DE102009034555B4 - Test bench and test procedure for dynamic testing of a test object with a hybrid drive - Google Patents

Abstract

Test stand, in particular drive train test stand or vehicle roller test stand, for dynamic testing of a test object (10), which has at least one hybrid drive consisting of an internal combustion engine (11) and an electric machine (12), a transmission (13), an engine control device (15), a transmission control device (16) ) and a hybrid control device (17),
with a measured value acquisition device (22) that can be connected to a data bus (18) of the test item (10),
with a test bench computer (23), and
with a simulation device (24) which interacts with an output (14) of the test object (10) and which, controlled and / or regulated by the test bench computer (23), simulates a driving resistance at the output (14) of the test object (10),
With a vehicle energy simulation device (26) which can be connected to the data bus (18) of the test item (25) and with the aid of which at least a state of charge and a temperature and a voltage of an electrical energy store can be dynamically simulated,
wherein the vehicle energy simulation device (26) interacts as a replacement energy storage device for the test item (25) with the electric machine (12) of the hybrid drive of the test item (25) in such a way that the vehicle energy simulation device (26) operates the electric machine (12) as a motor. of the hybrid drive serves as a voltage source and in generator operation of the electric machine (12) of the hybrid drive serves as a voltage sink,
wherein the vehicle energy simulation device (26) dynamically simulates at least the state of charge and the temperature and the voltage of the electrical energy store using cooling data, namely parameters of a cooling device serving for battery cooling as input variables.

Description

The invention relates to a test stand. The invention also relates to a test method.

Due to the desire for increasingly reduced fuel consumption and increasingly reduced exhaust gas emissions from motor vehicles, hybrid drives are increasingly being used as drive units in motor vehicles, a hybrid drive of a motor vehicle comprising an electric machine in addition to an internal combustion engine. The electrical machine of a hybrid drive is preferably designed as a synchronous machine and can be operated both as a motor and as a generator. In the motorized operation of the electric machine of a hybrid drive, electrical energy held ready in an electrical energy store is converted into kinetic energy, the electrical energy store then being discharged to a greater or lesser extent. In the generator operation of the electric machine of the hybrid drive, however, especially when braking, kinetic energy is converted into electrical energy in order to charge the electrical energy store of the hybrid vehicle to a greater or lesser extent.

In the context of the development of motor vehicles with a hybrid drive and thus a hybrid drive train, it is necessary to subject the individual assemblies of the hybrid drive train to a test. It is already known to check a drive train of a hybrid vehicle, which comprises the hybrid drive and a transmission, on a drive train test bench. Furthermore, vehicle roller test stands are known from practice, on which the entire vehicle is subjected to a test.

1 shows a highly schematic block diagram of a test stand known from the prior art, designed as a drive train test stand, together with a test item to be tested on the test stand 10 . To the test item 10 Associated assemblies are in 1 enclosed by a dotted frame, with the test specimen 10 a hybrid drive from an internal combustion engine as the drive unit 11 and an electric machine 12th includes. In addition, the test item includes 10 a gear 13th , which converts the tractive power of the hybrid drive and at one as a transmission output 14th provides trained downforce. The examinee 10 further comprises an engine control device 15th , a transmission control device 16 and a hybrid controller 17th all of which are connected to a data bus 18th of the test item 10 are connected and via the data bus with the internal combustion engine 11 , the electric machine 12th and the transmission 13th Exchange data in order to control and / or regulate the operation of the same.

According to 1 includes the test item 10 furthermore an electrical energy store 19th and a battery control device 20th , wherein the battery control device 20th integral part of the energy storage system 19th is and also to the data bus 18th of the test item 10 connected. In electrical energy storage 19th electrical energy is stored, with when the electrical machine 12th of the hybrid drive of the test object 10 is operated by a motor, the electrical energy storage 19th is discharged to a greater or lesser extent, whereas when the electrical machine 12th of the hybrid drive of the test object 10 is operated as a generator, the electrical energy storage 19th is charged more or less strongly. Between the electric machine 12th the hybrid drive and the electrical energy storage 19th of the test item 10 is according to 1 a pulse converter 21st switched, which is also connected to the data bus 18th is connected and which of the voltage conversion between the electrical energy storage 19th and the electric machine 12th of the hybrid drive.

