Protection device of motor test bench and motor test bench

Abstract

The embodiment of the invention relates to the technical field of motor testing, in particular to a protection device of a motor test bench and the motor test bench. The protection device comprises a monitoring unit and a control terminal, the monitoring unit comprises a water level monitoring sensor and a water pump, and the water level monitoring sensor is used for monitoring the water accumulation amount of the environment bin and generating a water level signal; the water pump is used for discharging leaked water of the water cooling machine in the environment bin to the outside of the motor test bench; the control terminal is used for judging the real-time water level of the water accumulation amount in the environment bin according to the water level signal, comparing the real-time water level with a water level early warning value, and controlling the protection device to execute protection operation in response to the situation that the real-time water level exceeds the water level early warning value. According to the embodiment of the invention, the monitoring unit is arranged in the environment bin, the water accumulation amount can be monitored in real time, and if the water level exceeds the water level early warning value, water is drained to prevent accumulated water from soaking a detected product; the control terminal is arranged outside the rack, automatically judges the real-time water level, triggers protection operation, does not need real-time monitoring of personnel, and guarantees the reliability of motor testing.

Description

Technical Field

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

[0002] In the process of R&D and mass production verification of new energy vehicle components, in order to simulate the complex working conditions in actual use, it is necessary to conduct rotary bench load tests on products such as drive motors, drive motor system assemblies, and hybrid assemblies under high and low temperature environments. Such tests not only need to cover high-speed rotation conditions and extreme temperature environments, but also often need to conduct long-term durability tests to fully verify the performance stability and service life of products under different working conditions. This is a key link to ensure the driving safety and operational reliability of new energy vehicles. However, the existing bench testing process presents multiple risks and hidden dangers, which can easily lead to test interruptions, product damage, and even safety accidents. Specifically, problems such as product malfunctions, bench equipment failures, communication link interruptions, poor contact or damage to various wiring harnesses, and operator errors may occur during testing. Of particular concern is the liquid cooling water circulation system, which is typically used to meet the heat dissipation requirements of the product during testing. Under the influence of long-term high-frequency use, alternating high and low temperature shocks, or improper installation and maintenance, water leaks are prone to occur. Since testing must be conducted in a relatively sealed environment chamber, leaked cooling water cannot be drained in time, forming and accumulating at the bottom of the chamber. This can result in the drive motor, drive motor system assembly, or hybrid assembly being submerged in water. This scenario not only directly causes short-circuit damage to the tested product, leading to invalid test data and extended R&D or verification cycles, but also poses a safety risk such as electrical leakage due to water contact with electrical equipment. This severely restricts the safety and reliability of motor testing and fails to meet the requirements for efficient and safe testing of new energy vehicle components. Summary of the Invention

[0003] One objective of this application is to provide a protective device and a motor test bench for a motor test bench, so as to solve the technical problem of water accumulation safety hazards in the motor testing process in the prior art.

[0004] In a first aspect, embodiments of this application provide a protection device for a motor test bench, comprising: a monitoring unit and a control terminal, wherein the monitoring unit includes a water level monitoring sensor and a water pump; The water level monitoring sensor is fixed on an aluminum substrate and is used to monitor the water accumulation in the environmental chamber and generate a water level signal. The environmental chamber provides a device for high and low temperature environmental testing for the motor test bench. The environmental chamber is circulated by a water chiller. The water pump is fixed on the aluminum base plate and is used to discharge the leaking water from the water chiller in the environmental chamber to the outside of the motor test bench. The control terminal is electrically connected to the water level monitoring sensor and the water pump, and is used to determine the real-time water level of the water accumulation in the environmental chamber based on the water level signal, compare the real-time water level with the water level warning value, and control the protection device to perform protection operation in response to the real-time water level exceeding the water level warning value.

[0005] Optionally, the water level warning value includes a first water level warning value and a second water level warning value, wherein the first water level warning value is less than the second water level warning value, and the step of controlling the protection device to perform protection operation in response to the real-time water level exceeding the water level warning value includes: In response to the real-time water level being greater than or equal to the first water level warning value and the real-time water level being less than the second water level warning value, the water pump is controlled to discharge the accumulated water in the environmental chamber to a preset proportion of the first water level warning value. In response to the real-time water level being greater than the second water level warning value, the water pump is controlled to discharge the accumulated water in the environmental chamber to a preset proportion of the first water level warning value, the power supply to the motor test bench is cut off, and the water chiller is turned off.

