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电子运动EMC测试解决方案

Our e-motor 电磁兼容 testing solution are tailoring to meet the growing demands for compliance, performance testing across industries such as automotive, marine, and aerospace. Therefore These solutions are both cost-effective and efficient, ensuring consistent and repeatable test results across a variety of setups and configurations.

We offer full vehicle test setups, which equips with multi-axle chassis load machines, four-wheel drive capabilities, fully automated remote antenna positioning, and specialized charging mode test configurations. This flexibility makes our solutions ideal for testing not only complete vehicles but also Electric or Electronic Sub-Assemblies (ESA), covering a wide range of applications.

One standout feature of our load machines is the conventional through-shaft EMC chamber installation, designed to meet the CISPR 25 standard. This installation is perfect for testing e-motors ranging from smaller 20 kW units found in motorcycles to larger 700 kW systems commonly used in commercial vehicles. It ensures a thorough evaluation of all dynamic e-motor requirements, helping to accurately assess performance characteristics.

Flexibility of the test bench

As situations where a permanent load machine installation isn’t feasible, we provide mobile testing equipment as a flexible alternative. This mobile setup can use in multi-purpose or existing EMC chambers, offering the same comprehensive capabilities and functionality as our stationary systems, though with a slightly limited power capacity range.

Moreover Our solutions are designed to ensure you can meet the highest standards of performance and compliance, all while maintaining flexibility and cost-efficiency for your testing needs.

1.电子运动EMC测试解决方案: Direct drive connection testing type

Furthermore the direct drive system is designed for performing precise EMC/EMI tests on high-speed motors and controllers. This system is ideal for testing both separate motors and controllers, as well as integrated motor-controller units.

In the setup, high-speed motors are mounting on the end face of an L-shaped tooling or T-slot platform, securely the controller places on the test table. This versatile configuration allows for thorough testing of individual components or integrated systems.

In Addition system can customize to match the specific parameters of the motor testing. Depending on the motor’s size and requirements, the appropriate dynamometer can do the customization. Below are the recommended dynamometer parameters for optimal testing performance:

All the parameters can be customized depends on the requirement, the solution can be integrated with gearbox in order to output more torque.

2.电子运动EMC测试解决方案: Mobile/ Portable e-motor EMC testing

In regard to mobile portable e-motor 电磁兼容 testing solution is an innovative addition, which is to our comprehensive range of load machine options for electric vehicle (EV) component EMC testing. This mobile setup features an EMC load machine with cutting-edge drive electronics and controls, all can be within a shielded, free-standing mobile unit.

As a result the system supports full four-quadrant (4Q) operation, allowing for testing of both the e-motor drive and regenerative functions. with functions to meet all current emission and immunity standards, ensuring the highest quality of the testing environment with no compromises.

Key Advantages:

One of the standout benefits of this mobile e-motor EMC testing solution is its flexibility. It uses in existing EMC chambers typically for testing consumer electronics or complete vehicles, which means minimal adjustments to the testing environment. This makes it an economical solution for manufacturers looking to streamline their testing procedures.

Many of these chambers already come equipped with essential features like turntables and raising flooring, which facilitate the routing of signal fiber optics and power cables beneath the floor. These built-in features help simplify the setup process and enhance overall operational efficiency.

Streamline Testing Process:

To maximize efficiency, the Unit Under Test can be prepared on the mobile load machine outside the EMC chamber. Once the setup is ready, it can easily transfer into the chamber using a standard pallet truck, furthermore quickly connect to the power supply. This simple transfer process reduces downtime and ensures more testing time.

Modular and Customizable:

The modular design of the mobile testing platform allows for customization, which bases on specific needs. For instance, if higher speed or torque testing is requiring, a larger and more capable e-motor and drive unit can add to the system. This flexibility ensures the mobile solution evolves with the growing demands of manufacturers and researchers, providing a versatile platform for comprehensive EMC testing of e-motor components.

In essence, the mobile e-motor EMC testing solution offers a cost-effective, efficient, and flexible approach to testing that can meet the complex needs of the evolving electric vehicle industry.

