A comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system

Abstract

The present invention discloses a comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system, comprising a mechanical system and a control system; the mechanical system comprises an elastic constraint mechanism for a drive motor, a vibration boundary simulation mechanism for a drive motor, a hollow shaft transmission mechanism with adjustable torsional vibration mode, and a bogie operation resistance torque characteristic simulation mechanism; the comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system of the present invention has a more complete consideration of the boundaries of the permanent magnet drive motor. The elastic constraint mechanism for the drive motor simulates the actual installation scenario of the permanent magnet drive motor on the frame; the vibration boundary simulation mechanism for the drive motor realistically simulates the vibration boundary of the permanent magnet drive motor on the frame, and the bogie operation resistance torque characteristic simulation mechanism realistically simulates the wind resistance of the train; the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system can be better explored under different working conditions, thereby providing support for related bogie designs.

Description

Technical Field

[0001] The invention relates to the technical field of permanent magnet direct-drive hollow shaft transmission system test equipment, in particular to a comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system. Background Art

[0002] Lightweight bogies are crucial for energy conservation and environmental protection in rail transit. Permanent magnet direct-drive hollow shaft transmission technology offers an effective solution for this purpose and has become a hot topic in recent years. In a permanent magnet direct-drive bogie, the permanent magnet motor rotor is typically connected to one end of the drive hollow shaft via a coupling. The other end of the hollow shaft is connected to the wheelset via a coupling, enabling the motor to drive the wheelset through the hollow shaft. For more details, please refer to the existing invention patent CN115257825A, "A Rail Vehicle Bogie and Its Drive Unit Structure."

[0003] Affected by factors such as its own characteristics, control strategy, and fault conditions, the electromagnetic torque of a permanent magnet motor often fluctuates, causing torsional vibration of the transmission hollow shaft. The torque ripple frequency can also vary with speed. When the torque ripple frequency intersects with the hollow shaft's torsional natural frequency, electromechanical coupling resonance can be induced. Therefore, establishing a test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system to study the electromechanical coupling effects and control measures between the electrical and mechanical systems is of great significance for guiding the design of permanent magnet direct-drive hollow shaft transmission bogies.

[0004] However, in the existing technology, most of them are based on a simple drag test bench, which is used to carry out relevant characteristic test research on the motor body, and there are few test benches for the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system. As a result, when the existing motor drag test bench is used in the permanent magnet direct-drive hollow shaft transmission system, it is impossible to achieve accurate test results, which is not conducive to the research on the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system. Summary of the Invention

[0005] In response to the above-mentioned problems in the prior art, the present invention provides a comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system, which studies the electromechanical coupling effects and control measures of the permanent magnet direct-drive hollow shaft transmission system under different working conditions, thereby providing support for the design of related bogies. It solves the problem that when the existing motor-drag test bench is used in a permanent magnet direct-drive hollow shaft transmission system, it cannot achieve accurate test results, which is not conducive to the study of the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system.

[0006] In order to achieve the above-mentioned object of the invention, the technical solution adopted by the present invention is as follows:

[0007] A comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system is provided, which includes a mechanical system and a control system; the mechanical system includes an elastic constraint mechanism of a drive motor arranged on the upper end surface of a base, a vibration boundary simulation mechanism of a drive motor, a hollow shaft transmission mechanism with adjustable torsional vibration mode, and a bogie running resistance torque characteristic simulation mechanism.

[0008] The elastic constraint mechanism of the driving motor includes a mounting seat for the motor under test, and the mounting seat for the motor under test includes a horizontal mounting plate and a vertical mounting plate, and the lower end surface of the horizontal mounting plate is connected to the upper end surface of the base through multiple electromagnetic exciters; multiple motor support seats and permanent magnet driving motors are arranged on the inner side surface of the vertical mounting plate, and the multiple motor support seats are fixedly connected to the rear side of the permanent magnet driving motor through rubber elastic nodes; in the elastic constraint mechanism of the driving motor, the permanent magnet driving motor is fixed to the mounting seat for the motor under test by setting rubber elastic nodes, simulating the actual installation scenario of the permanent magnet driving motor on the frame.

[0009] The drive motor vibration boundary simulation mechanism includes multiple electromagnetic exciters, and the multiple electromagnetic exciters are arranged between the lower end surface of the horizontal mounting plate and the upper end surface of the base; in the drive motor vibration boundary simulation mechanism, the excitation amplitude, frequency and phase between the electromagnetic exciters can be controlled by the control system, and the vibration service boundary characteristics of the permanent magnet drive motor can be reproduced to a certain extent, such as wheel polygon excitation, wheel flat scar excitation, long-wave track unevenness excitation, etc., to truly simulate the vibration boundary of the permanent magnet drive motor on the frame.

