AC dynamometer/AC Dyno Test Bench

AC dynamometer/AC Dyno

An AC dynamometer is a crucial piece of performance testing equipment used in motor manufacturing and product development. It simulates and regulates the motor’s load to evaluate its performance characteristics. The AC power dynamometer system consists of a test motor and a four-quadrant frequency conversion unit. This advanced frequency conversion technology enables precise control in all four quadrants, allowing the dynamometer to function as a test load for the motor under various operating conditions.

Econo Test offers a comprehensive range of dynamometers designed for diverse testing applications, from internal combustion engines and their components to electric and hybrid vehicle systems. Our solutions cater to small electric tools, large electric motors, off-road diesel engines, marine engines, complete drivetrains, integrated e-drive systems, electric axles, and core electrification components like EV gearboxes.

Additionally, our AC dynamometers are engineered to accommodate a wide range of engine types, from compact off-road engines to high-power industrial engines, with power capacities spanning from 10 kW to 2,000 kW. They are ideally suited for engine certification, calibration, research and development, and end-of-line testing, meeting the rigorous demands of heavy-duty applications.

Test Scope:

No-load test, rated test, peak torque, peak speed, durability test, temperature rise test, torque fluctuation, speed fluctuation, back EMF test, T-N curve test, motor start-up test, frequency response bandwidth, driver performance test, efficiency map (MAP), forward/reverse speed difference rate, electrical time constant, torque control response time, speed control response time, dynamic position tracking error, braking torque test, speed regulation rate, d-q axis inductance, locked rotor test, efficiency test, overspeed, thermal resistance, inertia simulation, electromechanical time constant.

Asynchronous dynamometer (induction dynamometer)/PM dynamometer (permanent magnet synchronous dynamometer)

The AC dynamometer used for engine testing consists of an asynchronous AC induction dynamometer paired with a 4Q-frequency converter cabinet, providing a specialized solution for evaluating dynamic and transient engine applications with high precision. When coupled with additional accessories, this system ensures professional-grade testing capabilities, making it ideal for both current and future generations of combustion and hybrid engines.

This dynamometer series strikes an ideal balance between total cost of ownership and performance. By combining reliable, proven components with innovative designs, it offers excellent power coverage across various performance classes. This means fewer types of test equipment are required, resulting in greater flexibility and cost-efficiency. Its advanced torque-to-inertia ratio makes it perfectly suited for testing the latest engine technologies.

The frequency converter cabinet includes a high-speed interface to the controller, enabling rapid torque changes that simulate real vehicle load transitions. High-precision torque and speed monitoring ensure repeatable and reliable load conditions, essential for accurate engine testing. This design supports continuous operation, guaranteeing optimal test equipment efficiency and allowing for quick progress in engine development.

AC dynamometer-Engine testing

A key feature of this AC dynamometer series is its exceptional range of speed and torque capabilities. Each unit is designed to handle a wide array of testing scenarios, which becomes even more effective when paired with a gearbox. This versatility enables users to achieve both high nominal torque and the required speeds for comprehensive testing, making it ideal for applications such as gearbox performance evaluation, drivetrain efficiency analysis, and durability testing. Its flexibility makes the AC dynamometer series an essential tool for engineers and researchers across various industries.

Furthermore, this AC dynamometer is especially suited for testing axles and drivetrains in heavy-duty machinery applications. It is capable of supporting tests for a wide range of equipment, including tractors, graders, bulldozers, compactors, excavators, articulated dump trucks, and loaders. With its powerful torque and speed capabilities, this dynamometer series ensures that heavy machinery can be rigorously tested under real-world conditions, helping to enhance performance, durability, and overall reliability in the field.

How to Choose a AC dynamometer Test Bench:

When choosing a AC dynamometer test bench, consider the following factors:

Motor Type: Ensure the test bench supports the type of motor you plan to test (e.g., AC, DC, BLDC, servo).
Test Requirements: Identify the parameters you need to measure (e.g., couple, vitesse, power, efficacité).
Speed Range: Choose a test bench that can handle the speed range of the motor you’re testing.
Load Capacity: Ensure the test bench can simulate the necessary loads for your motor’s application.
Accuracy and Precision: Select a test bench with accurate measurement instruments and high precision, especially for motors in critical applications like aerospace or automotive.

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Types Of Electric Motors

A motor test bench can be used to test various types of electric motors, each with its own set of testing requirements. The primary types of motors that can be tested on these benches include:

1. AC Motors (Alternating Current Motors):

Squirrel Cage Induction Motors: The most common type of AC motor used in industrial applications.
Slip Ring Induction Motors: Used for higher torque applications, where the rotor is connected to external resistors.
Synchronous Motors: Used in applications requiring constant speed, such as in power plants.
Single-phase AC Motors: Typically used in residential appliances and small machinery.
Three-phase AC Motors: Widely used in industrial machinery and large-scale applications due to their efficiency.

Test Bench Capabilities: AC motor test benches can measure parameters like power, couple, vitesse, efficacité, facteur de puissance, and current/voltage characteristics under various loads and conditions.

2. DC Motors (Direct Current Motors):

Brushed DC Motors: Commonly used in small devices, toys, and robotics.
Brushless DC Motors (BLDC): Used in applications that require higher efficiency, such as in electric vehicles and drones.
Permanent Magnet DC Motors: These motors use permanent magnets instead of electromagnets for the rotor and are common in small appliances and machinery.
Series-wound, Shunt-wound, and Compound-wound DC Motors: Various configurations, each suited to different types of load applications.

Test Bench Capabilities: DC motor test benches can measure current, voltage, vitesse, couple, power, and efficiency, with specific testing methods for both brushed and brushless configurations.

3. High-Speed Motors:

Turbochargers, Air Compressors, and High-speed industrial motors: Used in applications requiring high-speed rotations, such as aviation or high-precision industrial machinery.

Test Bench Capabilities: High-speed motor test benches are designed to measure the motor’s performance at high rotational speeds, including vibration analysis, noise levels, and efficiency at varying speeds.

4. Stepper Motors:

Permanent Magnet Stepper Motors: Used in precise position control applications such as CNC machines, printers, and robotics.
Hybrid Stepper Motors: Combine the features of permanent magnet stepper motors and variable reluctance motors.
Variable Reluctance Stepper Motors: Often used in automotive and industrial applications.

Test Bench Capabilities: These test benches are used to test the accuracy, couple, vitesse, and precision of stepper motors, ensuring they meet specific requirements for movement control.

5. Synchronous Motors (AC and DC):

Permanent Magnet Synchronous Motors (PMSM): Often used in electric vehicles (EVs) and industrial applications requiring high efficiency.
Reluctance Motors: Used for specialized applications where the rotor does not require windings or magnets.

Test Bench Capabilities: Synchronous motors require precise control of speed and torque, which is typically tested under varying load conditions to verify stability and efficiency.

6. Universal Motors:

These motors can run on either AC or DC power. They are typically found in portable power tools and small appliances.

Test Bench Capabilities: A motor test bench for universal motors will test performance under both AC and DC inputs, checking for speed, couple, and power consumption.

7. Servo Motors:

AC Servo Motors: Used for precise control applications such as robotics, CNC machinery, and aerospace applications.
DC Servo Motors: Used in precise control systems, often for feedback control loops in various automation applications.

Test Bench Capabilities: Servo motor test benches allow testing of dynamic response, position control, speed control, and torque output under controlled loads, providing data on the motor’s performance in closed-loop systems.