The drive train test stand known from the prior art according to 1 to check the in 1 shown test object 10 comprises a measured value acquisition device 22nd , a test bench computer 23 and a simulation device 24 , wherein the measured value acquisition device 22nd to the data bus 18th of the test item 10 can be connected and is used to record measured values relevant to the test.

The measured value acquisition device 22nd provides the measured values to the test bench computer 23 ready with the test bench computer 23 the simulation facility 24 controls and / or regulates so that the same at the transmission output 14th of the transmission 13th of the test item 10 simulates a driving resistance. In the case of a drive train test bench, the simulation device is used 24 an electrical machine that is directly connected to the gearbox output 14th of the transmission 13th attacks. In the case of a vehicle roller dynamometer, the simulation device is used 24 on the other hand, about roles that interact with the wheels of a motor vehicle output.

The in 1 shown test bench, it is imperative that the test object 10 to be tested on the test bench, its own real electrical energy storage device 19th includes, in order to operate the test object having a hybrid drive 10 to be able to check dynamically. Such a test stand, in which according to 1 the test item to be checked 10 a real electrical energy store 19th must have has a number of disadvantages. The test results of such a test stand depend on the type of electrical energy storage device used in the test item 19th from. As a real electrical energy store 19th continue due to chemically complex Processes can change its behavior relatively quickly despite identical initial conditions, the reproducibility of the test results of such a test stand is only guaranteed to a limited extent.

AT 010 495 U2 discloses a dynamometer for testing test items, namely drive trains of a motor vehicle with an internal combustion engine, an electric machine, a transmission and brakes. A control unit range of the dynamometer is used to pre-equip a control unit network consisting of the engine control device, transmission control device, hybrid control device and brake control device. The dynamometer also has a simulation computer which is connected to a data management unit and an automation system via a data network and which exchanges data with the control units of the control unit range via a data bus.

JP 2000 035 380 A discloses a tester for a hybrid vehicle.

Proceeding from this, the present invention is based on the problem of creating a new type of test stand and a new type of test method for dynamic testing of a test object with a hybrid drive.

This problem is solved by a test stand according to patent claim 1 and by a test stand according to patent claim 2.

The test bench comprises the vehicle energy simulation device that can be connected to the data bus of the test item to be tested, with the aid of which at least the state of charge and the temperature and voltage of an electrical energy storage device can be dynamically simulated, the vehicle energy simulation device as a replacement energy storage device for the test item to be tested with the electric machine of the hybrid drive of the to be tested interacts in such a way that the vehicle energy simulation device serves as a voltage source in the motor mode of the electric machine of the hybrid drive and as a voltage sink in the generator mode of the electric machine of the hybrid drive.

The present invention proposes a test stand on which a test item with a hybrid drive without its own real electrical energy storage device can be subjected to a dynamic test. For this purpose, the test bench comprises a vehicle energy simulation device, with the aid of which an electrical energy store of a hybrid drive train or a hybrid vehicle can be dynamically simulated in order to dynamically simulate at least the state of charge, the temperature and the voltage of the electrical energy store. These dynamically simulated data from the electrical energy store can be made available on the data bus of the test object.

Furthermore, the vehicle energy simulation device of the test bench according to the invention serves as a replacement energy storage device for the test object, which interacts with the electric machine of the hybrid drive of the test object to be tested in such a way that the vehicle energy simulation device serves either as a voltage source or as a voltage sink, namely depending on whether the electric machine of the hybrid drive is motor-driven or is operated as a generator.

The test method according to the invention is defined in claim 13.

