Motor test system based on sliding frame and guide plate

Abstract

The invention discloses a motor testing system based on a sliding frame and a guide plate, and relates to the field of motor testing. The test rack module is welded by a Q235B steel plate and is fixed by an expansion bolt; the sliding frame module is composed of a sliding base, a connecting beam and a supporting platform and is connected with a spring for buffering. The guide plate module comprises symmetrical guide plates which are finely adjusted through a sliding block and an adjusting assembly. The motor fixing module comprises an L-shaped baffle, a spring and a clamping bolt, and a built-in pressure sensor is used for measuring clamping force; an output shaft of the test driving module is connected with a torque sensor and a tested motor, and is provided with a controller and an acquisition module; the data acquisition module synchronously acquires multiple parameters, and a report is generated through a touch screen display, storage and software setting process; the buffering and damping module reduces noise and vibration and corrects the level through a gasket, a foot pad and a sizing block, and stable operation of the device is guaranteed. The method is fast adaptive to multi-model motor testing, optimizes the traditional technology, improves the detection efficiency and accuracy, guarantees the testing stability and reliability, and meets the batch testing requirements.

Description

Technical Field

[0001] This invention relates to the field of motor testing technology, and in particular to a motor testing system based on a sliding frame and a guide plate. Background Technology

[0002] Existing drive motor testing simulation devices typically fix the motor directly to the corresponding structure during installation, making subsequent motor position adjustments inconvenient. This is especially problematic when testing different motors, as slight differences in the height of the motor output shaft can prevent accurate connection between the output shaft and the power shaft of the testing mechanism. This fixing method not only makes motor replacement and calibration cumbersome and time-consuming but also easily affects the accuracy of test data due to installation deviations, resulting in low efficiency when testing multiple motor models in batches.

[0003] Current testing equipment suffers from limitations in its technical module design, lacking flexible adjustment and limiting mechanisms. From a technical perspective, the test frame structure layout is inadequate, the fit between the support blocks, tester, and the motor under test is insufficient, and the support adjustment mechanism has poor adaptability to different motor specifications. Furthermore, the clamping force of the clamping mechanism is difficult to control precisely; excessively loose clamping causes motor wobbling during testing, while excessively tight clamping damages the motor, affecting testing stability and equipment lifespan.

[0004] With the diversification of drive motor models, traditional testing systems struggle to meet the demands for efficient and accurate testing. Existing equipment cannot quickly switch between testing multiple motor models, suffers from insufficient coordination between modules, and lacks unified data acquisition and analysis capabilities, resulting in complex testing processes and difficulties in data traceability. These issues restrict the efficiency and quality of motor testing, necessitating a technical system that can adapt to multiple motor models and possesses precise adjustment and stable testing capabilities. Summary of the Invention

[0005] The present invention proposes a motor testing system based on a sliding frame and a guide plate to solve the problems mentioned in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a motor testing system based on a sliding frame and a guide plate, comprising:

[0007] Test frame module: It is made of Q235B steel plate and welded. The bottom is fixed to the ground by 6 sets of M12 expansion bolts. The left column of the frame is welded with a support base, and the right crossbeam is equipped with two parallel guide rails. Limit blocks are set at both ends of the guide rails. Reinforcing ribs are welded on the inside of the frame.

[0008] The sliding frame module consists of a sliding seat, a connecting beam, and a support platform. The sliding seat is fitted with the frame guide rail and a wear-resistant slider is installed at the bottom. The connecting beam is made of rectangular steel pipe and connected to the sliding seat by bolts. The support platform is machined with T-slots to fix the motor. Two first springs are connected to the frame on the right side of the sliding frame.

[0009] Guide plate module: The left and right guide plates are symmetrically arranged, and the bottom is connected to the sliding frame T-slot by a slider. The adjustment component can make horizontal fine adjustments to the guide plates by adjusting the screw and handwheel; the right side of the left guide plate is connected to the push plate by 4 sets of third springs.

[0010] Motor fixing module: The L-shaped baffle is connected to the sliding frame via a slide rail, and the bottom is connected to the sliding frame via a second spring; the clamping bolt is installed on the top of the L-shaped baffle, and a nylon pressure block is provided at the end for vertical adjustment of the clamping height; the module has a built-in pressure sensor to monitor the clamping force in real time;

[0011] Test drive module: The test motor is fixed to the support base on the left side of the frame by a flange. The output shaft is connected to the torque sensor. The other end of the sensor is connected to the motor under test through a flexible coupling. The coupling is covered with a protective cover. The test motor controller communicates with the data acquisition module.

[0012] Data acquisition module: Employs an industrial-grade data acquisition card to synchronously acquire torque, speed, current, and voltage parameters; features a touchscreen display for test curves and data; has a built-in storage unit; supports data export; and allows the system software to set test procedures and automatically generate test reports.

[0013] Buffer and shock absorption module: shock-absorbing pads are installed at the contact points between the sliding frame and the guide rail, shock-absorbing feet are installed at the bottom of the test motor, and anti-vibration pads are installed between the frame and the ground.

