A brushless motor load detection device and use method

Abstract

The present invention relates to the field of motor load detection technology, specifically a brushless motor load detection device and a method for use, comprising a detection table, a mounting table fixedly provided on the detection table, a brushless motor mounted on the mounting table, a load testing machine fixedly provided on the detection table, and a fixed disk fixedly provided on the connecting shaft of the load testing machine. In this brushless motor load detection device and method for use, a mechanical loosening alarm protection mechanism adopts a mechanical whistle alarm system to monitor the state of the motor shaft in real time through a roller assembly. When abnormal looseness of the shaft is detected, the rotational motion of the roller drives the whistle hole to generate high-frequency airflow, emitting a clearly identifiable alarm sound. This purely mechanical alarm method does not rely on power supply, has extremely high reliability, and is particularly suitable for use in complex industrial environments. After the alarm is triggered, the operator can immediately take corresponding measures to effectively prevent equipment damage and safety accidents.

Description

Technical Field

[0001] The present invention relates to the technical field of motor load detection, and in particular to a brushless motor load detection device and a use method thereof. Background Art

[0002] A brushless DC motor primarily consists of an electronic switching circuit, a permanent magnet synchronous motor, and a position sensor. When current is applied to a phase of the stator winding, this current interacts with the magnetic field generated by the rotor's magnetic poles to generate torque, driving the rotor's rotation. With the advancement of electronic technology and control theory, brushless DC motors have gradually improved and are widely used in various fields. Motor load testing equipment is one of the key methods for evaluating motor performance. By simulating the load conditions encountered during actual operation, motor performance can be comprehensively and accurately tested and evaluated. This helps ensure stable operation and meets design requirements under various operating conditions.

[0003] Most of the common motor load detection technologies currently have the following defects:

[0004] The connection stability is insufficient. The existing technology lacks a two-stage automatic locking mechanism and relies solely on bolts to directly fix the coupling and the testing machine. Vibration can easily loosen the bolts, affecting the accuracy of the test data.

[0005] Fault detection is passive. Traditional solutions require manual observation of the connection status and cannot detect coupling loosening in real time.

[0006] ‌Lack of safety protection: Existing equipment lacks active interception mechanisms for motor installation deviation and shaft deformation, which may cause testing accidents.

[0007] In view of this, we propose a brushless motor load detection device and a method for using the same. Summary of the Invention

[0008] The purpose of the present invention is to provide a brushless motor load detection device and a method of use, so as to solve the problems of insufficient connection stability, passive fault detection, and lack of safety protection raised in the above-mentioned background technology. In order to achieve the above-mentioned purpose, the present invention provides the following technical solutions: a brushless motor load detection device, comprising a detection table, a mounting table is fixedly provided on the detection table, a brushless motor is mounted on the mounting table, a load tester is fixedly provided on the detection table, a fixed disk is fixedly provided on the connecting shaft of the load tester, a coupling disk is rotatably provided on the fixed disk, and an axial hole for inserting the power supply motor shaft is opened on the coupling disk, and a hexagon socket bolt for fixing the motor shaft is rotatably provided on the coupling disk;

[0009] A sleeve is fixedly provided on the coupling disc, and a rotating shaft is rotatably provided in the sleeve. The rotating shaft extends between the coupling disc and the fixed disc, and a conical tooth surface is provided on the inner end of the rotating shaft. A conical gear ring for driving the conical tooth surface is fixedly provided on the fixed disc;

[0010] The sleeve is slidably connected to the inside of the sleeve, and the sleeve and the rotating shaft are provided with mutually matching threads. The rotating shaft rotates to drive the sleeve to slide, and a connecting rod is fixedly provided on the side surface of the sleeve, and a pin that matches the hexagon socket bolt is fixedly provided on the connecting rod.

[0011] Preferably, a roller that fits the motor shaft is rotatably provided on the connecting rod, and a whistle hole is provided on the surface of the roller.

[0012] Preferably, the sliding sleeve is composed of a main housing and a secondary housing, the connecting rod is connected to the main housing, a thread is provided on the inner wall of the secondary housing, a connecting pin is fixedly provided on the side of the main housing, a pin hole is provided on the secondary housing, and the secondary housing is slidably connected to the connecting pin through the pin hole, and a tension spring is provided on the connecting pin to pull the secondary housing to fit the main housing;

[0013] The upper side of the sleeve is set as an unlocking groove for the secondary shell to deflect, and the lower side of the sleeve is set as a cone mouth for squeezing the secondary shell onto the main shell.

