Method for performing a test run with a test stand
11243143 · 2022-02-08
Assignee
Inventors
Cpc classification
F02D2200/1002
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D35/023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
G01M15/05
PHYSICS
International classification
G01M15/05
PHYSICS
F02D35/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Aspects of the present disclosure are directed to controlling an inner effective torque or an effective torque of a drive unit via a unit controlling unit. In some embodiments, the control method may include providing desired values for the inner effective torque or the effective torque and determining actual values for the inner effective torque or the effective torque during operation of the drive unit on a test stand, and in that actuating dynamics of the drive unit are taken into account in the control by means of a transfer function by correcting the desired values of the control with the transfer function or in that for controlling the inner effective torque or the effective torque of the drive unit, a feed forward control of a manipulated variable of the drive unit is used.
Claims
1. A method for operating a test stand for performing a test run including the following steps: providing a drive unit connected via a connecting shaft to a load machine; driving or loading the drive unit with the load machine; controlling the load machine by a control device on the test stand for carrying out the test run; and controlling the drive unit by a unit controlling unit for carrying out the test run; reproducing given time courses of a rotational speed and a torque of the drive unit; controlling an inner effective torque or an effective torque of the drive unit by the unit controlling unit by providing desired values for the inner effective torque or the effective torque; and determining actual values for the inner effective torque or the effective torque during operation of the drive unit on the test stand; accounting for actuating dynamics of the drive unit by correcting the desired values of the control with a transfer function or by using a feed forward control of a manipulated variable of the drive unit for controlling the inner effective torque or the effective torque of the drive unit and correcting precontrol values of the manipulated variable or the desired values of the control with the transfer function.
2. The method according to claim 1, wherein the manipulated variable is an accelerator pedal position.
3. The method according to claim 1, wherein the precontrol values of the manipulated variable are determined from the actual rotational speed or the predetermined rotational speed, and the inner effective desired torque, the effective desired torque, an inner effective desired torque corrected with the transfer function or an effective desired torque corrected with the transfer function.
4. The method according to claim 1, wherein the step of determining actual values for the inner effective torque includes determining an inner effective actual torque from an actual rotational speed measured on the load machine, or the drive unit, or the connecting shaft and from an effective actual torque measured on the load machine, or the drive unit, or the connecting shaft, and the known mass inertia of the drive unit or wherein the step of determining actual values for the effective torque includes determining an effective actual torque is determined by measurement on the connecting shaft.
5. The method according to claim 4, wherein the step of determining the inner effective actual torque is determined by deriving the measured actual rotational speed with respect to time and multiplying by the known mass inertia of the drive unit and adding the product to the measured effective actual torque.
6. The method according to claim 1, wherein the drive unit is an internal combustion engine and wherein the step of determining actual values for the inner effective torque includes determining an inner effective actual torque by means of cylinder pressure indication on the internal combustion engine.
7. The method according to claim 6, wherein the step of determining the inner effective actual torque includes determining the difference between an indicated actual torque and a friction torque, wherein the indicated actual torque is determined by means of the cylinder pressure indication.
8. The method according to claim 1, wherein the step of the providing desired values for the inner effective torque includes determining an inner effective desired torque from the given course of the rotational speed of the drive unit, the given course of the torque of the drive unit and from the known mass inertia of the drive unit.
9. The method according to claim 8 characterized in that the inner effective desired torque is further determined, by deriving the course of the predetermined rotational speed with respect to time and multiplying with the known mass inertia of the drive unit, and adding the product to the given course of the torque of the drive unit.
10. The method according to claim 1, characterized in that the desired values of the control or the precontrol values of the manipulated variable are shifted by a dead time on a time axis using the transfer function.
11. The method according to claim 10, characterized in that the dead time is determined depending on the operating point of the drive unit.
12. The method according to claim 11, characterized in that the dead time for the operating point of the drive unit is determined depending on a gradient of the course of the inner effective desired torque or the effective desired torque in the operating point.
13. The method according to claim 10, characterized in that the dead time is set to be the same for all operating points of the drive unit.
