Motor detection device

Abstract

The invention relates to the technical field of motor detection, in particular to a motor detection device which comprises a detection bin, a detection frame, a multi-dimensional detection element and a programmable logic controller, the detection frame is arranged in the detection bin, and the detection frame is used for placing a pedal motor. The multi-dimensional detection element comprises a wiring board, a sound sensor, a Hall sensor, an electric leakage detection probe and a load sensor, and the programmable logic controller is used for detecting the electric leakage of the pedal motor according to sound in a first frequency range emitted by the pedal motor, rotating speed fluctuation of the pedal motor at a first angle and burrs appearing at the first angle according to the waveform of current of the pedal motor. Judging that windings of internal magnetic poles of the pedal motor have faults; according to the rotating speed of the pedal motor bearing the standard load lower than the standard rotating speed and the current of the pedal motor higher than the standard current, bearing friction of the pedal motor is judged. The pedal motor fault detection device has the effect that the fault position of the pedal motor can be judged through cooperation of the multi-dimensional detection element and the programmable logic controller.

Description

Technical Field

[0001] This application relates to the field of motor testing technology, and in particular to a motor testing device. Background Technology

[0002] With the electrification and intelligentization of automobiles, more and more high-chassis cars are being equipped with electric pedals to improve the convenience and comfort of getting in and out of the car. The pedal motor is the core component of the electric pedal, and its reliability directly affects the convenience of getting in and out of the car.

[0003] In traditional pedal motor quality inspection, the sound of the pedal motor is usually detected to determine whether there is a fault. Some equipment will also detect the vibration of the pedal motor when it is working. However, it is difficult to determine whether the overall performance of the pedal motor meets the requirements by only detecting these parameters, and it is also difficult to detect whether there is a potential fault in the pedal motor. This may lead to some faults being missed, affecting production efficiency and safety.

[0004] Regarding the aforementioned technologies, traditional methods for testing pedal motors suffer from limitations due to their overly simplistic testing dimensions, making it impossible to pinpoint the location of faults based solely on the test results. For instance, detecting only the sound or vibration of a pedal motor cannot distinguish between an internal winding short circuit and bearing friction, hindering accurate fault diagnosis and tracing. Summary of the Invention

[0005] In order to accurately determine the fault location of the pedal motor, this application provides a motor detection device.

[0006] The motor testing device provided in this application adopts the following technical solution: A motor testing device, comprising: Testing chamber; A testing rack is installed inside the testing chamber, and the testing rack is used to house the pedal motor; The multi-dimensional detection components include a terminal block, a sound sensor, a Hall sensor, a leakage current detection probe, and a load sensor. The terminal block is used to electrically connect to the pedal motor to read the current and voltage of the pedal motor during operation to generate current and voltage signals. The sound sensor is used to detect the sound of the pedal motor during operation to generate a sound signal. The Hall sensor is used to detect the Hall value of the pedal motor during operation to detect the speed of the pedal motor to generate a speed signal. The leakage current detection probe is used to detect the leakage current of the pedal motor to generate a leakage current signal. The load sensor is used to detect the load value of the pedal motor to generate a load signal. A programmable logic controller (PLC) is electrically connected to the terminal block, the sound sensor, the Hall sensor, the leakage current detection probe, and the load sensor. The PLC is configured to perform the following actions: when the sound signal indicates a sound within a first frequency range emitted by the pedal motor, the speed signal indicates a speed fluctuation in the pedal motor at a first angle, and the current waveform of the pedal motor shows glitches at the first angle, the PLC determines that the windings of the internal magnetic poles of the pedal motor are faulty; when the load signal indicates that the speed of the pedal motor under standard load is lower than the standard speed, and the current signal indicates that the current of the pedal motor is higher than the standard current, the PLC determines that the pedal motor experiences bearing friction.

[0007] By adopting the above technical solution, compared with traditional detection devices that can only judge the quality of the motor by detecting the sound of the motor, this application enables the detection of the voltage, current, sound, Hall value, leakage current and performance parameters of the pedal motor under load by using a terminal block, sound sensor, Hall sensor, leakage current detection probe and load sensor. Furthermore, the programmable logic controller can determine the fault location of the pedal motor based on the detection results.