[0014] Preferably, a track is fixedly provided on the detection platform, and the mounting platform is slidably provided on the track and has a locking structure.

[0015] Preferably, the meshing angle between the bevel gear ring and the bevel gear surface is 45°±5°.

[0016] Preferably, a pressure sensor is embedded in the side wall of the bevel gear ring, and the sensor is connected to the display terminal of the detection platform via a wireless module.

[0017] Preferably, a honeycomb-shaped shock-absorbing cavity is provided at the bottom of the table top of the testing table, and the shock-absorbing cavity is filled with nitrogen damping gel.

[0018] A method for using a brushless motor load detection device comprises the following steps:

[0019] S1. Fix the brushless motor on the mounting table, insert the motor shaft into the shaft hole, and tighten the hexagon socket bolt to secure it.

[0020] S2. Start the brushless motor to rotate the coupling disc. The bevel gear ring drives the rotating shaft to rotate along the bevel gear surface and drives the sliding sleeve to move. The synchronously moving connecting rod inserts the pin into the hexagon socket bolt. When the sliding sleeve moves to the bottom and stops the rotating shaft, the coupling disc and the fixed disc are rigidly connected through the rotating shaft and connected to the load test machine for testing.

[0021] S3. When the connecting rod moves, the roller is pressed onto the motor shaft. When the motor shaft and the coupling plate are loosened, the motor shaft pushes the roller to rotate. At this time, the whistle hole on the surface of the roller emits an alarm sound through the air flow.

[0022] S4. When the connecting rod presses the roller onto the motor shaft, if the connection position of the motor shaft and the coupling plate is not correct, the roller cannot move to the preset position. At this time, the main housing will not move to the bottom, and the sub-housing will not be squeezed by the tapered mouth. Therefore, the thread on the shaft pushes the sub-housing away and continues to rotate, so that the rigid connection between the fixed plate-rotating shaft-coupling plate is disconnected.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] In this invention, the automatic rigid connection and load testing linkage system uses a precisely designed bevel gear transmission mechanism to convert the motor's rotational motion into axial displacement, achieving automatic locking of the test system. When the motor starts, the meshing transmission between the bevel gear ring and the rotating shaft drives the sleeve assembly to precisely move, driving the latch mechanism to rigidly secure the motor shaft. The entire connection process is fully automated, requiring no human intervention, and ensures that the load tester and the motor shaft achieve an ideal coaxial fit. This design not only improves testing efficiency but also avoids the connection deviation problems caused by improper manual operation in traditional methods.

[0025] The present invention utilizes a mechanical loosening alarm system, employing a whistle alarm system that monitors the motor shaft status in real time via a specially designed roller assembly. When abnormal loosening of the motor shaft is detected, the rotation of the roller drives the whistle hole to generate high-frequency airflow, emitting a clearly audible alarm. This purely mechanical alarm method is independent of power supply and offers extremely high reliability, making it particularly suitable for use in complex industrial environments. Once the alarm is triggered, the operator can immediately take appropriate measures, effectively preventing equipment damage and safety accidents.

[0026] The intelligent error-proofing and safety interruption features of this invention utilize a unique dual-shell sliding sleeve design, enabling intelligent identification of connection anomalies. If the motor shaft is detected to be improperly installed or exhibits significant deviation, the protection mechanism automatically triggers, mechanically disconnecting the rigid connection to prevent the equipment from operating in an undesirable condition. This protection system accurately distinguishes between normal and abnormal operating conditions, ensuring comprehensive safety protection while ensuring test accuracy. Its fast response and reliable protection significantly reduce the risk of equipment damage caused by improper installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0028] Figure 2This is a schematic diagram of the brushless motor of the present invention connected to a load testing machine;

[0029] Figure 3 The explosion of the coupling disc and the sleeve of the present invention Figure 1 ;

[0030] Figure 4 The explosion of the coupling disc and the sleeve of the present invention Figure 2 ;

[0031] Figure 5 It is a front cross-sectional view of the sleeve of the present invention;

[0032] Figure 6 The explosion of the sleeve and the sliding sleeve of the present invention Figure 1 ;

[0033] Figure 7 The explosion of the sleeve and the sliding sleeve of the present invention Figure 2 ;

[0034] Figure 8 This is an exploded view of the main housing, auxiliary housing and rotating shaft of the present invention;

[0035] Figure 9 For the present invention Figure 8 Enlarged view of point A in the middle.

