Adaptive test system for multi-model driving motors

Abstract

The invention discloses a multi-model driving motor adaptive test system, and relates to the field of driving motor test. The rack bearing module is welded by low-alloy steel plates, the bottom is fixed, and vertical guide rails and horizontal sliding rails are arranged; the self-adaptive positioning module comprises a three-dimensional adjusting mechanism, so that accurate positioning is realized; the intelligent clamping module adopts a circumferential clamping assembly and an axial jacking device, and a clamping motor is stably clamped through an arc-shaped clamping jaw and the jacking device; the power test module collects parameters such as torque and rotating speed, and supports switching of vector control and torque control modes; the automatic calibration module is provided with a laser tracker and a standard torque meter, so that the measurement precision is ensured; the data processing module adopts an industrial computer to analyze data and generate a chart; and the safety protection module is provided with a three-level protection mechanism to guarantee the test safety. The method is fast adaptive to multi-model motor testing, improves the efficiency and precision, guarantees the safety, is reliable in data, is suitable for various testing scenes, and optimizes the traditional testing technology.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of driving motor testing, and in particular to a multi-model driving motor adaptive testing system. BACKGROUND

[0002] The existing driving motor test simulation device usually directly fixes the motor on the corresponding structure when installing the motor, which makes subsequent motor position adjustment extremely inconvenient. Especially when testing different models of motors, the height of the motor output shaft may differ, which can easily cause the motor output shaft to fail to accurately connect with the power shaft of the test mechanism, thereby affecting the accuracy of the test data. This fixed mode requires repeated disassembly and calibration of the motor in batch testing scenarios, which not only consumes a lot of time and manpower, but also increases human error due to frequent operation, thereby reducing overall testing efficiency.

[0003] The technical module design of the current testing equipment has limitations, and the traditional system lacks flexible support adjustment and clamping limiting mechanisms, making it difficult to adapt to the testing needs of different specifications of motors. In terms of specific technical processes, the structural layout of the test rack is not reasonable, and the cooperation precision of the support mechanism and the tester is insufficient, which can cause the motor to shake or deviate during testing, thereby affecting the measurement accuracy of key parameters such as torque and speed. At the same time, the coordination between modules is poor, and there is a lack of effective buffering and protection design, so the impact during motor installation can damage the testing equipment and shorten the service life of the equipment.

[0004] With the development of driving motors towards multi-model and high performance, the traditional testing system cannot meet the efficient and accurate testing needs. The existing equipment cannot achieve rapid switching testing of different models of motors, and the testing process is complicated and data tracing is difficult. In actual application, due to the lack of unified technical standards and adaptive adjustment functions, the consistency and reliability of the test results are low, which restricts the improvement of motor production quality. Therefore, it is an urgent need in the industry to develop an adaptive testing system that can adapt to multiple models of motors and has precise adjustment and stable testing functions. SUMMARY

[0005] The multi-model driving motor adaptive testing system proposed by the present application solves the problems mentioned in the above prior art.

[0006] To achieve the above purpose, the present application adopts the following technical scheme: a multi-model driving motor adaptive testing system, comprising:

[0007] The rack bearing module is integrally welded with a Q345B low-alloy steel plate, the bottom is fixed to the concrete foundation by 8 groups of M16 expansion bolts, the left side column of the rack is provided with a vertical guide rail, the right side cross beam is provided with a horizontal sliding rail, and the inner side is welded with a reinforcing rib;

[0008] Adaptive positioning module: composed of X-axis sliding table, Y-axis adjusting frame and Z-axis lifting platform, motor holder is installed at the end of the mechanism, and three groups of positioning pins are arranged at the edge of the holder;

[0009] Intelligent clamping module: adopts circumferential clamping assembly and axial pressing device, the circumferential clamping assembly arc-shaped clamping jaw is driven by a servo motor, and the axial pressing device adopts a cylinder driven ejector pin; the module is built-in pressure and displacement sensor, real-time monitoring of clamping state;

[0010] Power test module: the test motor selects a permanent magnet synchronous servo motor, and the test motor is connected through a diaphragm coupling; the torque sensor is flange-mounted, and is matched with a speed sensor and a current sensor to synchronously collect torque, speed, voltage and current parameters;

[0011] Automatic calibration module: the laser tracker is fixed on the top of the rack by a tripod to detect the deviation of two-axis centering; the standard torque instrument is connected to the test system to calibrate the torque sensor; the module is built-in temperature compensation circuit, and the measurement value is automatically corrected when the environmental temperature exceeds the threshold value;

[0012] Data processing module: industrial computer is adopted, sensor signals are received through PCIe data acquisition card, LabVIEW test software is run, and test process is self-defined; the software is built-in motor model database, automatically calls standard, and generates analysis chart;

[0013] Safety protection module: a 1.5m high iron protective fence is arranged around the rack, the fence door is equipped with an electromagnetic lock and a safety interlocking switch, and an infrared thermal imager is installed at the top of the test area; a three-level protection mechanism is set, and the trigger condition is set through software.