[0008] Optionally, the first frequency range is 6kHz to 8kHz, the first angle is 120°, the standard load is 5N·m, the standard speed is 3000rpm, and the standard current is 1.5A.

[0009] By adopting the above technical solution and limiting the detection conditions with specific values, the criteria for judging the faults of pedal motors become more operable and repeatable, avoiding misjudgments caused by ambiguous parameters and improving the accuracy of fault identification.

[0010] Optionally, it also includes a bracket and a mounting plate, the mounting plate being disposed at the bottom of the testing chamber, the testing frame and the bracket being fixed on the mounting plate, and the sound sensor being disposed on the bracket near the testing frame.

[0011] By adopting the above technical solution, the mounting plate provides a stable foundation for the bracket and the testing frame, reduces vibration interference, and the sound sensor is close to the testing frame, which improves the signal-to-noise ratio of the sound signal and enhances the sensitivity of sound detection of the pedal motor.

[0012] Optionally, it also includes a sound amplification device, which includes a microphone and a loudspeaker. The microphone is mounted on the bracket and is used to collect the sound of the pedal motor running. The loudspeaker is located outside the detection chamber and is electrically connected to the microphone. The loudspeaker is used to play the sound collected by the microphone.

[0013] By adopting the above technical solution, operators can monitor the running sound of the pedal motor in real time outside the warehouse using a microphone and loudspeaker, which facilitates manual judgment. Combined with automatic detection, this further improves the reliability of identifying pedal motor faults.

[0014] Optionally, it also includes a load device disposed outside the detection chamber. The load device is provided with a load input shaft for connecting to the output shaft of the pedal motor to apply a load to the output shaft of the pedal motor. The load sensor is electrically connected to the load device to detect the load value of the pedal motor.

[0015] By adopting the above technical solution, the load device can apply a standard load to the output shaft of the pedal motor, which can more realistically simulate the operating state of the pedal motor. Moreover, the load device is external, which makes it easy to adjust the load value of the pedal motor without affecting the internal structure of the testing chamber.

[0016] Optionally, the testing frame is provided with a testing hole and a positioning pin. The testing hole is for the output shaft of the pedal motor to pass through, and the positioning pin is used to fix the pedal motor.

[0017] By adopting the above technical solution, the detection hole and positioning pin can ensure that the output shaft of the motor is aligned with the input shaft of the load, avoiding installation deviation from affecting the detection results. Furthermore, the detection hole and positioning pin can quickly fix the pedal motor, improving detection efficiency.

[0018] Optionally, the testing frame is equipped with a cylinder clamping device, which includes a clamping cylinder and a clamping component. The clamping cylinder is mounted on the testing frame, and the clamping component is connected to the telescopic shaft of the clamping cylinder. The clamping component is used to clamp the pedal motor onto the testing frame. The clamping component is also equipped with a rubber pad to prevent the clamping component from damaging the pedal motor.

[0019] By adopting the above technical solution, the cylinder clamping device realizes the automatic fixing of the pedal motor, reduces manual operation, is safer, and the rubber pad prevents the clamping parts from damaging the pedal motor housing during the clamping process.

[0020] Optionally, the load input shaft is provided with a connecting tube, which is used to be sleeved on the output shaft of the pedal motor that passes through the detection hole. The connecting tube is provided with an output shaft connector, which is used to press the output shaft of the pedal motor against the inner wall of the connecting tube so that the connecting tube is connected to the output shaft of the pedal motor.

[0021] By adopting the above technical solution, the connecting pipe and output shaft clamping device provide a connection method that can adapt to different shaft diameters, enhancing the versatility of the motor detection device. Furthermore, the output shaft clamping device can ensure effective torque transmission and prevent slippage from affecting the accuracy of load simulation.

[0022] Optionally, the detection chamber is equipped with a telescopic cylinder on its exterior, which is used to open and close the detection chamber; the inner wall of the detection chamber is provided with sound-absorbing cotton, which is used to prevent external noise from affecting the detection results.