[0036] In the figure: 1. Test bench; 2. Mounting table; 3. Load testing machine; 4. Fixing plate; 5. Coupling plate; 6. Shaft hole; 7. Hexagon socket bolt; 8. Sleeve; 9. Rotating shaft; 10. Conical tooth surface; 11. Conical gear ring; 12. Sliding sleeve; 121. Main housing; 122. Auxiliary housing; 13. Thread; 14. Connecting rod; 15. Latch; 16. Roller; 17. Whistle hole; 18. Connecting pin; 19. Pin hole; 20. Tension spring; 21. Unlocking slot; 22. Conical mouth. DETAILED DESCRIPTION

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technical personnel in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0038] See also Figures 1 to 9The present invention provides a technical solution: a brushless motor load detection device, a brushless motor load detection device, including a detection platform 1, a mounting platform 2 is fixedly provided on the detection platform 1, a brushless motor is installed on the mounting platform 2, a load tester 3 is fixedly provided on the detection platform 1, a fixing plate 4 is fixedly provided on the connecting shaft of the load tester 3, a coupling plate 5 is rotatably provided on the fixing plate 4, and an axial hole 6 for inserting the power supply motor shaft is opened on the coupling plate 5, and a hexagon socket bolt 7 for fixing the motor shaft is rotatably provided on the coupling plate 5.

[0039] Fix the brushless motor on the mounting platform 2, insert the motor shaft into the shaft hole 6, and then tighten the hexagon socket bolt 7 to secure it.

[0040] A sleeve 8 is fixedly provided on the coupling disc 5, and a rotating shaft 9 is rotatably provided in the sleeve 8. The rotating shaft 9 extends between the coupling disc 5 and the fixed disc 4, and a conical tooth surface 10 is provided on the inner end of the rotating shaft 9. A conical gear ring 11 for driving the conical tooth surface 10 is fixedly provided on the fixed disc 4.

[0041] Start the brushless motor to rotate the coupling plate 5. The bevel gear ring 11 then drives the shaft 9 along the bevel gear surface 10, driving the sleeve 12 to move. The synchronously moving connecting rod 14 inserts the pin 15 into the hexagon socket bolt 7. When the sleeve 12 reaches its bottom position, stopping the shaft 9, the coupling plate 5 and the fixed plate 4 are rigidly connected via the shaft 9 and connected to the load tester 3 for testing.

[0042] A sleeve 12 is slidably connected inside the sleeve 8, and the sleeve 12 and the rotating shaft 9 are provided with mutually matching threads 13. The rotating shaft 9 rotates to drive the sleeve 12 to slide, and a connecting rod 14 is fixedly provided on the side surface of the sleeve 12, and a pin 15 that matches the hexagon socket bolt 7 is fixedly provided on the connecting rod 14.

[0043] In this embodiment, Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figures 5 to 9 As shown, a roller 16 is rotatably mounted on the connecting rod 14 and is in contact with the motor shaft. A whistle hole 17 is provided on the surface of the roller 16.

[0044] When the connecting rod 14 moves, the roller 16 is synchronously pressed onto the motor shaft. When the fixation between the motor shaft and the coupling disk 5 is loosened, the motor shaft pushes the roller 16 to rotate. At this time, the whistle hole 17 on the surface of the roller 16 emits an alarm sound through the airflow. This sound directly reflects the connection status of the coupling disk 5 and the motor shaft, and prompts the operator to stop the motor.

[0045] In this embodiment, Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figures 5 to 9 As shown, the sliding sleeve 12 consists of a main housing 121 and a secondary housing 122. The connecting rod 14 is connected to the main housing 121. The thread 13 is set on the inner wall of the secondary housing 122. A connecting pin 18 is fixedly set on the side of the main housing 121. A pin hole 19 is opened on the secondary housing 122, and the secondary housing 122 is slidably connected to the connecting pin 18 through the pin hole 19. The connecting pin 18 is provided with a tension spring 20 that pulls the secondary housing 122 to fit the main housing 121.

