Research And Design Of Electric Vehicle Motor Controller Test System

The motor controller is an important part of an electric vehicle,and its performance is related to the quality of the entire vehicle.Because the design and production process of the motor controller is more complicated,and its performance testing is also more complicated,it is very necessary to design an automatic test system that can reduce the cost of manual testing and simplify the test process.At present,most of the motor controller test systems on the market are complicated in structure,difficult to control,and have problems of poor adaptability to controllers of different voltage levels.In order to solve the above problems,this paper takes the detection of the performance of the motor controller as the starting point,and measures the speed,torque,voltage,current,power,efficiency as the data source,and designs a software monitoring platform for the host computer built in Lab VIEW language.The circuit and the C language program construct the control signal processing system of the lower computer,using the CAN bus as the communication method,and the test system with the test bench as the main body.This article mainly carried out the following work:First,referring to a large number of documents,and according to the composition and function of the motor controller,the overall design of the motor controller test system is planned.Through the selection of dynamometer,speed and torque sensor,motor performance analyzer and DC power supply,a test bench was built.In addition,the stress situation of the electric vehicle,the working mode of the test bench and the stability of the system are analyzed,and the stable and unstable conditions of the test system are analyzed in detail.Second,design the software and hardware of the lower computer system.In the hardware design,the ST company’s STM32F103VCT6 is used as the main control chip,and the design principles and circuit diagrams of the MCU circuit,power circuit,CAN communication circuit,control circuit and relay circuit are given.In software design,formulate communication protocols and use C language to develop functional modules.Then,formulate the communication protocol between the host computer and the motor controller,and use NI Lab VIEW development environment to design the host computer software,and design the communication module,user interface module,control and data processing module of the host computer.Finally,the test experiment of the motor controller is completed based on the test platform.By testing the communication,efficiency and drive control functions of the motor controller.The experimental results show that the upper and lower computer of the test system can cooperate well to complete the test of 60 V and 72 V motor controllers,and also extend to the test of more voltage level controllers.The control is within 1%,and a multi-channel relay interface circuit is also reserved,which enhances the scalability of the system.The system has been put into use and achieved good results.