1The AC power dynamometer test bench system is suitable for performance research and assessment testing of electric vehicle motors and controllers,Provide accurate and reliable test charts and data as a basis for testing the power performance, efficiency characteristics, and safety protection functions of the electric drive system, in order to evaluate the product performance of the electric drive system; And conduct research on vehicle motor control strategies by simulating actual vehicle operating conditions.This system can be used for testing electrical performance of electric vehicle motors and controllers.

2This system is mainly used for testing the performance, medium temperature and temperature rise, motor torque characteristics and efficiency of electric vehicle motors and controllers. Main test contents: motor three-phase resistance, no-load test, load efficiency test, locked rotor test, motor temperature, motor temperature rise, overload capacity test, maximum working speed, overspeed test, motor controller protection test, etc.

3The system can set a constant torque test below the rated speed of the motor; Constant power test above rated speed, displaying torque speed curve and efficiency speed curve on industrial computer

4Testing of motor power generation performance: The testing system can set the load motor power generation efficiency for controller testing.

5The rated working voltage of the frequency converter is 380V, and it is air-cooled.

6The frequency converter has good input harmonic suppression function, and the harmonics within the entire speed range do not affect other electrical equipment or control and communication systems.

7The frequency converter is designed and manufactured in accordance with national standards, international standards, and industry standards such as GB, ISO, IEO, IEEE, etc.

8The frequency converter adopts IGPT power components, and the power components are selected from ABB products.

9The frequency converter has good speed regulation and low-speed operation performance, with a frequency regulation accuracy of 0.1HZ and a stability of 0.5%, and has good loading characteristics.

10Has anti drag performance.

11It has protection functions such as overcurrent, overvoltage, undervoltage, phase loss, short circuit, overclocking, stall, overheating of power components, and instantaneous power outage.

12Compared with other load (dynamometer) devices, AC power dynamometers have the following unparalleled advantages:

(2) It can operate in four quadrants, which means it can be used as both a generator and an electric motor; It can be loaded forward or backward. This is similar to engine testing that requires reverse towing, and transmission testing that requires forward and reverse towingLoading and other experiments are very ideal.

(3) Energy saving: Due to the use of power generation feedback loading, the energy-saving effect of the DC bus power dynamometer system is particularly significant. Especially for fatigue life testing, the energy-saving effect is very significant. The energy-saving efficiency mainly depends on the efficiency of the test bench transmission, usually around 80%

(4) The loading characteristics are very good: constant torque loading can be maintained below the rated speed (0 speed or even reverse), and constant power loading can be achieved above the rated speed.

(5) Since the loader itself does not consume loading power (feedback to the grid or input), it does not require a device that requires a large amount of water as a medium like hydraulic dynamometers and cooling with water like eddy current dynamometers.

(6) The stability of constant torque and constant speed control is unparalleled by other loaders, as it can maintain extremely high stability (0.1% -0.3%) throughout the entire speed (even at zero speed) and torque range.

(7) There are two working modes available: constant torque (loading) and constant speed (reverse drag) to meet different testing needs.

(8) Simple structure, good stability and reliability, easy to use.

(9) It can easily achieve zero torque and zero speed starting, to achieve true impact free soft starting for the power grid and machinery.

2、 Equipment testing execution standards are based on:

1. GB/T18488.1-2015 "Technical Conditions for Test Methods of Electric Motors and Controllers for Electric Vehicles"

2. GB/T18488.1-2006 "Technical Conditions for Test Methods of Electric Motors and Controllers for Electric Vehicles"

3. GB/T18488.2-2006 "Test Methods for Motors and Controllers for Electric Vehicles"

4. GB/T755-2008 "Rating and Performance Test Methods for Rotating Electrical Machines"

5. GB/T1029-2006 Test Methods for Three phase Synchronous Motors

6. GB/T1032-2005 "Test Methods for Three phase Asynchronous Motors"

7. GB/T 18385-2005 "Test Methods for Power Performance of Electric Vehicles"

8. GB/T 19752-2005 "Test Method for Power Performance of Hybrid Electric Vehicles"

9. GB/T 18384.1-2001 "Safety Requirements for Electric Vehicles - Part 1: On Board Energy Storage Devices"

10. GB/T 18384.2-2001 "Safety Requirements for Electric Vehicles Part 2: Functional Safety and Fault Protection"

11. GB/T 18386-2005 "Test Method for Energy Consumption Rate and Range of Electric Vehicles"

12. GB/T 50054-95 "Code for Design of Low Voltage Distribution"

13. GB/T 50055-93 "Design Specification for Distribution of General Electrical Equipment"

3、 Composition of experimental equipment:

