High-speed motor test bench solution:

Высокоскоростная Моторная испытательная скамья is a special system, which designs to evaluate and validate the performance of high-speed electric motors under various operating conditions. In addition it consists of several key components, в том числе динамометр, контроллер в реальном времени, Система сбора данных, и различные датчики.

Электрический drivetrain development is faster, но все еще сложный из -за разнообразных типов моторных и конструкций. Econotest offers specialized динамометры, программное обеспечение, и инструменты для тестирования ливней электромобилей. Высокоскоростные моторные испытания оценивают производительность, Н.В., EMC, и долговечность электрических двигателей систем. Эти возможности тестирования помогают производителям соответствовать строгим качеству и стандартам производительности для электрифицированных трансмиссий. our solutions address challenges in testing EESM, Асм, и моторы PMSM в различных конфигурациях трансмиссии. Comprehensive testing ensures electric vehicle drivetrains certificate quickly, in order to achieve a high-quality standards. Advancing tools and procedures from us and supports help the development of modern electric propulsion systems.

Мы можем сделать ODM/OEM с настройкой бренда, Цвет,Упаковка, Размер и параметры.

Test bench's real-time dynamic control system:

Высокоскоростная Моторная испытательная скамья‘s real-time dynamic control system, using a real-time controller to achieve speed and torque control, Моделирование фактических условий нагрузки. The main control system can communicate and control environmental chambers, Силовые анализаторы, Системы охлаждения, и EUTS. In addition data acquisition system collects signals from torque sensors, датчики вибрации, датчики температуры, датчики давления, therefore other sensors, передача их на высокой скорости на основную систему управления. Sensor data can display, save, and process in the software program.

1. High-speed motor test bench with high-power:

High-Speed High-Power Мотор Test System is suitable for various high-speed motor applications, including electric vehicle drive motors, высокоскоростные двигатели воздушного компрессора, и высокоскоростные двигатели на магнитной подушке.. Moreover the installation platform can designs according to the motor under test, с опциями для конечных фланцевых или базовых монтажных конструкций

Motor Test Bench Selection Specifications:

The dynamometer selection base on the characteristic curve of the motor under test. Обычно он использует четырехквадрантный контроль инвертора и может работать в состояниях двигателя и генератора. The system can optionally equip with high and low-temperature environmental chambers, Симуляторы аккумуляторов или двунаправленные расходные материалы постоянного тока, Силовые анализаторы, и системы охлаждения.

Основные параметры следующие, Все параметры могут быть настроены по требованию :

2.Высокоскоростная с низкопрофильной тестовой скамейкой:

This system is available for testing small power high-speed motors, такие как генераторы малых мощных авиации, роботизированные двигатели, небольшие высокоскоростные компрессорные двигатели, и двигатели с помощью машинного инструмента. Therefore the installation platform can design according to the motor under test, с опциями для конечных фланцевых или базовых монтажных конструкций

Технические характеристики выбора испытаний

The solution selection bases on the characteristic curve of the motor under test. which typically uses four-quadrant inverter control and can operate in both motor and generator states. The solution can optionally offer with high and low-temperature environmental chambers, Симуляторы аккумуляторов или двунаправленные расходные материалы постоянного тока, Маленькая мощность регулируемых источников питания постоянного тока, Силовые анализаторы, и системы охлаждения. В зависимости от требований к шуму, water-cooled or air-cooled dynamometers are available.

1.Спецификация с воздушным охлаждением:

2.Спецификация с жидкостью:

3. High speed motor test bench

High-Speed Motor Test Bench Overview

Purpose and Application: The speed of our high-speed motor test bench can achieve more than 100,000 об/мин. It is commonly use in applications like high-speed compressor motors. Max speed of our test system can offer with speeds up to 165,000 об/мин.
System Components: The high-speed motor test system compose of several key components, including:
- динамометр
- Dynamometer driver
- Braking resistor
- Speed-increasing gearbox
- Источник питания постоянного тока
- Power analyzer or power meter
- Control system
- Mechanical system
- Sensor measurement system And other associated parts.

High-Speed Motor Test Bench key components:

High-Speed Gearbox: The ultra-high-speed gearbox is a two-stage power distribution gearbox with coaxial input and output shafts. Key specifications include:
- Номинальная выходная скорость: 165,000 об/мин
- Номинальный выходной крутящий момент: 1.5 Нм
- Rated power: 25 кВт
- Service life of all gearbox components: >10,000 часы
Кроме того, the gearbox includes a lubrication pumping station provided by the supplier, which is adjustable prior to shipment to ensure optimal performance.
Test Piece Torque Measurement: Torque can measure directly from the test piece, in order to avoid transmission losses that could mislead the accuracy. Unlike traditional configuration, where a torque sensor usually places on the low-speed end of the system, our direct measurement provides more accurate measurement for high-speed scenario.
Test Piece Connection: To accommodate different test specimens and ensure ease of tool replacement, the system includes a torque flange, переходной шлицевой фланец, and a spline between the bearing housing and the motor’s input shaft. So the design helps to reduce torsional vibrations and ensures reliable connections during testing.