[0014] Further, it further comprises:

[0015] Motor model identification module: composed of high-definition industrial camera and OCR identification algorithm, the camera is installed in front of the test station, and the motor nameplate parameters are identified; an RFID card reader is matched, label information built-in the motor is read, and cross verification is performed with the image identification result;

[0016] Load simulation module: adopts a magnetic powder brake, and the load mode is switched through closed-loop control; the brake is equipped with a water cooling system to simulate dynamic working conditions.

[0017] Further, it further comprises:

[0018] Environment simulation module: high and low temperature box and humidity adjusting device are installed, wind speed sensor and air pressure sensor are installed on the inner wall of the box, and different environmental conditions are simulated;

[0019] Remote monitoring module: using Ethernet and 4G wireless network transmission, real-time upload test data and equipment status; equipped with Web monitoring platform and mobile APP, authorized users view test curves, remote start and stop test; support multi-user permission management, automatically record operation logs.

[0020] Further, the data processing module motor efficiency calculation formula is η is the motor efficiency, T is the output torque, n is the speed, U is the input voltage, I is the input current, is the power factor; harmonic analysis voltage, current signal, eliminate high harmonic interference; through the instantaneous reactive power algorithm to calculate the power factor, combined with the rated power factor correction; asynchronous motor automatically introduced into the slip compensation, the calculation result is updated every 10ms, compared with the preset efficiency threshold, over limit when trigger data marker.

[0021] Further, the load simulation module load torque adjustment formula is

[0022] T load is the adjusted load torque, T set is the target load torque, T act is the actual load torque, K p is the proportional coefficient, K i is the integral coefficient, K d is the differential coefficient, t is the time; the parameters are dynamically optimized by self-tuning algorithm, the excitation current and load torque conversion relationship of magnetic powder brake is processed by piecewise linearization, stored in lookup table.

[0023] Further, the environmental simulation module temperature field uniformity correction formula is T corr = T meas + α × (d-500), T corr is the corrected temperature value, T meas is the sensor measured temperature, α is the temperature gradient coefficient, d is the distance between the measurement point and the center of the cabin; 9 temperature sensors are arranged in the cabin to collect real-time temperature of each point to calculate the gradient coefficient α; an infrared thermometer is used to measure the surface temperature of the motor, and the measured value is corrected by emissivity, and T corr is calculated by substituting the correction formula.

[0024] Further, the adaptive positioning module X-axis sliding table adopts double guide rail parallel arrangement, the screw support seat adopts angular contact ball bearing, and is installed in pairs; the driving motor is equipped with planetary reducer, and the output shaft is connected with the screw through the elastic coupling; the grating ruler is installed on the surface of the sliding table, and the full closed loop control is realized; the Y-axis adjusting frame worm and gear pair adopts double lead design, and the gap is adjusted by moving the worm axially; the Z-axis synchronous pulley adopts 45 steel quenching and tempering treatment, and the pulley groove precision is IT7 level.

[0025] Further, the arc-shaped clamping jaw of the intelligent clamping module adopts a hollow structure, the clamping jaw driving gear adopts 20CrMnTi material, the axial jacking device cylinder is provided with a magnetic ring and a proximity switch; the module controller adopts an STM32H743 microprocessor, communicates with the main system through a CAN bus, polyurethane buffer blocks are arranged at the end of the clamping jaw stroke, 10 kinds of clamping modes are built-in the system, and the clamping force is automatically matched.

[0026] Further, the motor model identification module industrial camera lens adopts an 8mm fixed-focus lens and is provided with a ring-shaped LED light source; the OCR identification algorithm adopts fuzzy identification and inclination correction; the RFID tag is passive and is installed on the non-stress surface of the motor; the identification module is linked with the adaptive positioning module, corresponding clamping parameters and positioning coordinates are automatically called after identification is completed; the camera collected image is transmitted to the data processing module through Ethernet, and the original image is saved; when identification fails, manual intervention is automatically triggered, and the failure reason is recorded.

[0027] Further, the remote monitoring module hardware adopts an industrial-grade router, the Web platform is based on the B / S architecture and is accessed through a browser, and the mobile APP pushes messages; the module is built-in a network diagnosis tool and remotely controls instructions through two-level verification.

[0028] Compared with the prior art, the present application has the following advantages:

[0029] The multi-model driving motor adaptive test system effectively solves the inconvenient adjustment problem of the traditional test device in the multi-model motor test. Through the three-dimensional adjustment mechanism of the adaptive positioning module, different output shaft heights and sizes of the motor can be quickly adapted, precise docking can be realized without repeated disassembly, and the operation efficiency during model replacement is greatly improved. The synchronous opening and closing design of the intelligent clamping module can not only ensure stable fixation of the motor, but also avoid damage to the shell caused by excessive clamping, thereby ensuring the safety of the test process.

