Brushless motor hall testing apparatus

Abstract

The application provides a brushless motor Hall test device and relates to the field of brushless motor testing. The brushless motor Hall test device comprises a machine table, a positioning assembly, a detection assembly, a simulation assembly and a controller. The upper surface of the machine table is fixedly connected with a bottom plate. The positioning assembly and the detection assembly are both installed on the upper surface of the bottom plate. In the application, the simulation assembly composed of a servo motor, a motor encoder and a Hall magnetic ring is introduced, and the physical magnetic field simulation is creatively adopted to replace the traditional motor energization driving test method. In the working process, the second air cylinder drives the whole simulation assembly to descend, so that the Hall magnetic ring is inserted into the fixed brushless motor body central cavity. Then, the servo motor drives the Hall magnetic ring to rotate in the brushless motor body through the shaft coupling, so that the rotating magnetic field completely consistent with the actual working state is reproduced in the brushless motor without energizing the brushless motor winding, and the built-in Hall sensor is directly excited to generate a signal.

Description

Technical Field

[0001] This invention relates to the field of brushless motor testing, specifically to a brushless motor Hall effect testing device. Background Technology

[0002] Brushless DC motors are widely used in industrial automation, consumer electronics, and new energy vehicles due to their high efficiency, long lifespan, and low noise. Their normal commutation and precise control rely heavily on accurate feedback from internal Hall sensors. Therefore, reliable testing of the Hall sensor's performance and installation accuracy after motor production and assembly, or during maintenance, is a crucial step in ensuring the overall quality of the motor.

[0003] A search revealed an existing patent (publication number: CN117074938B) that discloses a brushless motor testing device and method. During testing, the external rotor brushless motor to be tested is placed on the testing position of the carrier with its positioning holes facing upwards. When the main control device powers on the external rotor brushless motor, its casing rotates. Simultaneously, a lifting mechanism drives the testing component closer to the external rotor brushless motor until the three positioning pins of the three-jaw connector are inserted into the three positioning holes of the external rotor brushless motor. This allows the encoder and brake to rotate synchronously via the three-jaw connector. After testing, the external rotor brushless motor is braked, and the lifting mechanism drives the testing component to pull the positioning pins out of the positioning holes, removing the external rotor brushless motor. The above steps are then repeated. Therefore, this brushless motor testing device reduces the labor intensity of testing personnel and improves testing efficiency.

[0004] While the device described in the aforementioned document can achieve the testing effect, its prerequisite is that the windings of the brushless motor must be energized to drive the rotor to rotate. This method presents several problems in practical applications. First, direct energization testing poses safety hazards, especially during rapid testing on production lines or faulty motor detection, where abnormal winding or drive conditions may lead to accidents. Second, the test results are affected by the characteristics of the motor drive circuit and the winding parameters, making it impossible to independently evaluate the performance and installation accuracy of the Hall sensor itself. Therefore, the existing technical solutions still have room for improvement in terms of test safety, result independence, and measurement precision. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a brushless motor Hall effect testing device, which solves the technical problems of existing power-on testing methods having significant safety hazards and being unable to independently evaluate the performance of the Hall sensor itself and the installation angle error under the interference of isolated drive circuits.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A brushless motor Hall effect testing device includes a machine base, a positioning component, a detection component, a simulation component, and a controller. A base plate is fixedly connected to the upper surface of the machine base. The positioning component and the detection component are both mounted on the upper surface of the base plate. A brushless motor assembly is positioned inside the positioning component. The brushless motor assembly includes a brushless motor body and a connector mounted on the outer surface of the brushless motor body. The positioning component includes an inner magnetic bottom ring fixedly connected to the upper surface of the base plate. A non-magnetic upper ring is fixedly connected to the upper surface of the inner magnetic bottom ring. A magnetic inner ring is installed inside the inner magnetic bottom ring, and an excitation coil is installed outside the magnetic inner ring.

[0008] The detection assembly includes a base platform fixedly connected to the upper surface of a base plate. A first cylinder is fixedly connected to the upper surface of the base platform. A detection box is fixedly connected to the output end of the first cylinder. A multi-probe module is installed inside the detection box. Two auxiliary guide plates for auxiliary positioning are fixedly connected to the outer surface of the detection box. The multi-probe module is located between the two auxiliary guide plates.

