Automatic testing system for motor type testing

skill art instrument for drawing circles check book

1、 System Description

The dynamometer and its testing system consist of hysteresis dynamometer, dynamometer controller, DC parameter tester, single-phase electrical parameter measuring instrument, control cabinet, software, and fixtures. It can arbitrarily change the load of the tested motor and directly measure the input voltage, current, power, output torque, speed, output power, and efficiency of the motor under no-load, load, and locked rotor conditions.

The software can achieve manual and automatic testing methods, complete no-load, locked rotor, and load testing, and has functions such as drawing characteristic curves, storage, and printing.

2、 Test project

1. No load test: voltage, current, power.

2. Load test: Measure the load characteristic curve, including voltage, current, power, output torque, speed, power, and efficiency.

3. Lock up test: measure the lock up characteristic curve, including voltage, current, power, output torque, speed, power, and efficiency.

4. The system can transfer all test data to the computer and draw corresponding curves, with storage and printing functions.

5. The system is equipped with a complete set of Simplified Chinese software, which can create motor type test report forms and curve graphs.

3、 Main features of the system

1. Sampling time: Set the sampling time arbitrarily (20ms~1000ms) to meet the high-speed measurement needs of users.

2. Range and number of teeth setting: Users set the range and number of teeth on the gear plate or photoelectric encoder based on the torque range and speed of the dynamometer itself.

3. Hub function (station number selection): When configuring multiple (≥ 2) dynamometers, users can choose the VG2218C-JXQ type 8-way hub, which can be operated by computer software or VG2218C to select the specified dynamometer (or station). The hub automatically switches the corresponding signal, avoiding operational errors and safety caused by frequent plugging and unplugging of signal ports when changing dynamometer positions.

4. Automatic calibration and calibration function: In addition to retaining manual calibration (including positive full-scale, negative full-scale, and zero adjustment) functions, users can automatically calibrate the entire process of the dynamometer on the computer. The calibration process is clear, and the calibration data can be stored on the computer. The calibration data table can be automatically generated and printed out.

5. Load loading modes of dynamometer: excitation mode, constant torque mode, constant speed mode; The PID function ensures fast dynamic response and more stable operation of the load.

6. Synchronous sampling of input and output parameters for motor operation: input voltage, current, power and output torque, speed, input power, efficiency. Having synchronous sampling during measurement ensures data consistency.

7. Production line testing function: With the continuous improvement of customer quality control of motors, in addition to measuring and controlling the input parameters of motors, measurement and control of motor output parameters (torque, speed, output power, efficiency) are added at the factory. Under forward and reverse rotation conditions, the input voltage, current, power, output torque, speed, output power, and efficiency of motors can be automatically and continuously measured in sequence for no-load, load (or multi-point), and locked rotor states. Our company has been developing for many years, using unique image and curve simulation functions, adopting the optimal interval setting average algorithm, and automatically determining OK/NG based on the upper and lower limits set by the computer. This feature not only has good data repeatability, but also provides a more intuitive way to detect abnormal test data during motor installation or testing.

8. Dynamometer loading method: In addition to the traditional manual excitation loading method, this system has multiple automatic loading methods: constant excitation incremental loading method, constant torque incremental loading method, constant speed incremental loading method, constant torque loading method, constant speed loading method, and constant slope loading method.

9. Curve drawing and fitting function: The system can meet the testing requirements of users for various motors and test projects, and draw various parameter characteristic original curves, fit curves, and automatically generate no-load point parameters (current, speed), maximum torque point parameters (voltage, current, speed, efficiency, output power), maximum efficiency point parameters (speed, torque, current, output power), and maximum output power point parameters (speed, torque, current, output power).

10. Report and query function: Multiple curves can be drawn in the same coordinate to meet customers' analysis of product consistency and repeatability.

11. The powerful system function self-test and rapid on-site fault diagnosis capability are important indicators that the new generation of high-performance dynamometer systems must possess. Our company has carefully launched a portable dynamometer signal detection tool, which can detect the input and output signal size of various module units (such as sensors, acquisition boards, dynamometer controllers, etc.) of the dynamometer system on site, quickly identify the fault source (fault point), and greatly improve the system's service capability and efficiency.