[0030] The modules of the system work cooperatively to form a complete test closed loop. The efficient cooperation of the power test module and the data processing module can synchronously collect parameters such as torque, speed, voltage and current, automatically call corresponding test standards in combination with the built-in motor model database, and ensure the accuracy and consistency of the test data. The automatic calibration module corrects the measurement deviation in real time through the laser tracker and the standard torque instrument, thereby further improving the test precision.

[0031] The addition of the environment simulation module and the remote monitoring module expands the application scenarios of the system, can simulate motor performance testing under different environmental conditions, and supports remote data viewing and operation control, simplifying the testing process. The three-level protection mechanism of the safety protection module can respond to abnormal situations in the testing process in a timely manner, avoiding equipment damage and personnel injury. Overall, the system optimizes the traditional testing process, improves testing efficiency and data reliability, and has strong practical value and promotional significance. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 A schematic block diagram of a multi-model driving motor adaptive testing system is proposed for the present application;

[0033] Figure 2 A project development progress completion progress comparison diagram is shown in the figure;

[0034] Figure 3 A research and development expense use detail comparison diagram is shown in the figure;

[0035] Figure 4 A different motor testing efficiency improvement comparison diagram is shown in the figure;

[0036] Figure 5 A knowledge property right achievement output distribution comparison diagram is shown in the figure;

[0037] Figure 6 A technical risk loss bearing simulation comparison diagram is shown in the figure. DETAILED DESCRIPTION

[0038] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of the present application.

[0039] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation of the present application.

[0040] Furthermore, the terms "first", "second", "third", "fourth", "fifth", "sixth", "seventh" and "eight" are only used to describe purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined as "first", "second", "third", "fourth", "fifth", "sixth", "seventh" and "eight" can explicitly or implicitly include one or more of the features. In the description of the present application, the meaning of "a plurality of" is two or more, unless otherwise specifically limited. In addition, the terms "mounting", "connecting", "connecting" should be broadly understood, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be connected inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances, and the present application will be further described in detail below with reference to the drawings.

[0041] Reference Figures 1 to 6 A multi-model driving motor adaptive test system, comprising:

[0042] The rack carries the module: Q345B low alloy steel plate is cut down by numerical control laser cutting (size accuracy ± 0.5mm), welded by full-automatic submerged arc welding machine, segmented back welding method is used, preheating before welding (100-150℃) and stress relief heat treatment after welding (600-650℃ for 2h) are cooperated, the rack frame size is 2000mm×1200mm×1800mm, the diagonal line deviation is ≤1mm. The bottom is fixed on the concrete foundation by 8 groups of M16 stainless steel expansion bolts (tensile strength ≥520MPa), the drilling diameter is 20mm, the hole depth is 160mm, the bolt buried depth is 150mm, the fastening torque is 30N·m, the deviation of adjacent bolt spacing is ≤5mm, the anti-overturning safety factor is ≥3. The left side is equipped with THK SR35 vertical guide rail, the material is SUJ2, the hardness is HRC58-62, the length is 1500mm, the straightness error is ≤0.05mm / m, it is installed by M8 bolt with 15N·m pre-tightening force, the vertical stroke is 0-1500mm, the friction force is ≤5N, the repeat positioning accuracy is ±0.01mm. The right side horizontal sliding track is milled from 45# steel quenching and tempering (HB220-250), the section is 60mm×40mm, the length is 2000mm, the straightness is ≤0.1mm / m, the elastic deformation is ≤0.2mm when the static bearing is ≥500kg, the running resistance is ≤8N, the speed is controllable at 0-50mm / s. The inside is reinforced by 80mm×80mm×5mm Q345B angle steel, arranged in a network shape with longitudinal spacing of 300mm and transverse spacing of 400mm, the fillet weld leg is 6mm, and there is no defect after flaw detection. After simulation and test, the overall static deformation is ≤0.5mm / m under full load, the first order natural frequency is ≥50Hz, which meets the structural stability requirements of 0.5-50kW, 10-200kg multi-model motor test.