[0046] The upper side of the sleeve 8 is provided as an unlocking groove 21 for the secondary housing 122 to deflect, and the lower side of the sleeve 8 is provided as a tapered opening 22 for pressing the secondary housing 122 onto the main housing 121.

[0047] When the connecting rod 14 presses the roller 16 onto the motor shaft, if the connection position between the motor shaft and the coupling disk 5 is incorrect, the roller 16 cannot move to the preset position. At this time, the main shell 121 will not move down to the bottom, and the sub-shell 122 will not be squeezed by the tapered mouth 22. Therefore, the thread 13 on the shaft 9 pushes the sub-shell 122 away and continues to rotate, so that the rigid connection between the fixed disk 4-shaft 9-coupling disk 5 is disconnected, so that the roller 16 is used to detect the position of the motor shaft before the test, and the test process of the motor with an incorrect installation state is terminated.

[0048] In this embodiment, Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figures 5 to 9 As shown, a track is fixed on the test platform 1, and the mounting platform 2 is slidably set on the track and has a locking structure. The mounting platform 2 slides along the track to quickly adjust the motor test position to adapt to the load connection requirements of motors of different sizes.

[0049] In this embodiment, Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figures 5 to 9 As shown, the meshing angle between the bevel gear ring 11 and the bevel tooth surface 10 is 45°±5°. The meshing angle of 45°±5° balances the axial force and the radial force, reduces the eccentric wear of the gear, and uses the angle tolerance band to suppress the tooth surface impact noise during high-speed transmission.

[0050] In this embodiment, Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figures 5 to 9 As shown, a pressure sensor is embedded in the side wall of the bevel gear ring 11. The sensor is connected to the display terminal of the test bench 1 through a wireless module. The sensor on the side wall of the bevel gear ring 11 dynamically collects meshing pressure fluctuations, identifies early wear or overload risks, and wirelessly transmits the data to the terminal to generate a load-time curve, thereby supporting fault prediction analysis.

[0051] In this embodiment, Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figures 5 to 9 As shown, a honeycomb-shaped shock-absorbing cavity is provided at the bottom of the table top of the test bench 1, and the shock-absorbing cavity is filled with nitrogen damping gel. The honeycomb structure disperses the vibration energy of the motor to the porous wall, and the compression deformation of the nitrogen gel absorbs low-frequency resonance.

[0052] A method for using a brushless motor load detection device comprises the following steps:

[0053] S1. Fix the brushless motor on the mounting platform 2, insert the motor shaft into the shaft hole 6, and rotate the hexagon socket bolt 7 to fix it;

[0054] S2. Start the brushless motor to drive the coupling disc 5 to rotate. At this time, the bevel gear ring 11 drives the rotating shaft 9 to rotate along the bevel gear surface 10, and drives the sliding sleeve 12 to move. At this time, the synchronously moving connecting rod 14 inserts the latch 15 into the hexagon socket bolt 7. When the sliding sleeve 12 moves to the bottom to stop the rotating shaft 9, the coupling disc 5 and the fixed disc 4 are rigidly connected through the rotating shaft 9, and the load tester 3 is connected to perform the test. In this way, the rotating shaft 9 and the sliding sleeve 12 cooperate to divide the connection between the motor and the load tester 3 into a two-stage rotation-rigidity connection, and the latch 15 is automatically controlled to lock the hexagon socket bolt 7 to prevent the bolt body from vibrating and rotating and affecting the stability of the fixation, and then the test is automatically started;

[0055] S3. When the connecting rod 14 moves, the roller 16 is pressed onto the motor shaft. When the motor shaft and the coupling plate 5 are loosened, the motor shaft pushes the roller 16 to rotate. At this time, the whistle hole 17 on the surface of the roller 16 emits an alarm sound through the air flow. This sound directly reflects the connection status of the coupling plate 5 and the motor shaft, and prompts the operator to stop the motor.