14. The method according to claim 13, characterized in that the dead time is determined by measuring the drive unit or a reference drive unit on the test stand.
15. The method according to claim 14, characterized in that the dead time is further measured by suddenly changing the manipulated variable of the drive unit and measuring the time be-tween the sudden change in the manipulated variable and a change in the inner effective actual torque caused thereby.
16. A test stand for performing a test run, the test stand comprising: a drive unit connected to a load machine via a connecting shaft, the load machine configured and arranged for driving or loading the drive unit; a control device configured and arranged to control the load machine on the test stand for carrying out the test run; and a unit controlling unit configured and arranged to control the drive unit for carrying out the test run; wherein the test stand is configured and arranged to carry out the test run in the form of given time courses of a rotational speed and a torque of the drive unit, characterized in that the unit controlling unit is further configured and arranged to control an inner effective torque or an effective torque of the drive unit; wherein the unit controlling unit is configured and arranged to receive desired values for the inner effective torque or the effective torque, and determine actual values for the inner effective torque or the effective torque during operation of the drive unit on the test stand, and correct the desired values of the control with a transfer function for taking into account actuating dynamics of the drive unit or wherein a feed forward control of a manipulated variable of the drive unit is used for the control of the inner effective torque or the effective torque NEFF) of the drive unit, wherein the unit controlling unit is configured and arranged to correct precontrol values of the manipulated variable of the feed forward control or the desired values of the control using the transfer function.
17. The test stand according to claim 16, wherein the test stand further includes an observer in the form of hardware or software configured and arranged to determine the actual values of the inner effective torque.
18. The test stand according to claim 17 characterized in that the observer is further configured and arranged to determine the inner effective actual torque from an actual rotational speed measured on the load machine, or the drive unit, or the connecting shaft and an effective actual torque measured on the load machine, or the drive unit, or the connecting shaft, and the known mass inertia of the drive unit.
19. The test stand according to claim 16, wherein an internal combustion engine is the drive unit, and the test stand further includes a cylinder pressure indication system configured and arranged for cylinder pressure indication of the internal combustion engine, wherein the inner effective actual torque is determined from the cylinder pressure indication.
20. The test stand according to claim 19, characterized in that the inner effective actual torque is determined from the difference between an indicated actual torque and a friction torque, wherein the indicated actual torque is determined by the cylinder pressure indication.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention is described in greater detail in the following with reference to
(2)
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(4)
(5)
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(9)
DETAILED DESCRIPTION
(10)
(11) A load machine 4 is not only to be understood as the usual electrical machines, such as, for example, direct current machines, asynchronous machines or three-phase synchronous machines, which are connected directly to the connecting shaft 3, but also, for example, combinations of electrical machines and gears, for example in the form of so-called test rig transmission systems (TRT). In this case, for example, two or more electrical machines can be connected by means of a summation gearbox, which in turn is connected to the connecting shaft 3 for driving or for loading with the drive unit 2. The powers of the two (or a plurality of) electrical machines are added together in the summation gearbox, wherein a translation to a specific rotational speed level is also possible, if necessary. Of course, this is only an example; all other suitable machines or combinations of machines and transmissions can also be used as the load machine 4. To determine the inner effective actual torque M.sub.INT_EFF_IST of the drive unit 2, an observer 10 can be provided, for example, which is again designed as suitable hardware and/or software. All known algorithms can be used as the observer 10, which determine a torque, in which acceleration influences of the mass inertia I.sub.A of the drive unit 2 have been corrected and which, according to the invention, is used as the inner effective actual torque M.sub.INT_EFF_IST. The function of such an observer 10 is known in principle, but its basic functioning is to be explained briefly below with reference to
(12) If the drive unit 2 is designed as an internal combustion engine, a cylinder pressure indication system can be used alternatively to an observer 10 to determine the inner effective actual torque M.sub.INT_EFF_IST. The cylinder pressure in the combustion chamber of the internal combustion engine can thus be measured with an exact crank angle and, based on the measured cylinder pressure, an indicated actual torque M.sub.INT_IST can be determined by means of thermodynamic laws. If this indicated actual torque M.sub.INT_IST is corrected by the known inner friction of the internal combustion engine (which is present, for example, in the form of a characteristic map of the operating range of the internal combustion engine), the desired inner effective actual torque M.sub.INT_EFF_IST is obtained. The influences of friction can be determined, for example, in the form of a friction torque M.sub.R by drag measurements of the internal combustion engine on the test stand 1 or by means of other suitable methods. Since the method of cylinder pressure indication is well known, it will not be discussed in more detail here. A detailed description can be found, for example, in EP 3 067 681 A1.