[0043] Adaptive positioning module: composed of X-axis sliding table, Y-axis adjusting frame, Z-axis lifting table, three-dimensional adjusting mechanism. X-axis sliding table is driven by ball screw, lead 16mm, positioning accuracy ±0.02mm, equipped with resolution 16384ppr absolute value encoder, screw rod is quenched and ground with GCr15 steel, nut seat is ZCuAl10Fe3 alloy, pre-tightening gap, speed 0-100mm / s, accuracy ±1mm / s. Y-axis adjusting frame realizes ±30° angle adjustment by worm and gear, accuracy ±0.05°, transmission ratio 40:1, worm is ZCuSn10Pb1 bronze, worm gear is 45# steel quenching and tempering, surface is embedded with HB200 wear-resistant cast iron plate and covered with 0.2mm polytetrafluoroethylene coating, adjusting torque ≤5N·m. Z-axis lifting table adopts synchronous belt transmission, belt width 20mm, tensile strength ≥1500N, pulley is 6061-T6 aluminum alloy anodized, lifting range 0-600mm, speed 0-50mm / s adjustable and accuracy ±2mm / s, equipped with THK HSR20 linear slide rail and 0.05mm resolution sensor, straightness error ≤0.1mm / m. End motor clamp adapter φ50-φ200mm flange, numerical control machining, 0.1mm interference fit 2mm thick silicone rubber elastic bushing inside, 3 groups of SUS304 adjustable positioning pins on the edge, diameter 10mm, adjustment range 0-20mm, adjusted by precision screw rod, radial runout ≤0.01mm, positioning repeatability ±0.03mm, ensure motor coaxial error ≤0.05mm, meet the needs of various test installation.

[0044] Intelligent clamping module: contains a circumferential clamping assembly and an axial pressing device. The circumferential clamping assembly takes an arc-shaped clamping jaw made of 6061-T6 aluminum alloy as the core, with a profile tolerance error of ≤0.05 mm after CNC precision milling. A 400W servo motor is reduced in speed by a 10:1 planetary reducer, driving a synchronous gear set with a module of 2 and carburized and quenched, to drive the clamping jaw to open and close synchronously, achieving a clamping range of φ80-φ300 mm with a positioning accuracy of ±0.03 mm. The inner side of the clamping jaw is pasted with a 3mm-thick silicone pad with a Shore hardness of 50A, and the sanding treatment makes the friction coefficient ≥0.7, which can both stabilize the workpiece and prevent surface damage. The axial pressing device uses a double-acting aluminum cylinder with a cylinder diameter of 32 mm and a stroke of 50 mm, which is combined with a 45# steel tempered needle (diameter 20 mm) through a hard anodic oxidation cylinder, and a floating joint (±3° swing) is used to compensate for deviations. A high-speed proportional solenoid valve with a response time of ≤20 ms is combined with a pressure sensor with a range of 0-1000 N and an accuracy of 0.5% FS to achieve closed-loop control of the pressing force of 0-500 N with an accuracy of ±5 N. The module integrates the pressure sensor and an inductive displacement sensor with an accuracy of ±0.01 mm, and the data is transmitted to an ARMCortex-M4 kernel controller (120MHz main frequency) through Modbus-RTU protocol (9600 baud rate). Its intelligent algorithm can plan the clamping jaw stroke and pressing force according to the size of the workpiece (such as automatically adapting parameters for a φ100 mm workpiece), and can also diagnose faults such as silicone pad wear and sensor overrange by monitoring the clamping force-displacement curve, etc., and sound and light alarm, stop, adapt to motor rotor and other precision clamping scenes, to ensure safe and reliable operation.

[0045] Power test module: takes a permanent magnet synchronous servo motor as the core test source, the motor power can be flexibly adjusted in the range of 0.5-15kW, the speed covers the range of 0-6000rpm, and the installation deviation is effectively adapted by connecting the measured motor with a diaphragm coupling (with a compensation amount of ±0.1mm). The torque measurement adopts a flange-mounted torque sensor with a range of 0-500N·m and an accuracy of ±0.1% FS, combined with a sampling frequency of 2kHz, to accurately capture the dynamic changes of torque; the resolution of the supporting speed sensor is 2048ppr, which can clearly identify the speed signal, and the current sensor with a bandwidth of 10kHz synchronously collects current data, which is coordinated with torque, speed and voltage parameters to build a multi-dimensional test system. The test motor controller supports fast switching between vector control and torque control modes, with a switching response time of <10ms, meeting the needs of different test scenarios. Under vector control, the motor speed performance verification is focused on, and the speed steady-state accuracy is accurately controlled; the torque control mode focuses on load simulation, and stably outputs the set torque, helping to carry out motor efficiency, overload capacity and other tests, providing comprehensive and accurate data support for motor performance evaluation, from basic operating parameter collection to complex control mode application, realizing the coverage test of the measured motor from low-power small-speed working condition to high-power high-speed working condition, and deeply exploring the motor power characteristics.

[0046] Automatic calibration module: Equipped with a laser tracker (measurement accuracy ±0.01mm / m) and a standard torque meter (grade 0.1). The laser tracker is fixed to the top of the frame via a tripod (1.5m away from the test axis) and can detect the alignment deviation between the two axes in real time (detection range ±5mm). The standard torque meter is connected to the test system via a special fixture and is used to calibrate the torque sensor (calibration cycle ≤30min). The module has a built-in temperature compensation circuit, which automatically corrects the measured value when the ambient temperature deviates from 25℃±5℃ (temperature coefficient 0.02% / ℃).