[0006] Optionally, it also includes a multi-color light alarm, which includes multiple indicator lights and is configured to: In response to the real-time water level being lower than the first water level warning value, the first indicator light of the multi-color light alarm is driven to illuminate. In response to the real-time water level being greater than or equal to the first water level warning value and the real-time water level being less than the second water level warning value, the second indicator light of the multi-color light alarm is driven to illuminate; In response to the real-time water level being greater than the second water level warning value, the third indicator light of the multi-color light alarm is driven to illuminate and the buzzer to emit an audible alarm.

[0007] Optionally, the protective device further includes: A speed-torque sensor, electrically connected to the control terminal, is used to collect the real-time speed and real-time torque of the product under test. A display screen is installed outside the motor test bench and is electrically connected to the water level monitoring sensor, the speed-torque sensor and the control terminal. It is used to display the real-time water level in the environmental chamber, the real-time speed and real-time torque of the tested product. A water storage tank, located outside the motor test bench, is used to receive the water discharged from the environmental chamber by the water pump.

[0008] Optionally, the control terminal is further configured to: In response to the real-time rotational speed of the product under test being greater than the rotational speed threshold, the power supply to the motor test bench is cut off, the fourth indicator light of the multi-color light alarm is driven to illuminate, and the display screen is controlled to display the real-time rotational speed and the real-time torque at the moment of power failure. In response to the difference between the real-time torque and the target torque of the tested product being greater than or equal to the torque tolerance threshold, the power supply to the motor test bench is cut off, the fifth indicator light of the multi-color light alarm is driven to illuminate, and the display screen is controlled to display the real-time speed and the real-time torque at the moment of power failure.

[0009] Optionally, the multi-color light alarm further includes a buzzer, and the multi-color light alarm is further configured to: In response to the illumination of the third indicator light and / or the fourth indicator light and / or the fifth indicator light, the buzzer is driven to emit an audible alarm.

[0010] Optionally, the water level monitoring sensor is disposed above the first fixing structure of the aluminum substrate by a first adjustment mechanism, which can adjust the installation height and tilt angle of the water level monitoring sensor.

[0011] Optionally, the water pump is disposed above the second fixing structure of the aluminum substrate by a second adjustment mechanism, the second adjustment mechanism including a plurality of positioning holes and positioning grooves, which can adjust the installation height of the water pump.

[0012] Optionally, the control terminal is further configured to: In response to the real-time water level being lower than the first water level threshold, the rate of water level rise is calculated; In response to the water level rise rate exceeding a preset rate threshold, the water pump is started in advance and / or the power supply to the motor test bench is cut off, and the water chiller is shut down.

[0013] Secondly, embodiments of this application provide a motor test bench, including the protection device described above.

[0014] The embodiments of this application can achieve the following technical effects: In the protection device for the motor test bench provided in this application embodiment, the protection device includes: a monitoring unit and a control terminal. The monitoring unit includes a water level monitor and a water pump. The water level monitoring sensor is fixed on an aluminum substrate and is used to monitor the water accumulation in the environmental chamber and generate a water level signal. The environmental chamber provides a device for high and low temperature environmental testing for the motor test bench, and the environmental chamber is liquid-cooled by a water chiller. The water pump is fixed on the aluminum substrate and is used to discharge the leaking water from the water chiller in the environmental chamber to the outside of the motor test bench. The control terminal is electrically connected to the water level monitoring sensor and the water pump and is used to determine the real-time water level in the environmental chamber based on the water level signal, compare the real-time water level with a water level warning value, and control the protection device to perform protection operations in response to the real-time water level exceeding the water level warning value. This embodiment of the application places the monitoring unit inside the environmental chamber, which can capture the water level in real time. If the water level exceeds the warning value, drainage will be started quickly to avoid water immersion in the tested product and reduce the risk of short circuit damage. The control terminal is located outside the test bench and automatically judges the water level and triggers protection operations. No real-time monitoring by personnel is required, which improves the safety of operation, effectively avoids test interruption and data failure caused by water leakage, and ensures the reliability of motor testing. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments of this application will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 A schematic diagram of the structure of a protective device for a motor test bench provided in an embodiment of this application; Figure 2 A schematic diagram of a detection unit provided in an embodiment of this application; Figure 3 A schematic diagram of the structure of a motor test bench provided in an embodiment of this application; Figure 4 A schematic diagram of the structure of a protective device for another motor test bench provided in an embodiment of this application; Figure 5 This is a schematic diagram of the structure of a protective device for another motor test bench provided in an embodiment of this application. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application. All other embodiments obtained by those skilled in the art based on the embodiments in this application without inventive effort are within the scope of protection of this application.

