电动汽车驱动电机寿命预测及可靠性测试方法的研究

硕士学位论文电动汽车驱动电机寿命预测及可靠性测试方法的研究RESEARCHONLIFEPREDICTIONANDRELIABILITYTESTINGMETHODOFTHEELECTRICVEHICLEDRIVEMOTOR闵远亮哈尔滨工业大学2011年6月国内图书分类号：TM359.9学校代码：10213国际图书分类号：621.3密级：公开工学硕士学位论文电动汽车驱动电机寿命预测及可靠性测试方法的研究硕士研究生：闵远亮导师：崔淑梅教授申请学位：工学硕士学科：电气工程所在单位：电气工程及自动化学院答辩日期：2011年6月授予学位单位：哈尔滨工业大学ClassifiedIndex:TM359.9U.D.C:621.3DissertationfortheDoctoralDegreeinEngineeringRESEARCHONLIFEPREDICTIONANDRELIABILITYTESTINGMETHODOFTHEELECTRICVEHICLEDRIVEMOTORCandidate：MinYuanliangSupervisor：Prof.CuiShumeiAcademicDegreeAppliedfor：MasterofEngineeringSpeciality：ElectricalEngineeringAffiliation：SchoolofElectricalEngineeringandAutomationDateofDefence：June,2011Degree-Conferring-Institution：HarbinInstituteofTechnology哈尔滨工业大学工学硕士学位论文-I-摘要能源与环境的影响，使得电动汽车走向人们的生活。驱动电机是电动汽车的核心部分，其可靠性直接影响了整车性能和行车安全。由于工作环境恶劣、工作模式复杂，电机的可靠性问题更加突出，而目前在电动汽车驱动电机可靠性方面的研究还很少，对影响驱动电机可靠寿命的因素还不够清楚。研究电动汽车驱动电机的可靠性、寿命分布和测试验证电机的可靠性等变得非常重要。本文将可靠性理论和传统电机的可靠性研究成果运用到电动汽车驱动电机的可靠性研究中，以永磁同步电机为例，开展了相关方面的研究：结合汽车环境和电机故障，分析了驱动电机的故障模式和典型的可靠性影响因素，建立了电动汽车驱动电机的故障树模型，并分析了绕组绝缘、轴承和永磁体等驱动电机可靠性的薄弱环节。在故障模式和薄弱环节分析的基础上，建立了电动汽车驱动永磁同步电机的可靠性串联模型，分别建立了寿命服从指数分布和复合分布下的驱动电机可靠度函数，并分析了不同寿命分布类型的参数估计和假设检验方法，指出评价驱动电机可靠性的寿命特征与估计。从驱动电机的寿命周期出发，分析了驱动电机可靠性周期，重点研究了电机的可靠性设计，采用比例分配法和应力分析法进行了驱动电机的可靠性分配和预计，并指出了提高驱动电机可靠性的设计方法。最后结合驱动电机实际工作点的分布，探讨了电机的可靠性测试方法，指出加速截尾试验是验证驱动电机可靠性的较好方法。结合加速试验模型，分析了驱动电机加速系数的计算方法及加速应力的施加办法。通过LabView软件编写了驱动电机自动测试程序，搭建了实验平台并开展了相关实验研究。关键词：电动汽车；驱动电机；寿命；可靠性；测试方法；加速试验哈尔滨工业大学工学硕士学位论文-II-AbstractTheinfluenceofenergyandenvironmenthasmadeElectricVehicle(EV)trendtohuman’slife,andthedrivingmotoristhecorecomponentoftheEVs,whosereliabilitywilldirectlyimpactthewholevehicle’sperformanceanddrivingsafety.Themotor’sreliabilityismorepredominantforitssevereworkingenvironmentandcomplexoperationmodes.However,thereislessresearchonthereliabilityofEV’sdrivingmotor,theinfluencefactorstothemotor’sreliabilityisstillunclear,soitisveryimportanttostudydrivingmotor’sreliability,lifedistributionandtesttoverifythemotor’sreliabilityforEVs.Inthispaper,thereliabilitytheoryandresearchachievementaboutthereliabilityofthetraditionalmotorresearchareappliedtothevalidityresearchofEV’sdrivingmotor.TakingthePermanentMagnetSynchronousMotor(PMSM)forexample,thecorrelationstudieswerecarriedout.Combiningwiththevehiclesenvironmentandmotor,thispaperanalyzedthefailuremodesofthedrivingmotorandthetypicalreliabilityinfluencingfactors,andestablishedafaulttreemodelaboutEV’sdrivingmotor,andanalyzedtheweaknessesforthereliabilityofthedrivingmotor,suchaswindinginsulation,bearingandpermanentmagnets,etc.Onthebasisoffaultmodesandtheweaknessesanalysis,thereliabilityseriesmodelofEV’sdrivingPMSMwasestablished.Thedrivingmotor’sreliabilityfunctionsthatlifeobeysindexdistributionandcompounddistributionwerepresentedrespectively,andthemethodsaboutparameterestimationandtestinghypothesisonthedifferenttypesoflifedistributionwereanalyzed.Thelifecharacteristicsandestimateofevaluatingthedrivingmotorreliabilitypointedout.Fromthestandpointofthelifecycleofthedrivingmotor,thispaperanalyzedthereliabilitycycleofthedrivingmotor,andmadeafocusonthereliabilitydesignofthemotor,andconductedthereliabilitydistributionsandanticipationsaboutthedrivingmotorbyvirtueofproportionaldistributionmethodandstressanalysis,andpointedoutthedesignmethodstoimprovethedrivingmotor’sreliability.Finally,combiningwiththeactualworkingpointdistributionofthedrivingmotor,thispaperdiscussedtestingmethodsaboutmotorreliability,andpointedoutthatacceleratingtruncatedtestisthebetterwaytoverifythereliabilityofthedrivingmotor.Combiningwiththeaccelerationtestmodels,thispaperanalyzedthecomputingmethodsofacceleratedcoefficientandimposingmethodsoftheacceleratedstressforthedrivingmotor,thenthroughtheLabViewsoftware,finishedtheautomatictestprogramsofthe哈尔滨工业大学工学硕士学位论文-III-drivingmotorandsetuptheexperimentalplatformandthencarriedouttherelevantexperiments.Keyword:EV;drivingmotor;lifetime;reliability;testingmethod;acceleratedtest哈尔滨工业大学工学硕士学位论文-IV-目录摘要.........................................................................................................................IABSTRACT..................................................................................................................II目录.............................................................................................................................IV第1章绪论..................................................................................................................11.1课题背景及研究的目的和意义...........................................................................11.2电机可靠性..........................................................................................................11.2.1电机可靠性发展概况....................................................................................11.2.2电机可靠性理论............................................................................................21.3电机寿命预测技术..............................................................................................51.3.1电机寿命预测技术研究现状.........................................................................6