[0010] The hollow shaft transmission mechanism with adjustable torsional vibration mode includes a transmission hollow shaft, one end of which is connected to the output end of the permanent magnet drive motor through a coupling, and the other end is connected to the bogie operation resistance torque characteristic simulation mechanism through a coupling; by adjusting the type and structure of the coupling, the torsional stiffness damping coefficient of the coupling can be adjusted, thereby realizing the adjustable torsional vibration mode of the hollow shaft transmission mechanism.

[0011] The bogie running resistance torque characteristic simulation mechanism includes a load motor seat arranged on the upper end surface of the base, the load motor is arranged on the load motor seat, and the output end of the load motor is connected to the other end of the transmission hollow shaft through a coupling and a power transmission shaft; a dynamic torque sensor is arranged on the power transmission shaft, and a sensor mounting seat is arranged below the dynamic torque sensor, and the bottom of the sensor mounting seat is fixedly connected to the upper end surface of the base; in the bogie running resistance torque characteristic simulation mechanism, the output electromagnetic torque of the load motor is controlled by the control system to realize the simulation of the bogie running resistance torque and truly simulate the train wind resistance.

[0012] The control system includes a control system and a data acquisition system; the control system includes a controller and a power amplifier electrically connected to the controller, a first frequency converter, and a second frequency converter; the first frequency converter and the second frequency converter are electrically connected to the permanent magnet drive motor and the load asynchronous motor respectively; the power amplifier is connected to a plurality of electromagnetic exciters;

[0013] The data acquisition system includes a data collector electrically connected to the controller and a voltage sensor, a current sensor, a vibration acceleration sensor, a speed sensor, and a temperature sensor electrically connected to the data collector; the voltage sensor, current sensor, vibration acceleration sensor, speed sensor, and temperature sensor are respectively arranged on the permanent magnet drive motor and the load asynchronous motor; the dynamic torque sensor is electrically connected to the data collector.

[0014] The test process of the comprehensive test bench for the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system is as follows:

[0015] Step 1: Set the target speed, load torque, excitation amplitude, phase, and frequency of the permanent magnet drive motor in the controller;

[0016] Step 2: The controller sends a control signal to the first frequency converter, the second frequency converter, and the power amplifier;

[0017] Step 3: Sending a control signal through the first frequency converter to make the permanent magnet drive motor run at a specified speed, sending a control signal through the second frequency converter to make the load motor run at a specified torque, and sending a control signal through the power amplifier to make the electromagnetic exciter excite according to the instruction;

[0018] Step 4: The data collector collects signals such as the voltage, current, vibration acceleration, temperature, rotor speed of the permanent magnet drive motor and the load motor, as well as the speed and torque of the transmission hollow shaft, and transmits them to the controller for feedback adjustment.

[0019] Step 5: Explore the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system by analyzing and processing the vibration, speed, current, and voltage signals.

[0020] Furthermore, a flywheel is provided on the middle shaft section of the transmission hollow shaft. By adjusting the geometric dimensions of the flywheel, the overall inertia of the hollow shaft can be adjusted, thereby achieving adjustable torsional vibration modes of the hollow shaft transmission mechanism.

[0021] Furthermore, the flywheel is provided with a rotation speed testing mechanism electrically connected to the data collector.

[0022] Furthermore, the measurement of torsional vibration of the transmission hollow shaft, a typical form of electromechanical coupling vibration in a permanent magnet direct-drive hollow shaft transmission system, is a significant issue. Commercial photoelectric encoders are the primary means of measuring shaft torsional vibration. However, photoelectric encoders often require mounting on the shaft, employing a contact measurement method. This can cause changes in the hollow shaft's torsional modal frequency, hindering the study of electromechanical coupling mechanisms. To address this issue, the speed measurement mechanism in the present invention is a non-contact speed measurement mechanism. Specifically, the speed measurement mechanism comprises a grating code disk adhered to the outer circumference of the flywheel and a photoelectric sensor positioned on one side of the grating code disk, electrically connected to the data acquisition device. The grating code disk is affixed to the cylindrical surface of the flywheel. Because the diameter of the flywheel is larger than that of the transmission hollow shaft, the gratings in the grating code disk can be made denser. The denser the grating, the higher the speed resolution. When the transmission hollow shaft is in operation, the photoelectric sensor measures the speed pulse signal. Counting processing yields a fluctuating speed curve. Fourier analysis of this curve reveals the primary frequency components of the torsional vibration.

[0023] Furthermore, the permanent magnet drive motor is a normal motor or a faulty motor.