12. Unique anti-interference and reliability design: The application of multi-level electromagnetic compatibility (EMC) technology (such as grounding, shielding, isolation, filtering, etc.) and the guarantee of good manufacturing processes. Ensure the reliability and anti-interference ability of the system, and the system can operate stably and reliably in environments with interference, sparks, high frequency, high voltage, and strong electrical shocks. Especially in the current environment, there is radiation from high-frequency power electronic devices, which is particularly necessary.

13. The new generation of high-quality dynamometer systems focuses on current motor energy efficiency certification and high-precision testing, and therefore is committed to the overall accuracy consistency of the system. Research on measurement repeatability is an important aspect of dynamometer systems. According to the characteristics of the usage scenario of the dynamometer system (the workplace is not equipped with air conditioning, and the ambient temperature cannot be guaranteed), it is necessary to improve the working temperature range of all module units and instruments in the dynamometer system under measurement accuracy (considering 0 ℃~50 ℃), and solve the problem that is easily overlooked by users in terms of ambient temperature (i.e. poor efficiency measurement repeatability in summer and winter).

4、 Technical parameters

1. Voltage: 0-300VDC/0-300VAC Accuracy: Class 0.5

2. Current: 0-5ADC/0-20AAC Accuracy: Level 0.5

3. Power: U * A Accuracy: Level 0.5

4. Torque: 100mN. M, 500m N. M, 5 N. M Accuracy: Class 0.5

5. Speed: 25000r/min Accuracy: Class 0.2

5、 The fixture is made according to the customer's requirements, with motor samples provided by the customer

6、 System composition

1. Hysteresis dynamometer HD-102/HD-502/HD-503 1 each

Suitable for testing motors with small to medium torque and high speed, such as fan motors, asynchronous motors, low-power DC motors, and electric tools.

Accuracy: Torque ≤± 0.5%, speed ≤± 0.2%

Dynamometer	Model number	Rated torque (N.m)	Maximum speed (r/min)	Rated power within 5 minutes (W)	Continuous operating power (W)
hysteresis dynamometer	HD-102	100m	25000	90	25
hysteresis dynamometer	HD-502	500m	25000	250	65
hysteresis dynamometer	HD-503	5	25000	1000	200

3. 1 dynamometer controller VG2218C

The dynamometer controller is used in conjunction with various types of dynamometers, torque and speed sensors, 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);

4. One GDW1206A DC parameter tester

DC voltage (300V), DC current (5A), DC power, accuracy level 0.5,

Function: Three window conversion display, automatic range conversion, latch, external splitter range setting

B Single phase electrical parameter measuring instrument GDW1200C

5. One vertical system control cabinet

6. Test software VB1.0 1 set

The software integrates two testing methods: production line testing and type testing, mainly used for production line and type testing of motors. Using the method of delineating the range to determine measurement values in production line experiments can keep the measurement data stable.

U software unit

7. 3 sets of specialized fixtures and protective covers

3 sets of dynamometer racks

The dynamometer stand is compatible with the dynamometer system

1. Provide a complete set of operating instructions and a software CD. The manual must explain how to use the equipment, how to set parameters, precautions for equipment operation, and safety terms. The software CD should provide a complete computer operating system, testing software, and testing data analysis software.

1. The supplier shall provide training to at least one maintenance personnel and one equipment operator from the demand side until they have fully mastered the relevant skills. The training period shall not be less than 2 working days. The specific time will be determined according to the arrangement of the demand side.

1. After the equipment is manufactured, the supplier shall notify the purchaser to conduct a pre acceptance inspection. After the pre acceptance inspection is qualified, the equipment shall be sent to Party A.

2. The supplier is responsible for the installation and commissioning of the equipment on the demand side; After the equipment debugging is completed, both parties shall conduct acceptance according to the content of the technical agreement; The equipment shall meet all the requirements specified in this agreement.

1. After the equipment and installation debugging self acceptance are qualified and delivered for normal use, it enters the warranty period, which is 12 months.

1. The purchaser shall provide cooperation for the supplier's on-site work.

2. Both parties shall keep confidential all relevant information and materials, and shall not engage in any behavior that harms the interests of the other party for any reason or in any way without the permission of the other party (such as disclosing the other party's information and related technical information to third parties or imitating the other party's products, etc.).

3. The warranty period for the equipment is 12 months from the date of self acceptance (the supplier shall provide free replacement and maintenance warranty services as required by the demander). After receiving the demander's warranty service request, the supplier shall provide feedback within 2 hours and conduct on-site maintenance within 48 days. Even if the warranty period is exceeded, the supplier shall provide active and preferential services.