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Dyno Equip provides the electric vehicle motor test bench to meet the performance test of the motor and its controller system of the pure electric passenger vehicle and commercial vehicle. The motor test bench can automatically or manually test the normal performance, external characteristics, efficiency characteristics, NEDC and other tests of the motor, and can measure power, torque, speed, temperature and other parameters. Thereby, the motor performance parameters can be calculated and the correlation curve can be drawn.
Passenger vehicle motor and commercial vehicle motor test bench can complete the stall torque and locked rotor current test, temperature rise test, continuous electric working characteristic test, motor maximum speed test, motor over speed test and feed operation characteristic test. At the same time, the test bench can feed the electricity generated during the test to the company’s power grid through the frequency conversion system.
The real-time dynamic control system of the motor test bench, small motor testing systems can realize the speed and torque control through the real-time controller and simulate the actual load. The main control system can communicate with the environmental chamber, power analyzer, cooling system, EUT, etc., and realize control. The data acquisition system collects signals from torque sensors, vibration sensors, temperature sensors, pressure sensors, and other sensors, and transmits them to the main control system at a high speed. The sensor data can be displayed, saved and processed in the software interface.
High-speed and high-power motor test system
The high-speed and high-power motor test bench (test system) can be used in various high-speed motor applications such as new energy vehicle drive motors, high-speed air compressor motors and high-speed magnetic levitation motors. The installation platform can be designed according to the motor to be tested, and the end flange installation structure or the base installation structure can be selected.
Motor test bench, small motor testing systems selection specifications
The selection the dynamometer is according to the characteristic curves of the motor to be tested. The dynamometer is generally controlled by a four-quadrant inverter, and it can work as electric or power generation. The system can be equipped with high and low temperature environment chamber, battery simulator or DC bi-directional power supply, power analyzer, cooling system and other accessories.
Electric passenger vehicle motor test bench parameters (Dynamometer is air-cooled)
ModelRated power (kW)Rated torque (Nm)Rated speed (rpm)Max. speed (rpm)AHD-012831,5001,8029,000AHD-022507033,39412,000AHD-033005705,02615,000AHD-041604003,82016,000AHD-052505004,77316,000AHD-062605004,96617,000AHD-072604004,77518,000AHD-082505004,77320,000**
** Permanent magnet synchronous motor
Electric passenger vehicle motor test bench
Electric passenger vehicle motor test bench parameters (Dynamometer is water-cooled for low noise test environment)
ModelRated power (kW)Rated torque (Nm)Rated speed (rpm)Max. speed (rpm)WHD-011734303,84015,000WHD-022305004,39016,000
Water-cooled dynamometer for low noise test environment
Electric commercial vehicle motor test bench parameters
ModelRated power (kW)Rated torque (Nm)Rated speed (rpm)Max. speed (rpm)ALD-015005,0009555,500ALD-026504,5001,3806,000ALD-035004,5001,0606,000ALD-044403,5001,2007,500ALD-056503,2301,9226,850ALD-065502,9501,7809,000ALD-073452,9001,1408,000
Electric commercial vehicle motor test bench
System architecture of motor test bench
The real-time dynamic control system of the motor test bench, small motor testing systems can realize the speed and torque control through the real-time controller and simulate the actual load. The main control system can communicate with the environmental chamber, power analyzer, cooling system, EUT, etc., and realize control. The data acquisition system collects signals from torque sensors, vibration sensors, temperature sensors, pressure sensors, and other sensors, and transmits them to the main control system at a high speed. The sensor data can be displayed, saved and processed in the software interface.
Key technical indicators
Major test items of motor test bench
High performance AC dynamometer
One of the core components of the motor test bench, small motor testing systems are the dynamometer. The high-speed dynamometer has the characteristics of low moment of inertia, low vibration speed, small size, good acceleration performance and efficiency. The front and rear bearings, three-phase windings and bearing temperature of the dynamometer are monitored in real-time.
High dynamic real-time control system
The monitoring system of the motor test bench is based on an embedded real-time controller and adopts EtherCAT/ Profinet communication to achieve high dynamic control. The system’s no-load dynamic response time can reach within 10ms, which can meet the test of complex variable conditions.
