A device and method for testing water cooling effect of an electric machine

Abstract

The application discloses a device and method for testing water cooling effect of a motor, which comprises a test base, a test device arranged on the test base and a water cooling effect quick detection scheme, the test device comprises a motor to be tested, a water cooling circulation system and a magnetic powder brake, the motor to be tested is arranged between two motor support frames and is spaced apart from the test base, the water cooling circulation system is arranged on one side of the motor to be tested and is connected with a water channel shell pipeline outside the motor to be tested, and the magnetic powder brake is arranged on the other side of the motor to be tested and is provided with a torque sensor between the magnetic powder brake and the motor to be tested, the device does not need a complete packaging shell when testing the water channel effect, only needs a water channel partial shell, has a quick test installation process, greatly saves test cost, shortens a water channel effect test period and has strong practicability.

Description

Technical Field

[0001] The present invention relates to the technical field of motor testing, and in particular to a device and method for testing the water cooling effect of a motor. Background Art

[0002] High temperature is inevitable during the operation of the motor. Water channel cooling is a cooling solution with excellent cooling effect, mature and reliable structure, mature process and low noise. It has become the mainstream choice for motor cooling.

[0003] During the testing process of the cooling effect of different water channels on the motor, it is expensive to make a complete housing package, and each test process is complicated and requires the installation of a complete motor structure.

[0004] In the case of the whole machine temperature rise test, the motor condition cannot be observed in real time, and the temperature measurement of the motor stator and rotor and the impact of the temperature rise on the motor operation condition cannot be judged in real time.

[0005] During the performance test of the motor cooling water channel, factors such as the cooling water volume, water flow rate, and water channel style and width have a significant impact on the cooling performance. Traditional testing methods are difficult to comprehensively consider various influencing factors. Summary of the Invention

[0006] The purpose of the present invention is to address the above-mentioned deficiencies in the existing technology and provide a device and method for testing the water cooling effect of a motor, so as to solve the problems such as the incompatibility of multiple water channel housings during common motor water channel testing; the high cost of testing; the difficulty in observing the operating conditions of the motor and cooling system in real time; and the cumbersome testing process.

[0007] The technical solutions of the present invention are as follows:

[0008] A device for testing the water-cooling effect of a motor comprises a test base and a test device arranged on the test base, the test device comprising a motor to be tested, a water-cooling circulation system, and a magnetic powder brake; motor support frames are respectively provided on both sides of the motor to be tested, the motor to be tested is mounted between the two motor support frames, and a gap is left between the motor to be tested and the test base; the water-cooling circulation system is arranged on one side of the motor to be tested and connected to a water channel housing pipeline on the outside of the motor to be tested; the magnetic powder brake is arranged on the other side of the motor to be tested, a torque sensor is provided between the magnetic powder brake and the motor to be tested, and the motor to be tested and the torque sensor, as well as the magnetic powder brake and the torque sensor, are respectively connected by transmission.

[0009] Furthermore, the motor support frame includes a motor support base, a motor support beam and a stator and rotor support frame; the motor support base is fixedly set on the test base, the motor support beam is fixedly set on the side of the motor support base, and the motor support beam is provided with a stator and rotor support frame fitting hole, and the stator and rotor support frame is fitted in the stator and rotor support frame fitting hole and fixedly connected to the motor support beam.

[0010] Furthermore, a water channel casing support frame is provided on the stator and rotor support frame, and is provided with a shaft through hole and a bearing sleeve hole; the shaft of the motor under test is connected to the stator and rotor support frame through a bearing, and the shaft passes through the shaft through hole, and the water channel casing support frame is tightly arranged against the water channel casing.

[0011] Furthermore, the water cooling circulation system includes a water tank, a water pump and a circulating water channel; a water pump is provided in the water tank, and there are two holes on the water tank, one serving as a water outlet of the water tank and the other serving as a water inlet of the water tank, the water outlet of the water tank is connected to the water channel inlet on the water channel shell, and the water channel outlet of the water channel shell is connected to the water tank inlet, thereby realizing water cooling circulation; the circulating water channel includes a water pipe, an L-shaped elbow and a pipe clamp, the water tank and the water channel shell are connected to the water pipe through the L-shaped elbow, and are fastened to the water pipe through the pipe clamp.