This test bench consists of eight major parts

1. Mechanical bench section: used to install AC power dynamometer, torque speed sensor, and test motor

The requirements for the motor test bench are: it should be able to test the types of motors used in vehicle AC induction asynchronous motors and three-phase permanent magnet synchronous motor systems

AC electric dynamometer

Select an AC high-speed power dynamometer and encoder (using a high-speed three-phase AC variable frequency motor as the load motor, used to load the accompanying test load motor, and also as the driving motor)

B torque speed sensor

Using a high-speed response torque speed sensor of 200Nm for testing the mechanical torque, speed, and power of the motor

C coupling and motor clamping

The coupling is composed of cast steel diaphragms: quantity: 4 pieces.

The motor clamping adopts the L-shaped bracket for flange connection of the sample motor. Quantity: 1 piece

Number of calibration devices: 1 set

2. Electric dynamometer controller

Adopting ABB variable frequency control technology for driving and braking units, direct torque control is implemented to achieve two ways of motor drag and power generation

3. DC parameter measuring instrument model: GDW1206A

4. VG2218C dynamometer controller (torque and speed tester)

Test the output torque and speed, output power, and efficiency of the electric motor

Equipped with speed and torque sensors to measure motor output torque, speed, power, etc

The instrument adopts a new core with high-speed, assembly line, and advanced simplified instruction set structure, with a running speed of 10MIPS, and is equipped with an integrated high-speed digital filter A/D for sampling.

Measurement parameters: speed: 0-35000r/min, accuracy: ± 0.2%;

Torque: 20mN · m~5000N · m (total range of 20), manual switching, accuracy: ± 0.5%;

Power: 0.00W~9999KW, excitation current: (0-2) A (loading capacity);

Testing method: 2.1. Manual excitation regulation;

2.2. Fixed torque (P.I.D);

2.3. Constant speed (P.I.D);

2.4. Automatic slope loading;

5. RDC2512B Intelligent DC Low Resistance Tester

Used to test the cold and hot DC resistance of motor windings:

Measurement range: 0.01m Ω -19.88k Ω Measurement accuracy level 0.2

6. Multi channel temperature tester

Temperature measurement range: 0-300 degrees, measurement accuracy of 0.5 level, 8 channels

7. One set of industrial control computer+motor testing and control software

Xunyan P4 industrial grade computer, 2G memory, 500g hard drive, DVD drive, USB interface, 17 "Lenovo LCD display HP laser printer, testing software compatible with the dynamometer system. The software combines with the computer for data acquisition and processing, providing functions such as color graphic curve display, data table printing, and data storage. The data measurement system adopts two display modes: automatic computer acquisition and instrument display. Automatically collect experimental data on input speed, torque, power, and output speed, torque, power, etc; Automatically save and process data; Draw curves and automatically generate printed test reports; Establish a test database and product quality statistics table, with convenient and fast query methods. The test report can be automatically generated during the testing process, or manually inputted in a format that can be agreed upon by both parties. The report can also be compiled by importing raw data into Excel for easy manual operation, including manual participation functions such as adjusting certain data. Control the torque loading of ABB frequency converter through PLC control; Make torque control more convenient, efficient, and accurate.