[0023] By adopting the above technical solutions, the telescopic cylinder realizes the automatic opening and closing of the detection chamber, improving the convenience of operation and the level of automation. The sound-absorbing cotton can effectively isolate external noise and ensure that the data collected by the sound sensor is accurate enough.

[0024] Optionally, the detection frame is equipped with a leakage current cylinder, and the telescopic shaft of the leakage current cylinder is connected to the leakage current detection probe to control the leakage current detection probe to contact the pedal motor.

[0025] By adopting the above technical solution, the leakage current cylinder controls the leakage current detection probe to automatically contact the pedal motor, avoiding safety hazards and errors caused by manual operation and improving the reliability of leakage current detection.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. Compared to traditional testing devices that can only judge the quality of a motor by detecting its sound, this application uses a terminal block, a sound sensor, a Hall sensor, a leakage current detection probe, and a load sensor to detect the voltage, current, sound, Hall value, leakage current, and performance parameters of the pedal motor under load. Furthermore, the programmable logic controller can determine the fault location of the pedal motor based on the detection results. 2. The mounting plate provides a stable foundation for the bracket and testing frame, reducing vibration interference. The sound sensor is located close to the testing frame, which improves the signal-to-noise ratio of the sound signal and enhances the sensitivity of sound detection of the pedal motor. 3. The detection hole and positioning pin ensure that the output shaft of the motor is aligned with the input shaft of the load, avoiding installation deviations from affecting the detection results. In addition, the detection hole and positioning pin can quickly fix the pedal motor, improving the detection efficiency. 4. The cylinder clamping device automatically fixes the pedal motor, reducing manual operation and making it safer. The rubber pad prevents the clamping parts from damaging the pedal motor housing during the clamping process. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of a motor detection device from a first angle according to an embodiment of this application; Figure 2This is a schematic diagram of the structure of a motor detection device from a second angle according to an embodiment of this application; Figure 3 This is a structural schematic diagram of a motor detection device from a third angle according to an embodiment of this application; Figure 4 yes Figure 3 Enlarged view of area A in the middle; Figure 5 This is a schematic diagram of the structure of a motor detection device from a fourth angle according to an embodiment of this application; Figure 6 This is a detection process of a motor detection device according to an embodiment of this application.

[0028] Explanation of reference numerals in the attached drawings: 10. Detection chamber; 11. Telescopic cylinder; 12. Sound-absorbing cotton; 13. Load hole; 20. Detection frame; 21. Detection hole; 22. Positioning pin; 23a. Clamping cylinder; 23b. Clamping component; 23c. Rubber pad; 24. Leakage current cylinder; 31. Terminal block; 32. Sound sensor; 33. Hall sensor; 34. Leakage current detection probe; 35. Load sensor; 40. Load device; 41. Load input shaft; 42. Connecting pipe; 42a. Output shaft connector; 50. Bracket; 61. Microphone; 62. Amplifier; 70. Mounting plate. Detailed Implementation

[0029] The following is in conjunction with the appendix Figure 1-6 This application will be described in further detail.

[0030] This application discloses a motor testing device.

[0031] Figure 1 This is a schematic diagram of the structure of a motor detection device from a first angle according to an embodiment of this application. Figure 2 This is a structural schematic diagram of a motor detection device according to an embodiment of this application from a second angle. Figure 1 The motor detection device described in the text does not have a pedal motor installed. Figure 2 The motor detection device described herein is equipped with the pedal motor. (Refer to...) Figure 1 and Figure 2 The motor testing device includes a testing chamber 10, a testing frame 20, multi-dimensional testing elements, a support 50, a loudspeaker, a mounting plate 70, and a programmable logic controller (PLC). The testing chamber 10 is typically made of aluminum alloy, which has good mechanical strength and corrosion resistance, effectively supporting the weight of the testing frame 20, the support 50, and other components. Furthermore, the high density of aluminum alloy helps to isolate external noise and improves testing accuracy.

