Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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EOL4000 - EDS drive assembly on-line performance test system

The electric drive assembly system of new energy vehicles in the automotive industry must ensure that each vehicle passes the test and leaves the factory. Manufacturers have a growing demand for testing, and the EDS electric drive assembly production will be satisfied until the test leaves the factory. According to the output demand of each electric drive assembly, the time and process of the whole production beat and detection beat, the production line is directly connected with the test. EDS electric drive assembly must ensure the performance and quality of products (motor, controller and gearbox) in factory testing, so it is particularly important to strictly test the performance matching of the electric drive assembly of the whole vehicle system. According to the energy efficiency grade and test method of driving motor system and electric drive assembly for electric vehicles, and referring to other national standards and various assembly testing standards, the system determines and tests EDS assembly's factory qualification.

Case Presentation

EOL4000 - EDS drive Assembly on-line performance test system - Product background

Summary:

The electric drive assembly system of new energy vehicles in the automotive industry must ensure that each vehicle passes the test and leaves the factory. Manufacturers have a growing demand for testing, and the EDS electric drive assembly production will be satisfied until the test leaves the factory. According to the output demand of each electric drive assembly, the time and process of the whole production beat and detection beat, the production line is directly connected with the test. EDS electric drive assembly must ensure the performance and quality of products (motor, controller and gearbox) in factory testing, so it is particularly important to strictly test the performance matching of the electric drive assembly of the whole vehicle system. According to the energy efficiency grade and test method of driving motor system and electric drive assembly for electric vehicles, and referring to other national standards and various assembly testing standards, the system determines and tests EDS assembly's factory qualification.

Bench pictures

Reference standards:

L GB/T 18488.1-2015 Part I Technical Conditions for Electric Motors and Their Controllers for Electric Vehicles

Part II Test Methods for Electric Motors and Their Controllers for Electric Vehicles

L Energy efficiency grades and test methods for drive motor systems and electric drive assemblies for electric vehicles

Technical conditions for reducer Assemblies for pure electric passenger vehicles

L Gb6882-2008 "Determination of Sound Power Levels of Acoustic and Noise Sources - Determination of Semi-anechoic Chamber and Semi-Anechoic Chamber Precision Method"

L ISO03745 "Determination of Sound Power Levels of Acoustic and noise Sources - Determination of Semi-anechoic chamber and Semi-anechoic Chamber Precision Method"

L GB/T 18385-2005 Test Methods for Dynamic Performance of Electric Vehicles

L GB/T 18386-2005 Test Method for Energy Consumption rate and Driving Range of Electric Vehicles

L GB/T 755-2008 Rotary Motor Quota and Performance Test Methods

L GB/T 29307-2012 Reliability Test Method for Drive Motor System for Electric Vehicles

Test Methods for Three-phase Permanent Magnet Synchronous Motor (PMSM)

L GB/T 1032-2005 Three-phase Asynchronous Motor Test Methods

Low Voltage Distribution Design Specification

L GB/T 50055-93 Distribution Design Specification for General Electric Equipment

L Mechanical manufacturing system according to GB9061-85

L Electrical system according to GB5226-85

EOL4000 -- EDS drive Assembly on-line performance test system -- Topological structure

EOL4000 -- EDS electric drive assembly online performance testing system USES modular, integrated design, operation part conforms to ergonomic design, can complete manual/automatic mode control. It consists of three parts: mechanical system, system up-down flow control system, guarantee system, electrical system and upper computer software system.

Mechanical system: the whole mechanical platform, loading equipment, shafting connection part and other equipment composition.

L System up-down flow control system: The EDS assembly under test is composed of pre-installed tooling, EDS Assembly, transport roller way /AGV trolley in front of the roller way, positioning and clamping system, automatic completion of shafting, water, electricity, oil and other alignment systems.

L Guarantee system: temperature control system, filling system and other equipment composition.

L Electrical system: bidirectional DC power supply, load control, real-time data acquisition system of sensors (torque, speed, current, voltage, vibration and temperature), data acquisition, current sensor acquisition, electrical parameter measurement equipment, alarm system, NVH vibration, noise and other measuring equipment number scanning system and other equipment composition.

L Software system: Upper computer test software is divided into data acquisition and communication module, data acquisition and setting module, data real-time exchange and control module, and data processing module according to the system. The whole process control procedure is adopted to complete the product qualification evaluation through data acquisition, control and processing. The data link of the entire production system is complete through the connection between the EOL4000 production line workstation system and the production management system, so that the original data of the production inspection system can be traceable.

EOL4000 - EDS drive assembly on-line performance test system - System functions

Basic range and accuracy:

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

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

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

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

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

● Electric basic power measurement accuracy: ±0.03%;

● Speed measurement accuracy: ±1r/min;

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

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

Experimental items:

No-load test, load characteristic test, electric condition, power generation condition, various custom conditions, steady-state NVH test, accelerating and decelerating NVH test, howling, order analysis, frequency domain analysis, frequency octavo analysis, etc.

EOL4000 - EDS drive assembly on-line performance test system - Main features

01 Functional Modularization

The whole design of the platform is adopted, and the modular component combination is adopted inside, which is convenient for the platform combination and maintenance.

02 Advanced means of measurement

Advanced real-time measurement and control system is adopted, including input electrical parameters test, rotational speed torque test, etc. The sampling rate of torque and rotational speed is up to 1000Hz, which meets the requirements of high precision and rapid response of the test system. Moreover, transient data and eigenvalue data are provided to facilitate the comprehensive analysis of test process data by software in the later stage.

The test items are complete

According to the test requirements stipulated by the national standard, the test items can be added or subtracted according to the configuration module, which can meet all kinds of ex-factory test items

04 Motor load

Using asynchronous motor/permanent magnet motor as subjects load, change the traditional way of load and improve the system of dynamic measurement of torque and rotational speed range and precision, improve load (is/reverse, the drag), shorten the response time of load, which can realize arbitrary load curve of load, high simulation of the motor/drive real-time operation condition.

System up and down flow control system.

The EDS assembly is pre-installed through the lifting device to the pre-installed area, and the tested parts are transported to the test bench through the transport roller /AGV trolley mode, and to the test bench through the front roller table, and then the fixture is fixed through the positioning clamping system. The system automatically completes the alignment of shafting, water, electricity, oil, etc., thus completing the docking process of tested parts. After the test is completed, complete the offline process according to the on-line process inversion procedure.

06 Humanized design

Professional factory motor test bench, the fixture with fast clamping docking functions, and convenient loading and unloading can be adapted to different specimen installation, joint vibration analyzer can complete motor gearbox and harshness (NVH) testing, system controlled by computer cabinet + cantilever mode operation, and can complete all units are complete test operation layout.

Customized test software

The EDS electric drive assembly test software developed by Sichuan Chengbang software research and development team makes software design according to the test process, categorizes the software interface and control process, reduces repeated tests, and greatly improves the work efficiency of test personnel. It also has the functions of real-time curve drawing, transient value capture, trend curve drawing and analysis, multi-parameter combination display, qualification determination, report export and so on.

EOL4000 - EDS drive assembly on-line performance test system - main applications

L Passenger vehicle driving motor and control system

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