《新能源汽车驱动电机系统检修》课件-奇瑞瑞虎3xe电机控制系统检测-英文

CheryTiggo3xemotorcontrolsystemtest

ThedrivemotorusedintheCheryTiggo3xepureelectricvehicleisathree-phasepermanentmagnetsynchronousmotor,whichisusedasthedriveofthepureelectriccar,andisinstalledinthefrontcompartment,asshowninFigure1.Thistypeofmotorhasthecharacteristicsofsimplestructure,smallsize,lightweightandhighefficiency.Underthecontrolofthecontroller,themotorcanworkinawiderangeofspeedstomeettheoperatingconditionsofpureelectriccars.Themotorhasabuilt-inresolver,whichisusedtodetectthespeedandpositionoftherotortorealizethevectorcontrolofthemotor,andthemotorcoolingmodeisliquid-cooledstructure.ThestructureoftheelectricdrivesystemisshowninFigure2.Amongthem,theJ69-2103010drivemotorassemblymustmatchtheJ60-2142010motorcontroller.Fig.1.StructureofJ69-2103010drivemotorFig.2Structuraldiagramoftheelectricdrivesystem1.CherydrivemotorandmotorcontrollerThestructureofthemotorcontrollerisshowninFigure3,andthemainfunctionsofthemotorcontrollerareasfollows:(1)Controlthemotortoruninelectricmodeorpowergenerationmode.(2)Torquecontrolofthemotordrivesystem.(3)Ithastheprotectionfunctionsofover-temperature,over-current,over-voltage,etc.(4)IthasCANcommunicationanddiagnosisfunction.Figure3Structureofamotorcontroller2.Motorcontroller

ThepinsofthemotorsignalconnectoraredefinedinTable1,andthepinsoftheMCUlow-voltageconnectoraredefinedinTable2.Table2PindefinitionsofMCUlow-voltageconnectorsTable1Pindefinitionofmotorsignalconnectors3.Definitionofthemotoranditscontrolpins

1.DetectionofmotorphaselossThelackofphaseinthemotorisduetothephenomenonthatoneortwophasesarenotenergizedortheresistancevalueislargeforsomereasoninthemotor.Themaincausesmaybe:aphaseinthemotorisburned,thecableisdisconnectedfromtheinternalwindingofthemotor,orthecablejointisablatedduetountightened.Thedetectionprocessofmotorphaselossisasfollows:(1)AsshowninFigure4,openthesmallcoverplateofthecontroller,11M5bolts,checkwhetherthecablejointhasablationphenomenon(thisfaultismostlycausedbythejointisnottightenedduringinstallation),andthecablejointinthefiguremustbefastenedinplaceaftermaintenance.Figure4Checkthemotorcable4.faultdetection