[0014] Furthermore, it also includes:

[0015] Motor model identification module: A camera is installed directly above the sliding bracket to identify the motor nameplate information; an RFID reader reads the motor's built-in tag and compares it with the image recognition result.

[0016] Automatic alignment module: A laser alignment instrument is used, with the transmitter fixed to the end of the test motor shaft and the receiver installed on the end of the motor shaft under test. The alignment data is transmitted to the controller, and the sliding frame position and guide plate height are adjusted to automatically align. The alignment completes and triggers the clamping signal.

[0017] Furthermore, it also includes:

[0018] Environmental simulation module: Heating devices and fans are installed around the test area, equipped with temperature and humidity sensors to monitor environmental parameters in real time;

[0019] Safety protection module: Equipped with an infrared grating, the motor power is cut off when a human enters the test area; the test bench is surrounded by protective railings, and the protective railing doors are equipped with safety interlock switches; the system has built-in overload protection and over-temperature protection.

[0020] Furthermore, the formula for calculating the motor efficiency of the data acquisition module is as follows: Where η is the motor efficiency, T is the output torque, n is the speed, and P... in Input power; voltage and current signals are filtered for noise by a second-order Butterworth low-pass filter, and the torque signal has its DC drift removed; input power P in The instantaneous power integral calculation deducts the losses of the test motor itself; the efficiency correction coefficient is automatically switched, the calculation results are compared with the preset efficiency range, an early warning is issued when the threshold is exceeded, and abnormal data points are stored.

[0021] Furthermore, the automatic centering module position adjustment is calculated using the formulas ΔX = L·sinθ and ΔZ = L·(1-cosθ), where ΔX is the X-axis adjustment, ΔZ is the Z-axis adjustment, L is the distance between the two axes, and θ is the centering deviation angle. The laser centering instrument uses dual laser beams for measurement with a sampling frequency of 10Hz. After calculating ΔX and ΔZ, the sliding frame is driven by a servo motor to move according to the adjustment amount, and the movement process uses S-shaped acceleration and deceleration. The Z-axis is adjusted by an electric push rod at the bottom of the guide plate. After centering is completed, the system automatically records the adjustment amount and stores it in association with the motor model.

[0022] Furthermore, the temperature compensation formula for the environmental simulation module is T. comp =T meas +K·(T amb -25), where T comp To compensate for the temperature afterward, T meas For temperature measurement by the sensor, K is the temperature coefficient, and T is the temperature coefficient. amb The ambient temperature is used; the temperature sensor is a PT100 platinum resistance thermometer, which collects data every 1 second; when the rate of change of ambient temperature exceeds the threshold, the K value automatically increases, and the preheating program is automatically started in the low temperature range.

[0023] Furthermore, dust covers are installed on both sides of the sliding seat of the sliding frame module, and the sliding seat and guide rail are automatically lubricated periodically; the two ends of the first spring are connected by fisheye bearings, the surface of the support platform is chrome-plated, the position of the sliding frame is fed back by a closed loop grating ruler, the connecting bolts between the connecting beam and the sliding seat are made of anti-loosening nuts and thread-locking adhesive, and the edge of the support platform is provided with a retaining edge.

[0024] Furthermore, the guide plate module adjusting screw is equipped with a locking nut, which is locked after adjustment; the third spring is made of piano wire, and a displacement sensor is installed on the inner side of the push plate to monitor the fit between the motor and the push plate; a level is installed on the top of the guide plate, and the left and right guide plates are calibrated by a laser interferometer; lithium-based grease is applied between the bottom slider of the guide plate and the T-slot.

[0025] Furthermore, the motor model identification module uses a 6mm fixed-focus lens and is equipped with a ring LED fill light; the OCR recognition algorithm supports fuzzy character recognition and tilt correction; the RFID tag is passive and is installed on the non-load-bearing surface of the motor; the recognition result automatically calls the corresponding test program; when the recognition fails, the system automatically switches to manual input mode, displays a list of commonly used motor models on the screen, and records the reason for the failure.

[0026] Furthermore, the infrared grating of the safety protection module consists of 8 sets of transmitter-receiver pairs, the guardrail is made of Q235 steel pipe welded and the surface is powder coated; the safety interlock switch adopts a dual-channel design, and the system emergency stop button is installed on the operation panel and the side of the guardrail gate; the over-temperature protection adopts dual-sensor redundant detection, and triggers a sensor fault alarm when the temperature difference exceeds the threshold; the overload protection is set with three-level thresholds, responding step by step.

[0027] Compared with existing technologies, the beneficial effects of this invention are:

[0028] By combining the sliding bracket and guide rail, along with the adjustable design of the guide plate, it can quickly adapt to the installation requirements of different motor models, achieving precise docking of the output shaft without repeated disassembly, thus significantly improving testing efficiency.