[0047] Data Processing Module: The hardware utilizes an industrial computer equipped with an Intel Core i7-10700 CPU (8 cores, 16 threads, turbo boost 4.8GHz), 16GB DDR4 memory (2933MHz), and a 1TB SSD (read speed ≥3500MB / s). It features a 16-bit PCIe acquisition card (1MHz sampling rate) and 8 differential AI channels (CMRR ≥100dB@1kHz) for accurate high-frequency signal capture. The software is developed based on LabVIEW, employing a producer-consumer model with a 1GB FIFO cache to prevent data loss and a response time ≤50ms. It supports custom test flows, including 10+ loading curve types, with a time accuracy of 1ms and adjustable loop counts from 1 to 99999. It includes a built-in database of 100+ motor models, linked to IEC, GB / T, and other standards, automatically matching test clauses. Data storage is compatible with CSV, Excel, and TDMS formats; TDMS supports retrieval of 10GB of data within 1 second. It provides 12 types of analysis charts, including torque-speed curves, efficiency curves, and time / frequency domain graphs. The system has three reserved PCIe slots to support the expansion of high-speed acquisition cards. Its modular software design allows for online updates of the database and algorithms, with upgrades taking ≤3 minutes. This module enables high-speed data acquisition, accurate processing, and intelligent analysis, adapting to the full-process testing needs of motors.

[0048] Safety Protection Module: A 1.5m high-speed rail protective fence (50mm×50mm mesh) with a 50mm bottom edge is installed around the frame, secured with M12 expansion bolts (100mm embedment depth). The fence gate is equipped with a DC24V electromagnetic lock (unlocking force ≥100N) and a safety interlock switch (response time <10ms). An infrared thermal imager (temperature range -20~300℃, resolution 640×512) is installed at the top of the test area to monitor the motor temperature in real time. The system has a three-level protection mechanism: early warning (audible and visual alarm, sound pressure level ≥90dB), deceleration (reducing the test speed to 50%), and emergency stop (cutting off all power supply, response time <50ms). Trigger conditions can be set via software, with priority given to emergency stop > deceleration > early warning. Trigger information is recorded for traceability, comprehensively ensuring the safety of test personnel and equipment.

[0049] This invention also includes the following modules:

[0050] Motor model identification module: Composed of a high-definition industrial camera (5 megapixels, 30fps) and an OCR recognition algorithm. The camera is installed directly in front of the test station (1m away) and can identify parameters such as model, power, and rated speed on the motor nameplate (recognition accuracy ≥99%). It is equipped with an RFID reader (working frequency 13.56MHz, identification distance 0-100mm) to read the information of the motor's built-in tag (including factory parameters and test records) and cross-verify it with the image recognition results (verification time <1s).

[0051] Load simulation module: It adopts a magnetic powder brake (rated torque 0-1000 N·m) and realizes load modes such as constant torque, constant speed and linear loading through closed-loop control (control accuracy ±1%); the brake is equipped with a water cooling system (flow rate 2L / min, inlet temperature difference ≤5℃) to prevent overheating during long-term loading; the load adjustment response time is <50ms, which can simulate dynamic working conditions such as sudden load increase and sudden load decrease.

[0052] This invention also includes the following modules:

[0053] Environmental simulation module: Includes high and low temperature chamber (temperature control range -40~150℃, temperature fluctuation ±0.5℃) and humidity control device (humidity range 20%~95%RH, accuracy ±3%), test chamber volume 1000L, can accommodate motors with a maximum size of φ500mm×1000mm; wind speed sensor (range 0-10m / s) and air pressure sensor (range 80-120kPa) are installed on the inner wall of the chamber to simulate different environmental conditions.

[0054] Remote monitoring module: Supports Ethernet (1000Mbps) and 4G wireless network transmission, and can upload test data and device status in real time (upload interval 1s); equipped with a web monitoring platform and mobile APP, authorized users can view test curves and remotely start and stop tests (control command response time <1s); the system supports multi-user permission management (administrator, operator, visitor), and operation logs are automatically recorded (including operator, time, and content), and are stored for ≥1 year.