Convenient electrical parameter measurement system
The electrical parameter measurement system uses high-precision power analyzers and current transformers which can simultaneously access torque and speed signals to measure the efficiency, current, voltage and other parameters of the motor and controller.
Precision mechanical structure
The mechanical structural parts are processed by high-precision machining centers with very high machining accuracy. The shaft coaxiality is better than 0.02mm.
Precision high-speed bearing support
Perfect safety protection measures
Easy installation
The L mounting bracket of the motor test bench is designed with a positioning stop and a positioning mounting surface. Through the transitional mounting flange connection connected with the test motor, the test motor can be quickly installed without centering adjustment. The L-shaped mounting bracket is designed with an interface with the high and low temperature environment chamber, and the test motor can be placed in the high and low temperature environment chamber for testing.
Vibration sensors are installed in the X/ Y/ Z directions of the L-shaped installation tooling to monitor the vibration status of the motor under test in real time. The interface with the environmental chamber adopts four-pillar cantilever support, which can ensure that the axis of the test motor can be coaxial with the shaft system of the test bench when the high and low temperature environment changes.
For small high-speed motors, the dynamometer can be adjusted in the axial position, and the mounting platform of the motor under test can be adjusted in the vertical direction to adapt to the motors to be tested of different sizes.
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Complete monitoring software
The motor test bench software adopts a modular design architecture. User can customize the test process and working condition parameters to realize the motor speed and torque control. The system classifies users and opens different functional modules. The system has the function of automatic zero-point calibration at start-up. The software has a dedicated sensor calibration module, and user can calibrate the sensor regularly. The communication interface with EUT is reserved to realize the control of EUT. The software has the following functions:
The vehicle road simulation function is integrated in the real-time controller. The whole vehicle road simulation function is used to realize the road resistance, slope resistance simulation and inertia simulation of the whole vehicle on the test bench. These resistance simulations can be expressed by the following formula:
The system can provide various series of dynamometer electromechanical inertia simulation and simulate the road load according to the equation:
RL = F0 + F1VX + F2Vn + I dv/dt + mg * (Grad/100)
Among them:
RLRoad load (road traction)F0, F1, F2, nRoad load model coefficientF0Friction coefficient independent of speedF1Friction coefficient related to speedF2Drag coefficientnF2 speed index variable (range: 1.2—3.0)xF1 speed index variable (range: 0.8-1.2) (if any)VDrum surface linear speedIElectric simulated inertiadv/dtAccelerationmMassgGravitygradSlopeThe parameters F0, F1, F2, n, and x (if any) form the road load model, and they can be obtained in a variety of methods.
Shaft alignment measures
For high-speed shafting, we need to ensure that the coaxiality of the shafting is not greater than 0.02mm. Generally, the following measures are taken:
Treatment measures for shafting dynamic balance
The shaft system dynamic balance accuracy of the high-speed motor test bench reaches G1 and it is dynamically balanced on site. The general treatment measures are as follows:
The needs of test rig for small motor testing: Development of new drive systems for electric and high efficiency engines requires test technology that can meet the most stringent standards of serviceability and flexibility. In modern vehicles there are many electric motor. Traditionally these were limited to windshield wiper, window lift, fuel pump, sunroof, electric seat, air compressors, and lift gate or trunk latch release. With the advent of electric cars, coolant pump and refrigerant compressors have been added to the list.
Additionally, electric motor has infiltrated safety sensitive applications such as electronic throttle control, electric steering, electric door opening, cam phaser and traction motor. While all vehicle components must undergo rigorous testing, safety items must undergo more stringent durability and end-of-line testing. A number of methods can be used to physically load the motors, however, motor test rig, small motor testing systems are preferred for their high speed, flexibility and ability to back drive the test item while at high speed.
While the small motor testing systems are applying loads and temperature cycling, many data parameters are logged, some at high speed. Typical attributes are motor voltage, current, temperature, torque and speed. One area of primary interest is motor cogging (torque ripple), particularly at low speeds. Audible noise and vibration may also be a concern and sensors and data acquisition may be included for this as well.