[0018] It should be noted that, unless there is a conflict, the various features in the embodiments of this application can be combined with each other, all of which are within the protection scope of this application. Furthermore, although functional modules are divided in the device schematic diagram and a logical order is shown in the flowchart, in some cases, the steps shown or described can be executed in a different order than the module division in the device or the order in the flowchart. Moreover, the terms "first," "second," and "third" used in this application do not limit the data or execution order, but only distinguish identical or similar items with essentially the same function and effect.

[0019] The following embodiment of this application provides a protective device for a motor test bench. Please refer to [link / reference]. Figure 1 The protection device 100 of the motor test bench includes a monitoring unit 10 and a control terminal 20. The monitoring unit 10 includes a water level monitoring sensor 101 and a water pump 102, and the control terminal 20 is electrically connected to the water level monitoring sensor 101 and the water pump 102 respectively.

[0020] Please see Figure 2 , Figure 2 This is a schematic diagram of a monitoring unit 10 provided in an embodiment of this application. The monitoring unit 10 includes a water level monitoring sensor 101 and a water pump 102, which are fixed on an aluminum substrate. It should be noted that the monitoring unit 10 is not a component fixed inside the motor test bench. When performing motor testing, the tester will place the monitoring unit 10 inside the motor test bench, such as... Figure 3 As shown, a movement steering device is provided under the aluminum substrate to facilitate the movement of the monitoring unit 10. Specifically, the movement steering device can be configured with two casters and two omnidirectional wheels to make it easier to move the monitoring unit 10 into the motor test bench.

[0021] The water level monitoring sensor 101 can be an electrode-type water level sensor. Multiple detection electrodes of the electrode-type water level sensor extend vertically downward to ensure that when water leakage occurs in the water chiller in the environmental chamber, the accumulated water can contact the detection electrodes. When the water level rises to contact the detection electrodes at different heights, the internal circuit of the water level monitoring sensor 101 generates an electrical signal corresponding to the water level due to the change in the conduction state between the detection electrodes.

[0022] Please see Figure 3 , Figure 3 This is a schematic diagram of the architecture of a motor test bench provided in this application embodiment. It should be noted that the solid lines in the diagram represent components of a motor test bench in the prior art, while the dashed lines represent components of this application embodiment. A water level monitoring sensor 101 is fixed on an aluminum substrate and is used to monitor the water accumulation in the environmental chamber and generate a water level signal. The environmental chamber provides a high and low temperature environment for testing the motor test bench, and it is circulated using a water chiller. Specifically, the environmental chamber in the motor test bench is a dedicated device for providing high and low temperature environment testing for products under test such as drive motors, drive motor system assemblies, and hybrid assemblies. It can simulate the extreme temperature conditions of the products under test during actual use, enabling high-speed rotation, load-bearing, and durability tests. The environmental chamber is a relatively sealed space, circulated using a water chiller. The required high and low temperature environment within the chamber is achieved and maintained through the heat exchange of the liquid cooling system. It is understandable that if the water pipes of the water chiller leak during liquid cooling circulation, the leaked water will easily accumulate inside the environmental chamber due to its airtightness.

[0023] The water pump 102 can be a miniature water pump with high and low temperature resistance and waterproof characteristics. The water pump 102 is driven by a motor to rotate the impeller at high speed. Centrifugal force creates a low-pressure zone at the center of the impeller. External liquid (such as water in the environmental chamber) is drawn into the pump body under atmospheric pressure. The external liquid is pressurized by the impeller and discharged from the outlet. The water pump 102 is fixed on an aluminum base plate and is used to drain the leaking water from the water chiller in the environmental chamber to the outside of the motor test bench. Specifically, when the water chiller in the environmental chamber leaks and the real-time water level detected by the water level monitoring sensor 101 exceeds the water level warning value, the control terminal sends a start command to start the water pump 102. The water pump 102 can quickly drain the water in the environmental chamber to the outside of the motor test bench through the drain hose connected to the outlet of the water pump 102 and extending out of the environmental chamber, thus promptly removing the water in the environmental chamber and preventing the tested product from being soaked.

[0024] The control terminal 20 is electrically connected to the water level monitoring sensor 101 and the water pump 102. For details, please refer to [link / reference needed]. Figure 2 The control terminal is located outside the motor test bench and is wired to the water level monitoring sensor 101 and the water pump 102. The control terminal 20 is used to determine the real-time water level in the environmental chamber based on the water level signal, compare the real-time water level with the water level warning value, and control the protection device to perform protection operation in response to the real-time water level exceeding the water level warning value.