4.Hight Speed Motor Test Bench Architecture

Real-Time Dynamic Control System and Key Technical Indicators:

1. The motor test bench features a sophisticated real-time control system, that allows for precise speed and torque control through a real-time controller. However it simulates actual loading conditions and can communicate with various components, such as the environmental chamber, анализатор мощности, система охлаждения, and the Equipment Under Test (ИО). In addition the system collects data from a wide range of sensors, including torque, вибрация, temperature, and pressure sensors, and transmits it immediately to the main control system. The testing data can display, save, and process via the software program.

2.Key Technical Indicators:

Torque Measurement Accuracy: ±0.05% FS to ±0.1% FS

- Pulse Resolution of Speed Sensor: 1024/600 ппр
- Torque Control Accuracy: ±0.5% to ±1%
- Speed Control Accuracy: ±0.01% FS
- Maximum Vibration Speed of Dynamometer: ≤ 2mm/s (независимый), ≤ 3.5mm/s (under load)
- Temperature Rise of Intermediate Bearing: ≤ 35°C
- Vibration Speed of Intermediate Bearing Seat: ≤ 2mm/s (независимый), ≤ 3.5mm/s (under load)
- Test Motor Current Channels: 4 или 6 каналы
- Test Motor Voltage Channels: 4 или 6 каналы
- Power Analyzer Measurement Accuracy: ± (0.05%/0.1% of reading + 0.05%/0.1% of range)
- Data Acquisition System Sampling Rate: 1 kHz
- User Data Acquisition Channels: Optional
- Temperature Measurement Range: -50°C to 200°C
- Vibration Sensor Range: 0-20mm/s

Main Test Items:

Power and torque characteristics of motors with controllers

- Temperature rise testing of motors with controllers
- Locked-rotor tests for motors with controllers
- Verification tests for motor controller control strategies
- Maximum speed tests for motors and controllers
- Regenerative energy feedback tests (braking tests)
- External characteristics of motors
- Development and optimization tests of motor-controller powertrains
- Performance tests and calibration of motor-controller systems
- Efficiency map testing
- Accelerated response testing
- Torque response testing
- Durability tests with steady-state cyclic loading
- Back EMF constant and waveform analysis
- Electromechanical time constant testing
- Response characteristics testing for high-speed small motors

Key Technologies of the Test solution:

4.1 High-Performance Electric Dynamometer: The dynamometer, a core component, features a low moment of inertia, minimal vibration, compact size, and high acceleration performance. Therefore it also offers efficiency benefits, along with real-time monitoring of bearing conditions, temperature, and windings.
4.2 High-Dynamic Real-Time Control System: The test bench uses an embed real-time controller for high-dynamic control, supporting EtherCAT/Profinet communication. Moreover it boasts a no-load dynamic response time of under 10ms, allowing to meet complex variable conditions during testing.
4.3 Electrical Parameter Measurement System: The system uses high-precision power analyzers and current transformers for accurate measurements of efficiency, текущий, Напряжение, and other motor and controller parameters. It simultaneously measures torque and speed.
4.4 Precision Mechanical Structure: Components are machined with high precision, ensuring that shaft coaxiality is better than 0.02mm, providing optimal alignment and performance during testing.

High-Speed Bearing and Protection Measures:

4.5 Precision High-Speed Bearing Support: High-speed angular contact ceramic ball bearings equip, with spring preload to maintain bearing stability. The temperature rise does not exceed 35°C, and vibration speed stays under 2.5mm/s (RSM) at maximum speeds. The bearings are maintenance-free and capable of operating continuously for up to 20,000 часы.

4.6 Safety Protection Measures: The bench equips with multiple layers of safety protections:

Real-time monitoring of bearings, temperature, скорость, крутящий момент, and vibration
Real-time monitoring of motor vibration and safety cover protection
Electronic control system includes protection for short circuits, перегрузка, overvoltage, утечка, and power failures
Software includes an alarm system for when monitored values exceed preset thresholds, with three levels of protection
Durability tests include trend predictions based on historical data, with alerts if abnormalities are detected.

Installation and Monitoring:

4.7 Easy Installation: The L-shape mounting bracket designs with a positioning stop and mounting surface, moreover allowing for easy and quick installation of the test motor. It features an interface for high and low temperature chambers, ensuring that the test motor remains coaxial with the shaft system, even when temperature changes suddenly. the Vibration sensors capture motor vibrations in real time.

4.8 Complete Monitoring Software: The motor test bench software has a modular architecture, enabling users to customize test parameters and processes. It supports speed and torque control, temperature and speed monitoring, and includes safety features like automatic calibration and limit monitoring. The software supports both open-loop and closed-loop control.

4.9 Shaft Alignment Measures: Для высокоскоростной обработки валов, the system ensures shaft coaxiality is no greater than 0.02mm using laser alignment tools and fine-tuned mechanical structures.

4.10 Shafting Dynamic Balance Treatment: The shaft system balances to a G1 accuracy level, and dynamic balance perform onsite with specialized tools. Counterweight features integrate into the flange design, and an on-site dynamic balancer ensures proper balance during operation.