(13) In general, the method according to the invention is not limited to specific drive units 2, but can be used for a wide variety of drive units 2, such as internal combustion engines, electric motors, a combination of electric and internal combustion engines (so-called hybrid drives), provided the required variables are available. The method can also be used, for example, in drive trains in which the mentioned drive units 2 can be connected to the connecting shaft 3 via a transmission, clutch, differential, semi-axles, etc.
(14)
(15) In this context, “online” means the determination of the inner effective actual torque M.sub.INT_EFF_IST during a test run on a test stand 1 and “offline” means the determination of the inner effective desired torque M.sub.INT_EFF_SOLL outside of a test run on a test stand 1. However, it would also be possible to dispense with the filtering step in the “online” determination of the effective actual torque M.sub.INT_EFF_IST, but a type of filtering would then substantially take place implicitly due to the characteristics of the controller used in the unit controlling unit 6 and the deceleration behavior of the drive unit 2. In the case of a vehicle application of the internal combustion engine, the determination of the inner effective desired torque M.sub.INT_EFF_SOLL can be carried out, for example, from recorded measurement data from a real driving test (rotational speed/torque profile) or from other sources. The observer method described is of course not restricted to use in an internal combustion engine; it would also be applicable to other drive units 2, such as, for example, electric motors, hybrid drives, etc.
(16) The mass inertia I.sub.A of the drive unit 2 can be assumed to be known. Different mass inertias I.sub.A can also be used to calculate the inner effective desired torque M.sub.INT_EFF_SOLL. For example, the known mass inertia I.sub.A of the drive unit 2 can be used on the test stand 1. However, the mass inertia I.sub.A of the drive unit 2 from a reference run that is to be reproduced on the test stand can also be used. This means that the mass inertia I.sub.A of the drive unit 2 on the test stand 1 does not have to match the mass inertia of the drive unit with which the reference run was created or measured. For example, the internal power (power in the combustion chamber of an internal combustion engine as drive unit 2) of the test object will match well with the reference run. If a reference run is reproduced on the test stand and the actual mass inertia I.sub.A of the drive unit 2 is used on the test stand, then the power on the connecting shaft 3 will correctly match the reference run.
(17)
(18) In the next step, represented by block B, the inner effective desired torque M.sub.INT_EFF_SOLL is calculated from the given reference data using the same methodology that was already described with the aid of the observer 10 in
(19) Depending on the quality of the available reference data of the engine rotational speed N.sub.M_REF, the averaging over a working cycle and the number of cylinders can also be dispensed with, for example if such averaging has already taken place as part of the determination of the reference data or if the drive unit is designed as an electric motor with substantially uniform torque input over one revolution. The reference angular acceleration {umlaut over (φ)}.sub.REF is then multiplied by the known mass inertia I.sub.A of the drive unit 2 (for example I.sub.A of the internal combustion engine) to a reference correction torque ΔM.sub.M_REF. Finally, the reference correction torque ΔM.sub.M_REF is added to the effective reference torque M.sub.EFF_REF (in the case of an internal combustion engine with the effective reference torque M.sub.EFF_REF_FILT averaged over a working cycle and the number of cylinders of the internal combustion engine), from which the inner effective desired torque M.sub.INT_EFF_SOLL results, which can already be used to control the drive unit 2.