[0032] The mounting plate 70 is disposed at the inner bottom of the testing chamber 10. The testing frame 20 and the bracket 50 are fixed on the mounting plate 70. The testing frame 20 is used to place the pedal motor. The multi-dimensional detection element is disposed inside the testing chamber 10 and is used to detect various parameters of the pedal motor. The amplification device is disposed on the bracket 50 and outside the testing chamber 10. The amplification device is used to transmit the sound of the pedal motor running inside the testing chamber 10 to the outside of the testing chamber 10. The programmable logic controller is disposed outside the testing chamber 10. The programmable logic controller is used to detect various parameters of the pedal motor and determine the overall performance and fault location of the pedal motor based on the various parameters of the pedal motor.

[0033] The external side of the testing chamber 10 is equipped with a telescopic cylinder 11, which is used to open and close the testing chamber 10. The telescopic cylinder 11 is generally a thin-type cylinder, which has the advantages of small size, moderate stroke, good dynamic stability, and suitability for installation in confined spaces, and can meet the opening and closing requirements of the testing chamber 10. Sound-absorbing cotton 12 is provided on the inner wall of the testing chamber 10, which is used to isolate the influence of external noise on the testing results. The sound-absorbing cotton 12 is generally made of polyester fiber, which has good sound absorption effect, and the polyester fiber material is lightweight and flexible, making it easy to install on the inner wall of the testing chamber 10. In addition, it can also provide a certain degree of heat insulation, helping to maintain a stable temperature inside the testing chamber 10, providing a stable environment for the testing of the pedal motor.

[0034] The testing frame 20 is provided with a testing hole 21 and a positioning pin 22. The testing hole 21 is for the output shaft of the pedal motor to pass through, and the positioning pin 22 is used to engage with the positioning hole on the pedal motor to fix the pedal motor.

[0035] The amplification device includes a microphone 61 and a speaker 62. The microphone 61 is mounted on the bracket 50 and can collect the sound inside the detection chamber 10. The speaker 62 is located outside the detection chamber 10 and is electrically connected to the microphone 61 to play the sound collected by the microphone 61.

[0036] Figure 2 This is a schematic diagram of the structure of a motor detection device according to an embodiment of this application from a second angle. Figure 3 This is a structural schematic diagram of a motor detection device from a third angle according to an embodiment of this application. Figure 4 yes Figure 3 Enlarged diagram of area A in the middle, Figure 5 This is a structural schematic diagram of a motor detection device according to an embodiment of this application from a fourth angle. Figure 2 , Figure 3 , Figure 4 and Figure 5 The pedal motor is installed on all of the motor testing devices described herein. (Refer to...) Figure 2 , Figure 3 , Figure 4 and Figure 5 The motor testing device further includes a load device 40, which is disposed outside the testing chamber 10. The testing chamber 10 has a load hole 13, and the load device 40 has a load input shaft 41. The load hole 13 allows the load input shaft 41 to pass through, and the load input shaft 41 is used to connect to the output shaft of the pedal motor to apply a load to the pedal motor. The load input shaft 41 has a connecting tube 42, which is used to fit onto the output shaft of the pedal motor that passes through the testing hole 21. The connecting tube 42 is typically made of aluminum alloy, which is lightweight, easy to process, and corrosion-resistant. The connecting tube 42 has an output shaft connector 42a, which is used to press the output shaft of the pedal motor against the inner wall of the connecting tube 42, so that the load device 40 applies a load to the output shaft of the pedal motor through the connecting tube 42.

[0037] The testing frame 20 is also equipped with a cylinder clamping device, which includes a clamping cylinder 23a and a clamping component 23b. The clamping component 23b is provided with a rubber pad 23c. The clamping cylinder 23a is fixed on the testing frame 20, and the clamping component 23b is fixed on the telescopic shaft of the clamping cylinder 23a. The clamping component 23b is used to clamp the pedal motor onto the testing frame 20, and the rubber pad 23c is used for cushioning to prevent the clamping component 23b from damaging the housing of the pedal motor.

[0038] The multi-dimensional detection elements include a terminal block 31, a sound sensor 32, a Hall sensor 33, a leakage current detection probe 34, and a load sensor 35. The terminal block 31 has connecting wires for connecting to the input wires of the pedal motor. The terminal block 31 supplies power to the pedal motor and detects the voltage and current during operation, generating current and voltage signals. The sound sensor 32 is mounted on the bracket 50, near the detection hole 21. The sound sensor 32 can collect the sound of the pedal motor during operation and generate a sound signal. The sound sensor 32 typically uses a silicon-based microphone, which has high sensitivity, effectively capturing weak abnormal sounds during pedal motor operation. It also has advantages such as durability, vibration resistance, and interference resistance, making it suitable for the industrial environment where the motor detection device is located.