• 1 ein Blockschaltbild eines aus dem Stand der Technik bekannten, als Antriebsstrangprüfstand ausgebildeten Prüfstands;
• 2 ein Blockschaltbild eines erfindungsgemäßen als Antriebsstrangprüfstand ausgebildeten Prüfstands;
• 3 ein Detail des erfindungsgemäßen Antriebsstrangprüfstands;
• 4 ein Diagramm zur Verdeutlichung der Funktionsweise des erfindungsgemäßen Antriebsstrangprüfstands;
• 5 ein weiteres Diagramm zur Verdeutlichung der Funktionsweise des erfindungsgemäßen Antriebsstrangprüfstands;
• 6 ein weiteres Diagramm zur Verdeutlichung der Funktionsweise des erfindungsgemäßen Antriebsstrangprüfstands; und
• 7 ein weiteres Diagramm zur Verdeutlichung der Funktionsweise des erfindungsgemäßen Antriebsstrangprüfstands.

Preferred developments of the invention emerge from the subclaims and the following description. Embodiments of the invention are explained in more detail with reference to the drawing, without being restricted thereto. It shows:

• 1 a block diagram of a known from the prior art, designed as a drive train test bench;
• 2 a block diagram of a test bench designed as a drive train test bench according to the invention;
• 3 a detail of the drive train test bench according to the invention;
• 4th a diagram to illustrate the functionality of the drive train test bench according to the invention;
• 5 a further diagram to illustrate the functionality of the drive train test bench according to the invention;
• 6 a further diagram to illustrate the functionality of the drive train test bench according to the invention; and
• 7th a further diagram to illustrate the mode of operation of the drive train test bench according to the invention.

The invention relates to a test stand, in particular a drive train test stand or a vehicle roller test stand for dynamic testing of a test object, namely a drive train or a vehicle with a drive unit designed as a hybrid drive.

2 shows a block diagram of a test stand according to the invention, designed as a drive train test stand, on which the test piece is used 25 a hybrid powertrain is to be checked. To Avoid unnecessary repetitions for assemblies of the test items 10 or. 25 as well as for assemblies of the respective test bench in 1 and 2 The same reference numbers are used for the same assemblies, so that the above statements apply to these assemblies of the test stand according to the invention 1 can be referenced.

The test bench of 2 comprises a vehicle energy simulation device 26th connected to the data bus 18th of the test item 25 is connectable. Using the vehicle energy simulation facility 26th At least a state of charge and a temperature and an electrical voltage of an electrical energy store can be dynamically simulated and on the data bus 18th of the test item 25 can be provided, so that the dynamic test of the test item 25 can take place with the hybrid drive without the same having to have a real electrical energy store. The vehicle energy simulation device 26th serves as a substitute energy store for the test item to be tested 25 and works with the electric machine 12th the hybrid drive of the same together in such a way that the vehicle energy simulation device 26th in the motor operation of the electrical machine 12th of the hybrid drive of the test item to be tested 25 as a voltage source and in generator operation of the electrical machine 12th of the hybrid drive of the test item to be tested 25 serves as a voltage sink.

Between the vehicle energy simulation device 26th the test stand according to the invention and the electrical machine 12th of the hybrid drive of the test object 25 is the so-called pulse converter 21st of the test item 25 switched, which of the voltage conversion between the vehicle energy simulation device 26th and the electric machine 12th of the hybrid drive.

The present invention accordingly proposes a test stand for dynamic testing of a test item with a hybrid drive, in which an electrical energy storage device can be dynamically simulated so that the test item itself does not have to have its own real electrical energy storage device for dynamic testing of the same. This makes it possible to provide reproducible test results, since the dynamic simulation of an electrical energy store is independent of disruptive chemical reactions that take place within a real electrical energy store. In this way, interference from real electrical energy storage devices on the test bench is avoided, which guarantees good reproducibility of test results.

