Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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AT4000—NVH test system for electric drive assembly of new energy vehicles

Case Presentation

  AT4000—NVH Test System for Electric Drive Assembly of New Energy Vehicle—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

  ●GB6882-2008 "Acoustics, Determination of Sound Power Level of Noise Sources Semi-anechoic Chamber and Semi-anechoic Chamber Precision Method"

  ●ISO03745 "Acoustics, Determination of Sound Power Level of Noise Sources, Semi-anechoic Chamber and Semi-anechoic Chamber Precision Method"

  ●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—NVH test system for electric drive assembly of new energy vehicles—Topological structure

 

  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 is composed of three parts: sound insulation system, mechanical system, simulation guarantee system, electrical system and upper computer software system.

  ●Sound insulation system: composed of semi-anechoic room, through-wall soundproof cover, soundproof door, soundproof window, etc.

  ●Mechanical system: it is composed of cast iron platform, loading equipment, tool under test, clamping moving mechanism, shaft connection part and other equipment.

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

  ●Electrical system: two-way DC power supply, load control, sensors (torque, speed, current, voltage, vibration, temperature) real-time data acquisition system, data acquisition, current sensor acquisition, electrical parameter measurement equipment, NVH vibration, noise and other measurement equipment , Alarm system and other equipment.

  ●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—NVH Test System for Electric Drive Assembly of New Energy Vehicle—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;

  ●NVH test parameters: acceleration, speed, noise, order, etc.

  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 diagram, stability State NVH test, acceleration and deceleration NVH test, noise source identification sound contribution, three-dimensional sound field analysis, sound quality evaluation, sound power, sound pressure level test, howling, order analysis, frequency domain analysis, octave analysis, etc.

  AT4000—NVH test system for electric drive assembly of new energy vehicles—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

  Adopt advanced measuring equipment, including input electric parameter test, speed torque test, NVH test equipment, soundproof room, etc. Torque, rotational speed, vibration, noise, etc. adopt high sampling to meet the high precision and fast response requirements of the test system, and provide transient data and characteristic value data to facilitate the comprehensive analysis of the test process data in the later stage of the software.

  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

  04 Motor load

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

  05Humanized 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.

  06 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—NVH Test System for Electric Drive Assembly of New Energy Vehicle—Main Application

  ●Passenger car electric drive assembly

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