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KR-20260066146-A - Test system and method for detecting the operational behavior of at least one electrical domain of a vehicle

KR20260066146AKR 20260066146 AKR20260066146 AKR 20260066146AKR-20260066146-A

Abstract

The present invention relates to a test system (10) for performing a test operation and detecting the operational behavior of at least one electrical domain of a vehicle having a vehicle body, wherein the test system (10) comprises, in particular, a voltage source having a DC link (14) connected to a power grid (12), a first emulator module (20a) for emulating a first electrical component of a first electrical domain—the first electrical component is an actuator and/or sensor—and a second emulator module (20b) for emulating a second electrical component assigned to a first electrical domain or a second electrical domain—the second electrical component is an actuator and/or sensor—wherein the emulator modules (20a-g) are each connected to the voltage source and each comprises a converter having model-based control for emulating the electrical components; The conductive body replacement device (24) is configured to accommodate a test device (22) that can be connected to emulator modules, wherein the electrical and/or magnetic conductivity of the body replacement device (24) is modeled based on the electrical and/or magnetic conductivity of the vehicle body.

Inventors

  • 하머러 호르스트
  • 슈미트 마르틴

Assignees

  • 아페엘 리스트 게엠바흐

Dates

Publication Date
20260512
Application Date
20240906
Priority Date
20230908

Claims (18)

  1. A test system (10) that performs a test operation to detect the operation behavior of at least one electrical domain of a vehicle having a vehicle body, In particular, a voltage source having a DC link (14) connected to a power grid (12), A first emulator module (20a) for emulating a first electrical component of a first electrical domain - said first electrical component is an actuator and/or sensor -, It includes a second emulator module (20b) for emulating a second electrical component assigned to the first electrical domain or the second electrical domain—the second electrical component being an actuator and/or a sensor—and, The emulator modules (20a-g) are each connected to the voltage source and include a converter having model-based control for emulating the electrical components, and A test system (10) characterized in that a conductive vehicle body substitution device (24) is configured to accommodate a test device (22) that can be connected to the emulator modules, and the electrical and/or magnetic conductivity of the vehicle body substitution device (24) is modeled based on the electrical and/or magnetic conductivity of the vehicle body.
  2. In Article 1, The above-mentioned body replacement device (24) is electrically connected to ground potential through a partially insulated tire replacement device (25), test system (10).
  3. In Article 1 or Article 2, The test system (10) further includes a domain control device that generates and outputs control signals for the emulator modules (20a-g) to simulate one or more domains of the vehicle, wherein the control signals are generated based on emulation parameters stored in a domain model.
  4. In any one of paragraphs 1 to 3, The test system (10) further comprises one or more additional emulator modules (20a-g) for emulating one or more electrical components assignable to the first electrical domain, the second electrical domain, the third electrical domain and/or additional electrical domains of the vehicle.
  5. In any one of paragraphs 1 to 4, The above first emulator module (20a) comprises a battery emulator module for emulating a vehicle battery and/or a charging port emulator module for emulating a charging port, in a test system (10).
  6. In any one of paragraphs 1 to 5, In the case of the above electrical domain, or a plurality of electrical domains, the electrical domains include a test system (10) comprising a high-voltage system, a low-voltage system, a thermal system and/or signal and bus systems of the vehicle.
  7. In any one of paragraphs 1 to 6, A test system (10) in which at least one of the above electrical components is an electric drive unit, an electric motor, a charging port, a compressor, a heating device and/or a battery pack.
  8. In any one of paragraphs 1 to 7, A test system (10), wherein at least one of the above emulator modules (20a-g) is a bidirectional emulator module.
  9. In any one of paragraphs 1 through 8, A test system (10) having a multiphase AC output, wherein at least one of the above emulator modules (20a-g) is composed of three strands having single-phase AC voltages having a zero-phase angle offset by 120° relative to each other, or five strands having single-phase AC voltages having a zero-phase angle offset by 72° relative to each other.
  10. In any one of paragraphs 1 through 9, At least one of the above emulator modules (20a-g) has a multiphase AC output composed of a plurality of strands having single-phase AC voltages offset from each other by zero phase angles, and individual strands having different zero phase angles are interconnected to form bundles of 3-wire or 5-wire strands having a constant output power, and the formation of said bundles is said to occur before the bundles having a constant output power are interconnected. Test system (10).
  11. In any one of Articles 1 to 10, The above model-based control is configured to provide controlled control signals at the connection point of the device under test (22), test system (10).
  12. In any one of paragraphs 1 to 11, A test system (10) in which a voltage measuring device and/or a potential measuring device is placed on the vehicle body replacement device (24).
  13. In any one of paragraphs 1 to 12, A test system (10) further comprising a test device simulation model for simulating the components of the test device (22) to perform verification of the measurement results of the test system.
  14. In any one of paragraphs 1 to 13, The above-mentioned vehicle body replacement device (24) and tire replacement device are designed as an electrically conductive table top having at least one high-impedance table leg, test system (10).
  15. A method for detecting the operational behavior of at least one electrical domain of a vehicle, a) a step of providing a test system (10) according to any one of claims 1 to 14, (b) a step of placing a test device including the electric cables on the vehicle body replacement device (24) in such a manner that the electric cables are arranged according to the arrangement within the vehicle, c) connecting the above-mentioned test device (22) to the above-mentioned emulator modules, and d) a step of performing a test execution on the device under test (22) using the test system (10) above. A method including
  16. In Article 15, The above test device (22) is a method for simulating the electrical domain(s) of the high-voltage system and/or low-voltage system and/or thermal system and/or signaling system of the vehicle.
  17. In Article 15 or Article 16, The above test device (22) has coils and capacitors, a method.
  18. In Article 16 or Article 17, The test system (10) provided in step (a) of the above method is a test system (10) according to any one of claims 3 to 14, and the method is, e) a step of generating control signals using a domain control unit and a domain model, and f) A method further comprising the step of outputting the control signals to the emulator modules (20a-g) for the emulation of at least one domain.

