Motor rack test safety management method, device, equipment and medium

Abstract

The invention relates to a motor bench test safety management method and device, equipment and a medium, and relates to the field of motors. The method comprises the following steps: acquiring three-phase current ripple data of an energy flow in a feedback path; performing feature analysis based on the three-phase current ripple data, and determining abnormal heat source information; calculating an impedance value and an impedance change rate of each feedback path based on the monitoring data of the feedback paths, and determining a risk path; wherein the feedback path is a path through which the energy flow flows from the motor to the power grid and / or the energy storage unit; updating a first feedback path based on the abnormal heat source information and the risk path; and performing path switching based on the first feedback path, and triggering an early warning signal. By adopting the method, the test safety can be ensured.

Description

Technical Field

[0001] This application relates to the field of computer technology, and in particular to a method, apparatus, equipment and medium for safety management of motor bench testing. Background Technology

[0002] As the core power source of new energy vehicles, the performance of electric motors directly determines the vehicle's power output, range, and operational stability. Therefore, accurate evaluation of motor performance has become a crucial link in the industry's development. Motor bench testing, as a core method for evaluating the electrical, mechanical, and reliability of motors, simulates various real-world operating conditions such as vehicle starting, acceleration, and braking to achieve comprehensive testing of the motor's performance throughout its entire lifecycle.

[0003] Motor bench testing is a crucial step in evaluating motor performance, and its operational safety directly impacts the accuracy of test data, the continuity of the testing process, and the lifespan of the equipment. However, existing motor bench testing systems still have functional deficiencies, making it impossible to proactively mitigate safety hazards during testing and thus compromising safety.

[0004] Therefore, ensuring the safe operation of the motor bench testing system throughout the entire testing cycle has become an urgent problem to be solved. Summary of the Invention

[0005] This application provides a method, apparatus, equipment, and medium for safety management of motor bench testing, which can ensure the safety of the test.

[0006] To achieve the above objectives, this application adopts the following technical solution: Firstly, this application provides a method for safety management of motor bench testing, including: Obtain the three-phase current ripple data of the energy flow in the feedback path; Feature analysis based on three-phase current ripple data is used to determine information about abnormal heat sources; Based on the monitoring data of the feedback path, the impedance value and impedance change rate of each feedback path are calculated to determine the risk path; whereby the feedback path is the path of energy flow from the motor to the power grid and / or energy storage unit. Based on information about abnormal heat sources and risk paths, update the first feedback path; The path is switched based on the first feedback path, and an early warning signal is triggered.

[0007] In one embodiment, feature analysis based on three-phase current ripple data is used to determine abnormal heat source information, including: Feature analysis is performed based on three-phase current ripple data to obtain feature vectors; the feature vectors are then compared with fault vectors in a pre-set fault vector library to determine abnormal heat source information.

[0008] In one embodiment, determining a risk path includes: For each feedback path, if the impedance value of the feedback path is greater than the impedance reference value, and / or the impedance change rate of the feedback path is greater than the change threshold, the feedback path is determined to be a risk path.

[0009] In one embodiment, the first feedback path is updated based on abnormal heat source information and risk paths, including: For each feedback path, a first path value is calculated based on a first weight, a second weight, a first impedance value, a first heating rate value, the impedance value of the feedback path, and the heating rate. The first weight is a weighting coefficient corresponding to the impedance value; the second weight is a weighting coefficient corresponding to the heating rate; the first impedance value is a reference value for normalizing the impedance value; the first heating rate value is a reference value for normalizing the heating rate. Risk paths in the feedback path are eliminated to obtain candidate paths. Based on the first path values ​​corresponding to each candidate path, the candidate path with the smallest first path value is determined as the first feedback path.

[0010] In one embodiment, the first path value corresponding to the feedback path is calculated based on the first weight, the second weight, the first impedance value, the first heating rate value, the impedance value of the feedback path, and the heating rate, including: The ratio of the impedance value of the feedback path to the first impedance value is determined as the first impedance ratio; the product of the first impedance ratio and the first weight is determined as the second impedance ratio; the ratio of the heating rate of the feedback path to the first heating rate value is determined as the first heating ratio; the product of the first heating ratio and the second weight is determined as the second heating ratio; the sum of the second impedance ratio and the second heating ratio is determined as the first path value corresponding to the feedback path.

[0011] In one embodiment, path switching is performed based on a first feedback path, and an early warning signal is triggered, including: Obtain the impedance value of the main feedback path; if the impedance value of the main feedback path meets the switching requirements, switch the main feedback path to the first feedback path and trigger an early warning signal.

[0012] In one embodiment, it includes: Based on the bidirectional inverter, the reverse electromotive force energy generated during the motor bench test is fed back to the grid and energy storage unit.

[0013] Secondly, this application provides a safety management device for motor bench testing, comprising: The data acquisition module is used to acquire the three-phase current ripple data of the energy flow in the feedback path; The heat source location module is used to perform feature analysis based on three-phase current ripple data to determine information about abnormal heat sources. The monitoring module is used to calculate the impedance value and impedance change rate of each feedback path based on the monitoring data of the feedback path, and to identify risk paths; wherein, the feedback path is the path of energy flow from the motor to the power grid and / or energy storage unit; The path update module is used to update the first feedback path based on abnormal heat source information and risk paths; The path switching module is used to switch paths based on the first feedback path and trigger an early warning signal.

[0014] Thirdly, this application provides a computing device, including a memory and a processor; The memory stores one or more computer programs, the one or more computer programs including instructions; when the instructions are executed by the processor, the computing device performs the method as described in any one of the first aspects.