There are many reasons to perform motor testing. Durability testing ensures that the motor will last a calculated length of time that simulates an extended life of an automobile. Performance testing is required to benchmark the motor’s performance at various temperatures and loads. Regardless of the testing type, various loads are applied while thermally cycling the motors.
Simpler motor is typically subjected to different loads but kept at relatively constant speed, with just the input voltage changed to simulate high and low battery conditions. Motor in applications such as electric steering and traction motor are subjected to very different torque and speeds.
High-speed small motor test system
The small high-speed motor test bench (test system) is used to test low-power high-speed motors, mainly for the low-power aviation generators, robot motors, small high-speed compressor motors, machine tool spindle motors, etc. The installation platform can be designed according to the motor to be tested, and the end flange installation structure or the base installation structure can be selected.
Small motor testing systems selection specifications
According to the characteristic curve of the motor to be tested, select a dynamometer. The dynamometer is generally controlled by a four-quadrant inverter and can work as electric or power generation. The system can be equipped with high and low temperature environment chamber, battery simulator or DC bidirectional power supply, low power adjustable DC power supply, power analyzer, cooling system and other accessories. According to user noise requirements, water-cooled dynamometer or air-cooled dynamometer can be selected.
Parameter table of air-cooled dynamometer for small motor testing systems
ModelRated power (kW)Rated torque (Nm)Max. speed (rpm)Accuracy classSMTS-A014.53.6240000.1% FSSMTS-A027.05.1240000.1% FSSMTS-A035.715200000.1% FSSMTS-A0410.518200000.1% FSSMTS-A051437180000.05% FSSMTS-A0630.549150000.05% FSSMTS-A071869140000.05% FSSMTS-A0858.670200000.05% FSSMTS-A096070160000.05% FSSMTS-A1022.593150000.05% FSSMTS-A1136138150000.05% FSSMTS-A1269.3150160000.05% FSSMTS-A13100150120000.05% FSSMTS-A14150200120000.05% FSSMTS-A15132210165000.05% FS
Parameter table of water-cooled dynamometer for small motor testing systems
ModelRated power (kW)Rated torque (Nm)Max. speed (rpm)Accuracy classSMTS-W012.51.150,0000.1% FSSMTS-W025.54.640,0000.1% FSSMTS-W039.55.030,0000.1% FSSMTS-W04187.336,0000.1% FSSMTS-W057.5824,0000.1% FSSMTS-W0612.12024,0000.1% FSSMTS-W0712.73418,0000.05% FSSMTS-W0815.66.845,0000.1% FSSMTS-W09252030,0000.1% FSSMTS-W10205318,0000.05% FSSMTS-W11635824,0000.05% FSSMTS-W12607016,0000.05% FSSMTS-W133211515,0000.05% FSSMTS-W1412134075000.05% FS
Motor test rig, small motor testing systems technology
The scope of motor test rig, small motor testing systems comprise mechanical components such as drive test setups with torque sensor, dynamometer with torque and speed measurement and manual or external control, as well as computer controlled complete solutions for the analysis and documentation of electrical machinery.
By means of an integrated power analyzer, computer controlled dynamometers can be realized with up to 12-channel current and voltage measurement, so that a separate efficiency specification of motor and converter can be effected even for converter fed drive systems.
Motor test rig, small motor testing systems control software
The motor test rig, small motor testing systems control software serves for parameter assignment of the test stand including the converter for the active brake and the test sequences of the test system, so that an optimum of profitability and precision is achieved.
Environmental chamber as option
Electric motor laboratory and performance must include features to control the application of stimuli, the most difficult usually being temperature cycling. Many of the systems are designed to be wheeled into an environmental chamber, and if needed shield any of the sensitive test rig components from temperature extremes or humidity.
If the system is very intricate it may be necessary to replace the environmental chamber door with part of the test apparatus so that the small motor testing systems can be pushed on wheels and mated to the chamber. It is usually best not to build the test fixture rig into the chamber for serviceability reasons, but this is sometimes required for cleanliness reasons if the electric motor is part of a hydraulic pump system. External thermal generator systems are also sometimes used and a small custom thermal enclosure is built around the test item.
