Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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AT4000-Dynamometer system integrated with simulation vehicle model

Case Presentation

  AT4000—Dynamometer system with integrated simulation vehicle model—Product background

  Overview:

  New energy vehicle electric drive systems are increasingly widely used in passenger cars, commercial vehicles, logistics vehicles, and heavy trucks in the automotive industry. Dynamometers are used as power device loading devices for performance testing of automotive power components and subsystems. . This system is based on the national 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 Two Test Methods" and refer to other national standard requirements In addition to various motor test standards, test verification of automotive power components and subsystems, further expand the test range of traditional dynamometers, conduct richer dynamic road conditions tests, extreme dynamic conditions tests, and expand the range of ECU calibration data , Put forward a scheme to integrate the dynamometer bench and the simulated vehicle model. The establishment of a virtual vehicle environment in the laboratory can not only perform performance tests on the power system, but also predict in advance the matching of the power system and the target model, as well as the working conditions on the actual road.

 

 

  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"

  ●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-Dynamometer system with integrated simulation vehicle model-Topological structure

 

  AT4000—The dynamometer system of integrated simulation vehicle model 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 support system, electrical system, dynamometer operating software, and simulation vehicle model software system.

  ●Mechanical system: cast iron platform, loading equipment, quick clamping system of the tested part, 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 control, sensors (torque, speed, current, voltage, vibration, temperature) real-time data acquisition system, data acquisition, current sensor acquisition, electrical parameter measurement equipment, alarm system and other equipment components.

  ● Dynamometer operating 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.

  ●Simulated vehicle model: engine module, motor module, battery module, transmission module, clutch module, final drive module, vehicle longitudinal dynamics module, driver module, road and environment module, virtual controller module (engine controller ECU, Transmission controller (TCU, motor controller MCU) based on this simulation package, users can build a variety of electric drives, including typical structures such as pure electric, parallel hybrid, series hybrid, and hybrid hybrid.

  AT4000-Dynamometer system with integrated simulation vehicle model-system function

  Basic range and accuracy:

  Based on the new energy motor test system, new energy electric drive assembly test system, oil-electric hybrid test system and other bench parameters.

  Test items:

  Test items based on each type of bench.

  Based on each simulation model, users can build a variety of electric drives, including typical structures such as pure electric, parallel hybrid, series hybrid, and hybrid hybrid.

  AT4000—Dynamometer system with integrated simulation vehicle model—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 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.

  05Environmental 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.

  06Humanized design

  The professional motor test bench is adopted. The fixture has the function of quick docking, and is convenient for loading and unloading and adjustment of coaxiality. It can be adapted to the installation of the tested motor of any shape. The system operation adopts the piano table/closet + computer desk control mode, which can complete the order The location completes the layout of all test operations.

  07 Customized testing software

  The test system test software and simulation model developed by the Sichuan Chengbang Software R&D team: The standard new energy vehicle simulation package is used for the modeling of new energy vehicles. The vehicle model is based on Matlab/Simulink, and the entire vehicle model runs in a real-time system. According to the requirements of the national standard, the software interface and process are classified into the test items to reduce repeated tests and greatly improve the work efficiency of the 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-Dynamometer system integrated with simulation vehicle model-Main application

  ●Passenger car drive motor and control system

  ●Commercial vehicle drive motor and control system

  ●Logistics vehicle drive motor and control system

  ●Heavy truck drive motor and control system

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