[0025] Specifically, the water level warning values ​​include a first water level warning value and a second water level warning value. The first water level warning value is less than the second water level warning value. The first and second water level warning values ​​can be adaptively set according to the size of the environmental chamber. In this embodiment, the first water level warning value can be set to 20cm, and the second water level warning value can be set to 30cm. If the real-time water level is detected to be greater than or equal to the first water level warning value, and the real-time water level is less than the second water level warning value, the control terminal 20 will send a start command to the water pump 102 to control the water pump 102 to discharge the water in the environmental chamber to a preset proportion of the first water level warning value. The preset proportion can be set to half, that is, the water pump 102 will discharge the water in the environmental chamber to the outside of the motor test bench until the real-time water level reaches half of the first water level warning value. It can be understood that if the first water level warning value is set to 20cm, half of the first water level warning value is 10cm.

[0026] If the real-time water level is detected to be higher than the second water level warning value, the control terminal 20 will send a start command to the water pump 102. The water pump 102 will discharge the water in the environmental chamber to the outside of the motor test bench until the real-time water level reaches half of the first water level warning value. The first water level warning value is set to 20cm, and half of the first water level warning value is 10cm. At the same time, a power-off command is sent to the host computer of the motor test bench to make the motor test bench cut off the power supply and shut down the water chiller.

[0027] This embodiment of the application places the monitoring unit inside the environmental chamber, which can capture the water level in real time. If the water level exceeds the warning value, drainage will be started quickly to avoid water immersion of the tested product and reduce the risk of short circuit damage. The control terminal is located outside the test bench and automatically judges the real-time water level and triggers protection operations. No personnel are required to monitor in real time, which improves the safety of operation, effectively avoids test interruption and data failure caused by water leakage, and ensures the reliability of motor testing.

[0028] In some embodiments, the water level warning value includes a first water level warning value and a second water level warning value, wherein the first water level warning value is less than the second water level warning value. In response to the real-time water level exceeding the water level warning value, the control protection device performs a protection operation, including: in response to the real-time water level being greater than or equal to the first water level warning value and the real-time water level being less than the second water level warning value, controlling the water pump 102 to discharge the accumulated water in the environmental chamber to a preset proportion of the first water level warning value; in response to the real-time water level being greater than the second water level warning value, controlling the water pump 102 to discharge the accumulated water in the environmental chamber to a preset proportion of the first water level warning value, controlling the motor test bench to cut off the power supply, and shutting down the water chiller.

[0029] Specifically, the water level warning values ​​include a first water level warning value and a second water level warning value. The first water level warning value is lower than the second water level warning value. The first and second water level warning values ​​can be adaptively set according to the size of the environmental chamber. In this embodiment, the first water level warning value can be set to 20cm, and the second water level warning value can be set to 30cm.

[0030] If the real-time water level is detected to be greater than or equal to the first water level warning value, and the real-time water level is less than the second water level warning value, the control terminal will send a start command to the water pump 102 to control the water pump 102 to discharge the water in the environmental chamber to a preset proportion of the first water level warning value. The preset proportion can be set to one-half, that is, the water pump 102 will discharge the water in the environmental chamber to the outside of the motor test bench until the real-time water level reaches one-half of the first water level warning value. It can be understood that the first water level warning value is set to 20cm, and one-half of the first water level warning value is 10cm.

[0031] If the real-time water level is detected to be higher than the second water level warning value, the control terminal will send a start command to the water pump 102. The water pump 102 will then discharge the accumulated water in the environmental chamber to the outside of the motor test bench until the real-time water level reaches half of the first water level warning value. The first water level warning value is set at 20cm, and half of the first water level warning value is 10cm. At the same time, a power-off command will be sent to the host computer of the motor test bench to cut off the power supply to the motor test bench and shut down the water chiller. The second water level warning value is the maximum safe water level. If the real-time water level exceeds the maximum safe water level, the product under test is highly susceptible to a safety accident. It is necessary to urgently shut down the power supply of the motor test bench, stop the test process, and ensure the safety of the product under test and the test personnel.

[0032] Understandably, if the real-time water level is below the first water level warning threshold, it means that the water accumulation in the environmental chamber is within a safe and controllable range. This water accumulation does not pose a short circuit or immersion threat to the tested products such as the drive motor and motor system assembly, as well as the electrical links and equipment interfaces inside the test bench. At this time, the water accumulation in the environmental chamber is within an acceptable range, and the motor test bench's protection device 100 will remain in its initial standby state, without triggering drainage operations, power-off operations, or other protective actions. This ensures that the current motor testing process continues continuously according to the preset procedure, guaranteeing the integrity of test data acquisition and the stability of the test cycle.