[0012] Furthermore, a device for testing the water cooling effect of a motor also includes a flow meter, which is arranged at the water inlet of the water channel. The working state of the water pump is adjusted by detecting the flow rate at the water channel inlet to achieve the required circulating water volume.

[0013] Furthermore, a group of temperature sensors are provided axially on the stator of the motor under test, and data is transmitted to a host computer through the temperature sensors to detect the temperature rise of the motor under test in real time.

[0014] Furthermore, the test base includes a transverse long bracket, a longitudinal short bracket and a pulley. The longitudinal short bracket is vertically arranged at the two end positions of the transverse long bracket, and the right-angle contact part between the two brackets is fixed with bolts through right-angle angle braces. Multiple pulleys are arranged along the axial direction of the transverse long bracket. T-slots are respectively provided on the four sides of the transverse long bracket and the longitudinal short bracket, and T-nuts are arranged in the T-slots to connect with the test device.

[0015] Furthermore, a square observation hole is opened on the top of the water tank for observing the water volume and measuring the inlet and outlet water temperatures.

[0016] Furthermore, a method for inspecting a device for inspecting the water cooling effect of a motor is provided. First, the required heat dissipation can be obtained by calculating the expected temperature rise; then, a host computer is used to obtain the heat absorbed by the water channel by sampling parameters such as the inlet and outlet temperatures and the cross-sectional area of ​​the flow channel; then, a heat balance formula is used to determine whether the heat absorbed by the water channel is greater than the heat dissipation; thereby, a preliminary verification is made as to whether the water channel meets the requirements; finally, temperature sensor sampling is used to verify whether the cooling effect of the water channel meets the expected requirements.

[0017] The beneficial effects of the present invention are as follows:

[0018] 1) The motor under test is allowed to have an overhead height, and the design of the motor support frame is compatible with water channel shells of various thicknesses, which reduces the test cost and makes the test effect comparison more obvious.

[0019] 2) When testing the water channel effect, a complete packaging shell is not required, only a water channel shell is required. The test installation process is fast, which greatly saves the test cost and shortens the water channel effect test cycle, and has strong practicality.

[0020] 3) The water channel cooling system and the motor under test are equipped with obvious observation ports, which can observe the operating conditions of the cooling system and the motor in real time and better monitor the cooling effect data.

[0021] 4) Through flow meters, temperature sensors and host computers, the factors affecting the cooling effect can be comprehensively considered, and parameters such as water channel pattern and cross-sectional flow can be adjusted more accurately to optimize the cooling effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is the overall assembly diagram of the present invention;

[0023] Figure 2 This is an assembly diagram of the support base of the present invention;

[0024] Figure 3 This is an assembly diagram of the water circulation system of the present invention;

[0025] Figure 4 This is an assembly drawing of the support frame of the motor under test of the present invention;

[0026] Figure 5 This is an assembly diagram of the magnetic powder support seat of the present invention;

[0027] Figure 6 This is an assembly diagram of the torque sensor support base of the present invention;

[0028] Figure 7 This is a flow chart for optimizing the cooling effect of the motor according to the present invention;

[0029] Figure 8 A reference cloud diagram of the cooling effect of the motor of the present invention;

[0030] Figure: 1. Longitudinal support frame; 2. Horizontal support frame; 3. Right-angle support; 4. Support bolt; 5. Pulley; 6. Connecting bolt; 7. Water tank; 8. Water tank observation port; 9. Water tank outlet; 10. Water tank inlet; 11. L-shaped elbow; 12. Pipe clamp; 13. Water channel inlet; 14. Water channel outlet; 15. Flow meter; 16. Motor support base; 17. Motor support base fixing bolt; 18. Motor support base threaded hole; 19. Motor support beam; 20 , motor bracket bolt; 21, motor support beam threaded hole; 22, stator and rotor support frame fitting hole; 23, stator and rotor support frame; 24, bearing fitting hole; 25, stator and rotor support frame threaded hole; 26, bearing; 27, magnetic powder brake; 28, magnetic powder brake support seat; 29, magnetic powder base fixing bolt; 30, magnetic powder brake fixing bolt; 31, torque sensor; 32, torque sensor support seat; 33, torque base fixing bolt; 34 torque sensor fixing bolt. DETAILED DESCRIPTION

[0031] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings to facilitate understanding of the present invention by those skilled in the art. It is apparent that the embodiments described are only a portion of the embodiments of the present invention, not all of them. All other embodiments derived by those skilled in the art based on the embodiments of the present invention without creative effort are also within the scope of protection of the present invention.