[0056] S4. When the connecting rod 14 presses the roller 16 onto the motor shaft, if the connection position between the motor shaft and the coupling disk 5 is incorrect, the roller 16 cannot move to the preset position. At this time, the main shell 121 will not move down to the bottom, and the sub-shell 122 will not be squeezed by the tapered mouth 22. Therefore, the thread 13 on the shaft 9 pushes the sub-shell 122 away and continues to rotate, so that the rigid connection between the fixed disk 4-shaft 9-coupling disk 5 is disconnected. In this way, the roller 16 is used to detect the position of the motor shaft before the test, and the test process of the motor in the incorrect installation state is terminated, which has better safety. When the motor shaft is twisted due to load, the deformed motor shaft will also push the connecting rod 14 to terminate the test.

[0057] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely preferred examples of the present invention and are not intended to limit the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention, and such changes and modifications fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A brushless motor load detection device, characterized in that: include: Testing station (1); A mounting platform (2) fixedly arranged on the testing platform (1) and used for mounting a brushless motor; A load testing machine (3), the connecting shaft of which is fixedly provided with a fixing plate (4); The coupling disc (5) is rotatably mounted on the fixed disc (4) and is provided with a shaft hole (6) for inserting the motor shaft and a hexagon socket bolt (7) for fixing the motor shaft. The sleeve (8) is fixed to the coupling disc (5), and a rotating shaft (9) rotatably arranged inside the sleeve extends between the coupling disc (5) and the fixed disc (4). The inner end of the rotating shaft (9) is provided with a conical tooth surface (10), and a conical tooth ring (11) for driving the conical tooth surface (10) is provided at a corresponding position of the fixed disc (4); The sliding sleeve (12) is slidably connected in the sleeve (8), and the rotating shaft (9) drives the sliding sleeve (12) to move axially by rotating in conjunction with the thread (13). The side surface of the sliding sleeve (12) is connected to a pin (15) that cooperates with the hexagon socket bolt (7) through a connecting rod (14); The sliding sleeve (12) comprises: a main shell (121) connected to a connecting rod (14); The inner wall of the auxiliary housing (122) is provided with a thread (13) and is slidably connected to the main housing (121) via a connecting pin (18); A tension spring (20) is provided on the connecting pin (18) to make the secondary housing (122) fit the main housing (121); The inner wall of the sleeve (8) is provided with an unlocking groove (21) for the secondary shell (122) to deflect and a tapered opening (22) for forcing the secondary shell (122) to press against the main shell (121).

2. The brushless motor load detection device according to claim 1, characterized in that: A roller (16) is rotatably provided on the connecting rod (14) and is in contact with the motor shaft. An air whistle hole (17) is provided on the surface of the roller (16).

3. The brushless motor load detection device according to claim 2, characterized in that: The detection platform (1) is provided with a track, and the mounting platform (2) is slidably arranged on the track and is equipped with a locking structure.

4. The brushless motor load detection device according to claim 3, characterized in that: The meshing angle between the conical gear ring (11) and the conical gear surface (10) is 45°±5°.

5. The brushless motor load detection device according to claim 4, characterized in that: A pressure sensor is embedded in the side wall of the conical gear ring (11), and the sensor is connected to the display terminal of the detection platform (1) via a wireless module.

6. The brushless motor load detection device according to claim 5, characterized in that: The bottom of the testing platform (1) is provided with a honeycomb-shaped shock-absorbing cavity, and the shock-absorbing cavity is filled with nitrogen damping gel.

7. A method for using a brushless motor load detection device, using the brushless motor load detection device according to claim 6, characterized in that: The steps include: S1. Position the brushless motor on the mounting platform (2), insert the motor shaft into the shaft hole (6), and tighten the hexagon socket bolt (7) to complete the mechanical fixation; S2, start the motor to drive the coupling plate (5) to rotate, and realize through the bevel gear ring (11)-sleeve (12) mechanism: the connecting rod (14) automatically latches the bolt (15), the motor shaft and the load test machine (3) are rigidly connected, and the system automatically enters the test mode; S3, the roller (16) pressing mechanism detects the state of the motor shaft in real time, and triggers a whistle alarm when it is abnormally loose, forcing the motor to stop running; ‌S4. By detecting the displacement of the auxiliary housing (122), the rigid connection is automatically disconnected when the installation is offset, and the test is terminated in a linked manner when the motor shaft is deformed, ensuring that an undesirable state does not enter the test process.

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