[0033] In some embodiments, please refer to Figure 4The protection device 100 of the motor test bench also includes a multi-color light alarm 30, which includes multiple indicator lights. The multi-color light alarm 30 is configured to: illuminate the first indicator light of the multi-color light alarm 30 in response to the real-time water level being less than the first water level warning value; illuminate the second indicator light of the multi-color light alarm 30 in response to the real-time water level being greater than or equal to the first water level warning value and less than the second water level warning value; and illuminate the third indicator light of the multi-color light alarm 30 and activate the buzzer to sound an alarm in response to the real-time water level being greater than the second water level warning value.

[0034] Specifically, the multi-color light alarm 30 is installed outside the motor test bench and electrically connected to the control terminal. If the real-time water level is detected to be lower than the first water level warning value, the control terminal sends a first indication command to the multi-color light alarm 30, which drives the first indicator light of the multi-color light alarm 30 to light up. Specifically, the first indicator light is green, and the lighting of the first indicator light indicates that there are no abnormalities in the current test process.

[0035] If the real-time water level is detected to be greater than or equal to the first water level warning value and less than the second water level warning value, the control terminal sends a second instruction command to the multi-color light alarm 30. The multi-color light alarm 30 drives the second indicator light to light up. Specifically, the second indicator light is orange. The second indicator light being lit indicates that there is a risk in the current test process and the water pump 102 has been started to perform drainage operation.

[0036] If the real-time water level is detected to be higher than the second water level warning value, the control terminal sends a third instruction command to the multi-color light alarm 30, which drives the third indicator light of the multi-color light alarm 30 to light up. Specifically, the third indicator light is red, and the lighting of the third indicator light indicates that the current test process has been terminated.

[0037] In some embodiments, please refer to Figure 5 The protection device 100 of the motor test bench also includes a speed-torque sensor 40, a display screen 50, and a water tank 60. The speed-torque sensor 40 is electrically connected to the control terminal and is used to collect the real-time speed and real-time torque of the product under test. The display screen 50 is located outside the motor test bench and is electrically connected to the water level monitoring sensor 101, the speed-torque sensor 40, and the control terminal 20. It is used to display the real-time water level in the environmental chamber, the real-time speed, and the real-time torque of the product under test. The water tank 60 is located outside the motor test bench and is used to receive the water discharged from the environmental chamber by the water pump 102.

[0038] The speed-torque sensor 40 can be a flange-type dynamic speed-torque sensor. The flange-type dynamic speed-torque sensor uses a strain gauge measurement principle and has a wide measurement range (speed 0-20000 r / min, torque 0-5000 N). (m) and high precision characteristics. The speed-torque sensor 40 is used to acquire the real-time speed and real-time torque of the product under test. Specifically, the speed-torque sensor 40 is rigidly connected to the output shaft of the product under test and the input shaft of the motor test bench dynamometer through standard flanges at both ends, ensuring the coaxiality of the transmission shaft system and avoiding the influence of additional forces on measurement accuracy. The speed-torque sensor 40 converts the acquired speed (magnetoelectric pulse signal) and torque (strain gauge bridge signal) into 4-20mA standard analog signals, which are connected to the signal acquisition interface of the control terminal through a shielded cable to realize the dynamic monitoring of the real-time operating parameters of the product under test.

[0039] The display screen 50 can be an industrial-grade touchscreen display with a high-definition LCD panel, featuring wide operating temperature range and IP65 dust and water resistance. The display screen 50 is mounted externally on the motor test bench and is electrically connected to the water level monitoring sensor 101, the speed-torque sensor 40, and the control terminal. Specifically, the display screen 50 connects to the water level monitoring sensor 101, the speed-torque sensor 40, and the control terminal via an RS485 bus. The display screen 50 is used to display the real-time water level in the environmental chamber, the real-time speed of the tested product, and the real-time torque. Specifically, the display interface adopts a partitioned design: the left side is the "Environmental Chamber Status Area," displaying the real-time water level value (in mm) and the water level warning threshold; the right side is the "Test Product Parameter Area," simultaneously displaying the speed (in r / min) and torque (in N). The real-time curve and instantaneous value of m).

[0040] A water storage tank 60 is located outside the motor test bench and is used to receive water discharged from the environmental chamber by the water pump 102. Specifically, the water storage tank 60 has an inlet at the top, which connects to the outlet of the water pump 102 via a rubber hose. A sealing joint is installed where the rubber hose passes through the environmental chamber wall. The bottom of the water storage tank 60 has a drain outlet with a manual ball valve for easy periodic emptying of the water. A small float level switch is installed at the top inside the water storage tank 60. When the water level reaches the warning level, it is connected to a control terminal via a wire to trigger a full water tank indicator, allowing the test personnel to empty the water from the tank. The water storage tank 60 is located next to the motor test bench (e.g., ≤2m from the environmental chamber), ensuring that the rubber hose allows for natural drainage without bends.

