Method for detecting motor function based on detection table

Abstract

The invention provides a method for checking motor functions based on a detection table. The method comprises the following steps: S1, collecting motor parameters; s2, checking motor functions based on the obtained motor parameters; (S3); generating a test report; (S4); remote control and monitoring; according to the method for detecting the motor function based on the detection table, the multiple sensors and modules of the detection table are combined, the motor parameters are collected, the motor parameters are compared with the corresponding intervals and the specified values of the preset parameters meeting the motor factory setting standard, whether the motor meets factory setting or not is judged, and the motor function is detected. Various performance parameters of the motor can be monitored more accurately, abnormal changes of the motor can be found in time, and the accuracy of a detection result is ensured; according to the method, the residual life of the motor is predicted through the recession model; the system helps an enterprise or a user to maintain and replace the motor in advance, not only helps to reduce the fault risk, but also can improve the overall operation efficiency of equipment, and avoids meaningless shutdown and maintenance cost.

Description

Technical Field

[0001] The invention relates to the field of computer technology, and in particular to a method for testing motor functions based on a testing platform. Background Art

[0002] With the rapid development of industrial technology, motors, as the core power devices in various mechanical equipment, occupy an important position in modern production. The performance of motors directly affects the working efficiency, stability and service life of the entire equipment. In order to ensure that the quality of motors meets factory standards and avoid unqualified motors entering the market, motor testing is particularly critical. Traditional motor testing usually relies on manual inspection and experience judgment, which is prone to problems such as missed detection and misjudgment. It is impossible to timely and comprehensively evaluate the overall performance of the motor, especially it is impossible to accurately predict the remaining service life of the motor. Summary of the invention

[0003] The purpose of the present invention is to solve the shortcomings in the prior art and to propose a method for testing the function of a motor based on a test bench.