The vehicle energy simulation device 26th comprises a battery control device 27 that dynamically simulates at least the state of charge and the temperature and voltage of the electrical energy storage device. The energy control device 27 the vehicle energy simulation device 26th simulated using input variables, namely using battery data 28 , Environmental data 29 , Stream data 30th and cooling data 31 (please refer 3 ) dynamically the electrical energy storage of the test object with hybrid drive and provides at least the state of charge as output variables 32 , the temperature 33 and the tension 34 of the electrical energy storage.

As already stated several times, the vehicle energy simulation device 26th or the battery control device 27 the same a dynamic simulation of the electrical energy storage for a hybrid drive ready.

With the battery data 28 that are used for the dynamic simulation of an electrical energy store for a hybrid drive train, it is the mass of the electrical energy store and / or a number of cells of the electrical energy store and / or a capacity of the electrical energy store or the cells of the same and / or a Start temperature of the electrical energy store and / or a static and dynamic internal resistance of the same and / or a heat capacity of the same. All of these battery data are preferably used for dynamic simulation.

With the environment data 29 , which are used for dynamic simulation of the electrical energy store in the vehicle energy simulation device 26th or the battery control device 27 the same are used, it is an outside temperature for the electrical energy store.

A charging current and / or a discharging current of the electrical energy store is used as current data in the dynamic simulation, the charging current and the discharging current preferably being measured variables of the pulse converter 21st acts.

The cooling data that are used for the dynamic simulation of the electrical energy store are parameters of a cooling device used to cool the electrical energy store. When a fan is used as the cooling device, the cooling data used are, for example, the volume flow of the fan, the heat capacity of the air, the outside temperature of the air and a heat transfer factor from the electrical energy store to the air.

The vehicle energy simulation device simulates with preferably all of the above input variables 26th dynamically the behavior of an electrical Energy storage for a hybrid drive, namely at least the state of charge and the temperature and the electrical voltage of the same, and provides these simulated data on the data bus 18th of the test item 25 ready.

How the dynamic simulation of the electrical energy store takes place in detail is explained below with reference to FIG 3 as well as the diagrams of the 4th to 7th described.

First, the dynamic simulation of the electrical energy store of a hybrid drive according to the block 35 of the 3 a charge current or discharge current I. of the electrical energy storage to be simulated by measurement on the pulse converter 21st captured, being in a block 36 based on the charge current or discharge current I. an efficiency η of the electrical energy storage is calculated dynamically. The dynamic calculation of the efficiency η of the electrical energy store based on the charging current or the discharging current I. is in the diagram of 4th graphically represented.

In the diagram of the 4th is above the charge or discharge current I. the efficiency η of the electrical energy storage device applied. According to 4th increases with increasing electrical current I. , which can be the charging current or the discharging current, the dynamic efficiency η of the electrical energy storage to be simulated.

The vehicle energy simulation device then simulates or influences 26th in a block 37 based on the efficiency calculated dynamically in advance η the state of charge SOC (State of Charge) of the electrical energy storage device. This can be seen in detail from the diagram of 5 , where in the diagram the 5 over the time t, for which the charging current or discharge current I. works, the dynamic state of charge SOC (State Of Charge) is plotted. The dynamically simulated or influenced state of charge SOC of the electrical energy store is proportional to the time integral of the applied charging current or discharging current I. multiplied by the dynamically simulated efficiency η of electrical energy storage. The following applies: $$\mathrm{S.}O\mathrm{C.}\cong {\displaystyle \int \mathrm{I.}*\eta *dt}$$

The vehicle energy simulation device then simulates or influences 26th or the battery control device 27 same the dynamic electrical voltage based on the dynamically simulated state of charge SOC U of the electrical energy storage, whereby in the diagram the 6 the electrical voltage above the state of charge SOC U is applied. The two in 6 The brackets shown illustrate the minimum permissible state of charge SOC _MIN and the maximum permissible state of charge SOC _{MAX of} the electrical energy store to be simulated.