[0041] In some embodiments, the control terminal is further configured to: in response to the real-time rotational speed of the product under test being greater than a rotational speed threshold, control the motor test bench to cut off the power, drive the fourth indicator light of the multi-color light alarm 30 to illuminate, and control the display screen 50 to display the real-time rotational speed and real-time torque at the moment of power failure; in response to the difference between the real-time torque of the product under test and the target torque being greater than or equal to a torque tolerance threshold, control the motor test bench to cut off the power, drive the fifth indicator light of the multi-color light alarm 30 to illuminate, and control the display screen 50 to display the real-time rotational speed and real-time torque at the moment of power failure.

[0042] Specifically, the speed threshold and torque tolerance threshold need to be preset in the motor testing process. The speed threshold is set according to the rated speed of the motor under test. For example, if the rated speed of the motor under test is 15000 r / min, the speed threshold can be set to 16500 r / min. The torque tolerance threshold is set according to the target torque. For example, if the target torque is 1000 N... When m, the tolerance threshold is set to ±100N. m.

[0043] If the real-time speed of the motor under test is detected to be greater than the speed threshold, the control terminal sends a power-off command to the host computer of the motor test bench, controlling the motor test bench to cut off the power supply, disconnecting the power supply circuit of the motor under test and the dynamometer on the bench. Simultaneously, a fourth indication command is sent to the multi-color light alarm 30, driving the fourth indicator light to illuminate. Specifically, the fourth indicator light is blue. The illumination of the fourth indicator light indicates that the motor under test has experienced a runaway phenomenon (speed loss of control). The "runaway phenomenon" refers to a dangerous situation where the speed of the motor under test loses control and rises sharply on the motor test bench. The main reason is that the real-time torque output by the motor under test is much greater than the load torque applied by the dynamometer, causing all the excess torque to be converted into the kinetic energy of the motor rotor, causing the motor under test to continuously accelerate. The control terminal 20 simultaneously sends a fault command to the display screen 50, triggering the display screen 50 interface to freeze, so that the display screen 50 displays the real-time speed and real-time torque at the moment of power failure.

[0044] If the difference between the real-time torque and the target torque of the tested product is detected to be greater than or equal to the torque tolerance threshold, the control terminal sends a power-off command to the host computer of the motor test bench, controlling the motor test bench to cut off the power supply, disconnecting the power supply circuit of the tested motor and the test bench dynamometer. Simultaneously, a fifth indication command is sent to the multi-color light alarm 30, driving the fifth indicator light of the multi-color light alarm 30 to illuminate. Specifically, the fifth indicator light is white. The illumination of the fifth indicator light indicates that the tested motor has experienced a non-runaway phenomenon (torque failure phenomenon). The main cause of torque failure is a broken connecting shaft. At this time, the real-time speed of the tested motor will not be affected, but the real-time torque is 0. The control terminal 20 also sends a fault command to the display screen 50, triggering the display screen 50 interface to freeze, so that the display screen 50 displays the real-time speed and real-time torque at the moment of power failure.

[0045] In some embodiments, the multi-color light alarm 30 further includes a buzzer, and the multi-color light alarm 30 is also configured to drive the buzzer to emit an audible alarm in response to the illumination of the third indicator light and / or the fourth indicator light and / or the fifth indicator light.

[0046] Specifically, during the motor testing process on the motor test bench, the third, fourth, and fifth indicator lights of the multi-color light alarm 30 are respectively associated with preset abnormality types of the tested motor (such as water accumulation exceeding the maximum safe water level, speed loss, torque failure, etc.). When the control terminal triggers any one or more of the above indicator lights to illuminate by acquiring signals and performing logical operations on peripherals such as the speed-torque sensor 40 and the water level monitoring sensor 101, it indicates that the tested motor has exhibited an abnormal phenomenon matching the pre-configured fault type of the corresponding indicator light. At this time, the motor test bench will forcibly terminate the test process in advance according to the pre-set safety protection strategy. At the same time, the multi-color light alarm 30 will drive the built-in buzzer to emit an intermittent sound alarm, using a multi-modal sound and light warning to promptly remind the test personnel to intervene and handle the situation, ensuring the operational safety of the test equipment and the tested motor.

[0047] In some embodiments, the water level monitoring sensor 101 is disposed above the first fixing structure of the aluminum substrate by a first adjustment mechanism, which can adjust the installation height and tilt angle of the water level monitoring sensor 101.

