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Hybrid test system

Publication Time:

2022-05-12

Author:

Source:

1. Overview

Hunan Xiangyi Power Test Instrument Co., Ltd. The hybrid powertrain test bench designed by Xiangyi Power Test Instrument Co., Ltd. is mainly used for functional testing of hybrid vehicles: The hybrid test bench can provide the same test and debugging environment for engine systems, transmission systems, motor systems, power battery systems, and other components as the whole vehicle. Placing the components in a real test environment for relevant tests allows for research and development tailored to the specific requirements of hybrid vehicles.

It provides a large amount of reliable test data for users to select hybrid system components, match parameters, and develop, verify, and optimize control strategies, reducing users' development time.

2. Functions

In addition to the tests that can be performed on traditional engine performance test benches, the new energy multi-functional power system test bench can also perform the following tests for new energy vehicles:

Engine assembly external characteristics and fuel economy testing;

Optimization and verification of component parameter configuration;

Ability to simulate road conditions, such as typical urban bus cycles in China;

Motor and battery performance testing and combined operating condition testing capabilities;

Equipped with a new energy power system HCU and BMS development and calibration capabilities, capable of completing the development of component control functions and control strategies;

High-speed CAN network communication transmission and reception capabilities;

Can be combined with a battery simulator to develop battery management systems and energy control strategies;

Real-time simulation of the vehicle's translational and rotational inertia, ensuring accurate tracking of the target vehicle speed during acceleration and deceleration.

Hybrid system test and evaluation tests: Steady-state fatigue test, transient fatigue test, dynamic fatigue test (vehicle and driver simulation), playback of speed and torque operating curves obtained when the vehicle is driving on the road, full-load or high-speed test, driving performance evaluation, gear and bearing design life evaluation, transmission clutch and brake life evaluation.

Hybrid system control strategy development tests (acceleration, deceleration, load distribution, fuel consumption calibration, fuel consumption analysis and optimization, etc.), providing test support for the development and optimization of hybrid system vehicle control strategies;

Hybrid vehicle performance tests: Power performance, economy, power smoothness, road load simulation, load changes, full-load acceleration, partial-load acceleration, deceleration, partial-load or high-speed tests, etc.

3 Technical Standards

GB/T 19751-2005 "Safety Requirements for Hybrid Electric Vehicles"

GB/T 19752-2005 "Test Methods for Power Performance of Hybrid Electric Vehicles"

GB/T 19750-2005 "Regulations for Type Testing of Hybrid Electric Vehicles"

GB-T19754-2004 "Test Method for Energy Consumption of Heavy Hybrid Electric Vehicles"

GB/T 50054-2011 "Design Code for Low-Voltage Power Distribution"

GB/T 50055-2011 "Design Code for Power Distribution of General Electrical Equipment"

GB/T 50054-2011 "Design Code for Low-Voltage Power Distribution"

GB/T 50055-2011 "Design Code for Power Distribution of General Electrical Equipment"

GB/T 50063-2008 "Design Code for Electrical Measuring Instrument Devices of Power Equipment"

GB/T 8196-2003 Mechanical Safety - Protective Devices - General Requirements for Design and Manufacture of Fixed and Movable Protective Devices

GB5226.1-2008 Electrical Safety of Machinery - Electrical Equipment of Machinery - Part 1: General Technical Conditions

4 Topology

5 Xiangyi Advantages

Xiangyi Power Test Instrument The company has a long history and strong technical capabilities, and its comprehensive strength ranks among the leading enterprises. Relying on years of technological accumulation, excellent product quality, and a sound after-sales service system, the Xiangyi brand has gained high recognition and a good reputation in the power testing instrument and equipment industry.

6 Configuration List

Main Configuration List:

Serial Number	Equipment Name	Remarks
	Dynamometer Motor	Dynamometer Drive and Load
	Torque Sensor	Used for torque measurement
	Frequency Converter	Four-quadrant frequency converter is used Based on four-quadrant AC asynchronous motor speed and torque control technology, precise control and fast response.
	Lower-level Real-time Control System	Based on INtime Real-time control instrument based on the real-time operating system, which communicates with the frequency converter via EtherCAT bus, installed inside the industrial control computer, and runs in parallel with the win dows system. The system uses a real-time test and control instrument FC4012E to measure torque and speed, and performs closed-loop control to ensure control accuracy.
	Upper-level Control System	Used to control the load system to perform relevant operating condition tasks and provide a human-machine control interface to the user. Includes an industrial control computer, a test control software system, etc. The test data is automatically collected and processed by the computer, and a database is automatically established, reports are automatically printed, and characteristic curves are automatically displayed and drawn. Simple operation and control, easy maintenance.
	Engine Fuel Consumption Meter	Used for engine fuel consumption measurement
	Engine Temperature Control System	Water temperature, fuel, oil, intercooler, etc., temperature control system
	Battery Simulator	The battery simulator is specially developed for motor controllers, drive motors, and vehicle testing in the new energy electric vehicle industry. It is used to replace power batteries and provide efficient, low-cost, and accurate testing solutions.
	Power Analyzer	Mainly used to measure motors and controllers and other power conversion devices' power, efficiency, and other parameters
	Motor and controller water temperature control system	Used to absorb the heat of the device under test or mechanical transmission device to ensure the normal test process of the system and provide the reliability and service life of the system.
	Cast iron plate and shock absorption system	Dynamometer installation base