Based on the in block 38 dynamically simulated or influenced electrical voltage U of the electrical energy store as well as on the basis of the charging current or discharging current I. , namely the time t in which the charging current or discharging current I. flows takes place in a block 39 a dynamic simulation or influencing of the electrical internal resistance R of the energy store to be dynamically simulated, with the diagram in the 7th over the charging time t of the charging current I. or the discharge time t of the discharge current I. the dynamic internal resistance R is plotted, namely on the one hand an internal resistance valid for the charging process R _L and an internal resistance that is valid for the discharge process R _E .

The dynamically simulated or influenced electrical internal resistance R of the electrical energy store influences according to 3 in block 36 the dynamic simulation of the efficiency η of electrical energy storage.

In the block 40 of the 3 follows through the vehicle energy simulation device 26th based on the dynamically simulated, electrical internal resistance R as well as based on the charging current or discharge current I. as well as a dynamic simulation of the temperature T of the electrical energy store based on cooling data, the dynamic change over time in the temperature of the electrical energy store being proportional to the difference between a heat supply Pzu and a heat removal P _AB or from the electrical energy store. The following applies to the temperature T of the electrical energy store: $$\frac{dT}{dt}\cong P_{ZU}-P_{A\mathrm{B.}}$$

The heat supply Pzu results from the simulated, electrical internal resistance R and the charging current or discharge current I. . The heat dissipation P _AB results from the cooling data and environmental data for the electrical energy store.

With the above procedure, a complete dynamic simulation of an electrical energy store for a hybrid drive can take place in order to simulate at least the state of charge, the temperature and the voltage of the electrical energy store dynamically on the test bench and on the data bus 18th of a test item 25 provide so that the test item 25 itself does not have to have a real battery or a real electrical energy store.

List of reference symbols

10

Test item

11

Internal combustion engine

12th

electric machine

13th

transmission

14th

Output (gear output

15th

Engine control device

16

Transmission control device

17th

Hybrid control device

18th

Data bus

19th

real electrical energy storage

20th

real battery control device

21st

Pulse converter

22nd

Data acquisition device

23

Test bench computer

24

Simulation facility

25

Test item

26th

Vehicle energy simulation device

27

simulated battery control device

28

Battery data

29

Environmental data

30th

Stream data

31

Cooling data

32

State of charge / SOC

33

temperature

34

tension

35

block

36

block

37

block

38

block

39

block

40

block

Claims (13)