[0032] In the description of the present invention, terms such as "upper," "lower," "left," "right," "front," "back," "inner," and "outer" are used to refer to positions or locations based on the positions or locations shown in the accompanying drawings. These terms are used solely to facilitate the description of the present invention and to simplify the description. They are not intended to indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific manner. Therefore, they should not be construed as limitations of the present invention. Furthermore, terms such as "first," "next," and "following" are used for descriptive purposes only and should not be construed to indicate or imply relative importance.

[0033] Unless otherwise specified or limited, descriptive terms such as "mounted," "connected," and "connected" in this disclosure should be interpreted broadly. For example, these terms can refer to fixed, removable, or integral connections; mechanical or electrical connections; direct, indirect, or internal communication between two components. Those skilled in the art will understand the specific meanings of these terms in this disclosure based on the specific circumstances.

[0034] See Figure 1A device for testing the water cooling effect of a motor includes a longitudinal support frame 1, a transverse support frame 2, a right-angle support 3, a pulley 5, a water tank 7, an L-shaped elbow 11, a pipe clamp 12, a flow meter 15, a motor support base 16, a motor support beam 19, a stator and rotor support frame 23, a bearing 26, a magnetic powder brake 27, a magnetic powder brake support seat 28, a torque sensor 31, and a torque sensor support seat 32.

[0035] See also Figure 2 As a preferred embodiment, two longitudinal support frames 1 are arranged on both sides of the transverse support frame 2, and the right-angle connections are fastened by right-angle angle braces 3 and angle brace bolts 4; eight pulleys 5 with self-locking devices are evenly and symmetrically arranged along the bottom of the two transverse support frames 2, which can facilitate movement and disassembly and reduce vibration; T-slots are provided on the four sides of the longitudinal support frame 1 and the transverse support frame 2, and T-bolts are arranged on the transverse support frame 2 for fastening the test device.

[0036] See also Figure 3 As a preferred embodiment, a water tank observation port 8 is opened on the upper part of the water tank 7 for observing the water volume and detecting the water temperature and the pump body temperature. There are two circular holes in the front of the water tank, namely the water tank outlet 9 and the water tank inlet 10; the water tank inlet and outlet are connected to the L-shaped elbow 11, and are connected to the water pipe through the pipe clamp 12; the water channel inlet 13 and the water channel outlet 14 of the motor to be tested are also connected to the water pipe through the L-shaped elbow 11 and the pipe clamp 12, and a flow meter 15 is provided at the water channel inlet 13 of the motor to be tested, and the water inlet flow is measured by the flow meter to calculate the cooling water volume.

[0037] See also Figure 4 As a preferred embodiment, two sets of motor support frames are distributed on both sides of the motor under test; one set includes three parts: a motor support base 16, a motor support beam 19 and a stator and rotor support frame 23; the motor support base 16 has five threaded holes corresponding to the through holes of the motor support beam 19, and the two are installed together by bolts; the motor support base 16 also has four threaded holes corresponding to the horizontal support frame 2, and is installed together by bolts.

[0038] The motor support beam 19 is provided with a stator and rotor support frame fitting hole 22 and a motor support beam threaded hole, and the stator and rotor support frame 23 is fitted on the stator and rotor support frame fitting hole 22; the stator and rotor support frame 23 is provided with a water channel casing support frame, and is provided with a shaft through hole, a bearing fitting hole 24, and a stator and rotor support frame threaded hole 25; the bearing 26 is arranged in the bearing fitting hole 24, connecting the measured motor shaft and the stator and rotor support frame 23, the measured motor shaft passes through the shaft through hole, and the inner diameter of the water channel casing is in close contact with the water channel casing support frame.

[0039] During assembly, the motor support base 16 is first installed on the transverse support frame; then the motor support base 16 and the motor support beam 19 are connected together through the motor bracket bolts 20 and the corresponding motor support base threaded holes 18; then the motor support beam 19 and the stator and rotor support frame 23 are fastened together using bolts through the motor support beam threaded holes 21 and the corresponding stator and rotor support frame threaded holes 25. At this time, the stator and rotor support frame fitting holes 22 will fit over the tail of the stator and rotor support frame 23; finally, the bearing 26 fitted on the motor shaft to be tested is fitted on the bearing fitting holes 24 to fasten the shaft. After the fitting is completed, the stator and rotor support frame 23 supports the water channel casing part outside to fix the stator.

