Traction motor no-load test system and method

Abstract

The invention discloses a traction motor no-load test system and a traction motor no-load test method, which are used for overcoming the defect that the existing traction motor no-load test system cannot meet the requirements of maintenance quality and production progress. The system comprises a PLC, a data acquisition module and a voltage regulation module, the PLC receives an instruction of an upper computer to control the contactor to act, the data acquisition module acquires voltage and current data, and the voltage regulation module regulates the voltage of equipment to be tested. The method comprises the following steps that: after equipment to be tested is connected, an instruction is sent through the upper computer, the PLC controls the contactor to enable the voltage regulating module to apply load, and the data acquisition module acquires data and feeds back the data to the upper computer to complete the test. According to the scheme, automatic control and real-time data acquisition are realized, the test precision and efficiency are improved, and the requirements of traction motor maintenance quality and production progress are met.

Description

Technical Field

[0001] This invention relates to the field of testing devices for electric motors, and more specifically to a traction motor no-load testing system and method. Background Technology

[0002] As one of the core components of a locomotive, the performance of the traction motor directly affects the reliability and safety of locomotive operation. With the increasing service life of locomotives, the failure rate of traction motors gradually rises, and the difficulty and cost of maintenance also increase. Therefore, regular and precise maintenance and performance testing of traction motors are particularly important to ensure the normal operation of locomotives. However, many current traction motor no-load test benches have some shortcomings, such as aging equipment and limited functionality. This makes it difficult for existing test benches to comprehensively and accurately test the various performance aspects of traction motors, failing to meet the quality and schedule requirements of modern locomotive maintenance.

[0003] Traditional test benches, due to technological limitations, can often only perform basic motor performance tests and cannot accurately measure key parameters such as motor forward and reverse starting, and voltage and current curves during operation. This not only affects the quality of motor maintenance but may also lead to locomotive malfunctions due to motor performance issues during actual operation, thereby impacting the overall operational efficiency and safety of the locomotive. Furthermore, some test benches are complex to operate, requiring a high level of technical skill from operators, making them susceptible to inaccurate test results due to human error, further affecting the efficiency and quality of maintenance work. To meet the needs of modern locomotive maintenance and improve the quality and efficiency of traction motor maintenance, there is an urgent need for a new type of traction motor no-load test bench that can overcome the shortcomings of existing systems. Summary of the Invention

[0004] The purpose of this invention is to provide a traction motor no-load test system and method to overcome the shortcomings of existing traction motor no-load test systems that cannot meet the requirements of maintenance quality and production schedule.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides a traction motor no-load test system, comprising: The PLC controller is connected to a host computer and several contactors, receiving instructions from the host computer and controlling the corresponding contactor actions. The data acquisition module connects to the PLC controller and receives instructions from the PLC controller to acquire voltage and current data of the device under test. The voltage regulating module is connected to the PLC controller via a contactor, and can also be directly connected to the device under test for voltage adjustment.

[0006] The PLC controller is connected to the host computer via input terminals X0, X1, X2, and X3.

[0007] Input terminal X0 triggers a stop signal, input terminal X1 triggers a start signal, input terminal X2 triggers a forward rotation signal, and input terminal X3 triggers a reverse rotation signal.

[0008] The PLC controller drives the contactors to operate via intermediate relays. The contactors include contactors KM1, KM2, KM3, and KM4, which are connected to the PLC controller via intermediate relays KA1, KA2, KA3, and KA4, respectively.

[0009] The PLC controller and the data acquisition module are connected through an analog signal acquisition module.

[0010] The analog signal acquisition module is a 6AD expansion module.

[0011] The data acquisition module includes a voltage isolation transmitter and a current isolation transmitter.

[0012] The voltage regulation module is also connected to the panel potentiometer and receives control commands from the panel potentiometer.

[0013] Secondly, the present invention also provides a method for no-load testing of a traction motor, comprising: Connect the device under test to the traction motor no-load test system and issue test commands through the host computer; The PLC controller controls the contactor to operate according to the test instructions, thereby controlling the voltage regulating module to apply a load to the equipment under test; The data acquisition module collects the voltage and current data of the equipment under test and feeds them back to the host computer through the PLC controller to complete the no-load test of the equipment under test.

[0014] The PLC controller controls the contactor to operate according to the test command, thereby controlling the voltage regulation module to apply a load to the device under test. It also includes controlling the voltage regulation module through the panel potentiometer to adjust the load applied to the device under test.