[0009] The simulation components include a servo motor and a Hall effect magnetic ring for detection.

[0010] Through the above technical solution, the Hall magnetic ring in the simulation component physically rotates inside the brushless motor body, simulating a real working magnetic field inside the brushless motor body without energizing it. This excites the Hall sensor inside to generate a signal. The detection component connects to the connector outside the brushless motor body through a multi-probe module, collects these Hall signals, and transmits them to the controller for analysis. The entire solution achieves independent, safe, and pure testing of the performance and installation accuracy of the brushless motor Hall sensor. The positioning component consists of an inner magnetic bottom ring, a non-magnetic upper ring, a magnetic inner ring, and an excitation coil, forming a special electromagnetic positioning structure. When the excitation coil is energized, the magnetic inner ring and the highly permeable inner part of the inner magnetic bottom ring form an efficient magnetic circuit, generating a strong radial magnetic field that can quickly and firmly attract and position the brushless motor body placed within it. Meanwhile, the non-magnetic outer part of the inner magnetic bottom ring and the non-magnetic upper ring work together to effectively constrain and shield the upward diffusion of the magnetic field, greatly reducing the interference of the positioning magnetic field on the Hall sensor to be tested above. This creates a clean magnetic environment for subsequent high-precision electrical signal testing. Before electromagnetic positioning, the brushless motor body needs to be placed inside the inner magnetic bottom ring and the non-magnetic upper ring, with the connector facing the multi-probe module. Then, the first cylinder is activated to move the detection box toward the connector. When the two auxiliary guide plates approach each other and contact the two sides of the outer surface of the connector, the brushless motor body can be guided and positioned. At this time, the interface of the multi-probe module and the connector corresponds, which facilitates the subsequent docking work. Then, the positioning component can be activated to position the brushless motor assembly. Next, the detection box is reset, waiting for subsequent testing.

[0011] Furthermore, the inner side of the inner magnetic bottom ring is made of a highly magnetically permeable material, and the outer side of the inner magnetic bottom ring is made of a non-magnetically permeable material. The magnetic inner ring and the highly magnetically permeable inner part of the inner magnetic bottom ring constitute the main body of the closed magnetic circuit, and the excitation coil is connected to the external power supply component through a wire.

[0012] Through the above technical solution, the closed magnetic circuit body formed by the high magnetic permeability material on the inner side of the inner magnetic bottom ring and the magnetic inner ring, combined with the excitation coil, can form a stable and controllable external magnetic field auxiliary environment for the brushless motor assembly. In conjunction with the internal magnetic field of the Hall magnetic ring, it can more comprehensively simulate the magnetic field situation when the brushless motor is actually working. At the same time, the non-magnetic material on the outer side can reduce external magnetic field interference and further improve the test accuracy.

[0013] Furthermore, the multi-probe module is inserted inside the connector, and the spacing between the two auxiliary guide plates is equal to the length of the connector;

[0014] Through the above technical solution, during the movement of the test box toward the connector, the auxiliary guide plate can contact the two ends of the connector before the multi-probe module and achieve preliminary lateral centering and alignment. Then, the brushless motor assembly is magnetically positioned by the positioning component, and the test box is reset to wait for the connection test between the multi-probe module and the connector. This mechanical pre-positioning function ensures that the central axes of the two are aligned before docking, so that the multi-probe module can be inserted into the socket inside the connector more smoothly and accurately, effectively preventing pin bending or socket damage caused by position deviation.

[0015] Furthermore, two limiting posts are fixedly connected to one side of the detection box near the first cylinder, and two limiting blocks are fixedly connected to the upper surface of the base. The outer surfaces of the two limiting posts are slidably sleeved in the inner walls of the two limiting blocks, and a limiting plate is fixedly connected to the end of each limiting post away from the detection box.