[0004] To achieve the above object, the present invention adopts the following technical solutions: A method for testing the function of a motor based on a test bench comprises the following steps: S1: Collect motor parameters; The motor parameters include resistance, current, voltage, temperature, etc. of the motor; The test bench includes test interface, data collection module, data analysis module, report generation module, etc. The data collection module includes a current sensor, a voltage sensor, a speed sensor, a resistance tester, an AC withstand voltage tester, a power analyzer, etc.; Enter the motor number in the test bench and connect the motor's input and output ports to the test interface of the test bench. After the connection is successful, the staff starts the motor test; The data collection module of the test bench collects the actual values ​​of the motor's resistance, current, voltage and other parameters in real time; Specifically, the data collection module obtains the actual values ​​of the voltage, current and resistance of the motor in real time through the built-in current sensor, voltage sensor and resistance tester; the actual value of the power of the motor is obtained in real time through the built-in power analyzer; and the actual value of the insulation performance parameters of the motor is obtained through the AC withstand voltage tester; Furthermore, the data collection module detects whether there is a short circuit or insulation damage between the winding coils of the motor through a built-in turn-to-turn tester; The data collection module transmits the acquired parameters and the test results of the turn-to-turn tester to the data analysis module; S2: Checking the motor function based on the acquired motor parameters; The motor inspection function includes determining whether the motor meets the factory settings, whether the motor can reach the specified speed under fixed torque, and predicting the remaining life of the motor; The following sub-steps are included: S21: Determine whether the motor meets the factory settings; The data analysis module receives the data, and the corresponding intervals and specified values ​​of various parameters that meet the factory setting standards of the motor are pre-set in the data analysis module; The following sub-steps are included: S211: judging whether the motor complies with the factory settings based on the test results of the turn-to-turn tester; If the test result of the turn-to-turn tester received shows that there is a short circuit or insulation damage between the winding coils of the motor, the turn-to-turn parameters of the motor are judged to be unqualified; otherwise, the turn-to-turn parameters of the motor are judged to be qualified; S212: judging whether the motor meets the factory settings based on the motor parameters; Furthermore, if the motor is a multi-phase motor, the resistance of each phase winding of the motor is obtained by a resistance tester; and it is determined whether the resistance balance meets the standard; wherein the resistance balance is calculated as follows: The data analysis module obtains the average value of all phase winding resistances through the mean value method; The deviation of each phase winding resistance from the average resistance is obtained by the maximum deviation method, and the maximum deviation is found. The ratio of the maximum deviation to the average value is the resistance difference percentage, that is, the resistance balance; If the resistance balance is not within the range that meets the factory setting standard of the motor, the resistance balance does not meet the standard, and it is determined that the motor does not meet the factory setting; If the resistance balance is within the range that meets the motor factory setting standards, the resistance balance meets the standards, and continue to determine whether other parameters meet the motor factory setting standards; The data analysis module compares the received current, voltage, power and other parameters with the corresponding intervals; If all parameters are within the corresponding range that meets the motor factory setting standards, the motor meets the factory settings; if any parameter is not within the corresponding range that meets the motor factory setting standards, the motor does not meet the factory settings; S22: Detect whether the motor can reach the specified speed under fixed torque; The staff applies a fixed load torque to the motor through the test bench, and collects the speed of the motor when it is running under this fixed load torque through the speed sensor. The data analysis module compares this speed with the specified speed under the fixed torque set in advance. If this speed is greater than the corresponding specified speed, it is determined that the motor can reach the specified speed under the fixed torque; otherwise, it is determined that the motor cannot reach the specified speed under the fixed torque; S23: Predict the remaining life of the motor; Based on the motor parameters collected in real time by various sensors of the data collection module, the test bench simulates the extreme condition test of the motor, wherein the extreme condition test includes high load operation test, high temperature test, high current and voltage test, etc.; and obtains the parameter change value of the motor under the extreme condition test; The parameters include temperature, current, voltage, speed, vibration, noise, etc.; Specifically, the high-load operation test simulates the performance of the motor when working under high load by simulating the conditions close to the maximum load of the motor, and obtains the change values ​​of various parameters of the motor in the high-load operation test; The high temperature test simulates the motor or device being exposed to a high temperature environment far higher than normal working conditions, detects the motor's tolerance under extreme temperatures, and obtains the change values ​​of various parameters of the motor during the high temperature test; The high current and voltage test applies high current and high voltage to the motor to detect its performance under extreme electrical conditions; and obtains the change values ​​of various parameters of the motor during the high current and voltage test; The motor degradation model is constructed based on the obtained parameter change values ​​of the motor under extreme condition test using machine learning algorithm. The degradation trend of motor performance is analyzed through the degradation model to predict the remaining life of the motor. The decay model includes an exponential decay model, a linear regression model, etc.; The data analysis module transmits the determination result of whether the motor meets the factory settings, the detection result of whether the motor can reach the specified speed under fixed torque, and the prediction result of the remaining life of the motor to the report generation module; S3; Generate a test report; The report generation module receives the determination result and generates a corresponding test report; the test report includes the motor number, test date, actual values ​​of various motor parameters, corresponding intervals of various parameters meeting the motor factory setting standards, determination results of whether the motor meets the factory settings, detection results of whether the motor can reach a specified speed under a fixed torque, and prediction results of the remaining life of the motor; Based on the contents of the test report, the staff will be reminded to carry out repairs or replacements in a timely manner.

[0005] S4; Remote control and monitoring; The test bench is connected to the remote computer terminal via wifi, and the staff can start the motor test, stop the motor test and obtain the test report on the computer terminal.

[0006] Compared with the prior art, the present invention has the following beneficial effects: The method for inspecting the function of a motor based on a test bench proposed in the present invention combines multiple sensors and modules of the test bench to collect motor parameters, and compares the motor parameters with corresponding intervals and specified values ​​of various parameters that meet the factory setting standards of the motor to determine whether the motor meets the factory settings. It can more accurately monitor various performance parameters of the motor, timely discover abnormal changes in the motor, and ensure the accuracy of the test results; The method of the present invention simulates the extreme condition test of the motor, and constructs a motor degradation model in combination with a machine learning algorithm, and predicts the remaining life of the motor through the degradation model; it helps enterprises or users to perform maintenance and replacement of the motor in advance, which not only helps to reduce the risk of failure, but also can improve the overall operating efficiency of the equipment and avoid unnecessary downtime and maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 The present invention is a flowchart of the steps of a method for testing the function of a motor based on a test bench. DETAILED DESCRIPTION

[0008] In order to provide a further understanding of the purpose, structure, features, and functions of the present invention, the following detailed description is given in conjunction with the embodiments.