Description

Test system and method for detecting the operational behavior of at least one electrical domain of a vehicle The present invention relates to a test system and method for performing a test operation to detect the operational behavior of at least one electrical domain of a vehicle. The test system is used for product development of components within the electric powertrain, components of the DC vehicle electrical system electrically connected to the powertrain, and other electrical components and electrical networks of the vehicle. Test systems for testing devices under test are known, and in particular, systems are known in which components such as traction batteries are replaced by battery emulators in relation to inverters that convert driving power and control the phase currents of electric traction motors. These battery emulators simulate the power output of the battery to the inverter under test, specifically based on the virtual State of Charge (SOC) or the battery's internal resistance. However, in reality, there are numerous other factors that affect power flows and electrical systems. In a vehicle, the electric drive is connected to the battery via high-voltage cables. Due to the alternating current components of the mixed current within these cables, this high-voltage power supply through cables carrying high voltage results in the coupling of currents and voltages within the vehicle's conductive elements placed near the cables. In particular, this affects the vehicle body, but often also affects other electrical domains of the vehicle, at least partially. The vehicle's electrical domains are electrically isolated regions, such as 12V or 24V low-voltage systems separated from the vehicle's high-voltage system. Other domains may include heating systems, cooling systems, or sensor systems. The strength of the coupling depends on the electrical and magnetic conductivity of the materials involved, the geometry of the cables and the vehicle body, the intensity and frequency of the mixed or alternating current, and other factors that are often difficult to model. These coupling effects cannot be adequately simulated by known test systems. Further advantages, features, and details of the present invention are described in the following description, wherein exemplary embodiments of the present invention are described in detail with reference to the drawings. FIG. 1 schematically illustrates a test system according to the present invention, according to a specific embodiment of the present invention, connected to a device under test. The test system (10) is used to perform test operations to detect the operational behavior of multiple electrical domains of a vehicle. To this end, in the illustrated exemplary embodiment, the test system has a DC link (14) connected to a power grid (12) as a voltage source. A high-voltage transformer (16) is placed between the power grid (12) and the DC link (14). The test system (10) further includes a vehicle body substitution device (24) and a tyre substitution device (25). The DC link (14) serves to supply power to the components of the test system (10) and to recover power from the components of the test system (10). Ideally, when the test system (10) is operating, only power needs to be supplied, and accordingly, the input and output power during operation are substantially balanced with respect to system-related losses. Therefore, ideally, the connection to the power grid (12) does not need to be regenerative, which reduces the operating costs of the test system (10) compared to other solutions. Power regeneration in the DC link (14) is designed for an electric output of 10 kW to 2 MW common to vehicles, but the design is not limited to this. The DC link (14) supplies power to the emulator modules (20) of the test system (10). To this end, the test system (10) has a first emulator module (20a) for emulating a high-voltage compressor. The first emulator module (20a) is assigned to a high-voltage system, i.e., the high-voltage domain of the vehicle. Corresponding to the function of an actual high-voltage compressor, the first emulator module is configured to emulate power taken by the vehicle, for example, from the vehicle battery, and the power must be transferred sequentially within the test system from the first emulator module (20a) to the DC link (14). The directions and magnitudes of the power flows between the DC link (14) and the emulator modules (20a to 20h) are indicated by arrows (18). The second emulator module (20b) is configured to emulate the second electrical component, specifically the high-voltage heating device. The second emulator module (20b) is likewise assigned to a high-voltage system and is likewise configured to only supply power to the DC link (14) and not take power from it. Other emulator modules are configured to emulate the following units. The third emulator module (20c) is configured to emulate the first electric motor. The fourth emulat