[0015] Fourthly, this application provides a computer-readable storage medium for storing a computer program for performing the method as described in any one of the first aspects.

[0016] Fifthly, this application provides a computer program product comprising one or more computer instructions, wherein when the computer instructions are executed by a computer, the computer performs the method as described in any one of the first aspects.

[0017] As can be seen from the above technical solution, this application has at least the following beneficial effects: In this application, three-phase current ripple data of energy flow in the feedback path is acquired to provide a data foundation for data analysis. Based on the three-phase current ripple data, feature analysis is performed to identify abnormal heat sources, thus locating the fault. Based on the monitoring data of the feedback path, the impedance value and impedance change rate of each feedback path are calculated to identify risky paths, laying the foundation for ensuring test safety. Based on the abnormal heat source information and risky paths, the first feedback path is updated, providing options for path switching. Path switching is performed based on the first feedback path, triggering an early warning signal to ensure test safety. This scheme introduces three-phase current ripple data to lay the foundation for identifying abnormal heat sources; furthermore, by introducing impedance values ​​and impedance change rates, it provides a basis for evaluating the risk performance of each path; and by updating the first feedback path, it provides options for path switching, ultimately ensuring test safety.

[0018] It should be understood that the descriptions of technical features, technical solutions, beneficial effects, or similar language in this application do not imply that all features and advantages can be achieved in any single embodiment. Rather, it is understood that the description of a feature or beneficial effect means that a specific technical feature, technical solution, or beneficial effect is included in at least one embodiment. Therefore, the descriptions of technical features, technical solutions, or beneficial effects in this specification do not necessarily refer to the same embodiment. Furthermore, the technical features, technical solutions, and beneficial effects described in this embodiment can be combined in any suitable manner. Those skilled in the art will understand that embodiments can be implemented without one or more specific technical features, technical solutions, or beneficial effects of a particular embodiment. In other embodiments, additional technical features and beneficial effects may be identified in specific embodiments that do not embody all embodiments. Attached Figure Description

[0019] Figure 1 This is an application environment diagram of a motor bench testing safety management method provided in the embodiments of this application; Figure 2 This is a flowchart illustrating a method for safety management of motor bench testing provided in an embodiment of this application; Figure 3 This is a structural block diagram of a motor bench testing safety management device provided in the embodiments of this application; Figure 4 This is an internal structural diagram of a computer device provided in the embodiments of the application. Detailed Implementation

[0020] The terms "first," "second," and "third," etc., used in this application specification and accompanying drawings are used to distinguish different objects, not to limit a specific order.

[0021] In the embodiments of this application, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0022] To ensure clarity and conciseness in the description of the following embodiments, a brief introduction to the related technologies is given first: As the core power source of new energy vehicles, the performance of electric motors directly determines the vehicle's power output, range, and operational stability. Therefore, accurate evaluation of motor performance has become a crucial link in the industry's development. Motor bench testing, as a core method for evaluating the electrical, mechanical, and reliability of motors, simulates various real-world operating conditions such as vehicle starting, acceleration, and braking to achieve comprehensive testing of the motor's performance throughout its entire lifecycle.

[0023] Existing motor bench testing systems still have significant functional deficiencies, making it difficult to meet the requirements for safe and efficient testing. For example, in terms of fault detection, conventional monitoring methods rely excessively on motor surface temperature sensors, which can only obtain surface temperature data and cannot penetrate into the motor's interior. This makes it difficult to accurately detect abnormal heating caused by hidden faults such as poor winding contact and bearing wear, and even more difficult to locate specific fault points. Often, it is necessary to shut down the machine for disassembly and troubleshooting, which seriously slows down the testing progress. Furthermore, in terms of energy feedback path management, the system lacks intelligent control capabilities. It cannot monitor changes in path impedance in real time to predict the risk of line aging, nor is it equipped with an effective redundancy switching mechanism. When the line impedance increases, causing poor or even interrupted energy transmission, the testing process can be forced to stop, or even cause secondary damage to the equipment.

[0024] Motor bench testing is a crucial step in evaluating motor performance, and its operational safety directly impacts the accuracy of test data, the continuity of the testing process, and the lifespan of the equipment. Therefore, ensuring the safe operation of motor bench testing systems throughout the entire testing cycle has become a critical issue that urgently needs to be addressed in the field of motor testing technology.

[0025] To make the technical solution of this application clearer and easier to understand, the application scenarios of the technical solution of this application are described below with reference to the accompanying drawings. Figure 1 As shown in the figure, this figure is a schematic diagram of an application scenario provided by an embodiment of this application.

[0026] In this application scenario, terminal 102 can collect motor-related data in real time, such as sensor data. Terminal 102 transmits the collected data to server 104 in real time via a dedicated line or communication line, so that server 104 can process and analyze the data and send the analysis results back to terminal 102 for display by terminal 102 for relevant technical personnel to view.

[0027] To make the technical solution of this application clearer and easier to understand, the following describes a method for safety management of motor bench testing provided by an embodiment of this application, in conjunction with the above application scenarios. Figure 2 As shown in the figure, this is a flowchart of a motor bench test safety management method provided in an embodiment of this application.

[0028] S201. Obtain the three-phase current ripple data of the energy flow in the feedback path.

[0029] Among them, energy flow refers to the electrical energy flow generated around the motor during motor operation and transmitted between the "motor-bidirectional inverter-grid / energy storage unit" during motor bench testing. The core source is the reverse electromotive force energy generated under operating conditions such as motor braking, and it has both "energy recovery" (flowing to the grid / energy storage unit) and "energy replenishment" (flowing from the energy storage unit to the motor) bidirectional characteristics; three-phase current refers to the current transmitted in the AC transmission link according to the three-phase AC standard, which needs to be monitored synchronously to ensure data integrity; current ripple refers to the small fluctuation signal superimposed on the fundamental current in the three-phase current. Its characteristics (such as amplitude and frequency) will change with the motor operating state (such as poor winding contact and bearing wear will cause abnormal ripple), which can reflect the health status of the motor; three-phase current ripple data is the raw data including all fluctuation signals in the three-phase current.