[0040] See also Figure 5 As a preferred embodiment, four through holes are opened on the magnetic powder brake support seat 28, and the magnetic powder brake support seat 28 is fixed to the transverse support frame 2 through the magnetic powder base fixing bolts 29; four through holes are provided on the magnetic powder brake 27, and the magnetic powder brake 27 is fastened to the magnetic powder brake support seat 28 through the magnetic powder brake fixing bolts 30.

[0041] See also Figure 6 As a preferred embodiment, the torque sensor support base 32 has four through holes for connecting to the transverse support frame 2, and the torque sensor support base 32 is fixed to the transverse support frame 2 through the torque base fixing bolts 33; the torque sensor support base 32 has four through holes corresponding to the threaded holes at the bottom of the torque sensor 31, and the torque sensor 31 has a threaded hole at the bottom and is fixed to the torque sensor support base 32 through the torque sensor fixing bolts 34.

[0042] The temperature sensors are distributed in the axial direction of the stator and detect the real-time temperature rise in the axial direction of the motor by transmitting data to the upper computer. The temperature sensors are not shown in the figure.

[0043] The torque sensor is connected to the motor to be measured and the magnetic powder brake 27 through a coupling.

[0044] See also Figure 7 As a preferred embodiment, after preliminary finite element analysis of the motor temperature rise, the motor temperature rise cloud diagram is obtained as follows: Figure 8 shown.

[0045] During the test: the current cooling water channel type, cross-sectional area, material and other parameters are input into the host computer. Then, during the test, the motor axial temperature distribution, water inlet flow rate, inlet and outlet temperature difference and other parameters are detected by temperature sensors and flow meters, and transmitted to the host computer. The host computer then performs calculations and post-processing.

[0046] After inputting the parameters on the host computer, the following formula can be used to determine whether the waterway meets expectations.

[0047] Pcud +P Fed ≤βq

[0048] Where, P cud With P Fed is the heat difference between the expected temperature rise of the winding and stator and rotor and the actual natural cooling temperature rise, and β is the water channel heat absorption coefficient.

[0049] The winding copper loss is the loss caused by the current in the winding, and its heat generation formula is:

[0050] P cu =mI 2 R

[0051] Where: m is the number of motor phases; I is the effective value of the winding current; R is the effective resistance of each phase winding.

[0052] The motor stator iron loss mainly consists of three parts, namely hysteresis loss, eddy current loss and additional loss, and its calculation formula is:

[0053] P Fe =P h +P c +P e

[0054] in:

[0055]

[0056] Where: k h is the hysteresis loss coefficient; k c is the eddy current loss coefficient; k e is the additional loss coefficient; f is the magnetic field exchange frequency (Hz); B m is the magnetic flux density amplitude (T); α is an empirical coefficient, usually 2;

[0057] The heat absorption power of the water channel is closely related to the water inlet flow rate, water channel cross-sectional area, and water channel style. However, by detecting the water flow temperature at the inlet and outlet, the heat absorbed by the cooling water can be clearly calculated. The formula is:

[0058] q=ΔTmc

[0059] In the formula: △T represents the temperature difference between the inlet and outlet; m represents the mass of water; c is the specific heat capacity of water.

[0060] During the verification process, due to the uneven temperature distribution of the motor, it is necessary to use the temperature sensor to verify whether the temperature rise meets the requirements.

[0061] The host computer calculates and post-processes to obtain the temperature distribution of the winding, stator and rotor, and generates an effect comparison chart to obtain the optimization plan. After the optimization plan is determined, this step is repeated to find a better cooling plan.