[0055] In this invention, the formula for calculating the motor efficiency of the data processing module is as follows: Where η is the motor efficiency (%), T is the output torque (N·m), n is the speed (r / min), U is the input voltage (V), and I is the input current (A). The power factor is calculated as follows: During the calculation process, the data processing module first performs harmonic analysis on the collected voltage and current signals (analysis up to the 50th harmonic) to remove high-order harmonic interference (total harmonic distortion rate ≤ 5%); the power factor is calculated in real time using an instantaneous reactive power algorithm (updating frequency 1kHz) and corrected in conjunction with the rated power factor on the motor nameplate (correction coefficient 0.98-1.02); for asynchronous motors, slip compensation is automatically introduced (compensation value = 0.02 × (1-n / n0), where n0 is the synchronous speed) to ensure the accuracy of efficiency calculation in the low-speed range (error ≤ 1%); the calculation results are updated every 10ms and compared with the preset efficiency threshold (set according to the motor model), and a data marker is triggered (highlighted in red) when the threshold is exceeded.

[0056] In this invention, the load torque adjustment formula for the load simulation module is as follows:

[0057] Where T load T is the adjusted load torque (N·m). set T is the target load torque (N·m). act K represents the actual load torque (N·m). p K is the proportionality constant (0.1-2.0). i K is the integral coefficient (0.01-0.5). d Here, K represents the differential coefficients (0.05-1.0), and t represents time (s). The parameters are dynamically optimized using a self-tuning algorithm, with a relatively large K value used during the startup phase (0-3s). p (1.5-2.0) and smaller K i (0.01-0.05), to accelerate the response speed; during the stable phase (>3s), K automatically decreases. p (0.5-1.0) and increase K i (0.1-0.3), reduce steady-state error (≤0.5%); when a sudden load change (rate of change >50% / ms) is detected, K d Temporarily increase to 0.8-1.0 to suppress overshoot (overshoot ≤5%). The conversion relationship between the excitation current and load torque of the magnetic powder brake is processed by piecewise linearization (every 10 N·m segment) and stored in a lookup table (update cycle 100 ms) to ensure that the T_load of the regulated output can be accurately converted into current command (conversion error ≤1%).

[0058] In this invention, the formula for correcting the temperature field uniformity of the environmental simulation module is T. corr =T meas +α×(d-500), where T corr T represents the corrected temperature value (°C). measThe sensor measures the temperature (°C), α is the temperature gradient coefficient (0.01°C / mm), and d is the distance (mm) between the measurement point and the center of the chamber. Nine temperature sensors (distributed in a 3×3 matrix, spaced 300mm apart) are arranged inside the chamber to collect temperature data at each point in real time and calculate the gradient coefficient α (updated every 5 minutes). When the chamber temperature is in the range of -40°C to 0°C, α is automatically corrected to 0.012°C / mm; in the range of 0°C to 150°C, it remains at 0.01°C / mm to compensate for the larger temperature gradient in the low-temperature region. The motor surface temperature is measured using an infrared thermometer (measurement distance 500-1000mm). The measured value is first corrected by emissivity (emissivity is set according to the motor casing material: 0.3-0.5 for metal, 0.8-0.95 for plastic) before being substituted into the correction value to calculate T. corr The corrected temperature data is used to control the heating / cooling power of the high and low temperature chamber (adjustment accuracy ±0.2℃) to ensure that the motor's operating environment temperature meets the test standard requirements.

[0059] In this invention, the X-axis slide of the adaptive positioning module adopts a double-rail parallel arrangement (300mm spacing), a slider preload of 50N, and a running stability ≤0.01mm / m; the lead screw support uses angular contact ball bearings (model 7010C), installed in pairs (preload 100N), eliminating axial clearance; the drive motor is equipped with a planetary reducer (reduction ratio 1:10, backlash ≤3 arc minutes), and the output shaft is connected to the lead screw through a flexible coupling (radial compensation ±0.2mm); a grating ruler (resolution 0.1μm) is installed on the slide surface to form a fully closed-loop control, ensuring accurate and repeatable positioning. The accuracy is ≤0.005mm; the control cabinet of the three-dimensional adjustment mechanism is equipped with a servo driver (response frequency 2kHz), supporting pulse and analog control (0-10V corresponding to the full stroke); the worm gear pair of the Y-axis adjustment frame adopts a double lead design (lead difference 0.5mm), and the clearance is adjusted by axially moving the worm (adjustment range 0-0.1mm); the Z-axis synchronous pulley is made of 45 steel with heat treatment (hardness HB220), the pulley groove accuracy is IT7 grade, and the meshing clearance with the synchronous belt is ≤0.1mm, ensuring that there is no crawling phenomenon in the lifting motion (speed fluctuation ≤2%).