About dynamometer hyperlink..
1) 240V – 600V 1P ~ 3P IEC & NEMA Motor Starter: IEC or NEMA sizes. Max voltage ranges: 0-240V 1P L-L & 0-600V 3P L-L-L. Max amperage ranges: 0-200A. Max horsepower ranges: 0-200HP. Panel-mounted NEMA-rated enclosure includes four panel mounted cam-lok receptacles (two or three lines, neutral & ground), adjustable overload relay, main power switch, jog/run switch, start button, stop button, emergency stop button, run light, 2 or 3 phase digital power analyzer. (Remote start/stop option). Accessories include alligator clamp test leads for cam-lok receptacles
(2) Variable DC Power Supply: 30VDC/ 5A single variable output. Features include low output noise (1 mVrms), over voltage and over current protection, LCD display with backlight, standby output for safety, save-and-recall function up to three memory states, & keypad lock.
3) 5.5 Digit Multimeter: Measures VAC up to 750V, VDC up to 1,000V, resistance, amps (AC & DC), frequency, period & continuity, & diode test.
4) AC/DC Power Supply: Variable output 0-140VAC @ 7.2A, 0-280VAC @ 3.6A, 0-560VAC @ 1.8A/ 0-120VDC @ 7.2A, 0-240VDC @ 3.6A, 0-480VDC @ 1.8A. Equipped with volt meter. (20A output option available)
5) Tool Tester: Verifies the safety and performance of electrical equipment. Just plug in the tool, attach the ground clip and operate the push buttons 1-5. Tests 120V metal cased and double insulated tools and appliances drawing up to 20A. Features include 120VAC/ 20A output voltage, 3 Ohms @ 60V line to line short, 10mA AC @ 60V line to case short, 0.1-10mA leakage current test, +/-3% accuracy.
6) 5000V Megohmmeter: Digital/Analog Megohmmeter is a fully automated 250V, 500V, 1000V, 2500V & 5000V insulation tester. Large LCD with backlight. Test insulation on cables, transformers, motors, wiring installations & continuity checks. Displays test voltage and run time. Provides insulation measurements to 10 TΩ. Insulation test alarm. Rotary switch operation. Test results include IR, Timed IR, DAR, PI, DD, capacitance, voltage measurement. Test leads. (Memory optional)
7) Metered 240 VAC Outlet: 240 VAC, 20A NEMA L6-20-R receptacle panel mounted (Equipped with power analyzer)
8) Metered 120 VAC Outlet: 120 VAC, 20A GFCI receptacle panel mounted (Equipped with power analyzer)
9) 24 VDC Options: Continuity test, loop powered meter, fixed power supply, solenoid test
10) Digital Relay Timer: Designed to test protective relays by determining the reaction of the delay time of a relay in relation to a trip condition. NO/NC dry contact & 5 to 250V dc or ac inputs. Features include 40.00Hz to 500.0Hz measurement range, 0.001Hz resolution, +/- 0.002Hz accuracy, 00.000 to 99999 second measurement, 0000.0 to 9999.9 cycle measurement, 20.000 to 4000.0Hz frequency, & 5 to 250v DC or AC input. Includes test leads, alligator clips.
11) Solenoid Test Options: 24VDC, 120VAC, 120VDC, 240VAC. Multiple options are available for each electrical test bench.
Available Options
12) 10A Micro-Ohmmeter: Digital Micro-ohmmeter measures from 250 mΩ to 2500.0Ω. Measures low resistance values in applications like railways, aircraft, resistance of components, cable manufacturers, induction of electric motors & generators, thick conductors, bonds & welding applications. Digital display with backlight. Features include automatic, automatic bidirectional, normal, inductive, continuous test modes. 0.1mA, 1mA, 10mA, 100mA, 1A & 10A test current selections. Test current accuracy ±10%. Voltmeter input impedance >200 kΩ. Maximum lead resistance at 10 A <100 mΩ. Test leads. (Memory optional)
13) High Current Test Set/Power Supply: High current, low voltage test set good for many purposes such as testing circuit breakers, motor overload relays, current transformers, heat runs, ground faults, etc. Continuous current of 250 amps with peak maximum output 750 amps through a breaker and 1000 amps into a short. Equipped with an LED 4 digit panel displays readout of current and time, easy keypad control, PIC microcontroller, precision A/D converter, sophisticated current sensing system, automatic over range detection, & four output taps. Readout for current in eight ranges from 5.000 A to 1000 A full scale. 4-digit timer displays in seconds or cycles mode, with a resolution of 0.001 second or 0.1 cycle. Features include +/- 0.5% current accuracy, +/- 0.005 sec timer accuracy, 0-3.5 volts at 200 amps, 0-130 volts at 5 amps, continuous output, & pulse output up to 5X.