[0029] The system's modules work collaboratively to enhance testing stability and reliability. The spring-cushioned design of the sliding frame reduces impact during motor installation, protecting precision components such as the tester. The clamping and limiting mechanism, through reasonable clamping force control, ensures stable motor fixation while preventing damage from over-clamping. The comprehensive test data acquisition and analysis functions provide a reliable basis for motor performance evaluation.

[0030] The traditional testing process has been optimized to enhance compatibility with multiple motor models, making the testing process simpler and more flexible. Simultaneously, the rational structural design and precise component fitting extend the equipment's lifespan and reduce maintenance costs, offering significant advantages in batch testing scenarios and meeting the practical needs of efficient and accurate testing of drive motors. Attached Figure Description

[0031] Figure 1 This is a schematic block diagram of a motor testing system based on a sliding frame and a guide plate proposed in this invention;

[0032] Figure 2 A diagram showing the comparison of test times for different motor models;

[0033] Figure 3 This is a schematic diagram comparing the accuracy of centering deviation.

[0034] Figure 4 A diagram illustrating the comparison of environmental temperature compensation effects;

[0035] Figure 5This is a diagram comparing equipment maintenance costs.

[0036] Figure 6 This is a diagram comparing the response times of safety protection measures. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] 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.

[0039] 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 indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The invention will now be described in further detail with reference to the accompanying drawings.

[0040] Reference Figures 1 to 6 A motor testing system based on a sliding frame and guide plate, comprising:

[0041] Test rack module: Constructed from Q235B steel plates with moderate yield strength, good plasticity, and weldability, ensuring overall rigidity and stability. The overall dimensions of the rack are precisely controlled at 1800mm × 1000mm × 1500mm. The bottom is fixed to the ground with six sets of M12 expansion bolts arranged in a matrix with a strict spacing of 600mm, ensuring a reliable connection between the rack and the ground, distributing the load during equipment operation, and preventing overturning and displacement. The left-side column of the rack has a 20mm thick support base welded on it. The thick plate structure enhances the load-bearing capacity of the support base and can stably bear the force of the test components. The right-side crossbeam is equipped with two SBR30 parallel guide rails, each 1200mm long and 500mm apart. The high-precision linear motion characteristics provide smooth guidance for sliding components. 30mm thick polyurethane limit blocks are installed at both ends of the guide rails. Polyurethane has good buffering and energy absorption properties, effectively preventing overtravel of sliding components and protecting the guide rails and related components. The inner side of the frame is welded with reinforcing ribs of 50mm×50mm, which are made of equilateral angle steel or custom-made steel plate bending parts and connected to the frame body through full welding process, which greatly improves the frame's resistance to deformation. According to the test, the static load deformation is ≤0.3mm / m. That is, on each meter of frame length, when subjected to the rated static load, the deformation is controlled within a very small range, ensuring the geometric accuracy of the frame during the test and providing a solid structural foundation for the accuracy of the test data.

[0042] The sliding frame module consists of a sliding seat, a connecting beam, and a support platform. The sliding seat is a high-precision adapter component that mates with the frame guide rail, with the clearance strictly controlled to ≤0.1mm to ensure precise and smooth sliding. The wear-resistant slider installed at the bottom is made of PTFE, possessing excellent self-lubricating properties and low friction characteristics, with a friction coefficient ≤0.02, effectively reducing energy loss and component wear during sliding and extending the module's service life. The connecting beam is made of rectangular steel tubing with specifications of 80mm×50mm×3mm. The rectangular cross-section optimizes stress distribution while ensuring structural strength. It is rigidly connected to the sliding seat via bolts, with a pre-tightening torque set at 15N·m to ensure a tight connection, prevent loosening during operation, and maintain overall structural stability. The support platform surface is machined with T-slots, 12mm wide and 100mm apart. This standardized slot design facilitates the fixing requirements of different motor models. Using T-bolts and other accessories, motor installation and positioning are quickly completed, improving equipment assembly flexibility. Two first springs are connected between the right side of the sliding frame and the frame. The springs have a diameter of 8mm, a free length of 300mm, and a stiffness of 5N / mm. According to Hooke's Law, the springs provide buffering force when the sliding frame is subjected to external force, absorbing vibration and impact, and ensuring the stable operation of the module.

[0043] Guide Plate Module: Composed of a left guide plate, a right guide plate, and an adjustment assembly, the left and right guide plates are symmetrically arranged, with a spacing that can be flexibly adjusted within the range of 100-500mm to accommodate different sized workpieces. The main body of the guide plate is made of 45# steel, with a hardness of HB220 after heat treatment, possessing good strength and wear resistance, and can withstand the impact and friction during long-term guiding operations. A 5mm thick rubber pad with a Shore hardness of 60A is attached to the inner side, which not only buffers the rigid contact during guiding but also increases the friction between the rubber pad and the workpiece, improving guiding stability and preventing workpiece deviation. The bottom of the guide plate is connected to the sliding frame T-slot via a slider, which is convenient to assemble and allows for sliding along the slot. The adjustment assembly includes a 5mm lead adjusting screw and a 100mm diameter handwheel. The ergonomic design of the handwheel facilitates operation. Through screw transmission, utilizing the screw pitch characteristics, high-precision fine adjustment of ±0.5mm in the horizontal direction of the guide plate can be achieved to meet the requirements of fine guiding. The left guide plate is connected to the push plate via four sets of third springs on its right side. The springs are 3mm in diameter and 100mm in free length, providing elastic support and cushioning for the push plate. The push plate measures 150mm × 100mm × 10mm and has a 0.5mm deep anti-slip texture on its surface to increase the friction with the workpiece, stably pushing the workpiece during the guiding process and ensuring a smooth processing flow.