[0060] In this invention, the intelligent clamping module's arc-shaped gripper adopts a hollow structure (reducing weight by 30%), with spiral anti-slip texture (0.5mm depth) machined on the inner side; the gripper drive gear is made of 20CrMnTi material (carburized and quenched HRC58-62), with a tooth surface precision of grade 6 and a meshing clearance ≤0.02mm; the cylinder of the axial clamping device is equipped with a magnetic ring and a proximity switch (detection distance 1mm) to confirm the position of the ejector pin; the module controller uses an STM32H743 microprocessor (400MHz main frequency), communicates with the main system via CAN bus (1Mbps baud rate), and the clamping force... The control algorithm supports multi-segment nonlinear compensation (for different motor housing materials) to ensure clamping stability while avoiding housing deformation (deformation ≤0.1mm); a polyurethane buffer block (10mm thick, Shore A hardness 60A) is set at the end of the gripper stroke, with a buffer distance of 5mm, which can absorb 80% of the clamping impact energy; the system has 10 built-in clamping modes (divided according to motor weight 0-50kg, 50-100kg, 100-200kg, etc.), and automatically matches the clamping force (clamping force increases by 50N for every 10kg increase in weight) and clamping speed (adjustable from 0-50mm / s).

[0061] In this invention, the motor model identification module uses an 8mm fixed-focus lens (F1.4 aperture) and a ring LED light source (5500K color temperature, adjustable brightness), capable of continuous and stable operation under ambient light conditions of 0-1000 lux. The OCR recognition algorithm supports fuzzy recognition (character loss ≤20% is recognizable) and tilt correction (maximum correction angle ±15°). The RFID tag is passive (20mm × 10mm in size), installed on the non-load-bearing surface of the motor (0-50mm from the reader), with a storage capacity ≥2KB. The system writes information such as test date and pass / fail status; the recognition module and adaptive positioning module work together, and automatically call the corresponding clamping parameters and positioning coordinates within 3 seconds after recognition is completed; the image captured by the camera is transmitted to the data processing module via Ethernet (transmission delay < 50ms), and the original image (JPEG format, resolution 2592×1944) is saved for historical traceability; when recognition fails (three consecutive recognitions are inconsistent), manual intervention prompts are automatically triggered (the screen displays "Please manually enter the model number"), and the reason for failure is recorded (such as nameplate damage, insufficient light).

[0062] In this invention, the remote monitoring module hardware adopts an industrial-grade router (with firewall function), supporting VPN connection and data encryption (AES-256 algorithm); the web platform is based on B / S architecture, accessible via browser (Chrome, Edge), supporting real-time curve display (1Hz refresh rate), historical data query (filterable by motor model and test date), and test report generation (PDF format); the mobile APP supports iOS and Android systems, pushing messages such as device failure and test completion (push delay <5s); the module has a built-in network diagnostic tool that can automatically detect network bandwidth (≥1Mbps) and latency (≤100ms), automatically switching to local storage mode when the network is abnormal (storage capacity ≥1000 sets of test data), and automatically uploading after the network is restored; remote control commands require two-level verification (operator enters password + administrator authorization code) to prevent accidental operation; the system log contains all remote operation records (operator IP address, operation content, time), and the retention period is consistent with the test data (≥3 years).

[0063] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An adaptive testing system for multiple drive motor models, characterized in that, Includes the following modules: The frame support module is made of Q345B low alloy steel plate and welded as a whole. The bottom is fixed to the concrete foundation by 8 sets of M16 expansion bolts. The left column of the frame is equipped with a vertical guide rail, and the right crossbeam is equipped with a horizontal sliding rail. The inner side is welded with reinforcing ribs. Adaptive positioning module: It consists of a three-dimensional adjustment mechanism composed of an X-axis slide, a Y-axis adjustment frame, and a Z-axis lifting platform. A motor holder is installed at the end of the mechanism, and three sets of adjustment and positioning pins are set on the edge of the holder. Intelligent clamping module: It adopts a circumferential clamping component and an axial clamping device. The arc-shaped gripper of the circumferential clamping component is driven by a servo motor, and the axial clamping device uses a cylinder to drive the ejector pin. The module has built-in pressure and displacement sensors to monitor the clamping status in real time. Power testing module: The test motor is a permanent magnet synchronous servo motor, which is connected to the motor under test through a diaphragm coupling; the torque sensor adopts flange mounting, and is equipped with speed and current sensors to synchronously collect torque, speed, voltage and current parameters; Automatic calibration module: The laser tracker is fixed to the top of the frame via a tripod to detect the alignment deviation of the two axes; the standard torque meter is docked with the test system to calibrate the torque sensor; the module has a built-in temperature compensation circuit, which automatically corrects the measured value when the ambient temperature exceeds the threshold. Data processing module: It uses an industrial computer to receive sensor signals through a PCIe data acquisition card, runs LabVIEW testing software, and allows for customized testing processes; The software has a built-in motor model database, automatically calls up standards, and generates analysis charts; Safety protection module: A 1.5m high-speed rail protective fence is set around the rack, the fence gate is equipped with an electromagnetic lock and a safety interlock switch, and an infrared thermal imager is installed on the top of the test area; A three-level protection mechanism is set up, and trigger conditions are set through software.