[0030] For example, after the motor bench test is started, the motor generates a back electromotive force, and the energy flow begins to be transmitted in the "motor-energy feedback closed-loop module" link. Data can be collected through high-frequency sampling. For example, the energy flow transmission link (located between the motor and the bidirectional inverter) can be connected in series through a hardware interface to directly contact the three-phase current transmission channel, ensuring that the complete current signal can be captured. Alternatively, the three-phase current in the energy flow can be synchronously sampled at a high frequency to capture the fluctuation signal (i.e., current ripple) in each phase current in real time, avoiding the omission of weak ripple characteristics related to faults due to the sampling frequency being too low.

[0031] S202. Based on the three-phase current ripple data, perform feature analysis to determine the information of abnormal heat sources.

[0032] Feature analysis involves extracting energy distribution features related to motor faults from the data, transforming raw current data into structured information usable for fault matching, and connecting raw data with fault location. Abnormal heat source information includes, but is not limited to, the coordinates and heating rate of the abnormal heat source. This refers to the specific location of abnormal heating inside the motor due to a fault (such as poor winding contact). Optionally, the coordinates of the abnormal heat source can be represented in three-dimensional coordinates (x, y, z). For example, the x-axis typically corresponds to the axial direction of the motor (i.e., the direction of the central axis of the motor rotor), used to locate the axial position of the abnormal heat source between the front and rear ends of the motor. If the motor stator winding is divided into multiple segments along the axial direction, the x-coordinate can accurately identify which axial segment the heat source is located in, such as near the motor output end (larger x-value) or near the rear end cover (larger x-value). The y-axis corresponds to the radial direction of the motor (i.e., the horizontal direction perpendicular to the central axis of the motor rotor) and is used to locate the radial position of the abnormal heat source in the motor from the "inner to the outer" direction. For example, it can distinguish whether the heat source is located on the inner side of the stator winding (closer to the rotor, smaller y value), the outer side (closer to the motor housing, larger y value), or the radial position of the bearing (corresponding to a specific range of y values). The z-axis corresponds to the circumferential direction of the motor (i.e., the circumferential direction around the central axis of the motor rotor) and is used to locate the angular position of the abnormal heat source on the circumference of the motor. For example, when the stator winding of the motor is distributed in multiple phase groups on the circumference, the z-coordinate can identify which phase group the heat source is in and the corresponding circumferential angle, such as 0°-120° (A phase winding), 120°-240° (B phase winding) or 240°-360° (C phase winding).

[0033] One possible approach is to perform feature analysis based on three-phase current ripple data to obtain feature vectors; then compare the feature vectors with fault vectors in a preset fault vector library to determine abnormal heat source information.

[0034] Among them, the feature vector refers to the vector generated through feature analysis that reflects the energy distribution of three-phase current ripple and is the core carrier for quantifying current ripple characteristics; the fault vector library stores feature vectors (i.e., fault vectors) corresponding to various known motor faults (such as winding short circuits and bearing wear). Each fault vector is associated with a unique abnormal heat source coordinate and serves as a benchmark database for fault comparison; the fault vector is the feature vector corresponding to a specific motor fault stored in the fault vector library. For example, each fault vector can be generated by fitting historical fault data and bound to the abnormal heat source coordinates corresponding to the fault, which is used to compare with real-time feature vectors to identify the fault type.

[0035] For example, feature analysis of three-phase current ripple data can be performed by dividing the data into frequency bands and calculating the energy characteristics of each frequency band node. All Integrate into a structured sampled feature vector VE This completes the transformation of raw data into fault identification indicators, such as the energy distribution characteristics of current ripple, and calculates the first... Energy characteristics of each frequency band node for:

[0036] in, For frequency band number and , It is the signal characteristic at the i-th sampling point in the k-th frequency band. This represents the sampling point number in the k-th frequency band. The number of sampling points forms the sampling feature vector. .

[0037] Furthermore, the real-time generated sampled feature vectors can be calculated. Matching degree with each fault vector in the preset fault vector library For example, the calculation formula is: and ;in, Represents the first fault vector in the fault vector library The fault feature vectors corresponding to various fault modes are stored in a fault vector library, which stores feature vectors under various known fault conditions and compares them with those obtained from real-time monitoring. To make a comparison, Represents the sampled feature vector The norm of the sampled feature vector, which is the square root of the sum of the squares of the elements of the sampled feature vector, is used to evaluate the sampled feature vector. Normalize, Represents the fault feature vector The norm is also used for fault feature vectors. Normalize, Represents the current sampled feature vector Compared with the first in the fault mode library Fault feature vectors corresponding to various fault modes The matching score ranges from 0 to 1; further, matching scores can be filtered. The fault vector is greater than 0.85. Furthermore, based on the successfully matched fault vector, the coordinates (x, y, z) of the abnormal heat source bound to it can be retrieved, and the temperature rise rate α corresponding to the coordinates (x, y, z) of the abnormal heat source can be calculated to complete the location of the abnormal heat source.

[0038] S203. Based on the monitoring data of the feedback path, calculate the impedance value and impedance change rate of each feedback path to determine the risk path.

