performance matching of the electric drive assembly of the vehicle system. This system performs type verification tests on the assembly test purpose, test procedures and test methods based on the energy efficiency rating and test methods of the drive motor system for electric vehicles and the electric drive assembly, and with reference to other national standards and various assembly test standards.

 

Bench picture

 

  Reference standard:

  ●GB/T 18488.1-2015 "Electric Vehicle Motors and Controllers Part One Technical Conditions"

  ●GB/T 18488.2-2015 "Electric Vehicle Motors and Controllers Part II Test Methods"

  ●Electric vehicle drive motor system and electric drive assembly energy efficiency grade and test method

  ●QC/T1022-2015 Technical conditions of reducer assembly for pure electric passenger car

  ●GB/T 18385-2005 "Electric Vehicle Power Performance Test Method"

  ●GB/T 18386-2005 "Electric Vehicle Energy Consumption Rate and Driving Range Test Method"

  ●GB/T 755-2008 "Rating and performance test methods for rotating electrical machines"

  ●GB/T 29307-2012 "Reliability Test Method of Drive Motor System for Electric Vehicles"

  ●GB/T 22669-2008 "Three-phase permanent magnet synchronous motor test method"

  ●GB/T 1032-2005 "Three-phase asynchronous motor test method"

  ●GB/T 50054-95 "Code for Low Voltage Power Distribution Design"

  ●GB/T 50055-93 "General Electric Equipment Power Distribution Design Code"

  ●Mechanical manufacturing system according to GB9061-85

  ●Electrical system according to GB5226-85

  AT4000—New Energy Vehicle Electric Drive Assembly Performance Test System—Topological Structure

Passenger car series

 

Logistics vehicles, commercial vehicles, heavy truck series

  AT4000—The new energy vehicle electric drive assembly test system adopts modular and integrated design. The operating part is ergonomically designed and can complete manual/automatic mode control. It consists of three parts: mechanical system, simulation guarantee system, electrical system and upper computer software system.

  ●Mechanical system: cast iron platform, loading system, quick clamping system, reversing box, shaft connection part and other equipment.

  ●Simulation guarantee system: Environmental warehouse, temperature control system and other equipment components.

  ●Electrical system: two-way DC power supply, loading controller, sensors (torque, speed, current, voltage, vibration, temperature) real-time data acquisition system, data acquisition, current sensor acquisition, electrical parameter measurement equipment, vibration analysis system, alarm system And other equipment composition.

  ●Software system: The upper computer test software is divided into data acquisition communication module, data acquisition setting module, data real-time exchange control module, and data processing module according to the system. The upper computer completes the functions of test control, data analysis and display, data recording and export according to the test items.

  AT4000—New Energy Vehicle Electric Drive Assembly Performance Test System—System Function

  The basic scope and accuracy of the passenger car bench test:

  ●Recommended power range: 0~300KW power level, support other customization of other power, speed and torque levels;

  ●Recommended output speed measurement range: 0~3300r/min;

  ●Recommended output torque measurement range: 0~3700N.m;

  ●Recommended test voltage level: DC: 0~800~1200V;

  ●Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of range;

  ●Measurement accuracy of basic electric power: ±0.03%;

  ●Speed ​​measurement accuracy: ±1r/min;

  ●Torque measurement accuracy: ±0.05%F.S;

  The basic scope and accuracy of commercial vehicle bench testing:

  ●Recommended power range: 0~400~500KW power level, support other customization of other power, speed and torque levels;

  ●Recommended speed measurement range: 0~2800r/min;

  ●Recommended torque measurement range: 0~20000N.m;

  ●Recommended test voltage level: DC: 0~800~1200V;

  ●Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of range;

  ●Measurement accuracy of basic electric power: ±0.03%;

  ●Speed ​​measurement accuracy: ±1r/min;

  ●Torque measurement accuracy: ±0.05%F.S;

  The basic scope and accuracy of logistics vehicle bench testing:

  ●Recommended power range: 0~200KW power level, support other customization of other power, speed and torque levels;

  ●Recommended speed measurement range: 0~2000r/min;

  ●Recommended torque measurement range: 0~3000N.m;

  ●Recommended test voltage level: DC: 0~800~1200V;

  ●Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of range;

  ●Measurement accuracy of basic electric power: ±0.03%;

  ●Speed ​​measurement accuracy: ±1r/min;

  ●Torque measurement accuracy: ±0.05%F.S;

  The basic scope and accuracy of heavy truck bench testing:

  ●Recommended power range: 0~500~800KW power level, support other customization of other power, speed and torque levels;

  ●Recommended speed measurement range: 0~2000 r/min;

  ●Recommended torque measurement range: 0~20000N.m;

  ●Recommended test voltage level: DC: 0~800~1200V;

  ●Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of range;

  ●Measurement accuracy of basic electric power: ±0.03%;

  ●Speed ​​measurement accuracy: ±1r/min;

  ●Torque measurement accuracy: ±0.05%F.S;

  Test items:

  Assembly load test, assembly no-load test, assembly temperature rise test, efficiency characteristic test (torque-speed characteristic), reliability test (durability test), electric operating conditions, power generation conditions, efficiency MAP diagrams, etc.

  1 AT4000—New Energy Vehicle Electric Drive Assembly Performance Test System—Main Features

  01 Functional modularity

  All the benches are built using functional modularity, and are combined into one test system in the form of a combination of modules. Customers can add or remove test modules according to different test objects.

  02 Advanced measurement methods

  Adopting advanced real-time measurement and control system, including input electrical parameter test, speed and torque test, etc., the torque and speed sampling rate is up to 1000Hz, which meets the high precision and fast response requirements of the test system, and provides transient data and characteristic value data, which is convenient for the software to test Comprehensive analysis of process data.

  03 Complete test items

  According to the test requirements specified in the national standard, test items can be added or removed according to the configuration module, which can meet the test items for various types of tests

  04Environmental simulation equipment

  Using compressor refrigeration and heating mode as the test piece environmental simulation equipment and temperature control system, the high temperature, low temperature, high humidity, low humidity environment of the test piece is simulated, which shortens the aging durability test time of the test piece, thereby increasing The entire R&D efficiency reduces the R&D cycle.

  05 Motor load

  Using asynchronous motor as the load of the tested electric drive assembly, changing the traditional load mode, improving the system's dynamic measurement range and accuracy of torque and speed, improving loading performance (forward/reverse, reverse drag), and shortening the response time of loading , It can realize the loading of any load curve and highly simulate the real-time operating conditions of the electric drive assembly.

  06Humanized design

  It adopts a professional motor test bench, the fixture has a quick docking function, and is convenient for loading and unloading, which can be adapted to the installation of different test pieces. The system operation adopts the piano table/standing cabinet + computer table control mode, which can complete the entire test operation layout in a single position.

  07 Customized testing software

  The motor test system test software developed by the Sichuan Chengbang Software R&D team, according to the national standard requirements test items, classifies the software interface and process, reduces repeated tests, and greatly improves the work efficiency of testers. And it has the functions of real-time curve drawing, transient value capture, trend curve drawing and analysis, multi-parameter combination display, qualified judgment, report export and so on.

  AT4000—New Energy Vehicle Electric Drive Assembly Performance Test System—Main Application

  ●Passenger car electric drive assembly

  ●Commercial vehicle electric drive assembly

  ●Logistics vehicle electric drive assembly

  ●Heavy truck electric drive assembly

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