[0039] The Hall sensor 33 is disposed on the clamping member 23b. The Hall sensor 33 can detect the Hall value when the pedal motor is working to determine the speed of the pedal motor and generate a speed signal. The Hall sensor 33 generally uses semiconductor materials such as silicon (Si), gallium arsenide (GaAs), or indium arsenide (InSb). Silicon has low cost, good compatibility, and is suitable for mass production, and has excellent response to weak magnetic fields; gallium arsenide has high sensitivity and fast response, and is suitable for high-precision scenarios; indium arsenide has extremely high sensitivity and can provide a clear signal under extremely weak magnetic fields, making it suitable for high-precision detection environments.

[0040] The detection frame 20 is equipped with a leakage current cylinder 24, and the leakage current detection probe 34 is mounted on the telescopic shaft of the leakage current cylinder 24. The leakage current cylinder 24 can control the leakage current detection probe 34 to contact the connecting pipe 42, thereby detecting the leakage current of the pedal motor and generating a leakage current signal. The leakage current detection probe 34 is typically made of a combination of semiconductor materials (such as silicon or gallium arsenide) and insulating materials (such as ceramic or polytetrafluoroethylene), and may also have an additional metal shielding layer. This design can effectively sense weak leakage current signals, with high sensitivity and fast response. The insulating material provides safety protection, avoiding secondary leakage current or false alarms due to contact with high-voltage components, and the metal shielding layer can isolate electromagnetic interference, ensuring the reliability of the detection signal.

[0041] The detection chamber 10 is also equipped with a load sensor 35, which is electrically connected to the load device 40 to read the load value applied by the load device 40 to the output shaft of the pedal motor and generate a load signal.

[0042] The programmable logic controller is electrically connected to the sound sensor 32, the Hall sensor 33, the leakage current detection probe 34, and the load sensor 35 via the terminal block 31 to read the current signal, the voltage signal, the sound signal, the speed signal, the leakage current signal, and the load signal of the pedal motor.

[0043] Figure 6 This is a detection process of a motor testing device according to an embodiment of this application, referred to as follows. Figure 6 The detection process of a motor detection device according to an embodiment of this application is as follows: S10, The multi-dimensional detection element detects the pedal motor.

[0044] S20. The multi-dimensional detection element generates a detection signal based on the detection result.

[0045] S30. The programmable logic controller determines the fault location of the pedal motor based on the detection signal.

[0046] The testing process of the motor testing device is described in detail below.

[0047] In step S10, the multi-dimensional detection element detects the pedal motor. The multi-dimensional detection element includes the terminal block 31, the sound sensor 32, the Hall sensor 33, the leakage current detection probe 34, and the load sensor 35. The terminal block 31 detects the current and voltage of the pedal motor. The sound sensor 32 detects the sound of the pedal motor. The Hall sensor 33 detects the Hall value of the pedal motor. The leakage current detection probe 34 detects the leakage current of the pedal motor. The load sensor 35 detects the load value of the pedal motor.

[0048] In step S20, the multi-dimensional detection element generates a detection signal based on the detection result. The terminal block 31 generates the current signal and the voltage signal based on the detected current and voltage of the pedal motor. The sound sensor 32 generates the sound signal based on the detected sound of the pedal motor. The Hall sensor 33 generates the Hall signal based on the detected Hall value of the pedal motor. The leakage current detection probe 34 generates the leakage current signal based on the detected leakage current of the pedal motor. The load sensor 35 generates the load signal based on the detected load value of the pedal motor.

[0049] In step S30, the programmable logic controller (PLC) determines the fault location of the pedal motor based on the detection signal. The following example explains how the PLC determines the fault location of the pedal motor based on the detection results of the multi-dimensional detection elements.