[0009] like Figure 1 As shown, a method for testing the function of a motor based on a test bench comprises the following steps: S1: Collect motor parameters; The motor parameters include resistance, current, voltage, temperature, etc. of the motor; The test bench includes test interface, data collection module, data analysis module, report generation module, etc. The data collection module includes a current sensor, a voltage sensor, a speed sensor, a resistance tester, an AC withstand voltage tester, a power analyzer, etc.; Enter the motor number in the test bench and connect the motor's input and output ports to the test interface of the test bench. After the connection is successful, the staff starts the motor test; The data collection module of the test bench collects the actual values ​​of the motor's resistance, current, voltage and other parameters in real time; Specifically, the data collection module obtains the actual values ​​of the voltage, current and resistance of the motor in real time through the built-in current sensor, voltage sensor and resistance tester; the actual value of the power of the motor is obtained in real time through the built-in power analyzer; and the actual value of the insulation performance parameters of the motor is obtained through the AC withstand voltage tester; Furthermore, the data collection module detects whether there is a short circuit or insulation damage between the winding coils of the motor through a built-in turn-to-turn tester; Through the detection of the turn-to-turn tester, it can effectively prevent the potential safety hazards such as fire caused by current leakage or overheating caused by short circuit and insulation damage, and ensure the safety of operators and equipment; The data collection module transmits the acquired parameters and the test results of the turn-to-turn tester to the data analysis module; S2: Checking the motor function based on the acquired motor parameters; The motor inspection function includes determining whether the motor meets the factory settings, whether the motor can reach the specified speed under fixed torque, and predicting the remaining life of the motor; The following sub-steps are included: S21: Determine whether the motor meets the factory settings; The data analysis module receives the data, and the corresponding intervals and specified values ​​of various parameters that meet the factory setting standards of the motor are pre-set in the data analysis module; The following sub-steps are included: S211: judging whether the motor complies with factory settings based on the test results of the turn-to-turn tester; If the test result of the turn-to-turn tester received shows that there is a short circuit or insulation damage between the winding coils of the motor, the turn-to-turn parameters of the motor are judged to be unqualified; otherwise, the turn-to-turn parameters of the motor are judged to be qualified; S212: judging whether the motor meets the factory settings based on the motor parameters; Furthermore, if the motor is a multi-phase motor, the resistance of each phase winding of the motor is obtained by a resistance tester; and it is determined whether the resistance balance meets the standard; wherein the resistance balance is calculated as follows: The data analysis module obtains the average value of all phase winding resistances through the mean value method; The deviation of each phase winding resistance from the average resistance is obtained by the maximum deviation method, and the maximum deviation is found. The ratio of the maximum deviation to the average value is the resistance difference percentage, that is, the resistance balance; If the resistance balance is not within the range that meets the factory setting standard of the motor, the resistance balance does not meet the standard, and it is determined that the motor does not meet the factory setting; If the resistance balance is within the range that meets the motor factory setting standards, the resistance balance meets the standards, and continue to determine whether other parameters meet the motor factory setting standards; The data analysis module compares the received current, voltage, power and other parameters with the corresponding intervals; If all parameters are within the corresponding range that meets the motor factory setting standards, the motor meets the factory settings; if any parameter is not within the corresponding range that meets the motor factory setting standards, the motor does not meet the factory settings; By comprehensively judging the motor parameters based on the specific standards of different parameters, we can have a more comprehensive understanding of the motor's quality status and avoid misjudgment due to the deviation of a single parameter; comprehensive analysis of multiple parameters can identify different types of problems (such as winding short circuit, resistance unbalance, current and voltage abnormalities, etc.), thereby improving the accuracy and reliability of the judgment and ensuring that the motor can meet the standards when leaving the factory; By testing multiple key parameters of the motor, the consistency of performance of motors in different batches can be ensured; this is especially important for large-scale production, which can help manufacturers ensure the quality of each motor and reduce the differences between batches.

[0010] S22: Detect whether the motor can reach the specified speed under fixed torque; The staff applies a fixed load torque to the motor through the test bench, and collects the speed of the motor when it is running under this fixed load torque through the speed sensor. The data analysis module compares this speed with the specified speed under the fixed torque set in advance. If this speed is greater than the corresponding specified speed, it is determined that the motor can reach the specified speed under the fixed torque; otherwise, it is determined that the motor cannot reach the specified speed under the fixed torque; By testing the motor speed under a fixed load torque, it is possible to verify whether the motor can reach the expected speed under specific working conditions; verifying whether the motor's power output and load capacity meet the requirements helps improve the quality and reliability of motor products.