(2)Checkthelackofphase,usethemultimetertodetecttheresistancebetweenphaseAandphaseB,phaseBandphaseC,andphaseAandphaseCofthemotortojudgewhetherthereisphaseloss,andthedifferencebetweenAB,BC,ACisgreaterthan0.5Ω,whichisjudgedtobethelackofphaseofthemotor,pleasereplacethemotor.Note:Unplugthemaintenanceswitch,openthesmallcoverplateofthemotorcontroller,loosentheboltsoftheU,V,andWthree-phasewires(M8bolts),andbeatthemultimetertothesmallestunitscaletomeasuretheresistancebetweenthephases.Figure4Checkthemotorcable4.faultdetection2.StatictestmethodformotorpositionsensorsignalThemotorpositionsensorisresponsibleformonitoringthepositionofthemotorrotorandprovidingpositionsignalsformotorcontrol.Themotorpositionsensoradoptsaresolverstructure.Thepossiblefailuremodeisaninternalshortcircuitoropencircuit.Table3showsthePINdefinitionofthesignalcableplug-inattheendofthemotor.PA~PFpinistheresolversignal,PGandPHpinarethetemperaturesignal,andtheresistancevalueshouldbemeasuredinagroupofPA~PB,PC~PD,PE~PF,andPG~PH.ThetestparametersareshowninTable4.Table3PINdefinitionofsignallineplug-inattheendofthemotorTable4Testparameters4.faultdetection3.DetectionmethodofMCUlow-voltageplug-insignal(1)Firstofall,unplugthelow-voltageplug-infromthecontroller,checkwhetherthepinsoftheplug-inattheendoftheharnesshavethephenomenonofwithdrawingtheneedle,ifyoufindthatthepinsarewithdrawn,pleaseopentheplug-intorepairorreplacetheplug-in.(2)Useamultimetertodetectthesignalofeachpinoftheplug-in,andthetestreferencevalueisshowninTable5.Note:Whenusingamultimeterfortesting,thewatchneedlecannotbedirectlyinsertedintothelow-pressureplug-inpinsfortesting,soasnottomakethepinsretract,andthewatchneedlesneedtobeextendedandfined,andthentested,whileensuringthatnoliquidflowsintoorsplashesintothelow-pressureplug-in.Table5Signaldetectionmethodsandreferencevaluesforeachpinoftheharnessplug-in4.faultdetection4.Detectionofinsulationfaultsintheelectricdrivesystem1)TestinstructionsDuringthetest,firstremovethevehiclekeyorputitinOFFgear,unplugthehigh-voltagemaintenanceswitch(undertheshiftmechanismofthesub-dashboard),confirmthatthebusvoltageislowerthan5V,andthenunplugthesignalcableplug-inattheendofthemotorcontroller.2)InsulationtestingTheinsulationfailureofthedrivemotorisoftenduetowateringressinsidethemotor,ortheinsulationlayerofthemotorfailswhenheated,orthewindingisablatedsomewhereandshortstotheground;Theinsulationfailureofthemotorcontrollerisoftenduetowateringressinsidethecontroller,orthecreepagedistanceisreduced.4.faultdetection(1)Adjusttheinsulationtesttableandselectthetestvoltageas1000V.(2)Whentheinsulationfaultoccursintheelectricdrivesystem,itoftencausesthecontrollertoreportthemodulefault,orthevehicleinsulationfault.Whencheckingtheinsulationfaultoftheelectricdrivesystem,themotorsystemshouldbeseparatedfromthevehicle(thepowercableplug-infromthehigh-voltagedistributionboxtotheMCUshouldbepulledouttoensurethattheelectricdrivesystemisseparatedfromthevehicle),andthepositiveandnegativeinsulationmetersofthemotorsystemshouldbetestedwithaninsulationmeter,thetestvoltageoftheinsulationmeteris1000V,andthemotortemperatureisclosetonormaltemperatureduringthetest,andtheresistancevalueofthetestresultshouldbegreaterthan20MΩ.Ifitislowerthanthisvalue,itisnecessarytodeterminewhetheritisaproblemwiththemotororthecontroller.4.faultdetection(3)Openthesmallcoverplateofthecontroller,removetheboltsofthethree-phasewire,disconnectthewirefromthemountingbase,andconductaninsulationtestonthemotorcontrollerseparately(Figure5),ifthetestresultislowerthan20MΩ,itisjudgedthatthecontrollerisdamaged,pleasereplacethecontroller.(4)Iftheinsulationresistancevalueofthecontrollerisgreaterthan20MΩ,theinsulationtestofthemotormonomerisrequired,theredpenisconnectedtothethree-phaseterminalofthemotor,andtheblackpenisconnectedtothemotorhousing,ifthetestresultislessthan20MΩ,themotorisreplaced;Otherwise,themotorisconsideredtobeproperlyinsulated.Figure5Testingofamotorcontroller4.faultdetectionOverviewofhub/wheelmotor,themainstructuralfeatureofthehub/wheelmotoristhatthedrivemotorisdirectlyinstalledinthedrivewheel(hub)ornearthedrivewheel(wheeledge),andthedrivemodeofthehub/wheelmotormainlyhastwobasicforms:directdriveanddecelerationdrive,whichdependsonwhetheralow-speedexternalrotororahigh-speedinternalrotormotorisused.ThisisshowninFigure6.Fig.6.Hub/rimmotorExpandyourknowledgeThedirectdrivemodeusesalow-speedexternalrotormotor,theelectricwheelandthewheelformacompletecomponentassembly,themotorisinstalledinsidethewheel,thereisnodecelerationdevice,thedirectdrivewheeldrivesthecartodrive,themotorspeedisgenerally1000-1500r/min,thismotoriscalledthehubmotor.Itsmainadvantagesarethatthemotorissmallinsize,smallinmassandlowincost,highsystemtransmissionefficiencyandcompactstructure,whichisnotonlyconducivetothestructurallayoutandbodydesignofthewholevehicle,butalsoconvenientformodificationdesign.Thiselectricwheeldirectlymountstheoutrunneronthewheelgridtodrivethewheeltoturn.However,electricvehiclesrequirehightorqueatthestart,whichrequiresanelectricmotorinstalledinadrive-friendlyelectricwheelthatcanprovidehightorqueatlowspeeds.Inorderforthecartohavegooddynamics,theelectricmotormustalsohaveawiderangeoftorqueandspeedadjustment.Becausethemotorworkproducesacertainimp