[0039] The feedback path is the path through which energy flows from the motor to the power grid and / or energy storage unit, i.e., the transmission channel. It is a critical line for energy recovery and reuse in motor bench testing, and its operating status needs to be monitored in real time to ensure stable energy transmission. The monitoring data of the feedback path is the real-time operating data related to the feedback path, including but not limited to the impedance value of the path at different times. The impedance value is a physical quantity that measures the path's ability to impede current and can reflect the current conductivity of the path. The larger the impedance value, the greater the loss in the energy transmission process. The impedance change rate is an indicator that measures how fast the path impedance changes over time. It is calculated by the ratio of the impedance difference at different times to the historical impedance and the time interval, and can be presented in percentage form. This indicator can provide early warning of problems such as line aging. Risk paths refer to paths that are prone to problems such as poor transmission, increased loss, or even interruption in the energy transmission process.

[0040] One possible approach is to identify a feedback path as a risk path if, for each feedback path, the impedance value of the feedback path is greater than an impedance reference value, and / or the rate of change of the impedance of the feedback path is greater than a change threshold.

[0041] Among them, the impedance reference value can be used as a reference standard to determine whether the path impedance exceeds the standard. It is usually the initial impedance value under normal operating conditions of the path. The change threshold can be used as a critical value to determine whether the impedance change rate is abnormal. When the impedance change rate exceeds the change threshold, it indicates that the path impedance changes rapidly in a short period of time, which may be due to problems such as line aging or poor contact.

[0042] For example, the impedance of each feedback path can be measured in real time at the current time (t) to obtain the impedance value Z. j (t); Furthermore, based on the impedance values ​​monitored at different times, the impedance change rate of each feedback path can be calculated, and the calculation formula is as follows:

[0043] in, Representing the The impedance change rate of a feedback path measures how quickly the impedance of that path changes over time. This indicates that at time t, the first... The impedance value of the feedback path, and For path numbering, To account for the total number of feedback paths, Indicates in At that moment, the The impedance value of the feedback path, i.e. The impedance value before time, Represents a time interval.

[0044] Furthermore, the impedance value of each feedback path can be compared with the impedance reference value (Z). j0 Compare the impedance change rate with the change threshold (e.g., 5%), and if the impedance value > impedance reference value (Z) is satisfied... j0 If either "impedance change rate > change threshold (e.g., 5%)" is met, the path is determined to be a risk path.

[0045] S204. Update the first feedback path based on abnormal heat source information and risk path.

[0046] The first feedback path can be the optimal energy feedback path selected from the candidate paths. It must meet the condition of "minimum first path value" and take into account the safe distance from abnormal heat sources (such as a path distance from the heat source greater than 0.2m). It undertakes the main energy transmission task in motor testing and ensures efficient and stable energy feedback.

[0047] One possible approach is to calculate, for each feedback path, a first path value corresponding to that feedback path based on a first weight, a second weight, a first impedance value, a first heating rate value, the impedance value of the feedback path, and the heating rate; to eliminate risky paths in the feedback path to obtain candidate paths; and to determine the candidate path corresponding to the smallest first path value as the first feedback path based on the first path value of each candidate path.

[0048] Wherein, the first weight is the weighting coefficient corresponding to the impedance value; the second weight is the weighting coefficient corresponding to the heating rate; the first impedance value is the reference value for normalizing the impedance value; the first heating rate value is the reference value for normalizing the heating rate; that is, both the first weight and the second weight are weighting coefficients used to calculate the first path value, such as the first weight can be set. and the second weight The first weight corresponds to impedance-related parameters, and the second weight corresponds to heating rate-related parameters. This can be derived from... and The weighting method reveals an optimization logic that prioritizes path impedance (energy transfer efficiency) and then focuses on the temperature rise trend. Both the first impedance value and the first temperature rise rate value are normalized reference values ​​used when calculating the first path value. For example, setting the first impedance value... (i.e., maximum impedance), first heating rate value (i.e., the maximum temperature rise rate, which can be extended here to impedance change rate normalization to ensure a consistent calculation dimension) is used to convert impedance values ​​and impedance change rates of different magnitudes into ratios in the 0-1 range, avoiding the impact of parameter magnitude differences on path value calculation results; the candidate path is the set of paths remaining after removing risk paths from all feedback paths, and must simultaneously meet the two conditions of "non-risk path" and "safe distance from abnormal heat source (e.g., safe distance greater than 0.2m)", which is the basic range for screening the first feedback path.

[0049] Optionally, the ratio of the impedance value of the feedback path to the first impedance value is determined as the first impedance ratio; the product of the first impedance ratio and the first weight is determined as the second impedance ratio; the ratio of the heating rate of the feedback path to the first heating rate value is determined as the first heating ratio; the product of the first heating ratio and the second weight is determined as the second heating ratio; and the sum of the second impedance ratio and the second heating ratio is determined as the first path value corresponding to the feedback path.

[0050] The first impedance ratio can be used to normalize the impedance value, eliminating the influence of differences in the absolute values ​​of impedances across different paths, thus making the impedance parameters of different paths comparable. The second impedance ratio reflects the weighted contribution of the impedance parameter (i.e., the first weight) to the value of the first path. To determine its dominant role in path optimization; the first heating ratio can be used to normalize the heating rate and unify the dimension of parameter calculation; the second heating ratio can reflect the weighted contribution of the heating rate parameter (i.e., the second weight) to the first path value, the second weight The second path value reflects the dynamic stability of the path. The first path value is an indicator of the overall performance of the feedback path. It is obtained by adding the second impedance ratio and the second temperature rise ratio. The smaller the value, the lower the path impedance, the smoother the impedance change, and the better the overall performance.