[0044] The motor fixing module consists of an L-shaped baffle, second springs, clamping bolts, and a pressure sensor, forming a fixing system that combines elastic buffering with precise clamping. The L-shaped baffle, the main load-bearing component, is 200mm high and 10mm thick, precision-machined from high-strength steel. It connects to the sliding frame via a slide rail, which employs a silent linear guide structure and a high-precision slider, ensuring sliding resistance ≤5N. This guarantees smooth baffle sliding and excellent guiding accuracy, ensuring consistent motor installation position. Two sets of second springs are connected to the bottom of the baffle. These springs are 5mm in diameter and 150mm in free length, selected through rigorous mechanical testing. When the motor vibrates during operation, they absorb impact through elastic deformation, attenuating vibration transmission and preventing vibration accumulation that could affect the overall stability of the equipment. The springs are made of fatigue-resistant alloy, ensuring long-term reliability. The clamping bolts are M12×150mm, installed on the top of the L-shaped baffle, and feature a trapezoidal thread design, providing good self-locking and load-bearing capacity. The end nylon clamping block has a diameter of 30mm. The nylon material has moderate hardness, which avoids damage to the motor housing during clamping while increasing contact friction and improving clamping reliability. The vertical adjustment range is 0-100mm, adapting to motors of different heights. The module has a built-in pressure sensor with a range of 0-500N and an accuracy of ±2%FS. Based on the piezoresistive sensing principle, it collects clamping force data in real time, converts and transmits the signal, and feeds it back to the control system to achieve dynamic monitoring and adjustment of the clamping force. This ensures that the motor is always in a stable and safe clamping state, preventing problems such as motor displacement and increased vibration caused by abnormal clamping force.

[0045] Test Drive Module: The test motor is a 1.5kW variable frequency speed control motor with a speed of 0-3000rpm. It is fixed to the left support base of the frame with bolts via a high-strength flange. The connection surface between the flange and the support base is milled to ensure flatness, and precise alignment is achieved with locating pins to ensure the coaxiality of the motor output shaft and subsequent transmission components, providing a stable power source for testing. The output shaft is connected to a torque sensor with a range of 0-100N·m and an accuracy of ±0.2%FS. A high-precision strain gauge attached to the elastic shaft converts the strain generated by the torque into an electrical signal. After processing by the signal conditioning circuit, high-precision torque measurement is achieved, accurately capturing the torque changes during the operation of the motor under test. The other end of the torque sensor is connected to the motor under test via an elastic coupling. The elastic coupling adopts a metal diaphragm structure, which has the ability to compensate for radial deviation ±0.2mm, angular deviation, and axial deviation. During power transmission, it effectively absorbs the installation coaxiality error between the test motor and the motor under test, avoiding additional stress caused by misalignment, which could damage the equipment and affect the test accuracy. The coupling is covered with a 5mm thick transparent acrylic protective cover for easy observation of its operating status and to prevent parts from falling off and causing safety hazards during high-speed operation. The test motor controller supports vector control, allowing for fine-tuning of motor parameters such as speed and torque. It communicates with the data acquisition module via an RS485 interface at a baud rate of 9600bps, following the Modbus-RTU communication protocol. This enables the issuance of control commands and the uploading of test data, establishing a closed-loop test control link. This ensures the automation of the testing process and the real-time and accurate acquisition of data, providing reliable data support for motor performance analysis.

[0046] Data Acquisition Module: Utilizing an industrial-grade acquisition card with 16-bit resolution, it accurately quantifies analog signals. A 1kHz sampling frequency ensures thousands of data captures per second, simultaneously acquiring parameters such as torque, speed, current, and voltage. Equipped with a 10.1-inch touchscreen display panel with a 1280×800 resolution and IPS full-viewing-angle technology, along with a 1Hz refresh rate, it renders test curves and data in real time. It supports multi-finger touch zooming and curve dragging for tracing, allowing operators to quickly locate abnormal data nodes. The built-in 32GB storage unit, based on a high-speed flash memory architecture, employs both circular storage and event-marked storage modes to handle continuous recording of test data over long periods. It exports CSV files via a USB 2.0 interface, compatible with analysis software such as Excel and Origin, enabling offline deep data mining. The system software integrates a customized testing process, based on a modular programming framework, supporting test sequence arrangement for multiple scenarios such as constant speed (±0.1rpm closed-loop control) and variable load. An automatic test report generation engine, embedded with intelligent data analysis algorithms, can extract key indicators such as peak torque, efficiency curves, and voltage fluctuations, generating standardized reports containing data tables, trend curves, and performance evaluations. This facilitates rapid motor performance assessment, streamlining the entire "collection-analysis-application" process and providing an efficient and intelligent digital solution for motor testing.