3.电子运动EMC测试解决方案: Two-Axis EMC Loading Testing System

Regarding two-axis loading dynamometer system is designing to closely replicate the real-world installation of a vehicle powertrain, offering a highly accurate simulation. This system ensures that the differential is neither locked nor welded, and the output shafts on both sides of the powertrain can swap out for on-board half shafts. Additionally, the wheel spacing can adjust to match the actual vehicle specifications, providing a realistic testing environment.

In addition the system is particularly well-suited for EMC testing of passenger car motors, with capabilities that include a maximum speed of rpm and a nominal torque N·m. One of its key features is the ability to design the semi-axles on both sides of the powertrain, which insulate from the ground, effectively simulating the behavior of vehicle tires during testing.

low-speed shaft side shafting system

In regard to high-speed motor testing, the low-speed shaft side shafting system can easily remove to facilitate testing of faster motors. Additionally, for scenarios where space is limited in the EMC test chamber, 一个 right-angle transmission box can install to optimize space and maintain functionality.

This versatile system offers the flexibility to meet a wide range of testing needs, which make it an ideal solution for testing e-motors and powertrains in realistic conditions while ensuring accurate EMC/EMI performance evaluation.

4.电子运动EMC测试解决方案: Powertrain EMC Testing System

我们的 electric drive and powertrain universal dynamometers use for a variety of testing needs, including EMC/EMI testing for high-speed motors, low-speed high-torque powertrains, and low-speed high-torque motors. This versatile system is perfect for evaluating the full range of electric drive systems under real-world conditions.

In addition the system utilizes a medium-speed high-torque dynamometer that connects to a dual-output shaft gearbox. Through gear transmission, the high-speed shaft can increase to higher speeds, while the low-speed shaft is directly power by the dynamometer. This flexible configuration allows for testing both high-speed, low-torque 和 low-speed, high-torque electric drive systems.

然而, due to the introduction of a high-speed gearbox, the mounting surface area for the motor will be larger, and the reflecting surface area will also increase. This can lead to a slight impact on measurement uncertainty. To mitigate these effects, our product is equipped with several key design features to ensure optimal performance and accuracy.

key design features

Oil and Gas Absorption Device: The high-speed gearbox fully equips with a device, which prevents oil and gas from volatilizing into the anechoic chamber, maintaining the integrity of the testing environment.
Medium-Speed High-Torque Dynamometer: This dynamometer reduces the gearbox’s transmission ratio, lowers the center distance, and minimizes the gearbox’s cross-sectional area. This design effectively reduces the impact on measurement uncertainty, ensuring more precise test results.
Lubrication System with Power-Failure Protection: The gearbox’s lubrication system equips with a mechanism that continues to supply oil for at least 5 minutes after a power failure, preventing damage to the gearbox due to oil cutoff during testing.
Constant Temperature Lubrication System: The system features a constant temperature device that ensures the oil inlet temperature remains stable. This helps minimize the influence of lubricating oil viscosity on transmission efficiency and eliminates errors in torque measurement caused by fluctuations in transmission efficiency.

These thoughtful design elements ensure that our powertrain testing system delivers accurate and reliable results, even in complex testing scenarios. The system is highly adaptable and capable of addressing a wide variety of electric drive and powertrain testing requirements

Technical description-1. System Architecture of E-motor EMC testing solution

The electric drive 电磁兼容/EMI test system typically consists of an electric wave anechoic chamber, 测功机系统, and various measuring instruments. We primarily offer the anechoic chamber and dynamometer system.

The anechoic chamber is typically a standard CISPR25 chamber, which designs to ensure accurate testing in controlling conditions. The dynamometer system, on the other hand, customization bases on the specifications of the UUT. It generally includes several key components, such as:

A power dynamometer to simulate the load
A through-wall shielding shaft system for precise measurements
An installation stand for secure positioning
A frequency converter to adjust operational parameters
A battery simulator to mimic real-world energy sources
A cooling system to regulate temperature during tests
A sensor measurement system to capture critical data
A data acquisition system for processing and recording results
Monitoring software for real-time control and analysis

This comprehensive setup ensures that all necessary tests are conducting with high accuracy, helping you meet stringent EMC/EMI compliance standards for electric drives.