[0051] For example, the impedance value Z of the j-th feedback path can be used as a basis. j (t), heating rate Combined with the first weight Second weight First impedance value First heating rate value According to the calculation formula " "The first path value is calculated; further, risky paths are removed from the path set to ensure the safety of subsequent path selection; paths "greater than 0.2m from the abnormal heat source" are further screened to form a candidate path set; then, the first path values ​​of all candidate paths can be sorted, and the candidate path with the smallest value is selected as the first feedback path to ensure that the path with the best overall performance is selected for energy feedback, which can be expressed by the following formula:"

[0052] in, This is the first feedback path, i.e., the optimal path; As the first weight, As the second weight, it can be used to measure the importance of path impedance and temperature rise rate. This is the first impedance value, and the maximum impedance value. This is the first heating rate value, i.e., the maximum temperature rise rate; For the candidate path set; Indicating in the candidate path set Searching in The smallest path number.

[0053] S205. Switch the path based on the first feedback path and trigger an early warning signal.

[0054] Path switching is the switching operation of the energy transmission channel in motor bench testing. It is the process of transferring the energy flow from the main feedback path to the first feedback path when the main feedback path cannot work properly, ensuring that the energy feedback is not interrupted. The warning signal is the warning information generated before and after path switching, which includes key information such as the reason for switching (e.g., the impedance of the main feedback path exceeds the standard), the switching path number (main path → first path), and the switching time. It is used to remind operators to pay attention to the path status and to provide a basis for subsequent fault tracing. Optionally, the path with the lowest impedance and a temperature rise rate of less than 3 can be selected as the main feedback channel.

[0055] One possible approach is to obtain the impedance value of the main feedback path; if the impedance value of the main feedback path meets the switching requirements, switch the main feedback path to the first feedback path and trigger an early warning signal.

[0056] The main feedback path is the default energy feedback path used in motor bench testing, responsible for transmitting energy from the motor to the grid and / or energy storage units. Its operating status directly affects the overall energy feedback efficiency and system safety. The switching requirement is the critical condition for determining whether the main feedback path needs to switch to the first feedback path, such as the judgment logic being "main feedback path impedance value > initial reference impedance value (Z)". j0 If the condition is met, a path switch will be triggered.

[0057] For example, impedance data of key nodes in the main feedback path can be collected in real time to obtain the impedance value of the main feedback path at the current moment. When the impedance value of the main feedback path meets the switching requirements, the energy flow can be transferred from the main feedback path to the first feedback path by adjusting the energy transmission direction of the bidirectional inverter, ensuring continuous energy feedback. Furthermore, an early warning signal can be generated synchronously with the path switching operation. This signal can be output through system monitoring interface pop-ups, audible and visual alarms, and push notifications from operator terminals, achieving multi-dimensional early warning reminders. Optionally, the switching requirement can be that when the impedance value of the main feedback path is greater than the impedance reference value (Z... j0 The duration of the event is greater than a time threshold (such as 3 minutes).

[0058] In this application, three-phase current ripple data of the energy flow in the feedback path is acquired at a high frequency (e.g., synchronized with the motor test conditions), providing high-fidelity raw signals for subsequent safety analysis. Compared to traditional systems that only collect motor surface temperature or macroscopic current data, this acquisition method can capture subtle anomalies in the motor's internal operation contained in the current ripple (such as current fluctuations caused by poor winding contact, or changes in ripple characteristics caused by bearing wear). This avoids missing early latent faults due to insufficient data acquisition accuracy or too low frequency, providing a reliable basis for safety warnings and fault diagnosis within the test cycle from the source, preventing deviations in subsequent safety decisions due to data distortion, and ensuring the accuracy of safety analysis.

[0059] Secondly, by extracting energy distribution features, constructing feature vectors, and matching fault mode libraries, the three-dimensional coordinates and temperature rise rate of abnormal heat sources inside the motor can be accurately output. This design breaks through the limitations of traditional systems that "only monitor the surface temperature of the motor and cannot locate internal faults." It can quickly pinpoint the fault location (such as the axial section of phase A of the stator winding or the radial position of the bearing) in the early stages of abnormal heating caused by internal faults such as poor winding contact or bearing wear. In other words, by identifying the fault early and clarifying the fault point, the fault can be prevented from expanding as the test progresses (such as abnormal heating causing the motor insulation layer to burn out or the rotor to jam), effectively preventing equipment damage or fire and other safety accidents, and ensuring the physical safety of the motor body and the test bench throughout the entire test cycle.

[0060] Furthermore, by calculating the impedance values ​​and impedance change rates of each path in real time, and using the impedance reference value or change threshold as a threshold to determine risk paths, this design can identify problems such as aging and poor contact in the energy feedback path in advance. For example, on the one hand, it prevents excessive heat generation in risk paths due to excessive impedance, which could lead to line burnout or insulation melting; on the other hand, it avoids sudden interruption of risk paths that could obstruct energy transmission, thereby causing a sudden rise in motor terminal voltage and damaging the test equipment. This ensures the system hardware safety and stable energy flow during the test cycle from the energy transmission link.

[0061] Furthermore, by using weighted calculations to select the optimal first feedback path, the system ensures that the first feedback path always operates in a safe state with low impedance and low rate of change, reducing energy loss and the probability of failure during energy transmission. By constructing a low-risk energy transmission channel, uninterrupted energy feedback can be guaranteed during the test cycle, avoiding test interruptions or equipment damage due to path issues and maintaining the continuity and safety of the test process.