[0047] Buffer and vibration damping module: Nitrile rubber damping pads, 5mm thick, are installed at the contact points between the sliding frame and the guide rail. Nitrile rubber possesses excellent wear resistance, oil resistance, and elastic recovery properties. Its dynamic elastic modulus is adapted to the contact mechanical environment between the sliding frame and the guide rail, absorbing high-frequency vibration energy generated during sliding through microscopic elastic deformation. Vibration damping pads, 50mm in diameter, made of composite rubber material with a hardness of 50 Shore A, are installed at the bottom of the test motor. These pads are specially formulated with an internal microporous damping structure. When the motor vibrates, the micropores convert vibration energy into heat energy through a compression-rebound process, achieving a vibration attenuation rate ≥80%. This significantly reduces the transmission of motor vibration to the frame and surrounding components, avoiding equipment resonance problems caused by vibration coupling and ensuring the accuracy of test data acquisition. Anti-vibration pads, adjustable from 0-10mm, are installed between the frame and the ground. These pads are made of cast steel with a rust-proof surface and integrate a high-precision leveling mechanism. By rotating the adjusting bolts to change the height of the shim supports, and using a level (accuracy 0.02mm / m), the frame's levelness is calibrated to ≤0.1mm / m. Ensuring horizontal installation accuracy prevents uneven stress caused by equipment tilt, reduces vibration sources at the equipment foundation level, and provides a stable installation benchmark for precise coordination of each module, ensuring the stability of the entire testing system and the reliability of test results.

[0048] This invention also includes the following modules:

[0049] Motor model identification module: includes a high-definition camera (2 megapixels, 25fps) and an RFID reader (operating frequency 13.56MHz). The camera is mounted directly above the sliding bracket (500mm away) and can identify motor nameplate information (identification accuracy ≥98%). The RFID reader reads the motor's built-in tag (stores motor parameters: power, speed, shaft diameter) and compares it with the image recognition result (comparison time ≤1s).

[0050] Automatic centering module: A laser centering instrument (measurement accuracy ±0.01mm) is used. The transmitter is fixed to the test motor shaft end, and the receiver is installed on the test motor shaft end. The centering data is transmitted to the controller. Automatic centering is achieved by adjusting the position of the sliding frame (X-axis) and the height of the guide plate (Z-axis) (centering time ≤30s). After centering is completed, a clamping signal is triggered.

[0051] This invention also includes the following modules:

[0052] Environmental simulation module: Includes a heating device (temperature control range -10~80℃, accuracy ±1℃) and a fan (adjustable wind speed 0-5m / s), installed around the perimeter of the test area (forming a closed space with a volume of 1.5m³). 3 It is equipped with a temperature and humidity sensor (measurement range 20%-90%RH, accuracy ±3%) to monitor environmental parameters in real time.

[0053] Safety protection module: Equipped with an infrared grating (detection distance 2m, response time ≤10ms), the motor power is immediately cut off when a human body enters the test area; the test platform is surrounded by a protective railing (height 1200mm, grid size 50mm×50mm), and the railing door is equipped with a safety interlock switch (the machine stops when the door is opened); the system has built-in overload protection (the machine stops when the torque exceeds 150% of the rated value) and over-temperature protection (the alarm sounds when the motor temperature is ≥100℃).

[0054] In this invention, the formula for calculating the motor efficiency of the data acquisition module is: η is the motor efficiency (%), T is the output torque (N·m), n is the speed (r / min), and P is the torque output (N·m). in The input power is kW. Before calculation, the data acquisition module preprocesses the raw signal. The voltage and current signals are filtered for noise using a second-order Butterworth low-pass filter (cutoff frequency 50Hz), and the torque signal is de-DC drifted (drift ≤ 0.1 N·m). Input power P inThe system calculates instantaneous power integration (integration time 0.1s) and deducts the losses of the test motor itself (preset loss value according to the motor efficiency curve); for different motor types (asynchronous / synchronous), the system automatically switches the efficiency correction coefficient (1.02 for asynchronous motors, 0.98 for synchronous motors), compares the calculation results with the preset efficiency range (set according to the motor model), and displays a red warning sign on the touch screen when the limit is exceeded, while storing the abnormal data point (with timestamp).