[0024] Compared with the existing motor drive control test bench of the towing type, the beneficial effects of the present invention are:

[0025] 1. The present invention's comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system provides a more comprehensive consideration of the boundaries of the permanent magnet drive motor. Traditional towing platforms often consider the motor to be rigidly fixed to the supporting floor. However, many motors in actual bogies are connected to the frame using elastic suspension and are subject to forced vibration from the frame. To this end, the present invention employs multiple rubber elastic nodes to constrain the permanent magnet drive motor and simulates its vibration boundaries through electromagnetic excitation.

[0026] 2. The present invention's comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system features an adjustable torsional vibration modal frequency for the hollow shaft transmission mechanism. To address the need for electromechanical coupling mechanism research, the present invention achieves adjustable torsional vibration modal frequency for the hollow shaft transmission mechanism by adjusting the coupling type and structure and the geometric dimensions of the hollow shaft flywheel.

[0027] 3. The present invention's comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system utilizes a speed measurement mechanism to enable non-contact, high-precision measurement of torsional vibration parameters of the transmission hollow shaft. Conventional photoelectric encoders, which employ contact-based measurement methods, can cause changes in the hollow shaft's torsional modal frequency, hindering research into the electromechanical coupling mechanism. To this end, the present invention utilizes a grating code disk and a photoelectric sensor to measure the hollow shaft's speed pulse signal. This counting process yields a fluctuating speed curve. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a three-dimensional structural schematic diagram of a comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system.

[0029] Figure 2 This is an enlarged schematic diagram of the structure of the motor mounting base under test.

[0030] Figure 3 It is an enlarged schematic diagram of the structure of the transmission hollow shaft speed test mechanism.

[0031] Figure 4 This is the principle block diagram of the control system.

[0032] Among them, 1. Base; 2. Mounting base of the motor under test; 3. Permanent magnet drive motor; 4. Motor support base; 5. Electromagnetic exciter; 6. Transmission hollow shaft; 7. Load motor base; 8. Load motor; 9. Dynamic torque sensor; 10. Sensor mounting base; 11. Flywheel; 12. Grating code disk; 13. Photoelectric sensor 14. Coupling; 15. Force transmission shaft; 16. Rubber elastic node. DETAILED DESCRIPTION

[0033] The specific embodiments of the present invention are described below to facilitate understanding of the present invention by those skilled in the art. However, it should be clear that the present invention is not limited to the scope of the specific embodiments. For those skilled in the art, as long as various changes are within the spirit and scope of the present invention as defined and determined by the appended claims, these changes are obvious, and all inventions and creations utilizing the concepts of the present invention are protected.

[0034] like Figures 1 to 4 As shown, the present invention provides a comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system, which includes a mechanical system and a control system; the mechanical system includes an elastic constraint mechanism of a drive motor arranged on the upper end surface of a base 1, a vibration boundary simulation mechanism of a drive motor, a hollow shaft transmission mechanism with adjustable torsional vibration mode, and a bogie running resistance torque characteristic simulation mechanism.

[0035] The drive motor elastic constraint mechanism includes a motor mount 2 under test, which includes a horizontal mounting plate and a vertical mounting plate. The lower end surface of the horizontal mounting plate is connected to the upper end surface of the base 1 via multiple electromagnetic exciters 5. The inner side surface of the vertical mounting plate is provided with multiple motor support bases 4 and a permanent magnet drive motor 3. Each of the multiple motor support bases 4 is fixedly connected to the rear side of the permanent magnet drive motor 3 via a rubber elastic node 16. This simulates the actual installation scenario of the permanent magnet drive motor 3 on the frame. Specifically, the permanent magnet drive motor 3 is a normal motor or a faulty motor.

[0036] The driving motor vibration boundary simulation mechanism includes multiple electromagnetic exciters 5, and the multiple electromagnetic exciters 5 are arranged between the lower end surface of the horizontal mounting plate and the upper end surface of the base 1; in the driving motor vibration boundary simulation mechanism, the excitation amplitude, frequency and phase between the electromagnetic exciters 5 can be controlled by the control system, and the vibration service boundary characteristics of the permanent magnet driving motor 3 can be reproduced to a certain extent, such as wheel polygon excitation, wheel flat scar excitation, long-wave track unevenness excitation, etc., to truly simulate the vibration boundary of the permanent magnet driving motor 3 on the frame.