[0062] Finally, by introducing loop switching, a dual support of redundancy and emergency alerts is provided for the safe operation of the test cycle: On the one hand, the path switching function avoids the interruption of energy transmission after the main feedback path fails, preventing the motor from being damaged by overvoltage due to the inability to release energy, while ensuring that the test process is not interrupted and that the task is completed as planned within the test cycle; on the other hand, the early warning signal can notify the operator in real time of the main path fault type (such as impedance exceeding the standard) and the operating status of the first path, so that personnel can repair the faulty path in a timely manner and avoid the accumulation and expansion of the fault (such as the main path overheating spreading to other components), forming a closed-loop safety management of fault response - process continuation - personnel intervention, and comprehensively ensuring the stable, continuous and safe operation of the system within the test cycle.

[0063] The aforementioned motor bench test safety management method provides a data foundation for data analysis by acquiring three-phase current ripple data of energy flow in the feedback path; based on the three-phase current ripple data, feature analysis is performed to identify abnormal heat sources, thus locating faults; based on the monitoring data of the feedback path, the impedance value and impedance change rate of each feedback path are calculated to identify risky paths, laying the foundation for ensuring test safety; based on the abnormal heat source information and risky paths, the first feedback path is updated, providing options for path switching; path switching is performed based on the first feedback path, triggering an early warning signal, ensuring test safety. This scheme lays the foundation for identifying abnormal heat sources by introducing three-phase current ripple data; furthermore, by introducing impedance values ​​and impedance change rates, it provides a basis for judging the risk performance of each path; and by updating the first feedback path, it provides options for path switching, ultimately ensuring test safety.

[0064] Based on the above embodiments, the energy recovery process involved in this application embodiment specifically includes: Based on the bidirectional inverter, the reverse electromotive force energy generated during the motor bench test is fed back to the grid and energy storage unit.

[0065] The bidirectional inverter is the core power electronic device in the motor bench test safety management system that enables bidirectional energy flow. It can convert electrical energy from the grid / energy storage unit into AC power (drive mode) required for motor testing, and it can also rectify the back electromotive force (EMF) generated by the motor into DC power, and then invert it into AC power with the same frequency and voltage as the grid (feedback mode). It is a key conversion node in the energy feedback path. Motor bench testing is the process of detecting motor performance, reliability, and safety indicators on a dedicated test bench. During testing, the motor may generate back EMF due to changes in operating conditions (such as deceleration and braking). This energy needs to be processed by the energy feedback system to avoid energy waste or equipment damage. The back EMF energy is generated when the motor is not in a drive state (such as during deceleration or braking in the test). The energy corresponding to the electromotive force (EMF) generated by the rotor inertia driving the stator windings to cut magnetic field lines in the dynamic stage, which is opposite to the direction of the power supply voltage, is crucial. If this energy is not processed in time, it may cause the motor terminal voltage to rise and damage the test equipment. It needs to be recovered and utilized through a feedback system. The power grid is the public power network to which the motor bench test system is connected. It is one of the main receiving ends for the reverse EMF energy feedback. It is necessary to ensure that the frequency, voltage, and phase of the feedback power are matched with the grid parameters to avoid impacting the grid. The energy storage unit is a device used in the system to store electrical energy (such as lithium battery packs, supercapacitors, etc.). It is a backup receiving end for the reverse EMF energy feedback. It can store the feedback energy when the grid load is too high or when there is a power outage, and release it when the motor needs power, realizing energy recycling and improving the system's energy efficiency.

[0066] For example, the energy conversion function of a bidirectional inverter can be used to first rectify the reverse electromotive force energy (AC) generated by the motor into DC, and then, according to the grid status and the charge status of the energy storage unit, the DC can be inverted into AC that meets the grid requirements and fed back to the grid, or the DC can be directly stored in the energy storage unit, thus completing the core action of energy recovery and reuse. This action is the key to achieving energy saving and ensuring test safety.

[0067] It should be noted that bidirectional inverters can achieve efficient conversion and recovery of reverse electromotive force energy. The energy that would otherwise be wasted is rectified and inverted, and then fed back to the grid after being precisely matched with grid parameters (such as voltage within ±5% threshold and frequency synchronization), or stored in the energy storage unit to meet the voltage requirements of the energy storage unit. This process can improve the recovery rate of back EMF energy during testing, reducing energy waste. Simultaneously, the energy stored in the energy storage unit can be released again during the motor test drive phase to power the motor, reducing dependence on the external power grid and improving the overall energy efficiency of the testing system, indirectly reducing enterprise electricity costs and carbon emissions. Furthermore, the energy feedback function of the bidirectional inverter can directly transfer back EMF energy, avoiding energy accumulation and heat generation on the resistor, thus reducing the operating temperature of key system components (such as resistors and motor controllers) and minimizing equipment losses due to high temperatures. In addition, the bidirectional inverter has overvoltage, overcurrent, and overtemperature protection functions, and can monitor voltage and current parameters in real time during energy conversion, preventing excessively high back EMF from impacting the motor, power grid, and energy storage unit, further reducing equipment failure risks and extending the overall system lifespan. Furthermore, the bidirectional inverter can track the grid phase in real time through a built-in phase-locked module, keeping the phase difference of the feedback energy within a controllable range, and can also control harmonic content to avoid impacting the power grid and ensure stable grid operation. Moreover, the bidirectional inverter can dynamically adjust based on real-time grid conditions (such as load factor and voltage fluctuations). The system optimizes energy feedback ratios. For example, when the grid load factor exceeds 70%, it automatically prioritizes storing energy in the energy storage unit to prevent grid overload. When grid voltage fluctuations exceed the ±5% threshold, grid feedback is suspended, and storage is switched to the energy storage unit to prevent test system shutdowns due to grid anomalies, thus improving the continuity and safety of motor bench testing. Finally, the bidirectional inverter has bidirectional energy conversion capabilities, not only feeding back reverse electromotive force energy to the grid and energy storage unit, but also converting grid or energy storage unit energy into AC power required by the motor during the motor test drive phase, realizing "energy recovery-storage-reuse". The closed-loop management of the "bidirectional conversion" function allows the system to flexibly adapt to different test conditions: during motor braking tests, it efficiently recovers back electromotive force energy; during motor start-up and loading tests, it draws energy from the grid or energy storage unit as needed, eliminating the need for an additional independent drive power supply and simplifying the system structure; at the same time, the bidirectional inverter supports docking with different types of energy storage units (such as lithium battery packs and supercapacitors), automatically adapts to the rated voltage of the energy storage unit, and can select different energy storage solutions according to the test scenario requirements (such as short-term high-frequency tests and long-term endurance tests), enhancing the system's adaptability to diverse test requirements.