[0050] Example 1: When the sound sensor 32 detects noise in the first frequency range (6kHz-8kHz) emitted by the pedal motor, the Hall sensor 33 detects that the speed of the pedal motor fluctuates at the first angle (120°), and the waveform of the current on the terminal block 31 shows periodic spikes at the first angle (120°), the programmable logic controller can determine that there is a short circuit problem in the winding of a certain magnetic pole inside the pedal motor.

[0051] Example 2: When the load device 40 applies a standard load (e.g., 5 N·m) to the output shaft of the pedal motor through the connecting pipe 42, and the Hall sensor 33 detects that the speed of the pedal motor drops from the standard speed (3000 rpm) to 2700 rpm (a decrease of 10%, exceeding the allowable range of ±5%), and the current of the pedal motor increases from the standard current (1.5A) to 2.2A, the programmable logic controller can determine that the pedal motor has a bearing friction problem.

[0052] Example 3: The sound sensor 32 detects that the sound signal of the pedal motor fluctuates by more than 5dB in the 500Hz-1.5kHz frequency band, and the voltage waveform shows high-frequency glitches with a frequency greater than 50kHz and an amplitude greater than 0.5V at the same time point. Based on this information, the programmable logic controller can determine that the commutator surface of the pedal motor is not smooth, has an oxide layer, the brushes are worn, or the spring pressure of the brushes is insufficient, resulting in drastic changes in contact resistance.

[0053] Example 4: The Hall sensor 33 detects an abnormal speed of the pedal motor (e.g., a drop from the standard speed of 3000 rpm to below 2500 rpm or a fluctuation exceeding ±10%), and at the same time, the leakage current detection probe 34 detects that the leakage current of the pedal motor exceeds the safety threshold of 0.5mA. The programmable logic controller can then determine that there is a fault in the magnetic circuit or winding of the pedal motor.

[0054] Example 5: The leakage detection probe 34 detects leakage in the pedal motor (the leakage current reaches 2.5mA, exceeding the safety threshold of 0.5mA). The terminal block 31 shows that the voltage of the pedal motor is normal and there is no current fluctuation. Based on this information, the programmable logic controller can determine that the pedal motor may have problems such as damaged winding insulation varnish, poor shell contact, or moisture intrusion.

[0055] Example 6: The voltage of the pedal motor is stable and normal, but the actual speed of the pedal motor is abnormally high (for example, the standard speed is 3000rpm ±5%, and the actual speed exceeds 3500rpm). The programmable logic controller can determine that the permanent magnet (magnet) in the pedal motor has demagnetized.

[0056] The detection of the sound of the pedal motor is generally achieved by capturing the acoustic signal generated by the friction between the carbon brush and other equipment such as the commutator / slip ring through a noise testing system, and converting the time-domain acoustic signal into frequency-domain spectral features using Fast Fourier Transform (FFT). A spectral difference model between normal and abnormal states is established through statistical analysis of a large number of samples, and finally, the abnormal sound of the carbon brush is quantitatively determined.

[0057] The implementation process of the noise testing system is as follows: S1. Sample library construction.

[0058] S2, Signal preprocessing.

[0059] S3, FFT spectrum conversion.

[0060] S4. Feature spectrum identification.

[0061] S5, Statistical threshold calculation.

[0062] S6, Threshold verification.

[0063] S7, Real-time signal acquisition.

[0064] S8, Feature Matching.

[0065] S9, Decision Output.

[0066] The implementation process of the noise testing system is described in detail below.

[0067] In the main step S1, at least 100 sets of acoustic signals of qualified pedal motors (OK samples) and pedal motors with known carbon brush noise (NG samples) are collected, with a sampling rate of not less than 48kHz, to ensure coverage of acoustic characteristics under different operating conditions (such as the standard speed and load changes).

[0068] In the main step S2, the original audio signal is filtered (to eliminate environmental noise interference, usually using 20Hz-20kHz bandpass filtering), detrending is performed (to remove low-frequency interference such as mechanical vibration), and a windowing function (Hamming window) is applied to improve the accuracy of spectrum analysis.