[0016] Through the above technical solution, the limiting post fixed to the detection box and the limiting block fixed to the base platform constitute a precision sliding guide pair. This structure ensures that the detection box driven by the first cylinder can move forward and backward smoothly along a strictly defined straight trajectory without shaking or deviation during its movement, thereby guaranteeing the positioning accuracy of the multi-probe module and connector docking. The limiting plate fixed to the end of the limiting post cooperates with the limiting block to provide reliable mechanical stroke limit and buffering, preventing the detection box from overshooting and protecting the equipment structure.

[0017] Furthermore, a vertical plate is fixedly connected to the upper surface of the machine tool, a fixed plate is fixedly connected to the outer surface of the vertical plate, a second cylinder is fixedly connected to the upper surface of the fixed plate, a slider is fixedly connected to the output end of the second cylinder, two symmetrical slide rails are fixedly connected to the outer surface of the vertical plate, the two sides of the slider are respectively slidably sleeved on the outer surface of the two slide rails, a limit plate is fixedly connected to both ends of each slide rail, a rectangular plate is fixedly connected to the outer surface of the slider, a bracket is fixedly connected to the upper surface of the rectangular plate, a servo motor is fixedly connected to the upper surface of the bracket, a motor encoder is integrated at the tail end of the servo motor, a connecting rod is installed below the rectangular plate, a Hall magnetic ring is fixedly connected to the bottom end of the connecting rod, the Hall magnetic ring is a multi-pole magnetized permanent magnet, a rotatable coupling is installed inside the rectangular plate, the top end of the connecting rod is connected to the output shaft end of the servo motor through the coupling, and the Hall magnetic ring is located directly above the brushless motor body;

[0018] Through the above technical solution, the two slide rails fixed on the vertical plate and the corresponding sliding components installed on the slider provide a high-rigidity dual guide for the vertical movement of the simulation component. This makes the entire simulation component driven by the second cylinder move in a stable and unhindered trajectory when it drives the Hall magnetic ring to rise and fall. The limiting plates fixed at both ends of the slide rails physically and precisely limit the upper and lower limit positions of the slider and the Hall magnetic ring connected to it, ensuring that the Hall magnetic ring can be fully inserted into the brushless motor body for testing and can be safely retracted when not in operation, avoiding collision interference.

[0019] Furthermore, the multi-probe module is electrically connected to the internal electrical components of the controller via wires inside the detection box;

[0020] Through the above technical solution, the multi-probe module establishes a direct and reliable electrical connection channel with the data acquisition and processing electrical components inside the controller through the wires laid inside the detection box. This integrated wiring method enables the raw electrical signals collected by the multi-probe module from the connector to be stably transmitted to the controller, ensuring the authenticity and integrity of the signal acquisition, and laying a solid foundation for the controller to perform accurate signal logic analysis, timing calculation and performance judgment.

[0021] Furthermore, each of the four corners of the bottom surface of the machine base is fixedly connected with a support leg, and each of the four corners of the top surface of the machine base is fixedly connected with a vertical pole, the top of each of the four vertical poles being fixedly connected to the bottom surface of the controller.

[0022] The aforementioned technical solution provides stable support for the entire testing equipment by installing the feet at the corners of the machine base, ensuring overall stability during operation. The uprights installed at the corners of the upper surface of the machine base serve as robust frame supports, securely raising and fixing the controller above the working area. This layout makes efficient use of three-dimensional space, keeping the controller away from the mechanical moving parts below.

[0023] Furthermore, the upper surface of the machine tool is provided with three protective plates, which are installed between the four uprights;

[0024] Through the above technical solution, multiple protective plates arranged on the upper surface of the machine platform and located between the uprights form an effective physical isolation barrier between the machine platform and the controller. This can protect core components such as positioning components, detection components, and simulation components, reduce the impact of external debris on the components, and at the same time prevent accidental contact by personnel during equipment operation, thereby improving the safety of equipment use.

[0025] Furthermore, the controller integrates a display screen and buttons on its front side;

[0026] Through the above technical solution, the display screen and buttons integrated on the front of the controller together form an intuitive human-machine interface. The display screen can show the test status, step prompts, the collected Hall signal waveform, and the final performance judgment result, while the buttons provide operators with a convenient way to operate.