[0015] Compared with the prior art, the present invention has the following beneficial technical effects: Firstly, this invention provides a traction motor no-load testing system. A PLC controller connects to a host computer and contactors, receiving commands from the host computer and controlling the contactors' actions to automate the testing process. This changes the traditional system's reliance on manual operation, reducing human error and ensuring maintenance quality. A data acquisition module, connected to the PLC controller, collects voltage and current data from the device under test according to instructions. This data is fed back to the host computer, allowing operators to monitor motor operating parameters in real time, overcoming the limitations of traditional systems in data acquisition and real-time monitoring. A voltage regulation module, connected to the PLC controller via contactors, also directly connects to the device under test for voltage adjustment, enabling precise control of the motor load and simulating different operating conditions. Traditional systems, with their limited functionality, cannot perform such precise adjustments and comprehensive testing. This system improves the reliability and comprehensiveness of the test, meeting the diverse and high-precision testing needs of modern locomotive maintenance, thus ensuring production progress.

[0016] Secondly, this invention provides a traction motor no-load test method. After connecting the device under test to the traction motor no-load test system, a test command is issued through a host computer, realizing the digital start of the test. This changes the traditional system's reliance on manual operation and avoids the impact of human error on the test results. The PLC controller controls the contactor to operate according to the test command, thereby controlling the voltage regulating module to apply a load to the device under test. During this process, the PLC controller's automated control can accurately adjust the load and simulate the motor's operating state under different working conditions. Traditional systems cannot achieve such precise load control and cannot comprehensively test motor performance. The data acquisition module collects the voltage and current data of the device under test and feeds it back to the host computer through the PLC controller, completing the no-load test of the device under test. This achieves real-time data acquisition and feedback, allowing operators to monitor the motor's operating status based on real-time data and promptly identify potential problems, overcoming the shortcomings of traditional systems such as untimely data acquisition and lack of traceability. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the control circuit of a traction motor no-load test system in an embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of a traction motor no-load test method in an embodiment of the present invention.

[0019] Figure 3 This is a flowchart of a traction motor no-load test method according to an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of a data acquisition module for a traction motor no-load test system in an embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the main circuit of a traction motor no-load test system in an embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram of the power supply connected to a traction motor no-load test system in an embodiment of the present invention. Detailed Implementation

[0023] In the field of railway locomotive parts maintenance, the application of electrical control technology is of great significance for ensuring the safety and reliability of locomotive operation. As the core equipment of railway transportation, the performance of the key components of locomotives directly affects the operational efficiency and safety of the entire railway system. In recent years, with the continuous increase in the service life of locomotives, the failure rate of locomotive parts has gradually increased, leading to increased difficulty and cost in maintenance.

[0024] In the overhaul of traction motors, no-load testing is a crucial step in evaluating motor performance. Currently, common methods for no-load testing of traction motors primarily rely on traditional test benches, which typically employ simple electrical control systems and manual operation. These traditional test benches are old, severely worn, and have a high failure rate. Furthermore, their testing functions are incomplete and cannot meet the high-precision requirements of modern locomotive maintenance. In addition, the operation of traditional test benches is complex, requiring significant manual intervention, which is not only inefficient but also prone to inaccurate results due to human error. Traditional test benches also have limited data acquisition and analysis capabilities, failing to achieve real-time data storage and traceability, which creates difficulties for subsequent quality control and fault diagnosis.

[0025] Therefore, there is an urgent need for a new traction motor no-load testing system and method to solve the above problems. Based on this background, this application proposes a traction motor no-load testing system and method to achieve the testing of traction motors and provide reliable technical support for the maintenance of key locomotive components.

[0026] 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 technicians 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.

[0027] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0028] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a number" means two or more, unless otherwise explicitly specified.

[0030] Reference Figure 1 The diagram shows a specific embodiment of the traction motor no-load test system provided by the present invention, comprising: The PLC controller is connected to a host computer and several contactors, receiving instructions from the host computer and controlling the corresponding contactor actions. The data acquisition module connects to the PLC controller and receives instructions from the PLC controller to acquire voltage and current data of the device under test. The voltage regulating module is connected to the PLC controller via a contactor, and can also be directly connected to the device under test for voltage adjustment.

[0031] Specifically, the PLC controller is connected to the host computer via input terminals X0, X1, X2, and X3. Operators input different commands through the host computer, including but not limited to stop, start, forward, and reverse. Input terminal X0 triggers a stop signal, input terminal X1 triggers a start signal, input terminal X2 triggers a forward signal, and input terminal X3 triggers a reverse signal.