[0037] The hollow shaft transmission mechanism with adjustable torsional vibration mode includes a transmission hollow shaft 6, one end of which is connected to the output end of the permanent magnet drive motor 3 through a coupling 14, and the other end is connected to the bogie running resistance torque characteristic simulation mechanism through a coupling 14; by adjusting the type and structure of the coupling 14, the torsional stiffness damping coefficient of the coupling 14 can be adjusted, thereby realizing the adjustable torsional vibration mode of the hollow shaft transmission mechanism.

[0038] The bogie running resistance torque characteristic simulation mechanism includes a load motor seat 7 arranged on the upper end surface of the base 1, and a load motor 8 is arranged on the load motor seat 7. The output end of the load motor 8 is connected to the other end of the transmission hollow shaft 6 through a coupling 14 and a power transmission shaft 15; a dynamic torque sensor 9 is arranged on the power transmission shaft 15, and a sensor mounting seat 10 is arranged below the dynamic torque sensor 9, and the bottom of the sensor mounting seat 10 is fixedly connected to the upper end surface of the base 1; in the bogie running resistance torque characteristic simulation mechanism, the output electromagnetic torque of the load motor 8 is controlled by the control system to realize the simulation of the bogie running resistance torque and truly simulate the train wind resistance.

[0039] The control system includes a control system and a data acquisition system; the control system includes a controller and a power amplifier electrically connected to the controller, a first frequency converter, and a second frequency converter; the first frequency converter and the second frequency converter are electrically connected to the permanent magnet drive motor 3 and the load asynchronous motor respectively; the power amplifier is connected to a plurality of electromagnetic exciters 5;

[0040] The data acquisition system includes a data collector electrically connected to the controller and a voltage sensor, a current sensor, a vibration acceleration sensor, a speed sensor, and a temperature sensor electrically connected to the data collector; the voltage sensor, current sensor, vibration acceleration sensor, speed sensor, and temperature sensor are respectively arranged on the permanent magnet drive motor 3 and the load asynchronous motor; the dynamic torque sensor 9 is electrically connected to the data collector.

[0041] The test process of the comprehensive test bench for the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system is as follows:

[0042] Step 1: Set the target speed, load torque of the permanent magnet drive motor 3, and the excitation amplitude, phase, and frequency of the electromagnetic exciter 5 in the controller;

[0043] Step 2: The controller sends a control signal to the first frequency converter, the second frequency converter, and the power amplifier;

[0044] Step 3: Send a control signal through the first frequency converter to make the permanent magnet drive motor 3 run at a specified speed, send a control signal through the second frequency converter to make the load motor 8 run at a specified torque, and send a control signal through the power amplifier to make the electromagnetic exciter 5 excite according to the instruction;

[0045] Step 4: The data collector collects signals such as the voltage, current, vibration acceleration, temperature, rotor speed of the permanent magnet drive motor 3 and the load motor 8, as well as the speed and torque of the transmission hollow shaft 6, and transmits them to the controller for feedback adjustment.

[0046] Step 5: Explore the electromechanical coupling mechanism of the permanent magnet direct-drive hollow shaft transmission system by analyzing and processing the vibration, speed, current, and voltage signals.

[0047] Furthermore, a flywheel 11 is provided on the middle shaft section of the transmission hollow shaft 6. By adjusting the geometric dimensions of the flywheel 11, the overall inertia of the hollow shaft can be adjusted, thereby achieving adjustable torsional vibration modes of the hollow shaft transmission mechanism.

[0048] Furthermore, the flywheel 11 is provided with a speed test mechanism electrically connected to the data collector. The torsional vibration of the transmission hollow shaft 6 is a typical form of electromechanical coupling vibration in the permanent magnet direct drive hollow shaft transmission system, and its testing is an important issue. Commercial photoelectric encoders are the main means of measuring the torsional vibration of the shaft system. However, photoelectric encoders often need to be installed on the shaft, which is a contact measurement method. This may cause the torsional modal frequency of the hollow shaft to change, which is not conducive to the study of the electromechanical coupling mechanism. In order to solve this problem, the speed test mechanism in the present invention is a non-contact speed measurement mechanism. Specifically, the speed test mechanism includes a grating code disk 12 attached to the outer wall of the circumference of the flywheel 11 and a photoelectric sensor 13 provided on one side of the grating code disk 12. The photoelectric sensor 13 is electrically connected to the data collector. The grating code disk 12 is attached to the cylindrical surface of the flywheel 11. Since the diameter of the flywheel 11 is larger than the diameter of the transmission hollow shaft 6, the grating in the grating code disk 12 can be made very dense. The denser the grating, the higher the speed resolution. When the hollow shaft 6 is driven, the speed pulse signal is measured by the photoelectric sensor 13. After counting, a fluctuation speed curve can be obtained. By performing Fourier analysis on the fluctuation speed curve, the main frequency component of the torsional vibration can be obtained.

