Customized Testing Equipment
Electric drive assembly vibration loading test stand
Test Products
The electric drive assembly, which integrates a number of core drive components such as the drive motor, motor controller, gear box, differential, etc., is the heart on the new energy vehicle.
Difficulties in loading under vibration conditions
The electric drive assembly, which is an important component for generating and transmitting torque, is tested using a dynamometer to simulate the actual load torque. But this loading method, in the vibration loading test can not be used, one is because the dynamometer volume is too large, need a larger table and greater thrust shaker, the shaker cost is too high, not conducive to the reduction of test costs; two is because of the complexity of the structure of the dynamometer, the vibration life and the product under test is comparable to the vibration life and can not be subjected to long periods of time to withstand the changes in high and low temperatures, it is very easy to damage, and can not reach the verification of the requirements of the product life. Due to the above two reasons, very often, the bridge vibration test is forced to give up the requirement of applying torque load, and only drive the bridge to run at no load, which can not simulate the actual working conditions, which causes difficulties in the subsequent prediction of vibration life and affects the quality of development.
Problem Solution Points
By utilizing the high energy density of hydraulic motors, the torque load of the bridge is simulated with a hydraulic motor instead of a dynamometer, which makes up for the shortcomings of dynamometers that can't be mounted on the vibration table and makes the vibration loading of the electric drive assembly possible, and this method also effectively reduces the comprehensive cost of vibration tests.
Working Principle of Test Bench
(1) tank, storage, recycling, cooling transmission hydraulic oil; (2) pump, to provide power to the circulating oil; (3) relief valve, to limit the outlet pressure of the pump; (4) oil distributor, the oil circuit is divided into two, so that the pressure of the two are equal; (5) pressure sensors, the pressure data here to the centralized control system; (6) temperature sensors, the temperature data here to the centralized control system; (7) flowmeter, the flow of the two oil pipes here to the flow of data Transmitted to the central control system; (8) hydraulic hose, to prevent the vibration of the vibration table energy transfer to the hydraulic system; (9) test box (temperature box), the parts under test in which to create the actual working environment of the parts under test; (10) the electric drive assembly, the parts under test; (11) hydraulic motors, to provide loads to the product to simulate the actual loads of the product; (12) vibration table, to create the product's actual vibration conditions; (13) throttle valve, adjusting the outlet pressure of the hydraulic motor to make its torque motor outlet pressure, so that its torque meets the test requirements; (14) pressure sensors, the pressure data here to the electronic control center; (15) circulating pumps, so that the oil in the tank circulating flow, so that it cools; (16) relief valves, to maintain the circulating pump outlet pressure; (17) plate heat exchanger, the heat in the tank to the external water-cooled system.
The rotation of the electric drive assembly is controlled by the upper computer through the CAN bus, and the working mode and the system need to be matched. The above principle matches the electric drive assembly working in torque mode.
Test Capability
Environment Simulation
- Test station: 1
- Ambient temperature: -40 ~ 150 ℃
- Temperature rise and fall rate: 3 K/min (no load, average throughout)
- Cooling water temperature: -40 ~ 95 °C
- Cooling water flow rate: 1 ~ 15 L/min
Sample drive
High voltage power supply:
- Voltage: 0 ~ 1000 VDC
- Current: 0 ~ 30 A
- Power: 15 kW
- Low Voltage Power Supply:
- Voltage: 0 ~ 32 VDC
- Current: 0 ~ 18 A
- Power: 600 W
Torque Loading
- Single Axis Speed: 0 ~ 3000 rpm
- Single-axis torque: 0 ~ 65 Nm
- Cooling condition: water-cooled / air-cooled (optional)
- Maximum line pressure: 250 bar
Core Components
|
⚫Environmental simulation (triple integrated temperature chamber)
|
|
|
⚫ Chiller
|
|
|
⚫ High Voltage Power Supply
|
|
|
⚫ Hydraulic motor
|
|
|
⚫ Data Acquisition
|
|
Software Architecture
Development Tools
Labview, the leader in development software for the test field
Module distribution and data association
Developed based on the endurance test platform, each module shares the same data and control bus, and works together to meet all mainstream endurance test requirements.
The application of state machines and servers makes the architecture clear, facilitates the completion of additional functionality extensions, and improves code reuse
User Interface
User Management
MD5 encrypted user password saving
Real-time data display
Real-time data of all channels, protection upper and lower limit value display interface
Device Alarm Information
Keep a record of device alarms to assist in investigating the cause of the problem
Test Sequence Control
Import/preview test curves for precise control of the test flow
Manual and Monitoring Interface
Record-keeping device alarms to assist in investigating the cause of the problem