[0069] In the main step S3, a fast Fourier transform is performed on the preprocessed time-domain signal to decompose the signal into energy distributions of different frequency components, resulting in a spectrum diagram with frequency (Hz) on the horizontal axis and sound pressure level (dB) on the vertical axis.

[0070] In main step S4, through comparative analysis of the spectra of OK / NG samples, analysis of variance (ANOVA) and principal component analysis (PCA) algorithms are used to locate the significant characteristic frequency band of carbon brush noise (usually concentrated in the high-frequency range of 10400Hz-10650Hz, which is related to the carbon brush material and contact pressure). This frequency band is manifested as abnormal peak energy or spectral distortion in NG samples.

[0071] In the main step S5, based on the 3σ principle (99.7% confidence interval under normal distribution), the sound pressure level of the characteristic frequency band of the OK sample is statistically analyzed to determine the upper limit threshold (usually the mean + 3 times the standard deviation).

[0072] In main step S6, the accuracy of the threshold is verified by using an additional OK / NG sample set to ensure that the false positive rate (Type I error / Type II error) is below 0.5%.

[0073] In the main step S7, real-time signal acquisition is performed by acquiring the acoustic signal of the pedal motor during operation through a microphone array (sampling rate 48kHz, dynamic range ≥120dB), and FFT analysis is triggered synchronously (the spectrum is updated every 10ms).

[0074] In the main step S8, the peak sound pressure level and energy integral value of the target frequency band in the real-time spectrum are extracted and compared with the preset threshold.

[0075] In the main step S9, a judgment output is made. If the feature value exceeds the threshold within the detection period, it is judged as NG, triggering an audible and visual alarm and recording the abnormal spectrum; otherwise, it is judged as OK and proceeds to the next round of detection.

[0076] Traditional testing devices can only determine whether a motor is qualified based on its sound or vibration. Qualified motors are used normally, while unqualified motors are recycled. This simple binary judgment cannot truly improve motor production efficiency. However, the motor testing device of this application can accurately determine the fault location of the pedal motor by cooperating with a programmable logic controller and the multi-dimensional detection elements.

[0077] The programmable logic controller (PLC) can also input the performance data of all qualified pedal motors (such as no-load current, load efficiency, noise level, and speed stability) into a database, and then classify the pedal motors, for example, into Class A and Class B. Class A pedal motors have excellent performance and can be matched with high-end vehicles, while Class B motors meet performance standards and can be matched with economy vehicles, thus maximizing the value of the product. Furthermore, when used in pairs (such as the left and right pedal motors in the same vehicle), motors with highly consistent performance parameters can be selected to avoid inconsistent user experience due to performance differences.

[0078] Compared to traditional methods that can only detect the sound and vibration of a pedal motor, the motor testing device described in this application can also trace and improve the motor's manufacturing process. For example, if a batch of pedal motors generally exhibits excessive leakage current, it can be traced back to the possibility that defective insulation materials were used in that batch or that there was a problem with the potting process. If a batch of pedal motors generally exhibits electromagnetic noise at a specific frequency, it can be traced back to whether there was a deviation in the stator winding equipment or the magnetizing equipment.

[0079] The implementation principle of the motor detection device in this application embodiment is as follows: Compared with traditional detection devices that can only judge the quality of the motor by detecting the sound of the motor, this application embodiment uses the terminal block 31, the sound sensor 32, the Hall sensor 33, the leakage detection probe 34, and the load sensor 35 to detect the voltage, current, sound, Hall value, leakage condition, and performance parameters of the pedal motor under load, and generates the voltage signal, the current signal, the sound signal, the Hall signal, the leakage signal, and the load signal. The programmable logic controller can determine the fault location of the pedal motor based on the generated multiple signals.