[0068] In this embodiment of the application, by introducing a bidirectional inverter, a way to achieve energy recovery is provided, and ultimately, efficient energy conversion and recovery are achieved.

[0069] The above text combined Figures 1 to 2 The method for safe management of motor bench testing provided in this application has been described in detail. The apparatus and equipment provided in this application will be described below with reference to the accompanying drawings.

[0070] like Figure 3 As shown in the figure, this is a schematic diagram of a motor bench test safety management device 600 provided in an embodiment of this application. The motor bench test safety management device 600 includes: a data acquisition module 601, a heat dissipation module 602, a monitoring module 603, a path update module 604, and a path switching module 605, wherein: Data acquisition module 601 is used to acquire three-phase current ripple data of energy flow in the feedback path; The heat source location module 602 is used to perform feature analysis based on three-phase current ripple data to determine abnormal heat source information. The monitoring module 603 is used to calculate the impedance value and impedance change rate of each feedback path based on the monitoring data of the feedback path, and to determine the risk path; wherein, the feedback path is the path of energy flow from the motor to the power grid and / or energy storage unit; The path update module 604 is used to update the first feedback path based on the abnormal heat source information and the risk path; The path switching module 605 is used to switch paths based on the first feedback path and trigger an early warning signal.

[0071] In one embodiment, the heat dissipation positioning module 602 is specifically used for: Feature analysis is performed based on three-phase current ripple data to obtain feature vectors; the feature vectors are then compared with fault vectors in a pre-set fault vector library to determine abnormal heat source information.

[0072] In one embodiment, the monitoring module 603 is specifically used for: For each feedback path, if the impedance value of the feedback path is greater than the impedance reference value, and / or the impedance change rate of the feedback path is greater than the change threshold, the feedback path is determined to be a risk path.

[0073] In one embodiment, the path update module 604 is specifically used for: For each feedback path, a first path value is calculated based on a first weight, a second weight, a first impedance value, a first heating rate value, the impedance value of the feedback path, and the heating rate. The first weight is a weighting coefficient corresponding to the impedance value; the second weight is a weighting coefficient corresponding to the heating rate; the first impedance value is a reference value for normalizing the impedance value; the first heating rate value is a reference value for normalizing the heating rate. Risk paths in the feedback path are eliminated to obtain candidate paths. Based on the first path values ​​corresponding to each candidate path, the candidate path with the smallest first path value is determined as the first feedback path.

[0074] In one embodiment, the path update module 604 is specifically used for: The ratio of the impedance value of the feedback path to the first impedance value is determined as the first impedance ratio; the product of the first impedance ratio and the first weight is determined as the second impedance ratio; the ratio of the heating rate of the feedback path to the first heating rate value is determined as the first heating ratio; the product of the first heating ratio and the second weight is determined as the second heating ratio; the sum of the second impedance ratio and the second heating ratio is determined as the first path value corresponding to the feedback path.

[0075] In one embodiment, the path switching module 605 is specifically used for: Obtain the impedance value of the main feedback path; if the impedance value of the main feedback path meets the switching requirements, switch the main feedback path to the first feedback path and trigger an early warning signal.

[0076] In one embodiment, the motor bench test safety management device 600 further includes: The energy feedback module is used to feed back the reverse electromotive force energy generated during motor bench testing to the grid and energy storage unit, based on a bidirectional inverter.

[0077] The motor bench test safety management device 600 according to the embodiments of this application can correspondingly execute the method described in the embodiments of this application, and the other operations and / or functions of each module / unit of the motor bench test safety management device 600 are respectively for implementing Figure 2 For the sake of brevity, the corresponding processes of each method in the illustrated embodiments will not be described in detail here.

[0078] This application also provides a computing device. This computing device can be a local computing device or an application server.

[0079] like Figure 4As shown in the figure, this is a schematic diagram of a computing device provided in an embodiment of this application. The computing device 700 includes a bus 701, a processor 702, a communication interface 703, and a memory 704. The processor 702, the memory 704, and the communication interface 703 communicate with each other via the bus 701.

[0080] The 701 bus can be a Peripheral Component Interconnect (PCI) bus or an Extended Industry Standard Architecture (EISA) bus, etc. Buses can be categorized as address buses, data buses, control buses, etc. For ease of representation, Figure 4 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0081] The processor 702 can be any one or more of the following processors: central processing unit (CPU), graphics processing unit (GPU), microprocessor (MP), or digital signal processor (DSP).

[0082] Communication interface 703 is used for external communication. For example, communication interface 703 can be used to communicate with terminal 102. Communication interface 703 is used to send a warning signal to terminal 102 so that terminal 102 can display the warning signal.

[0083] Memory 704 may include volatile memory, such as random access memory (RAM). Memory 704 may also include non-volatile memory, such as read-only memory (ROM), flash memory, hard disk drive (HDD), or solid state drive (SSD).