[0062] The above description is only a preferred embodiment of the present invention and does not limit the implementation mode and protection scope of the present invention. For those skilled in the art, it should be aware that all solutions obtained by equivalent substitutions and obvious changes made using the description and illustrations of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for testing a device for testing the water cooling effect of a motor, characterized in that: The device includes a test base and a test device arranged on the test base, wherein the test device includes a motor under test, a water-cooling circulation system, and a magnetic powder brake; motor support frames are respectively provided on both sides of the motor under test, and the motor under test is mounted between the two motor support frames with a gap between the motor under test and the test base; the water-cooling circulation system is arranged on one side of the motor under test and connected to a water channel housing pipeline on the outside of the motor under test; the magnetic powder brake is arranged on the other side of the motor under test, and a torque sensor is provided between the magnetic powder brake and the motor under test, and the motor under test and the torque sensor, as well as the magnetic powder brake and the torque sensor, are respectively connected by transmission. The method comprises the following steps: 1) Build the physical object of the device; 2) Obtain the water channel pattern and cross-sectional area, the temperature sensor value of the stator axial direction of the motor under test, and the flow meter value at the water channel inlet; and input them into the host computer; 3) Determine whether the water channel as a whole meets the cooling requirements. The formula is as follows: P cud +P Fed ≤βq Where, P cud The heat difference between the expected temperature rise of the winding and the natural cooling temperature rise; P Fed The heat difference between the expected temperature rise of the stator and rotor and the temperature rise of natural cooling; β is the water channel heat absorption coefficient; q = ΔTmc, where ΔT represents the temperature difference between the inlet and outlet of the waterway; m represents the mass of water; and c represents the specific heat capacity of water. 4) If the water channel meets the requirements of step 3), verify whether the water channel meets the requirements by using temperature sensors; Compare the temperature sensor values ​​of the stator axial direction of the motor under test obtained in step 2) with the expected temperature rise at the corresponding positions. If both meet the requirements, the water channel cooling effect meets the requirements.

2. The method for testing a device for testing the water cooling effect of a motor according to claim 1, characterized in that: The motor support frame includes a motor support base, a motor support beam and a stator and rotor support frame; the motor support base is fixedly set on the test base, the motor support beam is fixedly set on the side of the motor support base, the motor support beam is provided with a stator and rotor support frame fitting hole, the stator and rotor support frame is fitted in the stator and rotor support frame fitting hole and is fixedly connected to the motor support beam.

3. The method for testing a device for testing the water cooling effect of a motor according to claim 2, characterized in that: The stator and rotor support frame is provided with a water channel casing support frame, and is provided with a rotating shaft through hole and a bearing sleeve hole; the rotating shaft of the motor under test is supported by the stator and rotor support frame through the bearing, and the rotating shaft passes through the rotating shaft through hole, and the water channel casing support frame is tightly arranged with the water channel casing.

4. The method for testing a device for testing the water cooling effect of a motor according to claim 1, characterized in that: The water cooling circulation system includes a water tank, a water pump and a circulating water channel; a water pump is provided in the water tank, and there are two holes on the water tank, one serving as a water outlet of the water tank and the other serving as a water inlet of the water tank. The water outlet of the water tank is connected to the water channel inlet on the water channel shell, and the water channel outlet of the water channel shell is connected to the water tank inlet, thereby realizing water cooling circulation; the circulating water channel includes a water pipe, an L-shaped elbow and a pipe clamp. The water tank and the water channel shell are connected to the water pipe through the L-shaped elbow and are fastened to the water pipe through the pipe clamp.

5. The method for testing a device for testing the water cooling effect of a motor according to claim 4, characterized in that: It also includes a flow meter, which is arranged at the water inlet of the water channel. The flow meter adjusts the working state of the water pump by detecting the flow at the water channel inlet, so as to achieve the required circulating water volume.

6. The method for testing a device for testing the water cooling effect of a motor according to claim 1, characterized in that: A group of temperature sensors are provided axially on the stator of the motor under test, and data is transmitted to a host computer through the temperature sensors to detect the temperature rise of the motor under test in real time.

7. The method for testing a device for testing the water cooling effect of a motor according to claim 1, characterized in that: The test base includes a transverse long bracket, a longitudinal short bracket and a pulley. The longitudinal short bracket is vertically arranged at the two end positions of the transverse long bracket, and the right-angle contact part between the two brackets is fixed with bolts through a right-angle angle brace. Multiple pulleys are arranged along the axial direction of the transverse long bracket. T-slots are respectively opened on the four sides of the transverse long bracket and the longitudinal short bracket, and T-nuts are arranged in the T-slots to connect with the test device.

8. The method for inspecting the device for inspecting the water cooling effect of a motor according to claim 4, wherein a square observation hole is provided on the top of the water tank for observing the water volume and measuring the inlet and outlet water temperatures.

Images