[0032] The PLC controller drives the contactors to operate via intermediate relays. The contactors include contactors KM1, KM2, KM3, and KM4, which are connected to the PLC controller via intermediate relays KA1, KA2, KA3, and KA4, respectively.

[0033] After the operator sends a start command through the host computer, the PLC controller receives the start command and outputs a signal to energize the coil of intermediate relay KA1, which closes the normally open contact of intermediate relay KA1, energizes the coil of contactor KM1, and closes the contact of contactor KM1, thus connecting the main circuit and allowing current to flow to the voltage regulating module.

[0034] After the current enters the voltage regulating module, the traction motor no-load test system will check whether the output voltage of the voltage regulating module is zero. Only when the output voltage of the voltage regulating module is zero is the subsequent starting action allowed to continue. This is to ensure that the motor is not damaged by residual voltage during startup.

[0035] It should be noted that KM2 and KM3 are unconducted phase contactors that change the phase sequence of the motor to achieve forward and reverse rotation. Similarly, after the operator sends a forward rotation command via the host computer, the PLC controller receives the command and outputs a signal, energizing the coil of intermediate relay KA2. This closes the normally open contact of intermediate relay KA2, driving contactor KM2 to close, thus achieving forward rotation of the motor. Conversely, after the operator sends a reverse rotation command via the host computer, the PLC controller receives the command and outputs a signal, energizing the coil of intermediate relay KA3. This closes the normally open contact of intermediate relay KA3, driving contactor KM3 to close, thus achieving reverse rotation of the motor.

[0036] The PLC controller and the data acquisition module are connected via an analog signal acquisition module, which provides additional analog input channels. In this specific embodiment, the analog signal acquisition module uses a 6AD expansion module, which receives analog signals from the data acquisition module through multiple analog input channels and converts them into digital signals so that the PLC controller can process these data.

[0037] The data acquisition module includes voltage isolation transmitters and current isolation transmitters, used to acquire key electrical parameters of the equipment under test during operation. The voltage isolation transmitters acquire voltage signals during motor operation, while the current isolation transmitters acquire current signals. These transmitters convert the raw voltage and current signals into standard analog signals, such as 0-10V or 4-20mA signals, facilitating subsequent signal transmission and processing. The converted signals are transmitted to the 6AD expansion module of the PLC controller, which converts the analog signals into digital signals for further data processing and analysis by the PLC controller, thereby achieving precise monitoring of the motor's operating status.

[0038] The voltage regulating module can adjust the load applied to the equipment under test. In addition to adjusting it through instructions from the PLC controller, the voltage regulating module is also connected to the panel potentiometer and receives control instructions from the panel potentiometer. The operator can provide a voltage instruction of 0-10 volts to the voltage regulating module through the panel potentiometer. The voltage regulating module adjusts the output voltage according to the instruction to adjust the load of the equipment under test.

[0039] In another specific embodiment of the present invention, a method for testing a traction motor under no-load conditions is also provided, referring to... Figure 2 and Figure 3 As shown, it includes: S1, connect the device under test to the no-load test system and send test commands through the host computer; S2, the PLC controller controls the contactor to operate according to the test command, thereby controlling the voltage regulating module to apply a load to the device under test; S3, the data acquisition module collects the voltage and current data of the equipment under test and feeds it back to the host computer through the PLC controller to complete the no-load test of the equipment under test.

[0040] Electrically connect the traction test device (DDT) to all components of the no-load test system. This includes connecting the DDT's power input to the voltage regulator module output of the test bench to ensure the DDT receives adjustable power. Simultaneously, the DDT's output also needs to be connected to the voltage and current isolation transmitters in the data acquisition module to monitor the DDT's operating parameters in real time during the test. After completing the hardware connection, the operator issues test commands via a host computer. The host computer software provides a user-friendly interface where the operator can select different test modes, set test parameters, and initiate the test process. These commands are sent to the PLC controller via the communication interface, preparing for subsequent automated testing.

[0041] As the core of the entire traction motor no-load test system, the PLC controller receives test commands from the host computer and begins executing the preset control program. According to the test commands, the PLC controller outputs control signals to drive the corresponding contactors. The contactors here function as circuit switches; by controlling the closing and opening of the contactors, the output of the voltage regulating module can be connected or disconnected to the input of the motor under test, thus controlling the power supply to the motor. When the contactor closes, the voltage regulating module begins to apply voltage to the motor under test. The voltage regulating module can adjust the output voltage according to further instructions or preset programs from the PLC controller, simulating different load conditions and allowing the motor to operate under various conditions. This process achieves precise control of the motor load, providing a foundation for subsequent data acquisition and performance evaluation.