[0055] In this invention, the automatic centering module's position adjustment is calculated using the formulas ΔX = L·sinθ and ΔZ = L·(1-cosθ), where ΔX is the X-axis adjustment (mm), ΔZ is the Z-axis adjustment (mm), L is the distance between the two axes (mm), and θ is the centering deviation angle (°). The laser centering instrument uses dual laser beams for measurement (horizontal / vertical direction) at a sampling frequency of 10Hz. A deviation ≤0.02mm after three consecutive measurements is considered stable. After calculating ΔX and ΔZ, the sliding frame is driven by a servo motor (400W power, reduction ratio 1:20) to move according to the adjustment amount. The movement process uses S-shaped acceleration and deceleration (acceleration 0.5m / s²). 2 To avoid impact; Z-axis adjustment is achieved through an electric push rod at the bottom of the guide plate (50mm stroke, ±0.01mm accuracy), with a 100ms pause for every 0.05mm adjustment to ensure stable positioning; after alignment, the system automatically records the adjustment amount and stores it in association with the motor model, which can be directly recalled for subsequent tests of the same model of motor (alignment time reduced to 10s).

[0056] In this invention, the temperature compensation formula for the environmental simulation module is T. comp =T meas +K·(T amb -25), where T comp To compensate for the temperature (°C), T meas The sensor measures temperature (°C), K is the temperature coefficient (related to motor type: 0.02 for asynchronous motors, 0.015 for synchronous motors), and T... amb The ambient temperature (°C) is used. Temperature sensors employing PT100 platinum resistance thermometers (accuracy class A) are distributed across the motor stator, rotor, and ambient environment (3 points in total), collecting data every 1 second. When the ambient temperature change rate is >2°C / min, the K value automatically increases by 20% to accelerate the compensation response. The compensated temperature data is used to correct the torque sensor reading (torque temperature coefficient 0.03% / °C) and adjust the heating device power (PID control, proportional band 5°C, integral time 100s). In the low-temperature range of -10 to 0°C, the system automatically initiates a preheating program (heating to 5°C) to prevent sensor low-temperature drift from affecting measurement accuracy (drift controlled within ±0.5%).

[0057] In this invention, dust covers (accordion type, 1200mm elongation) are installed on both sides of the sliding seat of the sliding frame module to prevent dust from entering the guide rail; the sliding seat and the guide rail are automatically lubricated periodically (50ml capacity, 24-hour lubrication cycle, 0.5ml lubrication per cycle); the two ends of the first spring are connected by fisheye bearings (rotatable angle ±10°) to avoid spring torsion failure; the surface of the support platform is chrome-plated (5μm thickness), with a hardness ≥HV600, improving wear resistance by 30%; the position of the sliding frame is fed back by a closed-loop grating ruler (1μm resolution), with a positioning accuracy of ±0.02mm; the connecting bolts between the connecting beam and the sliding seat are made of anti-loosening nuts (tightening torque 18N·m), and are used with thread-locking adhesive (medium strength grade) to prevent vibration from loosening; a 5mm high guard is provided at the edge of the support platform to prevent tools or parts from slipping off.

[0058] In this invention, the guide plate module adjusting screw is equipped with a locking nut (M10), which is locked after adjustment (anti-loosening torque 8 N·m); the third spring is made of piano wire (diameter 3 mm, yield strength ≥ 1800 MPa), with a fatigue life ≥ 100,000 cycles; a displacement sensor (range 0-50 mm, accuracy ± 0.1 mm) is installed on the inner side of the push plate to monitor the fit between the motor and the push plate (fit ≥ 90% is considered qualified); a level (accuracy 0.02 mm / m) is installed on the top of the guide plate to ensure that the guide plate is perpendicular to the motor axis (perpendicularity error ≤ 0.05 mm / m); the symmetry of the left and right guide plates is ≤ 0.1 mm, calibrated by a laser interferometer; lithium-based grease (dropping point ≥ 180℃) is applied between the bottom slider and the T-slot of the guide plate, and replenished monthly to ensure smooth sliding (resistance ≤ 3 N).

[0059] In this invention, the motor model identification module uses a 6mm fixed-focus lens (F2.0 aperture) and is equipped with a ring LED fill light (color temperature 6500K, brightness 3000 lux), which can work stably in backlight environments (illuminance 100-10000 lux); the OCR recognition algorithm supports fuzzy character recognition (character loss ≤15% can be recognized) and tilt correction (maximum correction angle ±10°); the RFID tag is passive (size 15mm×25mm), installed on the non-load-bearing surface of the motor (0-80mm away from the reader), with a storage capacity ≥1KB and a data retention time ≥10 years; the identification result automatically calls the corresponding test program (such as rated speed, load curve), with a call time ≤2s; when the identification fails (3 consecutive inconsistent attempts), the system automatically switches to manual input mode, the screen displays a list of commonly used motor models (which can be slidably selected), and records the reason for the failure (such as damaged tag, blurred nameplate).