[0027] Furthermore, a first switch electrically connected to the first cylinder is installed on the upper surface of the machine tool, a second switch electrically connected to the servo motor is installed on the upper surface of the machine tool, and a third switch electrically connected to the second cylinder is installed on the upper surface of the machine tool.

[0028] Through the above technical solution, the first switch can be used to control the first cylinder to move at a preset distance, the second switch can be used to control the servo motor to rotate at a preset speed, and the third switch can be used to control the second cylinder to move at a preset distance.

[0029] This invention provides a Hall effect testing device for brushless motors. It has the following beneficial effects:

[0030] This invention provides a Hall effect testing device for brushless motors. By introducing a simulation component consisting of a servo motor, a motor encoder, and a Hall effect magnetic ring, it creatively replaces the traditional motor-driven testing method with a physical magnetic field simulation. During operation, a second cylinder drives the entire simulation component to descend, allowing the Hall effect magnetic ring to be inserted into the central cavity of the fixed brushless motor body. Subsequently, the servo motor drives the Hall effect magnetic ring to rotate inside the brushless motor body via a coupling. This reproduces a rotating magnetic field that is completely consistent with the actual working state inside the brushless motor without energizing the motor windings, directly stimulating the built-in Hall sensor to generate a signal. This purely physical simulation method eliminates the influence of factors such as differences in drive circuits, winding parameters, and current interference on the test results, ensuring that the detection signal fully reflects the performance and installation accuracy of the Hall sensor itself. The testing environment is safer, and the results are more comparable and authoritative.

[0031] This invention provides a brushless motor Hall effect testing device. By designing a composite positioning component consisting of an inner magnetic bottom ring, a non-magnetic upper ring, a magnetic inner ring, and an excitation coil, it achieves rapid, non-destructive, and high-precision automated clamping and magnetic field isolation of the brushless motor assembly. After the operator places the brushless motor body into the annular space guided by the non-magnetic upper ring, the excitation coil is energized. At this time, the magnetic inner ring and the highly permeable inner part of the inner magnetic bottom ring form an efficient closed magnetic circuit, generating a strong radially focused magnetic field. This field firmly attracts and automatically centers the brushless motor body, providing uniform positioning force without mechanical damage. More importantly, the non-magnetic outer part of the inner magnetic bottom ring and the non-magnetic upper ring together form a top-down magnetic field shielding channel, forcing the positioning magnetic field to circulate within the lower half of the motor housing. This effectively prevents it from diffusing upwards to the test area where the Hall sensor is located inside the motor. This creates a magnetically clean environment for subsequent Hall signal acquisition, avoiding interference from the positioning magnetic field on the measured signal and ensuring high accuracy and reliability of the test.

[0032] This invention provides a brushless motor Hall effect testing device. Through a testing box with auxiliary guide plates, a precision guide pair composed of limiting posts and blocks, and a multi-probe module, a coordinated, orderly, and reliable test probe docking and signal acquisition mechanism is formed. When the first cylinder pushes the testing box towards the connector, the auxiliary guide plates on both sides, with their spacing matching the connector length, first contact its sides, completing preliminary lateral alignment and centering, laying the foundation for subsequent docking. Subsequently, the brushless motor assembly is electromagnetically positioned by a positioning component, and then the testing box is reset to await subsequent testing. During testing, the first cylinder can be activated to move the testing box towards the connector, allowing the precisely aligned multi-probe module to be inserted vertically and smoothly into the connector. The acquired Hall effect signal is stably transmitted to the controller through integrated wiring within the testing box. This series of tightly connected mechanical actions ensures the one-time success of the electrical connection and the reliability of the signal path, effectively preventing component damage caused by mis-insertion or removal. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall front view of the present invention;

[0034] Figure 2 This is a partial side view of the structure of the present invention;

[0035] Figure 3 This is a first schematic diagram of the partial top view structure of the present invention;

[0036] Figure 4 This is a second schematic diagram of the partial top view of the structure of the present invention;

[0037] Figure 5 This is a top view schematic diagram of the structure of the present invention;

[0038] Figure 6 This is a cross-sectional view of the inner magnetic bottom ring of the present invention from a bottom angle.