[0048] Specifically, the first fixing structure is a mounting base on an aluminum substrate, which is fastened to the aluminum substrate by multiple bolts, and the mounting base has a threaded hole in the center. The first adjustment mechanism includes a height adjustment component and an angle adjustment component.

[0049] The height adjustment assembly includes a threaded rod and an adjusting nut: the bottom end of the threaded rod is screwed into the threaded hole of the mounting base, and the top end is connected to the angle adjustment component; height adjustment is achieved by rotating the adjusting nut (which engages with the threaded rod), and the adjustment is locked with double nuts afterward. The angle adjustment assembly is a ball joint structure: a ball joint is provided at the top of the threaded rod, and a matching ball socket is built into the base of the water level monitoring sensor 101, which can achieve ±25° tilt angle adjustment.

[0050] In some embodiments, the water pump 102 is disposed above the second fixing structure of the aluminum substrate by a second adjustment mechanism, the second adjustment mechanism including a plurality of positioning holes and positioning grooves, which can adjust the installation height of the water pump 102.

[0051] Specifically, the second fixing structure includes upright reinforcing ribs, a crossbeam, and a crossbeam limiting groove on the aluminum substrate. All components of the second fixing structure are made of aluminum alloy, combining lightweight design with structural strength. Two upright reinforcing ribs are vertically fixed to the aluminum substrate, with positioning holes machined every 20mm along the height direction. The crossbeam is a horizontal aluminum alloy beam with positioning grooves at both ends that fit the upright reinforcing ribs with a clearance, and positioning grooves are machined corresponding to the positioning holes on the upright reinforcing ribs. The second adjustment mechanism adjusts the height of the water pump 102 through the combination of the positioning holes and positioning grooves.

[0052] It should be noted that the environmental chamber of the motor test bench is a fixed cavity with limited space, while the motors under test vary in size and specifications. During the motor testing process, after ensuring that the motor under test is connected to the dynamometer, the testing personnel place the monitoring unit 10, which integrates the water level monitoring sensor 101 and the water pump 102, into the environmental chamber. To accommodate motors of different sizes, the testing personnel can adjust the installation positions of the water level monitoring sensor 101 and the water pump 102 through the first and second adjustment mechanisms, so that the monitoring unit 10 can be placed in the environmental chamber and meet the test space adaptability requirements.

[0053] In some embodiments, the control terminal 20 is further configured to: calculate the water level rise rate in response to the real-time water level being less than a first water level threshold; and start the water pump 102 in advance and / or control the motor test bench to cut off the power supply and shut down the water chiller in response to the water level rise rate being greater than a preset rate threshold.

[0054] Specifically, the preset rate threshold can be set according to the actual drainage rate of the environmental chamber and the water pump 102. In this embodiment, the preset rate threshold can be set to 2 cm / min. When the real-time water level is lower than the first water level threshold, the control terminal 20 starts the sliding window algorithm to continuously record the water level data for 5 sampling cycles and calculates the water level rise rate per unit time (unit: cm / min) through linear fitting. If the water level rise rate is greater than the preset rate threshold, the control terminal sends a start command to the water pump 102 to make the water pump 102 perform drainage operation in advance, and at the same time sends a power-off command to the host computer of the motor test bench to make the motor test bench cut off the power supply and shut down the water chiller.

[0055] This application's embodiments overcome the passive protection mode of "based on static water level thresholds" by actively monitoring the dynamic rate of water level change, thus identifying the risk of rapid leakage in the water chiller in advance and shortening the response time. Differentiated protection is implemented for different leakage scenarios, ensuring continuous motor testing during minor leaks while guaranteeing equipment safety during severe leaks.

[0056] As another aspect of this application, this application provides a motor test bench that integrates the aforementioned protection device. This motor test bench is mainly used for high and low temperature environment rotational load testing and durability testing of key components of new energy vehicle drive motors, drive motor system assemblies, hybrid assemblies, etc. The integrated protection device can monitor and actively protect against safety risks caused by abnormal conditions such as water leakage from the water chiller in the environmental chamber during testing, effectively ensuring the safety and reliability of the test bench and the tested product under complex operating conditions such as high-speed rotation and extreme environments, providing a stable and safe testing environment for the performance verification of motor components.

[0057] It should be noted that in the above embodiments, there is no necessarily a certain order between the steps. Those skilled in the art can understand from the description of the embodiments of this application that the above steps may have different execution orders in different embodiments, that is, they may be executed in parallel or in turn, etc.

[0058] The above-disclosed embodiments are merely preferred embodiments of this application and should not be construed as limiting the scope of this application. Therefore, any equivalent variations made in accordance with the claims of this application shall still fall within the scope of this application.