[0060] In this invention, the infrared grating of the safety protection module consists of 8 sets of transmitter-receiver pairs (50mm spacing), forming a blind-spot-free protection; the protective barrier is welded from Q235 steel pipe (30mm diameter, 2mm wall thickness), with a powder-coated surface (warning yellow color, 80μm thickness); the safety interlock switch is a dual-channel design (redundant structure) to ensure reliable shutdown even in the event of a single fault; the system emergency stop button (red mushroom head, 60mm diameter) is installed on the operation panel and the side of the protective barrier gate (2 locations in total), pressing it cuts off all power circuits (response time ≤50ms), restarting requires rotation reset and input of a password (6 digits); the over-temperature protection uses dual-sensor redundant detection (thermocouple + infrared), triggering a sensor fault alarm when the temperature difference between the two is >5℃; the overload protection has three threshold levels (80% warning, 120% load reduction, 150% shutdown), responding step by step to avoid sudden stop impact.

[0061] Reference Figure 2 This indicates the time advantage of this patented system in testing various motor models, with a particularly significant difference in high-power motors. This is due to the rapid movement of the sliding frame and the precise positioning of the guide plate, reducing the time spent on repeated disassembly and calibration in traditional systems. For example, the testing time for a 7.5kW motor is reduced by 76%, verifying the system's high adaptability to multiple motor models. This aligns with the design goal of "improving testing efficiency" stated in the claims, making it highly practical for mass production testing scenarios.

[0062] Reference Figure 3 This indicates that the alignment accuracy of this system is significantly superior to that of traditional systems, with deviations controlled within 0.08mm. This stems from the laser measurement and precise adjustment of the automatic alignment module, which achieves accurate displacement compensation through ΔX and ΔZ calculations. The improved alignment accuracy directly reduces test data errors, especially significantly improving the accuracy of torque measurement. This solves the problem of inaccurate testing caused by alignment deviations in traditional devices, demonstrating the technical advantage of "precise adjustment" as stated in the claims.

[0063] Reference Figure 4 This indicates the effectiveness of the system's temperature compensation function, especially its significant error control effect under extreme temperatures. Through the T_comp compensation formula, the system automatically corrects for the influence of ambient temperature on the sensor, keeping the error consistently within 1.3%. This solves the data distortion problem caused by temperature drift in traditional testing, ensuring the consistency of test results under different environments, and meeting the design requirement of "improving test reliability" in the claims.

[0064] Reference Figure 5This indicates that the maintenance cost of this system is significantly lower than that of traditional systems, with cumulative savings of over 60% over 30 months. This is attributed to designs such as automatic lubrication of the sliding frame and dust cover protection, which reduce guide rail wear; spring buffers reduce impact damage to components; and the modular structure simplifies maintenance and replacement. Low maintenance costs extend the effective service life of the equipment, improve long-term economic benefits, and demonstrate the practical value of the "optimized structural design" mentioned in the claims.

[0065] Reference Figure 6 This indicates the system's rapid response capability for safety protection, with response times for all anomaly types controlled within 50ms. This stems from designs such as infrared gratings and dual-sensor redundant detection, coupled with optimized emergency stop circuits, resulting in a 5-8 times improvement over traditional systems. This rapid response effectively reduces the risk of equipment damage and personnel injury, conforming to the "multiple safety protections" design concept in the claims and ensuring the safety of the testing process.

[0066] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A motor testing system based on a sliding frame and a guide plate, characterized in that, Includes the following modules: Test frame module: It is made of Q235B steel plate and welded. The bottom is fixed to the ground by 6 sets of M12 expansion bolts. The left column of the frame is welded with a support base, and the right crossbeam is equipped with two parallel guide rails. Limit blocks are set at both ends of the guide rails. Reinforcing ribs are welded on the inside of the frame. The sliding frame module consists of a sliding seat, a connecting beam, and a support platform. The sliding seat is fitted with the frame guide rail and a wear-resistant slider is installed at the bottom. The connecting beam is made of rectangular steel pipe and connected to the sliding seat by bolts. The support platform is machined with T-slots to fix the motor. Two first springs are connected to the frame on the right side of the sliding frame. Guide plate module: The left and right guide plates are symmetrically arranged, and the bottom is connected to the sliding frame T-slot by a slider. The adjustment component can make horizontal fine adjustments to the guide plates by adjusting the screw and handwheel; the right side of the left guide plate is connected to the push plate by 4 sets of third springs. Motor fixing module: The L-shaped baffle is connected to the sliding frame via a slide rail, and the bottom is connected to the sliding frame via a second spring; the clamping bolt is installed on the top of the L-shaped baffle, and a nylon pressure block is provided at the end for vertical adjustment of the clamping height; the module has a built-in pressure sensor to monitor the clamping force in real time; Test drive module: The test motor is fixed to the support base on the left side of the frame by a flange. The output shaft is connected to the torque sensor. The other end of the sensor is connected to the motor under test through a flexible coupling. The coupling is covered with a protective cover. The test motor controller communicates with the data acquisition module. Data acquisition module: Employs an industrial-grade data acquisition card to synchronously acquire torque, speed, current, and voltage parameters, and is equipped with a touchscreen to display test curves and data; Built-in storage unit, supports data export, system software sets test procedures and automatically generates test reports; Buffer and shock absorption module: shock-absorbing pads are installed at the contact points between the sliding frame and the guide rail, shock-absorbing feet are installed at the bottom of the test motor, and anti-vibration pads are installed between the frame and the ground.