[0080] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A motor testing device, characterized in that, include: Detection chamber (10); A testing rack (20) is disposed inside the testing chamber (10), and the testing rack (20) is used to place the pedal motor; The multi-dimensional detection components include a terminal block (31), a sound sensor (32), a Hall sensor (33), a leakage current detection probe (34), and a load sensor (35). The terminal block (31) is used to electrically connect to the pedal motor to read the current and voltage of the pedal motor during operation to generate current and voltage signals. The sound sensor (32) is used to detect the sound of the pedal motor during operation to generate a sound signal. The Hall sensor (33) is used to detect the Hall value of the pedal motor during operation to detect the speed of the pedal motor to generate a speed signal. The leakage current detection probe (34) is used to detect the leakage current of the pedal motor to generate a leakage current signal. The load sensor (35) is used to detect the load value of the pedal motor to generate a load signal. A programmable logic controller (PLC) is electrically connected to the terminal block (31), the sound sensor (32), the Hall sensor (33), the leakage current detection probe (34), and the load sensor (35); wherein the PLC is configured to perform the following actions: when the sound signal determines that the pedal motor emits a sound within a first frequency range, the speed signal determines that the pedal motor experiences speed fluctuations at a first angle, and the current signal determines that the waveform of the pedal motor's current exhibits glitches at the first angle, the PLC determines that the winding of the internal magnetic poles of the pedal motor is faulty; when the load signal determines that the speed of the pedal motor under standard load is lower than the standard speed, and the current signal determines that the current of the pedal motor is higher than the standard current, the PLC determines that the pedal motor experiences bearing friction.

2. The motor testing device according to claim 1, characterized in that, The first frequency range is 6kHz to 8kHz, the first angle is 120°, the standard load is 5N·m, the standard speed is 3000rpm, and the standard current is 1.5A.

3. The motor testing device according to claim 1, characterized in that, It also includes a bracket (50) and a mounting plate (70), the mounting plate (70) being disposed at the bottom of the detection chamber (10), the detection frame (20) and the bracket (50) being fixed on the mounting plate (70), and the sound sensor (32) being disposed on the bracket (50) near the detection frame (20).

4. The motor testing device according to claim 3, characterized in that, It also includes a sound amplification device, which includes a microphone (61) and a loudspeaker (62). The microphone (61) is mounted on the bracket (50) and is used to collect the sound of the pedal motor running. The loudspeaker (62) is mounted outside the detection chamber (10) and is electrically connected to the microphone (61). The loudspeaker (62) is used to play the sound collected by the microphone (61).

5. The motor testing device according to claim 1, characterized in that, It also includes a load device (40), which is disposed outside the detection chamber (10). The load device (40) is provided with a load input shaft (41), which is used to connect to the output shaft of the pedal motor to apply a load on the output shaft of the pedal motor. The load sensor (35) is electrically connected to the load device (40) to detect the load value of the pedal motor.

6. The motor testing device according to claim 5, characterized in that, The testing frame (20) is provided with a testing hole (21) and a positioning pin (22). The testing hole (21) is for the output shaft of the pedal motor to pass through, and the positioning pin (22) is used to fix the pedal motor.

7. The motor testing device according to claim 6, characterized in that, The testing frame (20) is equipped with a cylinder clamping device, which includes a clamping cylinder (23a) and a clamping component (23b). The clamping cylinder (23a) is mounted on the testing frame (20), and the clamping component (23b) is connected to the telescopic shaft of the clamping cylinder (23a). The clamping component (23b) is used to clamp the pedal motor onto the testing frame (20). The clamping component (23b) is also equipped with a rubber pad (23c), which is used to prevent the clamping component (23b) from damaging the pedal motor.

8. The motor testing device according to claim 6, characterized in that, The load input shaft (41) is provided with a connecting tube (42), which is used to be sleeved on the output shaft of the pedal motor that passes through the detection hole 21. The connecting tube (42) is provided with an output shaft connector (42a), which is used to press the output shaft of the pedal motor and the inner wall of the connecting tube (42) to connect the connecting tube (42) with the output shaft of the pedal motor.

9. The motor testing device according to claim 1, characterized in that, The detection chamber (10) is provided with a telescopic cylinder (11) on the outside, which is used to open and close the detection chamber (10); the inner wall of the detection chamber (10) is provided with sound-absorbing cotton (12), which is used to avoid external noise from affecting the detection results.

10. The motor testing device according to claim 1, characterized in that, The detection frame (20) is equipped with a leakage current cylinder (24), and the telescopic shaft of the leakage current cylinder (24) is connected to the leakage current detection probe (34) to control the leakage current detection probe (34) to contact the pedal motor.

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