2. Key technical indicators of系统架构

2.1 屏蔽效能-(东南欧) 电驱动EMC加载CISPR25暗室的屏蔽效能, 控制室, and power amplifier room implement in accordance with the standard EN50147-1 or the latest GB/T12190 standard (频率范围10KHz～18GHz). The specific test frequency determine in according to the test frequency of the third-party testing agency, which meets the following indicators:

安装所有相关配件后 (包括墙轴), 电驱动EMC测功机工作原理 (small non-radiation load can provide), 和监控系统, 灯, 天线塔工作, and the filter are active, 屏蔽效能水平比Class低至少10dB 5 限制 (PK&QP&的) specifying by CISPR25.

2.2 测量控制精度 1) 扭矩测量精度: ±0.05%FS

2) 速度传感器脉冲分辨率: 1024/600ppppr

3) 扭矩控制精度: ±1%

4) 调速精度: ±0.01%满量程

5) 测功机最大振动速度值 (RSM): ≤2毫米/秒 (独立的), ≤3.5毫米/秒 (加载中)

6) 中间轴承座温升: ≤35℃

7) 中间轴承座最大振动速度值 (RSM): ≤2毫米/秒 (独立的), ≤3.5毫米/秒 (加载中)

2.3 长线法——(其他) 根据CISPR25最新版本, 模拟长线天线法 (其他) 采用频率范围150kHz～1GHz, 并且误差超过 90% 实际测试点与模型理论值相比不大于±6dB. 测试区域为电机侧和非电机侧. 测试邀请权威第三方计量机构进行测试并提供报告.

Background noise and radio anechoic chamber

2.4 背景噪音-(荷兰银行) 当没有 DUT 时, 监控系统, 灯, and filters are active, 9KHz～6GHz范围内, 测试背景噪声水平应至少低于本等级水平 5 限制 (PK&QP&的) 最新版CISPR25规定10dB, 比 GJB151B RE102 限值至少低 6dB. This test invites third-party measurement institutions to certify by the state to conduct tests and provide reports.

2.5 Air quality After the construction of the radio anechoic chamber complete, once an inspection agency with CNAS and CMA qualification, it should invite to conduct air quality testing in the darkroom, in addition to issue a test for the air quality in the darkroom. such as (至少含有甲醛, 苯, 甲苯, 二甲苯和TVOC) 报告, however the test results meet the limit requirements, such as: GB50325-2010 \”室内环境污染控制规定” 和国标 18883-2002 \”Indoor Air Quality Standards\”.

2.6 Grounding resistance The anechoic chamber and shielding room grounding by single-point floor, in addition we design and construct the grounding resistance. with grounding device process uses physical resistance reducers, 但不使用耐化学性降低剂. Maintainable with our grounding. The grounding resistance of dark room and shield room is less than 1Ω.

3. 执行标准

1. CISPR16-1-4 \”无线电干扰和抗扰度测试设备和方法部分规范 1-4: Radio Interference and Immunity Test Equipment with Interference by Auxiliary Equipment\”

2. CNAS-CL01-A008 \”测试和校准实验室能力标准在电磁兼容测试领域的应用说明”

3. EN50147 \”Measurement method of shielding effectiveness of high-performance Shielding room\”

4. 国标/T 12190 \”Measurement Method of Shielding Effectiveness of Electromagnetic Shielding Room\”

5. 国际标准化组织 4589-2 \”塑料氧指数燃烧行为的测定第一部分 2: Ambient-temperature test\”

6. GB/T2406塑料燃烧性能试验方法氧指数法

7. 国标 8624 建筑材料及制品燃烧性能分级;

8. 国际标准化组织 11452-1/-2/ Road vehicles-Test methods for immunity of electronic/electrical components to narrowband, which with radiate electromagnetic energy-Radio anechoic chamber method;

9. CISPR 25 车辆无线电骚扰特性的限值及测量方法, Ships and Internal Combustion Engines use to Protect Vehicle-mounted Receivers.

10. MIL-STD-461G 子系统和设备电磁干扰特性控制要求

11.GJB 151B “军事设备和子系统电磁发射和灵敏度的要求和测量”

12.GBT 36282-2018 电动汽车驱动电机系统电磁兼容性要求及测试方法.