(20) Again, depending on the quality of the available reference data, an averaging of the inner effective torque M.sub.INT_EFF_SOLL over a working cycle and the number of cylinders of the internal combustion engine can also be dispensed with, for example if such averaging has already taken place as part of the determination of the reference data or depending on the execution of the drive unit 2 (e.g. as an electric motor). If the required measurement data for such a procedure are not available, analog methods can be used to determine the inner effective desired torque M.sub.INT_EFF_SOLL from the available reference data.
(21) For example, in the course of a driving test of a vehicle with a corresponding drive unit 2, the required torque for accelerating the vehicle mass could be calculated from a measured vehicle acceleration and the necessary inner effective torque M.sub.INT_EFF can be calculated for this via known mass inertia, and can be used as an inner effective desired torque M.sub.INT_EFF_SOLL. It would also be conceivable to determine the inner effective desired torque M.sub.INT_EFF_SOLL of a drive unit 2 from stored data of a unit control unit, such as an engine control unit (ECU) of an internal combustion engine. Alternatively, as described above, the values for the inner effective desired torque M.sub.INT_EFF_SOLL could also be determined from indicating data of the reference run.
(22) The resulting inner effective desired torque M.sub.INT_EFF_SOLL can already be used directly to control the drive unit 2, for example the internal combustion engine on the test stand 1, which is symbolized by block D. For this purpose, the inner effective actual torque M.sub.INT_EFF_IST can be determined as described above during the test run, for example in the observer 10 or in the case of an internal combustion engine also by means of a cylinder pressure indicating system. The deviation between the inner effective desired torque M.sub.INT_EFF_SOLL and the inner effective actual torque M.sub.INT_EFF_IST can then be adjusted on the test stand 1 using a suitable controller, for example a simple PI controller.
(23) However, the control can also use a given characteristic map KF for the manipulated variable in a feed forward control, for example accelerator pedal position α of an internal combustion engine over the engine rotational speed N.sub.M and the effective torque M.sub.EFF or the inner effective torque M.sub.INT_EFF. For this purpose, a precontrol value of the manipulated variable for example the accelerator pedal position α, is determined, for example, from the characteristic map KF from the effective torque M.sub.EFF (or the filtered effective torque M.sub.EFF_FILT) and the engine rotational speed N.sub.M (or generally the unit rotational speed). The controller, preferably the unit controlling unit 6, to which the deviation between the inner effective desired torque M.sub.INT_EFF_SOLL and the inner effective actual torque M.sub.INT_EFF_IST is again fed, then determines a controller manipulated variable with which only minor deviations are then adjusted which result from inaccuracies of the characteristic map KF.
(24) The manipulated variable for the drive unit 2 thus results in a known manner as the sum of the feed forward manipulated variable and the controller manipulated variable. Such a characteristic map KF can be determined, for example, by stationary test stand measurements in various operating points in the relevant operating range of the drive unit 2. In an internal combustion engine, stationary operating points are set, for example, by means of the accelerator pedal position α and the engine rotational speed N.sub.M, and the effective torque M.sub.EFF is measured on the connecting shaft 3 at the respective operating point and stored in a characteristic map KF. Due to the lack of dynamics of mass inertia, the effective torque M.sub.EFF corresponds to the inner effective torque M.sub.INT_EFF during stationary operation. The obtained characteristic map is inverted, in order to obtain a characteristic map KF of the accelerator pedal position α, plotted against the inner effective torque M.sub.INT_EFF and the engine rotational speed N.sub.M.
(25) In principle, any suitable controller can be used as the controller, which may also need to be parameterized in an application-specific and known manner and which is preferably implemented as hardware or software in the unit controlling unit 6.
(26) According to the invention, the limited adjustment dynamics of the drive unit 2 on the test stand 1 are taken into account when carrying out the test run. It is irrelevant here whether the test run is carried out with the inner effective torque M.sub.INT_EFF or with the effective torque M.sub.EFF which acts on the connecting shaft 3. If the inner effective torque M.sub.INT_EFF is used, then this can be determined and used as described above. The effective torque M.sub.EFF can easily be measured on the connecting shaft 3. The consideration of the actuating dynamics is therefore independent of the use of the inner effective torque M.sub.INT_EFF and can therefore be implemented independently of the torque used. In an advantageous embodiment, the test run is carried out with the inner effective torque M.sub.INT_EFF and the adjustment dynamics of the drive unit 2 are taken into account when carrying out the test run on the test stand 1 as described below.