[0042] During motor operation, voltage and current isolation transmitters in the data acquisition module monitor the motor's input voltage and current in real time. These isolation transmitters convert the acquired analog signals into electrical signals and transmit them to the analog input module of the PLC controller. The PLC controller's analog input module converts the received analog signals into digital signals for data processing. The processed data is then fed back to the host computer via a communication interface. The host computer software receives this data, performs further analysis and processing, and displays this information in real time on the interface for operator observation and analysis. When the test reaches the preset time or meets specific termination conditions, the PLC controller issues a stop signal, controls the contactor to disconnect, stops power supply to the motor, and the entire no-load test process ends. Operators can evaluate the motor's performance and determine whether it meets the requirements based on the data displayed on the host computer and the generated report.

[0043] Preferably, after executing S2, where the PLC controller controls the contactor to apply a load to the device under test (DUT) according to the test command, the operator can also adjust the load applied to the DUT by controlling the voltage regulator module via the panel potentiometer. Specifically, after the PLC controller controls the contactor to apply a load to the DUT according to the test command, the operator can fine-tune the load applied to the DUT by operating the panel potentiometer as needed. The panel potentiometer is connected to the voltage regulator module, and its output signal directly acts on the voltage regulator module, thereby achieving fine adjustment of the output voltage or current. This design provides the operator with greater flexibility, allowing them to supplement and optimize manual load adjustment based on specific needs or real-time conditions during the test, ensuring the accuracy of the test results.

[0044] Preferably, in the traction motor no-load test system used in this specific embodiment, the PLC control program also includes a protection control program. This program monitors the potentiometer's output signal in real time to determine whether it is at zero. Only when the potentiometer output is confirmed to be zero will the power supply to the voltage regulation module be turned on to prevent voltage surges to the device under test.

[0045] To make the solution provided by this invention easier to understand, a specific implementation method combined with a practical application scenario is provided below for further explanation.

[0046] The host computer interface adopts a graphical design, including a parameter setting area where target voltage, current, speed, and other parameters can be set; a history recording area where previously conducted test data can be viewed; and a test area, which displays buttons for "Start," "Stop," "Forward," and "Reverse," as well as a real-time data display area showing motor operating data in numerical and graph formats. Operators send commands by clicking control buttons, set parameters, and then click the "Start" button to begin the test. The interface displays real-time data such as motor voltage, current, and speed, and plots graphs to show the motor's operating status. When the test ends or an abnormality occurs, a prompt appears on the interface, and the data is saved for subsequent analysis.

[0047] The PLC controller runs the control program, receives instructions from the host computer, parses them, and executes the corresponding operations. The program includes start, stop, forward, and reverse control logic, as well as data acquisition, processing, and uploading functions. Based on the acquired data, the PLC controller automatically adjusts the output of the voltage regulation module to ensure stable motor operation. The voltage regulation module receives instructions from the PLC controller and adjusts the output voltage. Fine control is achieved through manual adjustment using a potentiometer. The panel potentiometer is connected to the voltage regulation module; the operator can directly adjust the output voltage by rotating the potentiometer to meet specific requirements.

[0048] The data acquisition module includes voltage isolation transmitters and current isolation transmitters, such as... Figure 4 As shown. A voltage isolation transmitter is installed at the input terminal of the equipment under test (UDT) to collect the voltage signal; a current isolation transmitter is installed on the input line of the UDT to collect the current signal. The isolation transmitters convert the signals into standard analog signals (0-10V / 4-20mA) and transmit them to the 6AD expansion module of the PLC controller. The 6AD module converts the analog signals into digital signals and transmits them to the PLC controller processor. After processing the data, the PLC controller uploads it to the host computer via the communication interface to achieve real-time monitoring of the motor's operating status. The host computer's data display area and graphs show the real-time data for operator monitoring.

[0049] The main circuit structure is as follows Figure 5 As shown, it is connected to Figure 6The three-phase AC power supply (L1, L2, L3, N) shown is connected to the main contactor KM1 via circuit breaker QF. The output of KM1 connects to a voltage regulator module, and the output of the voltage regulator module connects to the motor. Contactors KM2 and KM3 control the forward and reverse rotation of the motor, and their operation is controlled by the PLC controller. The control circuit includes the PLC controller, contactors, relays, and protection devices. The PLC controller outputs signals to control the contactors and relays, thus achieving motor control. The control circuit power supply is provided by a transformer, converting the main circuit AC power to 24V AC, which is then rectified and filtered to provide 24V DC power to the PLC controller and other equipment. The PLC controller connects to the host computer via an RS485 interface or Ethernet. The host computer sends commands and receives feedback data. The PLC controller connects to the 6AD expansion module via an internal bus to acquire analog signals. The voltage regulator module connects to the PLC controller via an analog output channel to receive control signals. The panel potentiometer connects to the voltage regulator module via an analog input channel to provide manual adjustment signals.