Claims

1. A protection device for an electric machine test bench, characterized in that, The utility model relates to a motor test bench, comprising: a monitoring unit and a control terminal, the monitoring unit comprising a water level monitoring sensor and a water pump; the water level monitoring sensor is fixed on an aluminum substrate, used for monitoring the water accumulation amount of an environmental chamber, generating a water level signal, the environmental chamber is a device for providing high and low temperature environment test for the motor test bench, and the environmental chamber is liquid-cooled by a water cooling machine for liquid cooling circulation; the water pump is fixed on the aluminum substrate, used for discharging the water leakage of the water cooling machine in the environmental chamber to the outside of the motor test bench; the control terminal is electrically connected with the water level monitoring sensor and the water pump, used for judging the real-time water level of the water accumulation amount in the environmental chamber according to the water level signal, comparing the real-time water level with a water level warning value, and controlling the protection device to perform a protection operation in response to the real-time water level exceeding the water level warning value.

2. The protection device according to claim 1, characterized in that the water level warning value comprises a first water level warning value and a second water level warning value, the first water level warning value is less than the second water level warning value, and the response to the real-time water level exceeding the water level warning value, controlling the protection device to perform a protection operation, comprises: in response to the real-time water level being greater than or equal to the first water level warning value and less than the second water level warning value, controlling the water pump to discharge the water accumulation in the environmental chamber to a preset proportion of the first water level warning value; in response to the real-time water level being greater than the second water level warning value, controlling the water pump to discharge the water accumulation in the environmental chamber to a preset proportion of the first water level warning value, controlling the motor test bench to cut off the power supply, and closing the water cooling machine.

3. The protection device according to claim 2, characterized in that It further comprises a multi-color light alarm, the multi-color light alarm comprising a plurality of indicator lights, the multi-color light alarm being configured to: in response to the real-time water level being less than the first water level warning value, driving a first indicator light of the multi-color light alarm to emit light; in response to the real-time water level being greater than or equal to the first water level warning value and less than the second water level warning value, driving a second indicator light of the multi-color light alarm to emit light; in response to the real-time water level being greater than the second water level warning value, driving a third indicator light of the multi-color light alarm to emit light and a buzzer to emit a sound alarm.

4. The apparatus of claim 3, wherein, It further comprises: a rotational speed-torque sensor, electrically connected with the control terminal, used for collecting the real-time rotational speed and real-time torque of the measured product; a display screen, disposed outside the motor test bench, electrically connected with the water level monitoring sensor, the rotational speed-torque sensor and the control terminal, used for signal display of the real-time water level in the environmental chamber, the real-time rotational speed and real-time torque of the measured product; a water storage tank, disposed outside the motor test bench, used for receiving the water accumulation discharged from the environmental chamber by the water pump.

5. The protection device according to claim 4, characterized in that the control terminal is further configured to: in response to the real-time rotational speed of the measured product being greater than a rotational speed threshold value, controlling the motor test bench to cut off the power supply, driving a fourth indicator light of the multi-color light alarm to emit light and controlling the display screen to display the real-time rotational speed and real-time torque at the instant of power-off; In response to the difference between the real-time torque of the measured product and the target torque being greater than or equal to a torque tolerance threshold, the motor test bench is controlled to cut off power, drive the fifth indicator light of the multi-color light alarm to emit light, and control the display screen to display the real-time speed and the real-time torque at the moment of power failure.

6. The protection device according to claim 5, characterized in that The multi-color light alarm further comprises a buzzer, and the multi-color light alarm is further configured to: In response to the third indicator light emitting and / or the fourth indicator light emitting and / or the fifth indicator light emitting, the buzzer is driven to emit a sound alarm.

7. The protection device of claim 1, wherein The water level monitoring sensor is arranged above a first adjusting mechanism of the first fixing structure of the aluminum substrate, and the first adjusting mechanism can adjust the installation height and the inclination angle of the water level monitoring sensor.

8. The protection device of claim 1, wherein The water pump is arranged above a second adjusting mechanism of the second fixing structure of the aluminum substrate, and the second adjusting mechanism comprises a plurality of positioning holes and positioning grooves and can adjust the installation height of the water pump.

9. The protection device of claim 1, wherein The control terminal is further configured to: In response to the real-time water level being less than the first water level threshold, a water level rising rate is calculated; In response to the water level rising rate being greater than a preset rate threshold, the water pump is started in advance and / or the motor test bench is controlled to cut off power, and the water cooler is turned off.

10. An electrical machine test bed, characterized in that, The protection device as claimed in claims 1-9.

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