(27) A transfer function UF, which corrects the time behavior of the drive unit 2, is used to take the actuating dynamics into account when controlling the drive unit 2. The time behavior of the drive unit 2 substantially describes the temporal inertia of the controlled system (i.e. everything between setting the manipulated variable and the torque build-up) and maps the delayed torque build-up of the drive unit 2 to the manipulated variable. For example, the time between the setting of the accelerator pedal position α and the delayed increase (or decrease) in the inner effective torque M.sub.INT_EFF (or of the effective torque M.sub.EFF).
(28) Because of its physical mode of operation, an electric motor generally has higher actuating dynamics than an internal combustion engine, which is why it is advantageous to take the actuating dynamics into account when carrying out the test run, particularly in the case of an internal combustion engine. This is substantially due to the fact that an internal combustion engine requires more time to implement a torque request due to the underlying physical processes, i.e. the time between the specification of the manipulated variable (e.g. accelerator pedal position α) and the actual torque build-up. An internal combustion engine with direct injection and exhaust gas turbocharging requires, for example, sufficient time for the boost pressure build-up, mixture formation, combustion, etc. In contrast, fewer physical processes are required in an electric motor, for example, substantially less time is required to build up a magnetic field.
(29) In a simple embodiment, the transfer function UF can shift the values of the inner effective desired torque M.sub.INT_EFF_SOLL (or the effective desired torque M.sub.EFF_SOLL) by a so-called dead time Δt on the time axis. Thus an inner effective desired torque M.sub.INT_EFF_SOLL_UH that has been shifted by the dead time Δt is obtained (or an effective desired torque M.sub.EFF_SOLL_UH). This is symbolized in
(30) Alternatively, an associated, time-corrected manipulated variable, for example the accelerator pedal position α, can also be determined from the inner effective desired torque M.sub.INT_EFF_SOLL (or the effective desired torque M.sub.EFF_SOLL) and the desired rotational speed N.sub.M using the transfer function UF. For this purpose, the manipulated variable can be determined, for example, via a characteristic map KF from the inner effective desired torque M.sub.INT_EFF_SOLL (or the effective desired torque M.sub.EFF_SOLL) and the desired rotational speed N.sub.M and this manipulated variable can be shifted by the dead time Δt, as shown in
(31) In the simplest case, the dead time Δt can be a given or parameterized constant time value. Ideally, however, the dead time Δt is determined as a function of an operating point (torque/rotational speed) of the drive unit 2. For this purpose, the dead time Δt can be determined, for example, from characteristic maps in which the dead time Δt is plotted, for example depending on the unit rotational speed N.sub.M and the inner effective torque M.sub.INT_EFF (Δt=f (N.sub.M, M.sub.INT_EFF)) of the drive unit 2 or the effective torque M.sub.EFF (Δt=f (N.sub.M, M.sub.EFF)). Such characteristic maps can be determined, for example, by prior measurement of the drive unit 2 on a test stand 1 or approximately from empirical values or from the measurement of design-like reference drive units. Internal combustion engines of similar design can be, for example, internal combustion engines with comparable parameters, e.g. similar displacement, same number of cylinders, same supercharging concept, same mixture formation, etc.
(32) When determining the dead time Δt by measuring the drive unit 2 beforehand on a test stand 1, a characteristic map for the increase in the torque of the drive unit 2 and a characteristic map for the decrease in the torque of the drive unit 2 are preferably determined in each case. Sudden changes in the manipulated variable, for example the accelerator pedal position α of the internal combustion engine or changes in the electrical current, in the form of short ramps, so-called α ramps in the internal combustion engine, are preferably given at selected operating points of the drive unit 2, and the dead time Δt is measured until delayed reaction of the inner effective torque M.sub.INT_EFF or the effective torque M.sub.EFF, which substantially represents a measure of the inertia of the torque build-up of the drive unit 2. This determination of the dead time Δt by means of ramps should be carried out both for the sudden increase and the sudden decrease in the inner effective torque M.sub.INT_EFF or the effective torque M.sub.EFF, which results in two dead time characteristic maps. The ramps should be chosen so steep that the drive unit 2 demands the maximum dynamics.