[0011] S23: Predict the remaining life of the motor; Based on the motor parameters collected in real time by various sensors of the data collection module, the test bench simulates the extreme condition test of the motor, wherein the extreme condition test includes high load operation test, high temperature test, high current and voltage test, etc.; and obtains the parameter change value of the motor under the extreme condition test; The parameters include temperature, current, voltage, speed, vibration, noise, etc.; Specifically, the high-load operation test simulates the performance of the motor when working under high load by simulating the conditions close to the maximum load of the motor, and obtains the change values ​​of various parameters of the motor in the high-load operation test; The high temperature test simulates the motor or device being exposed to a high temperature environment far higher than normal working conditions, detects the motor's tolerance under extreme temperatures, and obtains the change values ​​of various parameters of the motor during the high temperature test; The high current and voltage test applies high current and high voltage to the motor to detect its performance under extreme electrical conditions; and obtains the change values ​​of various parameters of the motor during the high current and voltage test; The motor degradation model is constructed based on the obtained parameter change values ​​of the motor under extreme condition test using machine learning algorithm. The degradation trend of motor performance is analyzed through the degradation model to predict the remaining life of the motor. The decay model includes an exponential decay model, a linear regression model, etc.; By predicting the remaining life of the motor in advance, companies can effectively plan maintenance time and avoid downtime caused by equipment failure during peak production periods, thereby minimizing downtime and production losses, taking preventive maintenance measures in a timely manner, and improving the overall efficiency of the production line; Traditional maintenance methods often rely on fixed inspection cycles, which may cause waste of resources (for example, unnecessary maintenance when equipment has not yet encountered problems). However, through remaining life prediction, accurate resource allocation can be achieved, making maintenance costs more economical and reducing unnecessary resource investment.

[0012] The data analysis module transmits the determination result of whether the motor meets the factory settings, the detection result of whether the motor can reach the specified speed under fixed torque, and the prediction result of the remaining life of the motor to the report generation module; S3; Generate a test report; The report generation module receives the determination result and generates a corresponding test report; the test report includes the motor number, test date, actual values ​​of various motor parameters, corresponding intervals of various parameters meeting the motor factory setting standards, determination results of whether the motor meets the factory settings, detection results of whether the motor can reach a specified speed under a fixed torque, and prediction results of the remaining life of the motor; By generating a test report, we can ensure that all motor tests follow unified standards and processes, avoid deviations and errors caused by manual judgment, and improve the accuracy and repeatability of the test process; provide detailed historical data support for subsequent motor performance analysis, fault diagnosis and maintenance; Based on the contents of the test report, the staff will be reminded to carry out repairs or replacements in a timely manner.

[0013] S4; Remote control and monitoring; The test bench is connected to the remote computer terminal via wifi, and the staff can start the motor test, stop the motor test, and obtain the test report on the computer terminal; Remote control allows inspectors to manage the inspection process of multiple motors without being on site, saving time and manpower and improving work efficiency. If the motor test involves potential dangers such as high temperature and high voltage, the staff can operate remotely to avoid being in a dangerous environment; the staff can monitor the operating status of the motor in real time, detect abnormal situations in time, and reduce the risk of accidents.

[0014] The present invention has been described by the above-mentioned relevant embodiments, however, the above-mentioned embodiments are only examples for implementing the present invention. It must be pointed out that the disclosed embodiments do not limit the scope of the present invention. On the contrary, changes and modifications made without departing from the spirit and scope of the present invention are all within the scope of patent protection of the present invention.

Claims

1. A method for testing the function of a motor based on a test bench, characterized in that: The following steps are involved: S1: Collect motor parameters; The test bench includes a test interface, a data collection module, a data analysis module, and a report generation module; Enter the motor number in the test bench and connect the motor's input and output ports to the test interface of the test bench. After the connection is successful, the staff starts the motor test; The data collection module collects the actual values ​​of the motor parameters in real time and transmits them to the data analysis module; S2: Checking the motor function based on the acquired motor parameters; The motor inspection function includes determining whether the motor meets the factory settings, whether the motor can reach the specified speed under fixed torque, and predicting the remaining life of the motor; The following sub-steps are included: S21: Determine whether the motor meets the factory settings; The data analysis module receives the data, wherein the corresponding intervals and specified values ​​of various parameters that meet the factory setting standards of the motor are pre-set in the data analysis module; S22: Detect whether the motor can reach the specified speed under fixed torque; S23: Predict the remaining life of the motor; S3; Generate a test report; The report generation module receives the determination result and generates a corresponding test report; the test report includes the motor number, test date, actual values ​​of various motor parameters, corresponding intervals in which various parameters meet the motor factory setting standards, determination results of individual parameters, determination results of whether the motor meets the factory settings, detection results of whether the motor can reach a specified speed under a fixed torque, and prediction results of the remaining life of the motor; S4; Remote control and monitoring; The testing station is connected to a remote computer terminal via wifi, and the staff performs relevant operations on the motor on the computer terminal; the operations include starting the motor test, stopping the motor test, and obtaining a test report.