2. The motor testing system based on a sliding frame and guide plate according to claim 1, characterized in that, Also includes: Motor model identification module: The camera is installed directly above the sliding bracket to identify the motor nameplate information; The RFID reader reads the tag built into the motor and compares it with the image recognition result. Automatic alignment module: A laser alignment instrument is used, with the transmitter fixed to the end of the test motor shaft and the receiver installed on the end of the motor shaft under test. The alignment data is transmitted to the controller, and the sliding frame position and guide plate height are adjusted to automatically align. The alignment completes and triggers the clamping signal.

3. The motor testing system based on a sliding frame and guide plate according to claim 1, characterized in that, Also includes: Environmental simulation module: Heating devices and fans are installed around the test area, equipped with temperature and humidity sensors to monitor environmental parameters in real time; Safety protection module: Equipped with an infrared grating, the motor power is cut off when a human enters the test area; the test bench is surrounded by protective railings, and the protective railing doors are equipped with safety interlock switches; the system has built-in overload protection and over-temperature protection.

4. The motor testing system based on a sliding frame and guide plate according to claim 1, characterized in that, The formula for calculating the motor efficiency of the data acquisition module is: Where η is the motor efficiency, T is the output torque, n is the speed, and P is the torque. in Input power; voltage and current signals are filtered for noise by a second-order Butterworth low-pass filter, and the torque signal has its DC drift removed; input power P in The instantaneous power integral calculation deducts the losses of the test motor itself; the efficiency correction coefficient is automatically switched, the calculation results are compared with the preset efficiency range, an early warning is issued when the threshold is exceeded, and abnormal data points are stored.

5. The motor testing system based on a sliding frame and guide plate according to claim 2, characterized in that, The automatic centering module position adjustment is calculated using the formulas ΔX = L·sinθ and ΔZ = L·(1-cosθ), where ΔX is the X-axis adjustment, ΔZ is the Z-axis adjustment, L is the distance between the two axes, and θ is the centering deviation angle. The laser centering instrument uses dual laser beams for measurement with a sampling frequency of 10Hz. After calculating ΔX and ΔZ, the sliding frame is driven by a servo motor to move according to the adjustment amount, and the movement process uses S-shaped acceleration and deceleration. The Z-axis is adjusted by an electric push rod at the bottom of the guide plate. After centering is completed, the system automatically records the adjustment amount and stores it in association with the motor model.

6. The motor testing system based on a sliding frame and guide plate according to claim 3, characterized in that, The temperature compensation formula for the environmental simulation module is T. comp =T meas +K·(T amb -25), where T comp To compensate for the temperature afterward, T meas For temperature measurement by the sensor, K is the temperature coefficient, and T is the temperature coefficient. amb The ambient temperature is used; the temperature sensor is a PT100 platinum resistance thermometer, which collects data every 1 second; when the rate of change of ambient temperature exceeds the threshold, the K value automatically increases, and the preheating program is automatically started in the low temperature range.

7. The motor testing system based on a sliding frame and guide plate according to claim 1, characterized in that, Dust covers are installed on both sides of the sliding frame module sliding seat, and the sliding seat and guide rail are automatically lubricated periodically; the two ends of the first spring are connected by fisheye bearings, the surface of the support platform is chrome-plated, the position of the sliding frame is fed back by a closed loop grating ruler, the connecting beam and the sliding seat connecting bolts are made of anti-loosening nuts and thread sealant, and the support platform edge is provided with a retaining edge.

8. The motor testing system based on a sliding frame and guide plate according to claim 1, characterized in that, The guide plate module adjusting screw is equipped with a locking nut, which is locked after adjustment; the third spring is made of piano wire, and a displacement sensor is installed on the inside of the push plate to monitor the fit between the motor and the push plate; a level is installed on the top of the guide plate, and the left and right guide plates are calibrated by a laser interferometer; lithium-based grease is applied between the bottom slider and the T-slot of the guide plate.

9. The motor testing system based on a sliding frame and guide plate according to claim 2, characterized in that, The motor model identification module uses a 6mm fixed-focus lens and is equipped with a ring LED fill light; the OCR recognition algorithm supports fuzzy character recognition and tilt correction; the RFID tag is passive and is installed on the non-load-bearing surface of the motor; the recognition result automatically calls the corresponding test program; when the recognition fails, the system automatically switches to manual input mode, displays a list of common motor models on the screen, and records the reason for the failure.

10. The motor testing system based on a sliding frame and guide plate according to claim 3, characterized in that, The safety protection module's infrared grating consists of 8 sets of transmitter-receiver pairs. The guardrail is made of Q235 steel pipe welded together with a powder-coated surface. The safety interlock switch adopts a dual-channel design, and the system's emergency stop button is installed on the operation panel and the side of the guardrail gate. The over-temperature protection uses dual-sensor redundant detection, triggering a sensor fault alarm when the temperature difference exceeds the threshold. The overload protection is set with three threshold levels, responding step by step.

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