2. The adaptive testing system for multiple drive motor models according to claim 1, characterized in that, Also includes: Motor model identification module: Composed of a high-definition industrial camera and OCR recognition algorithm. The camera is installed in front of the test station to identify the parameters on the motor nameplate. Equipped with an RFID reader, it reads the information from the motor's built-in tag and cross-verifies it with the image recognition results; Load simulation module: It adopts a magnetic powder brake and switches the load mode through closed-loop control; the brake is equipped with a water cooling system to simulate dynamic working conditions.

3. The adaptive testing system for multiple drive motor models according to claim 1, characterized in that, Also includes: Environmental simulation module: Equipped with high and low temperature chambers and humidity control devices, with wind speed and air pressure sensors installed on the inner wall of the chamber to simulate different environmental conditions; Remote monitoring module: Employs Ethernet and 4G wireless network transmission to upload test data and equipment status in real time; equipped with a web monitoring platform and mobile APP, authorized users can view test curves and remotely start and stop tests; It supports multi-user permission management and automatically records operation logs.

4. The adaptive testing system for multiple drive motor models according to claim 1, characterized in that, The formula for calculating the motor efficiency of the data processing module is as follows: η is the motor efficiency, T is the output torque, n is the speed, U is the input voltage, and I is the input current. The system calculates the power factor; analyzes voltage and current signals for harmonics to eliminate high-order harmonic interference; calculates the power factor using an instantaneous reactive power algorithm, combined with a rated power factor correction; automatically introduces slip compensation for asynchronous motors, updates the calculation results every 10ms, compares them with a preset efficiency threshold, and triggers data marking when the threshold is exceeded.

5. The multi-model adaptive testing system for drive motors according to claim 2, characterized in that, The load torque adjustment formula for the load simulation module is as follows: T load To adjust the afterload torque, T set For the target load torque, T act K represents the actual load torque. p K is the proportionality coefficient. i K is the integral coefficient. d The coefficients are differentials, and t is time. The parameters are dynamically optimized through a self-tuning algorithm. The relationship between the excitation current and load torque of the magnetic powder brake is processed by piecewise linearization and stored in a lookup table.

6. The multi-model adaptive testing system for drive motors according to claim 3, characterized in that, The formula for correcting the temperature field uniformity in the environmental simulation module is T. corr =T meas +α×(d-500), T corr For the corrected temperature value, T meas Temperature is measured by sensors, where α is the temperature gradient coefficient and d is the distance between the measurement point and the center of the cabin. Nine temperature sensors are arranged inside the cabin to collect temperature data at each point in real time and calculate the gradient coefficient α. An infrared thermometer is used to measure the surface temperature of the motor, and the measured value is corrected by emissivity. The corrected value is then substituted into the correction formula to calculate T. corr .

7. The adaptive testing system for multiple drive motor models according to claim 1, characterized in that, The adaptive positioning module's X-axis slide table adopts a parallel arrangement of dual guide rails, and the lead screw support seat uses angular contact ball bearings, installed in pairs; the drive motor is equipped with a planetary reducer, and the output shaft is connected to the lead screw through a flexible coupling; a grating ruler is installed on the slide table surface for full closed-loop control; the Y-axis adjusting frame's worm gear adopts a double-lead design, and the clearance is adjusted by axially moving the worm gear; the Z-axis synchronous pulley is made of 45# steel with heat treatment, and the pulley groove accuracy is IT7 grade.

8. The adaptive testing system for multiple drive motor models according to claim 1, characterized in that, The intelligent clamping module features a hollowed-out arc-shaped gripper, with the gripper drive gear made of 20CrMnTi material. The axial clamping device cylinder is equipped with a magnetic ring and a proximity switch. The module controller uses an STM32H743 microprocessor and communicates with the main system via a CAN bus. A polyurethane buffer block is installed at the end of the gripper's stroke. The system has 10 built-in clamping modes and automatically matches the clamping force.

9. The adaptive testing system for multiple drive motor models according to claim 2, characterized in that, The motor model identification module uses an 8mm fixed-focus lens in its industrial camera, equipped with a ring LED light source; the OCR recognition algorithm employs fuzzy recognition and tilt correction; the RFID tag is passive and installed on the non-load-bearing surface of the motor; the identification module is linked with the adaptive positioning module, automatically calling the corresponding clamping parameters and positioning coordinates after identification is completed; the camera captures images and transmits them to the data processing module via Ethernet to save the original images; when identification fails, it automatically triggers manual intervention prompts and records the reason for the failure.

10. The multi-model adaptive testing system for drive motors according to claim 3, characterized in that, The remote monitoring module uses an industrial-grade router as its hardware, and its web platform is based on a B / S architecture and accessed via a browser. It also supports push notifications from a mobile app. The module has built-in network diagnostic tools and enables remote control commands to be verified through a two-level authentication process.

Images