[0050] This solution addresses the shortcomings of existing traction motor no-load testing systems through various improvements and optimizations, effectively overcoming their inability to meet maintenance quality and production schedule requirements. Existing traction motor no-load testing systems often suffer from aging equipment, limited functionality, complex operation, and inconvenient data management, making it difficult to meet modern locomotive maintenance standards in terms of testing accuracy, efficiency, and reliability. This solution, however, utilizes an advanced PLC controller and a meticulously designed electrical control system to achieve precise control and automated operation of the motor testing process. The PLC controller receives instructions from the host computer through multiple input terminals, accurately controlling the contactor's action and the voltage regulation module's output, thereby achieving precise adjustment of the motor load. Simultaneously, the data acquisition module equipped in the traction motor no-load testing system monitors the motor's voltage and current in real time, feeding this crucial data back to the host computer for analysis and display, ensuring the accuracy and real-time nature of the test data. Furthermore, the panel potentiometer introduced in this solution provides operators with the flexibility of manual adjustment, allowing for rapid adjustments when fine-tuning of the load is needed, improving the adaptability and convenience of the test. In terms of electrical connections, standardized interfaces and modular design are adopted, which not only improves the stability and reliability of the traction motor no-load test system but also facilitates subsequent maintenance and expansion. Regarding communication, the PLC controller and the host computer exchange data via a high-speed communication interface, ensuring rapid command transmission and real-time data updates, greatly improving test efficiency. In summary, this solution, through significant improvements in control accuracy, data acquisition, operational flexibility, electrical connection stability, and communication efficiency, successfully solves the problems faced by existing traction motor no-load test systems and meets the stringent quality and schedule requirements of modern locomotive maintenance.

[0051] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A traction motor no-load test system, characterized in that, include: The PLC controller is connected to a host computer and several contactors, receiving instructions from the host computer and controlling the corresponding contactor actions. The data acquisition module connects to the PLC controller and receives instructions from the PLC controller to acquire voltage and current data of the device under test. The voltage regulating module is connected to the PLC controller via a contactor, and can also be directly connected to the device under test for voltage adjustment.

2. The traction motor no-load test system according to claim 1, characterized in that, The PLC controller is connected to the host computer via input terminals X0, X1, X2, and X3.

3. The traction motor no-load test system according to claim 2, characterized in that, The input terminal X0 triggers a stop signal, the input terminal X1 triggers a start signal, the input terminal X2 triggers a forward rotation signal, and the input terminal X3 triggers a reverse rotation signal.

4. The traction motor no-load test system according to claim 1, characterized in that, The PLC controller drives the contactors to operate via intermediate relays. The contactors include contactors KM1, KM2, KM3, and KM4, which are connected to the PLC controller via intermediate relays KA1, KA2, KA3, and KA4, respectively.

5. The traction motor no-load test system according to claim 1, characterized in that, The PLC controller and the data acquisition module are connected through an analog signal acquisition module.

6. The traction motor no-load test system according to claim 5, characterized in that, The analog signal acquisition module is a 6AD expansion module.

7. The traction motor no-load test system according to claim 1, characterized in that, The data acquisition module includes a voltage isolation transmitter and a current isolation transmitter.

8. The traction motor no-load test system according to claim 1, characterized in that, The voltage regulation module is also connected to the panel potentiometer and receives control commands from the panel potentiometer.

9. A method for no-load testing of a traction motor, characterized in that, include: Connect the device under test to the traction motor no-load test system and issue test commands through the host computer; The PLC controller controls the contactor to operate according to the test instructions, thereby controlling the voltage regulating module to apply a load to the equipment under test; The data acquisition module collects the voltage and current data of the equipment under test and feeds them back to the host computer through the PLC controller to complete the no-load test of the equipment under test.

10. A traction motor no-load test method according to claim 9, characterized in that, The PLC controller controls the contactor to operate according to the test command, thereby controlling the voltage regulation module to apply a load to the device under test. It also includes controlling the voltage regulation module through the panel potentiometer to adjust the load applied to the device under test.

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