14) RTD Simulator/Decade Box: Features include 50 ppm absolute accuracy, 1 mOhm resolution, 10 ohms to 1111.110 ohms, no “zero” resistance, & direct setting. Ideal for DIN PT-100, PT-100 ANSI, PT-50 and NI-120 systems.
15) Power Quality & Motor Analyzer: Motor analysis test tool for evaluating the electrical and mechanical performance of electric motors, and troubleshooting power quality. LCD display. Measures direct-on-line motor torque, RPM, mechanical power and motor efficiency. Plots motor derating factor against load according to NEMA/IEC guidelines. Calculate mechanical power and efficiency. Measures voltage, current, power, apparent power, power factor, harmonic distortion and unbalance. Identifies dips, swells, transients, harmonics and unbalance. PowerWave data technology captures fast RMS data, half-cycle averages and waveforms. Mechanical motor range 0.7 kW to 746 kW. Power 1 hp to 1000 hp. Torque 0 Nm to 10 000 Nm. RPM 0 – 3600 rpm, Voltage 1-1000V phase to neutral. Hertz 50/60. Phase angle, Flicker. Supports motor design types NEMA A, B, C, D & E and IEC type H and N. Includes Test lead set, (4) i430 Thin flexible current probes, PowerLog 430-II software. Combination WiFi/8GB SD card.
16) Vibration Tester: Vibration diagnostic unit features on-board identification and location of the most common mechanical faults (bearings, misalignment, unbalance, looseness) and focuses mechanical maintenance efforts on root cause. Quickly assess overall machine health directly from the diagnosis screen. Fault severity scale. Actionable recommendations. Detailed diagnostic reports and spectral diagrams. Provides analysis for: Motors, fans, blowers, belts and chain drives, gearboxes, couplings, centrifugal pumps, piston pumps, sliding vane pumps, propeller pumps, screw pumps, rotary thread/gear/lobe pumps, piston compressors, centrifugal compressors, screw compressors, closed coupled machines, spindles. Motor Rotational Speed Range 200 rpm to 12000 rpm. Diagnosis Details: Plain-text diagnosis, fault severity (slight, moderate, serious, extreme), repair details, cited peaks, spectra. Usable Bandwidth 2 Hz to 20 kHz. Digital Signal Processing Functions: Automatically configured anti-alias filter, high-pass filter, decimation, overlapping, windowing, FFT, and averaging. Sampling Rate 2.5 kHz to 50 kHz. Dynamic Range 128 dB. Signal To Noise Ratio 100 dB. FFT Resolution 800 lines. Spectral Windows: Hanning. Frequency Units: Hz, orders, cpm. Amplitude Units in/sec, mm/sec, VdB (US). Display: ¼ VGA, 320 × 240 Color (5.7 inch diagonal) TFT LCD with LED backlight. Input/Output connections: Triaxial sensor connection, 4 pin M12 connector, Single axis sensor connection, BNC connector, Tachometer connection, Mini DIN 6 pin connector, PC connection, Mini ‘B’ USB (2.0) connector. SD micro memory card, 2 GB internal + user accessible slot for additional storage. Accessories included: Viewer PC software, tri-axial TEDS accelerometer, accelerometer magnet mount, accelerometer mounting pad kit with adhesive, accelerometer quick-disconnect cable, laser tachometer and storage pouch, smart battery pack with cable and adapters, shoulder strap, adjustable hand strap, mini-USB to USB cable. Hand-held unit.