Test stand, in particular drive train test stand or vehicle roller test stand, for dynamic testing of a test object (10), which has at least one hybrid drive consisting of an internal combustion engine (11) and an electric machine (12), a transmission (13), an engine control device (15), a transmission control device (16) ) and a hybrid control device (17) with a measured value acquisition device (22) that can be connected to a data bus (18) of the test item (10), with a test bench computer (23), and with one with an output drive (14) of the test item to be tested (10) cooperating simulation device (24) which, controlled and / or regulated by the test bench computer (23) at the output (14) of the test object (10), simulates a driving resistance, with one connected to the data bus (18) of the test object (25) connectable vehicle energy simulation device (26), with the aid of which at least a state of charge and a temperature and a voltage of an electrical energy giespeichers can be dynamically simulated, the vehicle energy simulation device (26) as a replacement energy store for the test object (25) with the electric machine (12) of the hybrid drive of the test object (25) in this way cooperates that the vehicle energy simulation device (26) serves as a voltage source in the motor mode of the electric machine (12) of the hybrid drive and as a voltage sink in the generator mode of the electric machine (12) of the hybrid drive, the vehicle energy simulation device (26) using cooling data, namely from Characteristic variables of a cooling device used for battery cooling are simulated dynamically as input variables at least the state of charge and the temperature and the voltage of the electrical energy store. Test stand, in particular drive train test stand or vehicle roller test stand, for dynamic testing of a test object (10), which has at least one hybrid drive consisting of an internal combustion engine (11) and an electric machine (12), a transmission (13), an engine control device (15), a transmission control device (16) ) and a hybrid control device (17), with a measured value acquisition device (22) that can be connected to a data bus (18) of the test item (10), with a test bench computer (23), and with a simulation device (24) which interacts with an output (14) of the test object (10) and which, controlled and / or regulated by the test bench computer (23), simulates a driving resistance at the output (14) of the test object (10), With a vehicle energy simulation device (26) which can be connected to the data bus (18) of the test item (25) and with the aid of which at least a state of charge and a temperature and a voltage of an electrical energy store can be dynamically simulated, wherein the vehicle energy simulation device (26) interacts as a replacement energy storage device for the test item (25) with the electric machine (12) of the hybrid drive of the test item (25) in such a way that the vehicle energy simulation device (26) operates the electric machine (12) as a motor. of the hybrid drive serves as a voltage source and in generator operation of the electric machine (12) of the hybrid drive serves as a voltage sink, wherein the vehicle energy simulation device (26) dynamically simulates at least the state of charge and the temperature and the voltage of the electrical energy store using input variables such as battery data and / or environmental data and / or current data and / or cooling data, wherein the vehicle energy simulation device (26) dynamically calculates an efficiency of the electrical energy store based on a charging current or discharge current, the same dynamically influencing the state of charge of the electrical energy store based on the dynamically calculated efficiency. Test bench after Claim 1 or 2 , characterized in that the vehicle energy simulation device (26) comprises a battery control device (27) which dynamically simulates at least the state of charge and the temperature and the voltage of the electrical energy store. Test bench after Claim 1 , characterized in that the vehicle energy simulation device (26) furthermore dynamically simulates at least the state of charge and the temperature and the voltage of the electrical energy store using input variables such as battery data and / or environmental data and / or current data. Test bench after Claim 2 or 4th , characterized in that the vehicle energy simulation device (26) as battery data is a mass of an electrical energy store and / or a starting temperature of the same and / or a heat capacity of the same and / or a number of cells of the same and / or a static and dynamic internal resistance of the same and / or a capacity of the same used. Test bench after Claim 2 or 4th or 5 , characterized in that the vehicle energy simulation device (26) uses an outside temperature as environmental data. Test bench after Claim 2 , characterized in that the vehicle energy simulation device (26) uses parameters of a cooling device used to cool the battery as cooling data. Test bench after Claim 2 or 4th or 5 or 6 or 7th , characterized in that the vehicle energy simulation device (26) uses a charging current or a discharging current as current data. Test bench after Claim 1 , characterized in that the vehicle energy simulation device (26) dynamically calculates an efficiency of the electrical energy store based on a charging current or discharge current, the same dynamically influencing the state of charge of the electrical energy store based on the dynamically calculated efficiency. Test bench after Claim 2 or 9 , characterized in that the vehicle energy simulation device (26) dynamically influences the electrical voltage of the electrical energy store on the basis of the dynamically simulated state of charge. Test bench after Claim 10 , characterized in that the vehicle energy simulation device (26) dynamically influences an electrical internal resistance of the electrical energy store on the basis of the dynamically influenced electrical voltage, the dynamically influenced electrical internal resistance influencing the dynamically calculated efficiency of the electrical energy store. Test bench after Claim 11 characterized in that the vehicle energy simulation device (26) dynamically influences the temperature of the electrical energy store on the basis of the dynamically simulated electrical internal resistance, the dynamic simulation of the temperature of the electrical energy store taking into account the charging current or the discharging current. Test method for dynamic testing of a test object on a test bench according to one of the Claims 1 to 12th The vehicle energy simulation device (26) that can be connected to the data bus of the device under test (25) is used to dynamically simulate at least the state of charge and the temperature and voltage of an electrical energy storage device, the vehicle energy simulation device (26) as a substitute energy storage device for the device under test (25 ) is operated as a voltage source in the motor mode of the electric machine (12) of the hybrid drive and as a voltage sink in the generator mode of the electric machine (12) of the hybrid drive.

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