13.国标 50325-2010 “土木建筑工程室内环境污染控制规范

14.GB/T18883-2002 Indoor Air Quality

4. Key technology description

The key technologies of the EMC test system for motors and drives include: 高速穿墙屏蔽轴系, 完整的电气隔离系统, 暗室无辐射传感器监测系统, 低噪声电池模拟器等系统, 实时监控系统等部分.

4.1 高速穿墙屏蔽轴系

CISPR25 定义的测试布局

The CISPR25 standard clearly requires that the distance between the controller EUT, and the center of the absorbing material is not less than 1m.

用于三合一电驱动总成, however the distance between the inner side of the controller (靠近暗室一侧), and the top of the absorbing material is not less than 1M, in addition the distance between the mounting end of the motor drive assembly, furthermore the top of the absorbing material is not less than 1M.

为了满足这个要求, 轴系统的长度更长, 同时, 需要满足高速时振动较小的要求. with current solution is to use carbon fiber shaft or glass fiber shaft, 测试条件要求轴的长度必须大于 1.6 米. (international standards stipulate that the distance between the end face of the motor, and under test and the top of the anechoic chamber absorbing material is not less than 1M.

Material environment:

Considering the absorbing material Thickness, 铁素体厚度, 和屏蔽层厚度, 同时还要考虑到安装过程中的错误). Although these two non-metallic shafts are excellent materials, which are non-conductive and non-magnetic, 因为新能源汽车的电驱动系统已经进入高速大扭矩阶段, 玻璃纤维或碳纤维轴的绝对弹性模量不适合高速和高扭矩测试. 场景.

The high-speed through-wall shielding shaft designs by ourselves, which has the following characteristics:

采用高精度低惯量刚性轴, 同时兼顾高速、大扭矩的特点.
作为电波暗室的一部分, 转轴具有良好的导电性, 从根本上屏蔽外界电磁辐射, 达到优异的屏蔽效果, 并减少暗室中的背景噪音.
通过可拆卸屏蔽盖, the test motor can be completely shielding, and the electromagnetic compatibility characteristics of the drive axle can test independently.

High-precision long-axis system

为了满足高速, 同时满足大扭矩和屏蔽要求, 系统采用高精度长轴系统.

全速度范围内振动速度小于3.5mm/s.
轴系采用多点支撑结构, 便于暗室中底座对中，同轴度优于0.02mm.
轴系采用全动平衡结构, 动平衡精度达到G1级.
轴系一阶临界转速高于系统最高转速. 4.2 完全电气隔离的系统
In order to prevent electromagnetic waves and charges from conducting outside the anechoic chamber to the anechoic chamber, 除了特殊的电磁屏蔽方法, 测功机必须完全电气隔离. 电驱动电机或动力总成需要满足单点接地要求.
1. The dynamometer and the shielding shaft adopt high-speed insulation coupling.
2. The dynamometer is completely electrically isolating from the base.
3. The high-speed shielding shaft and the tested electric drive motor shaft adopt high-speed insulation coupling.
4. The installation base in the anechoic chamber is completely electrically isolating from the anechoic chamber.
5. The anechoic chamber designs with a removable complete shielding cover, 可以完全屏蔽电机并单独测试控制器的EUT.

4.3 Non-radiation sensor monitoring system in dark chamber room

The electric drive system and shaft system under test in the anechoic chamber， however design with vibration and temperature monitoring sensors. The sensors need to collect by a high-speed data acquisition system and transmit to the monitoring software for signal analysis and processing.

With data acquisition system is placed in the anechoic chamber. 由于其本身的辐射, affect the background noise of the anechoic chamber, and low noise processing is requiring.

我公司对电波暗室数据采集系统做了以下设计:

数据采集系统电源经过24V滤波器滤波，消除进入电波暗室的电源干扰.
数据采集系统的信号传输设计. 实时以太网光纤转换器, 通过安装在电波暗室壁上的光纤和光纤波导, 将信号传输至电波暗室, 然后通过逆变器将其转换为数字信号, 并进入机器的上部位置.
数据采集系统安装在屏蔽箱内. 屏蔽箱内设计有通风波导，保证散热的同时保证箱内的电磁波不会传输到暗室.
传感器电缆采用专用屏蔽电缆, 将传感器和屏蔽盒连接成一个整体.