Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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AT4000—Commercial vehicle hybrid power performance test system

Case Presentation

  AT4000—Commercial vehicle hybrid power performance test system—product background

  Overview:

  Commercial vehicle hybrids have more and more extensive application requirements for hybrid systems in the automotive industry. The product development and factory inspections of gasoline-electric hybrid systems must ensure the matching performance and product quality of the hybrid system. Therefore, the performance of the hybrid system is Rigorous testing. This system carries out type verification test according to the national standard GB-T19752-2005 hybrid electric vehicle dynamic performance test method test purpose, test procedure and test method.

 

Bench picture

 

  Reference standard:

  ●GB-T19750-2005 Hybrid Electric Vehicle Modeling Test Regulations

  ●GB-T19751-2005 Safety Requirements for Hybrid Electric Vehicles

  ●GB-T19752-2005 Hybrid Electric Vehicle Power Performance Test Method

  ●GB-T19754-2004 Heavy-duty hybrid electric vehicle energy consumption test method

  ●GB/T 29307-2012 Reliability test method of drive motor system for electric vehicles

  ●GB/T 18488.1-2015 Electric Vehicle Drive Motor System Part 1: Technical Conditions

  ●GB/T 18488.2-2015 Drive Motor System for Electric Vehicle Part 2: Test Method

  ●GB 755-2008 Rotating motor rating and performance

  ●GB 50150 Electrical equipment installation engineering electrical equipment handover test standard

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

  ●Mechanical manufacturing system according to GB9061-85

  ●Electrical system according to GB5226-85

  AT4000—Commercial vehicle hybrid performance test system—Topological structure

 

  Topological structure diagram

  AT4000—Commercial vehicle hybrid power performance test system adopts modular and integrated design. The operating part is ergonomically designed and can complete manual/automatic mode control. It is composed of mechanical system, drive system, loading system, simulation guarantee system, electrical system and upper computer software system.

  ●Mechanical system: cast iron platform, engine mechanical connection device, generator mechanical connection device, drive motor mechanical connection device, load connection device, coupling device, shaft connection part and other equipment.

  ●Drive system system: engine, ISG motor, drive motor, etc.

  ●Loading system: low-speed and high-torque load dynamometer, high-torque and speed measuring device.

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

  ●Electrical system: drive load controller, real-time data acquisition system, data acquisition, 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. The upper computer completes the functions of test control, data analysis and display, data recording and export according to the test items.

  AT4000—Commercial vehicle hybrid power performance test system—system function

  Basic range and accuracy:

  ●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;

  Test items:

  Hybrid load test, efficiency characteristic test (torque-speed characteristic), reliability test (durability test), electric operating conditions, power generation conditions, efficiency MAP diagrams, hybrid control logic tests, etc.

  AT4000—Commercial vehicle hybrid power 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

  04 Guarantee equipment

  The temperature control system is adopted to make the engine and electric drive system of the test piece work to the optimal state.

  05 Load dynamometer

  The high-torque low-speed dynamometer is used as the system loading, and the high-precision torque and speed sensors are used according to the characteristics of the tested part to increase the data dynamic response rate. The system loading adopts the vector/DTC mode to achieve the required high-speed dynamic loading characteristics. , So as to highly simulate the real-time operating conditions of the gearbox output.

  06Humanized design

  It adopts a professional motor test bench. The fixture adopts a quick centering function, and is convenient for loading and unloading to adapt to the installation of the tested part. The system operation adopts the piano table / cabinet + computer desk control mode, which can complete the entire test operation layout in a single position.

  07Customized 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—Commercial vehicle hybrid power performance test system—main application

  ●Hybrid system

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