(33) The dead time Δt for an operating point of the drive unit 2 can also be determined by analyzing the course of the inner effective torque M.sub.INT_EFF or the effective torque M.sub.EFF, for example, the dead time Δt can be dependent on the gradient of the course of the inner effective torque M.sub.INT_EFF in the corresponding operating point. This method is preferably chosen when no separate measurements can be carried out on the drive unit 2 to determine the dead time Δt.
(34) The transfer function UF can, however, also be configured in any other way, wherein the transfer function UF in the general case is a function of the inner effective torque M.sub.INT_EFF or the effective torque M.sub.EFF, i.e. UF=f(M.sub.INT_EFF or M.sub.EFF). The transfer function UF is preferably a function of the operating point of the drive unit 2, i.e. UF=f(N, M.sub.INT_EFF or M.sub.EFF). The given desired values of the inner effective torque M.sub.INT_EFF_SOLL the effective torque M.sub.EFF_SOLL are now corrected with the transfer function UF in order to take into account the time behavior of the drive unit 2 (the adjustment dynamics), as will be explained below using the example of a dead time Δt as the transfer function UF.
(35) To carry out the test run, the given desired values are shifted by the dead time Δt, in particular shifted forward in time, and adjusted on the test stand 1 as described above to carry out the test run.
(36) The resulting course of the given inner effective desired torque M.sub.INT_EFF_SOLL or the effective desired torque M.sub.EFF_SOLL after the shift by the corresponding dead times Δt can further be adapted such that all those data points are deleted which have larger absolute time values than their subsequent points. This creates a continuously increasing time vector. In the next step, the resulting course of the desired values should be brought to a common time base with the course of the reference unit rotational speed N.sub.A_REF in order to be suitable for the control of the drive unit 2 symbolized by block D on the test stand 1.
(37)
(38)
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(40) As described, it is advantageous if the time behavior of the transfer function UF of the internal combustion engine is taken into account by advancing the inner effective desired torque M.sub.INT_EFF_SOLL by the dead time Δt, as will be shown below with reference to
(41)
(42) However, this effect can also be avoided by using a feed forward control to control the inner effective torque M.sub.INT_EFF and by applying the correction of the time behavior not to the desired torque M.sub.INT_EFF_SOLL (or M.sub.EFF_SOLL), but rather to a precontrol value of the manipulated variable of the feed forward control. For this purpose, for example, the precontrol value of the accelerator pedal position α is determined from the inner effective desired torque M.sub.INT_EFF_SOLL and the desired rotational speed N.sub.M_SOLL by means of a characteristic map KF. This precontrol value (accelerator pedal position α) is then shifted by the dead time Δt. The inner effective torque M.sub.INT_EFF is now controlled without correction of the inner effective desired torque M.sub.INT_EFF_SOLL by means of the unit controlling unit 6 (see
(43) According to a particularly advantageous embodiment of the invention, the inner effective torque M.sub.INT_EFF_SOLL is advanced by a dead time Δt, which is selected as a function of the operating points of the drive unit 2. Thereby, further improvements in the correspondence of the courses of the reference and actual values of the effective torque M.sub.EFF and accelerator pedal position α can be achieved. For this purpose, as already described, operating point-dependent characteristic maps can be created for the dead time Δt, which can be determined, for example, by measuring the drive unit 2 beforehand on a test stand 1, as has already been discussed with reference to
(44) If a previous measurement should not be possible, the dead time Δt in an operating point of the drive unit 2 can also be determined, for example, as a function of the gradient of the course of the inner effective desired torque M.sub.INT_EFF_SOLL in the corresponding operating point. However, approximately a constant dead time Δt can also be selected, as was described on the basis of the results of the third test run in