8. DC stabilized power supply for vehicles: (to be provided by the customer)

Voltage 0-600V, current 0-150A per unit

Main technical indicators of the product
1. Input/output	Input: AC three-phase 380V ± 10% 50Hz/60Hz Output: DC voltage stabilization Output maximum voltage and current value 600V 150A
2. Voltage stabilization accuracy	Source effect (when the source voltage changes by ± 10%): ≤ 0.3% of the rated value Time drift (continuous working time greater than 8 hours): ≤ 0.3% of rated value Temperature drift (rate of change caused by temperature changes within a temperature range): ≤ 0.04% rated value/℃ Load effect (when the output current changes from zero to rated value): ≤ 1% of rated value
3. Steady current accuracy	Source effect (when the source voltage changes by ± 10%): ≤ 0.3% of the rated value Time drift (continuous working time greater than 8 hours): ≤ 0.3% of rated value Temperature drift (rate of change caused by temperature changes within a temperature range): ≤ 0.04% rated value/℃ Load effect (when the output current changes from zero to rated value): ≤ 1% of rated value
4. Ripple	When stabilizing voltage: effective value ripple ≤ 0.5% rated value+10mV, ripple peak to peak value ≤ 5% rated value (measured at rated input, 80% to 100% rated output, measurement method according to relevant standards)
5. Output voltage regulation range	0-Adjustable rated value (indicated in different levels)
6. Output current	0-Adjustable rated value (output at rated value when the equipment leaves the factory)
7. Output voltage setting	Button settings
8. Protection method	1. Automatic output cut-off and trip protection for overvoltage, overcurrent, overtemperature, phase loss, and short circuit; This machine has an emergency stop protection button; 2. Equipped with external node signal control emergency stop function;
9. Status indication	Equipped with power on, overvoltage, overcurrent, overtemperature, phase loss, and short-circuit status indicators
10. Alarm function	All overvoltage, overcurrent, overtemperature, phase loss, short circuit, and protection methods are equipped with alarm display and alarm sound, and have output ports for switch signals (disconnected when the node signal is normal and closed when the fault occurs). The emergency stop function has alarm and node signal output
11. Working methods	Can work continuously at full load for a long time
12. Soft start function during startup	The soft start time is between 2s and 5s (approximately)
13. Output voltage and current display mode	LCD display
14. Output voltage and current display resolution	1V；1A
15. Error of overall voltage and current meter	≤± 1% ± 1 word (measurement range 1%~100% rated value)
16. Test the absorbed power of the power supply of the motor during braking	The power supply during motor braking is 15KW of the rated power when absorbed
17. Environmental conditions	Usage location: Only for indoor use Temperature: -20 ℃ to 40 ℃ Air humidity: ≤ 80%

4、 Main testing items:

1. Motor temperature rise test

2. Motor torque characteristics and efficiency testing

A stalling torque and stalling current

B torque speed curve

Calculation of C motor efficiency and control efficiency

D Voltage fluctuation and peak torque, power measurement

3. Maximum operating speed test

4 overspeed test

5. Motor no-load characteristic test

6. Motor load characteristic test

Overload test of 7 motors and their controllers

8 Motor and its controller protection test

5、 Function

1. Manual control

In order to ensure the completion of certain new special test projects and to ensure that the computer system does not have a significant impact on the test progress in the event of short-term unrecoverable faults, the bidder must provide complete manual operation control functions (control and measurement of the computer can be completed by manually reading the test items when it is not running), and the operator can complete the test through the switches, buttons, and adjustment devices on the control console.

2. Automatic control

2.1 To ensure the safety of the experiment, power switches, output voltage conversion switches, etc. are not automatic and are operated manually through buttons or buttons designed on the computer.

2.2 After inputting the rated parameters of the tested motor, select the test item. The system can be controlled by computer and PLC to automatically complete the entire process of the test item with the participation of manual labor according to the initial set test item and test plan.

3. The operation control system must have an emergency stop (power button) function.

4. Realize the collection, analysis, processing, display, printing of test reports, data storage, and partial control functions of experimental data through computer software. The entire testing system consists of an industrial computer, range gear switching device, sensors, signal conditioning module, hardware for data acquisition and measurement instruments, measurement software, and other components.

5. The data measurement system adopts two display modes: computer automatic acquisition and instrument display.

6. Automatically collect test data such as DC voltage, current, power, speed, torque, output power, temperature, etc; Automatically save and process data; Draw curves and automatically generate printed test reports; Establish a test database and product quality statistics table, and the query method should be convenient and fast.

7. The test report can be automatically generated during the testing process or manually inputted, and its format is agreed upon by both parties. The report should be prepared using the most convenient computer language currently available, which is easy for manual operation, including manual participation functions such as adjusting certain data.

8. The accuracy of measuring instruments should meet the electrical testing requirements for electric vehicle motors and controllers according to standards.

9. The accuracy of the torque speed sensor is 0.2 level, requiring high dynamic stability.

10. The measurement of input power (voltage, current, power, etc.) has an accuracy of 0.5 level.

11. The accuracy of temperature measurement is level 0.5.

12. The accuracy of resistance measurement is 0.2 level.

13. The measurement system and control system must be equipped with backup software CDs.

14. The experimental parameters are automatically collected by the computer, with modular functions. After each functional test is completed, relevant curves are generated and the test report can be printed.

6、 Test environment requirements:

Power supply voltage: 380V ± 10%, ambient temperature: 0-40C ° C, relative humidity:<90%

Grounding requirement: There must be an independent grounding wire

Power supply system connection: manually operated disconnect device.