[0084] The memory 704 stores executable code, and the processor 702 executes the executable code to perform the aforementioned motor bench test safety management method.

[0085] Specifically, in achieving Figure 3 In the case of the illustrated embodiment, and Figure 3When the modules or units of the motor bench test safety management device described in the embodiment are implemented through software, the execution... Figure 3 The software or program code required for the functions of each module / unit can be partially or wholly stored in the memory 704. The processor 702 executes the program code corresponding to each unit stored in the memory 704 to execute the aforementioned motor bench test safety management method.

[0086] This application also provides a computer-readable storage medium. The computer-readable storage medium can be any available medium that a computing device can store, or a data storage device such as a data center containing one or more available media. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium (e.g., solid-state drive). The computer-readable storage medium includes instructions that instruct the computing device to execute the aforementioned motor bench test safety management method.

[0087] This application also provides a computer program product comprising one or more computer instructions. When the computer instructions are loaded and executed on a computing device, all or part of the processes or functions described in this application are generated.

[0088] The computer instructions may be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions may be transmitted from one website, computer, or data center to another website, computer, or data center via wired (e.g., coaxial cable, fiber optic, digital subscriber line) or wireless (e.g., infrared, wireless, microwave, etc.) means.

[0089] When the computer program product is executed by a computer, the computer performs any of the methods described in the aforementioned motor bench test safety management method. The computer program product can be a software installation package; when any of the aforementioned methods of the motor bench test safety management method needs to be used, the computer program product can be downloaded and executed on the computer.

[0090] The descriptions of the processes or structures corresponding to the above figures each have their own emphasis. For parts of a process or structure that are not described in detail, please refer to the relevant descriptions of other processes or structures.

[0091] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions within the technical scope disclosed in this application should be covered within the scope of protection of this application.

Claims

1. A method for safety management of motor bench testing, characterized in that, The method includes: Obtain the three-phase current ripple data of the energy flow in the feedback path; Feature analysis based on three-phase current ripple data is used to determine information about abnormal heat sources; Based on the monitoring data of the feedback path, the impedance value and impedance change rate of each feedback path are calculated to determine the risk path; wherein, the feedback path is the path of energy flow from the motor to the power grid and / or energy storage unit; Based on information about abnormal heat sources and risk paths, update the first feedback path; The path is switched based on the first feedback path, and an early warning signal is triggered.

2. The method according to claim 1, characterized in that, The feature analysis based on three-phase current ripple data to determine abnormal heat source information includes: Feature analysis is performed based on three-phase current ripple data to obtain feature vectors; The feature vector is compared with the fault vector in the preset fault vector library to determine the abnormal heat source information.

3. The method according to claim 1, characterized in that, The determination of risk paths includes: For each feedback path, if the impedance value of the feedback path is greater than the impedance reference value, and / or the impedance change rate of the feedback path is greater than the change threshold, the feedback path is determined to be a risk path.

4. The method according to claim 1, characterized in that, The abnormal heat source information includes the heating rate. The step of updating the first feedback path based on the abnormal heat source information and the risk path includes: For each feedback path, a first path value is calculated based on a first weight, a second weight, a first impedance value, a first heating rate value, the impedance value of the feedback path, and the heating rate. The first weight is a weighting coefficient corresponding to the impedance value; the second weight is a weighting coefficient corresponding to the heating rate; the first impedance value is a reference value for normalizing the impedance value; and the first heating rate value is a reference value for normalizing the heating rate. Risky paths are eliminated from the feedback paths to obtain candidate paths; Based on the first path value corresponding to each candidate path, the candidate path corresponding to the smallest first path value is determined as the first feedback path.

5. The method according to claim 4, characterized in that, The calculation based on the first weight, the second weight, the first impedance value, the first heating rate value, the impedance value of the feedback path, and the heating rate yields the first path value corresponding to the feedback path, including: The ratio of the impedance value of the feedback path to the first impedance value is determined as the first impedance ratio. The product of the first impedance ratio and the first weight is determined as the second impedance ratio. The ratio of the heating rate of the feedback path to the first heating rate value is determined as the first heating ratio value; The product of the first heating ratio and the second weight is determined as the second heating ratio; The sum of the second impedance ratio and the second temperature rise ratio is determined as the first path value corresponding to the feedback path.

6. The method according to claim 1, characterized in that, The path switching based on the first feedback path and the triggering of the warning signal include: Obtain the impedance value of the main feedback path; If the impedance value of the main feedback path meets the switching requirements, the main feedback path will be switched to the first feedback path, and an early warning signal will be triggered.

7. The method according to claim 1, characterized in that, The method further includes: Based on the bidirectional inverter, the reverse electromotive force energy generated during the motor bench test is fed back to the grid and energy storage unit.

8. A safety management device for motor bench testing, characterized in that, The device includes: The data acquisition module is used to acquire the three-phase current ripple data of the energy flow in the feedback path; The heat source location module is used to perform feature analysis based on three-phase current ripple data to determine information about abnormal heat sources. The monitoring module is used to calculate the impedance value and impedance change rate of each feedback path based on the monitoring data of the feedback path, and to determine the risk path; wherein, the feedback path is the path of energy flow from the motor to the power grid and / or energy storage unit; The path update module is used to update the first feedback path based on abnormal heat source information and risk paths; The path switching module is used to switch paths based on the first feedback path and trigger an early warning signal.

9. A computing device, characterized in that, Including memory and processor; The memory stores one or more computer programs, the one or more computer programs including instructions; when the instructions are executed by the processor, the computing device performs the method as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium is used to store a computer program for performing the method as described in any one of claims 1 to 7.

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