17) Motor Surge Tester & Winding Analyzer: Static Motor Analyzer automatically performs repeatable, user-programmable tests to thoroughly assess the strength of a motor’s insulation and circuit for motor repair, reliability and maintenance in industrial environments. A 12kV Output Motor Surge Tester & Winding Analyzer features fully automatic testing capabilities that include: surge, winding resistance, Megohm, PI, DA, continuous ramp DC step-voltage, and DC hipot tests. Intuitive, touch-screen user interface that offers computer control and waveform monitoring. Windows-based instrument that can be programmed to perform a specific set of tests on a given motor with attributes like tests and sequences, target test voltage, pass/fail criteria and motor nameplate information all saved for future use. Analysis data can also be saved to a server or PC database. Additional tests include a pulse-to-pulse EAR (error area ratio) calculation that is applied to compare waveform differences not easily detected by eye sensitive to <1% variance. Also performs armature tests & shunt fields tests. USB ports for data transfer and printing with Windows 7 plug-and-play printers. Wireless networking capability. RJ-45 ethernet port for wired local-area network connections. Power pack compatibility. IEEE- and IEC-compliant surge test. Surge test specs: Output 12K volts. Max output current 600A. Pulse energy 2.55 J. Storage capacitance 0.04 μF. Sweep range 2.5 to 200 μs/Div. Volts per division 250 / 500 / 1000 / 2000. Repetition rate 5Hz. Voltage measurement and accuracy ±12%. DC Hipot test specs: Output 12K volts. Max output current 5mA. Current resolution 0.1, 1, 10, 100 μA/Div. Overcurrent trip settings 1, 10, 100, 1000 μA. Voltage & current accuracy ±5%. MΩ accuracy ±10%. Max MΩ reading >50 GΩ. Resistance measurements 1 mΩ to 800 Ω. Accessories include: USB flash drive with software(Windows 10 compatable), test leads, keyboard with mouse. Optional accessories not included: Baker Power Pack, ZTX low-impedance test accessory, USB plug-and-play printer, USB wireless network adapter. (Other options available)
18) Function Generator: Features include 10 MHz sine & square waveforms, pulse, ramp, triangle, noise, & DC waveforms, AM, FM, & PWM modulation types, linear & logarithmic sweeps and burst operation, 10 mVpp to 10 Vpp amplitude range, graph mode for visual verification of signal settings, & USB, GPIB & LAN connections.
19) Digital Oscilloscope: Features include a 8.5″ display with 64 intensity levels, 800 x 480 resolution, 100 MHz bandwidth, 5 Gsa/s sample rate, 2 analog channels, 4 Mpts MegaZoom III deep memory, Vertical resolution: 8 bits, Modes: Main, zoom, roll, XY. Trigger modes, Trigger coupling, Search & navigate, update rate of 1,000,000 waveforms/sec. Counter. Arithmetic functions. FFT. Waveforms: Sine, square, ramp, pulse, DC, noise, sine cardinal (sinc), exponential rise, exponential fall, cardiac, Gaussian pulse, and arbitrary. Modulation: AM, FM, FSK. USB front port. 500 MHz passive probe (10:1 attenuation).
20) RF Frequency Counter: Features include a 10 digit display, one 350 MHz input channel, frequency, frequency ratio, period & voltage measuring. Built-in math analysis and color, graphical display (trend and histogram).
21) Adjustable Motor Cart: Secures motors for run testing to prevent flipping or movement. Adjustable locking rails and footing bolts allows mounting of various motor sizes. Adjustable motor base accommodates 50 different NEMA motor frame/plate sizes (56 – 400). Easy to use hydraulic foot lever lifts 2,200 lbs. Heavy duty steel construction. Height adjustable from 15” to 39”. Table measures approximately 47” L x 24” W. Portable ergonomic elevating carts minimize worker bending and lifting. Promotes safe work positioning and ergonomic handling. Heavy-duty cast iron polyurethane casters; 2 swivel casters and 2 fixed casters.
22) Custom electrical test bench options
NOTE: Items listed here are dependent on the options you choose for your electrical test bench.
Contact us to discuss your requirements of ly-70. Our experienced sales team can help you identify the options that best suit your needs.