[0049] In summary, compared with the existing towing type motor drive control test bench, the comprehensive test bench for the electromechanical coupling mechanism of the permanent magnet direct drive hollow shaft transmission system of the present invention has a more comprehensive consideration of the boundaries of the permanent magnet drive motor 3. Multiple rubber elastic nodes 16 are used to constrain the permanent magnet drive motor 3, simulating the actual installation scenario of the permanent magnet drive motor 3 on the frame; the vibration of the permanent magnet drive motor 3 is simulated by the electromagnetic exciter 5, and the vibration boundary of the permanent magnet drive motor 3 on the frame is realistically simulated. The load motor 8 outputs electromagnetic torque to the transmission hollow shaft 6 to simulate the running resistance torque of the bogie and realistically simulate the wind resistance of the train. This can better explore the electromechanical coupling mechanism of the permanent magnet direct drive hollow shaft transmission system under different working conditions, thereby providing support for related bogie design.

Claims

1. A comprehensive test bench for the electromechanical coupling mechanism of a permanent magnet direct-drive hollow shaft transmission system, characterized in that: Including mechanical systems and control systems; The mechanical system includes a drive motor elastic constraint mechanism arranged on the upper end surface of the base, a drive motor vibration boundary simulation mechanism, a hollow shaft transmission mechanism with adjustable torsional vibration mode, and a bogie running resistance torque characteristic simulation mechanism; The elastic constraint mechanism of the driving motor includes a mounting seat for the motor under test, and the mounting seat for the motor under test includes a horizontal mounting plate and a vertical mounting plate. The lower end surface of the horizontal mounting plate is connected to the upper end surface of the base through multiple electromagnetic exciters; multiple motor support seats and permanent magnet driving motors are provided on the inner side surface of the vertical mounting plate, and the multiple motor support seats are fixedly connected to the rear side of the permanent magnet driving motor through rubber elastic nodes; The driving motor vibration boundary simulation mechanism includes a plurality of electromagnetic exciters, and the plurality of electromagnetic exciters are arranged between the lower end surface of the horizontal mounting plate and the upper end surface of the base; The hollow shaft transmission mechanism with adjustable torsional vibration mode includes a transmission hollow shaft, one end of which is connected to the output end of the permanent magnet drive motor through a coupling, and the other end is connected to the bogie running resistance torque characteristic simulation mechanism through a coupling; The bogie running resistance torque characteristic simulation mechanism includes a load motor seat arranged on the upper end surface of the base, the load motor seat is provided with a load motor, the output end of the load motor is connected to the other end of the transmission hollow shaft through a coupling and a power transmission shaft; a dynamic torque sensor is provided on the power transmission shaft, a sensor mounting seat is provided below the dynamic torque sensor, and the bottom of the sensor mounting seat is fixedly connected to the upper end surface of the base; The control system includes a control system and a data acquisition system; the control system includes a controller and a power amplifier electrically connected to the controller, a first frequency converter, and a second frequency converter; the first frequency converter and the second frequency converter are electrically connected to the permanent magnet drive motor and the load asynchronous motor respectively; the power amplifier is connected to a plurality of electromagnetic exciters; The data acquisition system includes a data collector electrically connected to the controller and a voltage sensor, a current sensor, a vibration acceleration sensor, a speed sensor, and a temperature sensor electrically connected to the data collector; the voltage sensor, current sensor, vibration acceleration sensor, speed sensor, and temperature sensor are respectively arranged on the permanent magnet drive motor and the load asynchronous motor; the dynamic torque sensor is electrically connected to the data collector.

2. The electromechanical coupling mechanism comprehensive test bench of the permanent magnet direct drive hollow shaft transmission system according to claim 1 is characterized in that: A flywheel is arranged on the middle shaft section of the transmission hollow shaft.

3. The electromechanical coupling mechanism comprehensive test bench of the permanent magnet direct drive hollow shaft transmission system according to claim 2 is characterized in that: The flywheel is provided with a rotation speed testing mechanism electrically connected to the data collector.

4. The electromechanical coupling mechanism comprehensive test bench of the permanent magnet direct drive hollow shaft transmission system according to claim 3 is characterized in that: The rotation speed testing mechanism includes a grating code disk adhered to the outer wall of the flywheel and a photoelectric sensor arranged on one side of the grating code disk, and the photoelectric sensor is electrically connected to the data collector.

5. The electromechanical coupling mechanism comprehensive test bench of the permanent magnet direct drive hollow shaft transmission system according to any one of claims 1 to 4, characterized in that: The permanent magnet drive motor is a normal motor or a faulty motor.

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