2. The method for testing the function of a motor based on a test bench according to claim 1, characterized in that: In step S1, the data collection module includes a current sensor, a voltage sensor, a speed sensor, a resistance tester, an AC withstand voltage tester, and a power analyzer; The actual values ​​of the motor's voltage, current, and resistance are obtained in real time through the built-in current sensor, voltage sensor, and resistance tester; the actual value of the motor's power is obtained in real time through the built-in power analyzer; the actual value of the motor's insulation performance parameters is obtained through the AC withstand voltage tester; The built-in inter-turn tester is used to detect whether there is a short circuit or insulation damage between the turns of the motor, that is, between the winding coils of the motor, and transmit the information to the data analysis module.

3. The method for testing the function of a motor based on a test bench according to claim 1, characterized in that: Step S21 includes the following sub-steps: S211: judging whether the motor complies with factory settings based on the test results of the turn-to-turn tester; If the test result of the turn-to-turn tester received shows that there is a short circuit or insulation damage between the winding coils of the motor, the turn-to-turn parameters of the motor are judged to be unqualified; otherwise, the turn-to-turn parameters of the motor are judged to be qualified; S212: judging whether the motor meets the factory settings based on the motor parameters; The data analysis module determines the remaining parameters received. If all the parameters are within the corresponding range that meets the motor factory setting standards, the motor meets the factory settings; if any parameter is not within the corresponding range that meets the motor factory setting standards, the motor does not meet the factory settings; And transmit the judgment result to the report generation module.

4. The method for testing the function of a motor based on a test bench according to claim 1, characterized in that: In step S22, if the motor is a multi-phase motor, the resistance of each phase winding of the motor is obtained by a resistance tester; and it is determined whether the resistance balance meets the standard; wherein the resistance balance is calculated as follows: The data analysis module obtains the average value of all phase winding resistances through the mean value method; The deviation of each phase winding resistance from the average resistance is obtained by the maximum deviation method, and the maximum deviation is found. The ratio of the maximum deviation to the average value is the resistance difference percentage, that is, the resistance balance; If the resistance balance is not within the range that meets the factory setting standard of the motor, the resistance balance is unqualified, that is, the motor is judged to be not in compliance with the factory setting; If the resistance balance is within the range that meets the motor factory setting standards, the resistance balance meets the standards, and the other parameters continue to be judged whether they meet the motor factory setting standards; and the judgment results are transmitted to the report generation module.

5. The method for testing the function of a motor based on a test bench according to claim 1, characterized in that: The specific contents of step S22 are as follows: A fixed load torque is applied to the motor through the test bench, and the speed sensor is used to collect the speed of the motor when it is running under this fixed load torque. The data analysis module compares this speed with the specified speed under the fixed torque set in advance. If this speed is greater than the corresponding specified speed, it is determined that the motor can reach the specified speed under the fixed torque; Otherwise, it is determined that the motor cannot reach the specified speed under the fixed torque; And transmit the judgment result to the report generation module.

6. The method for testing the function of a motor based on a test bench according to claim 1, characterized in that: The specific contents of step S23 are as follows: Based on the motor parameters collected in real time by various sensors of the data collection module, the test bench simulates the extreme condition test of the motor, wherein the extreme condition test includes high load operation test, high temperature test, and high current and voltage test; and obtains the parameter change value of the motor under the extreme condition test; A motor degradation model is constructed based on the obtained parameter change values ​​of the motor under extreme test conditions using a machine learning algorithm. The degradation trend of the motor performance is analyzed through the degradation model to predict the remaining life of the motor. The prediction results are then transmitted to the report generation module.

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