[0039] Figure 7 This is a partial bottom view of the structure of the present invention.

[0040] Among them, 1. machine base; 2. base plate;

[0041] 3. Positioning assembly; 301. Inner magnetic bottom ring; 302. Non-magnetic upper ring; 303. Magnetic inner ring; 304. Excitation coil;

[0042] 4. Detection components; 401. Base platform; 402. First cylinder; 403. Detection box; 404. Multi-probe module; 405. Auxiliary guide plate; 406. Limiting post; 407. Limiting block; 408. Limiting plate;

[0043] 5. Simulation components; 501. Vertical plate; 502. Fixed plate; 503. Second cylinder; 504. Slider; 505. Slide rail; 506. Limiting plate; 507. Rectangular plate; 508. Coupling; 509. Bracket; 510. Servo motor; 511. Motor encoder; 512. Connecting rod; 513. Hall effect magnetic ring;

[0044] 6. Brushless motor assembly; 601. Brushless motor body; 602. Connector;

[0045] 7. Support legs; 8. Upright pole; 9. Protective plate; 10. Controller; 11. Display screen; 12. Button; 13. First switch; 14. Second switch; 15. Third switch. Detailed Implementation

[0046] The technical solutions of the specific embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described specific embodiments are only a part of the specific embodiments of the present invention, and not all of them. Based on the specific embodiments of the present invention, all other specific embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Detailed Implementation Method 1:

[0048] like Figure 1-7 As shown, a specific embodiment of the present invention provides a brushless motor Hall effect testing device, including a machine base 1, a positioning component 3, a detection component 4, a simulation component 5, and a controller 10. A base plate 2 is fixedly connected to the upper surface of the machine base 1. The positioning component 3 and the detection component 4 are both installed on the upper surface of the base plate 2. A brushless motor assembly 6 is positioned inside the positioning component 3. The brushless motor assembly 6 includes a brushless motor body 601 and a connector 602 installed on the outer surface of the brushless motor body 601. The positioning component 3 includes an inner magnetic bottom ring 301 fixedly connected to the upper surface of the base plate 2. A non-magnetic upper ring 302 is fixedly connected to the upper surface of the inner magnetic bottom ring 301. A magnetic inner ring 303 is installed inside the inner magnetic bottom ring 301. An excitation coil 304 is installed outside the magnetic inner ring 303.

[0049] Reference Figure 3 , Figure 4 and Figure 5The detection assembly 4 includes a base platform 401 fixedly connected to the upper surface of the base plate 2. A first cylinder 402 is fixedly connected to the upper surface of the base platform 401. A detection box 403 is fixedly connected to the output end of the first cylinder 402. A multi-probe module 404 is installed inside the detection box 403. Two auxiliary guide plates 405 for auxiliary positioning are fixedly connected to the outer surface of the detection box 403. The multi-probe module 404 is located between the two auxiliary guide plates 405 and is inserted into the connector 602. The distance between the two auxiliary guide plates 405 is equal to the length of the connector 602. When the detection box 403 faces the connector 602... During the movement, the auxiliary guide plate 405 can contact the two ends of the connector 602 before the multi-probe module 404 and achieve preliminary lateral alignment and guidance. Then, the brushless motor assembly 6 is magnetically positioned by the positioning component 3. Next, the detection box 403 is reset, waiting for the connection detection work between the multi-probe module 404 and the connector 602. This mechanical pre-positioning function ensures that the central axes of the two are aligned before docking, so that the multi-probe module 404 can be inserted into the socket inside the connector 602 more smoothly and accurately, effectively preventing pin bending or socket damage caused by position deviation.

[0050] Reference Figure 3 , Figure 4 and Figure 5Two limiting posts 406 are fixedly connected to the side of the detection box 403 near the first cylinder 402, and two limiting blocks 407 are fixedly connected to the upper surface of the base 401. The outer surfaces of the two limiting posts 406 are slidably fitted into the inner walls of the two limiting blocks 407. A limiting plate 408 is fixedly connected to the end of each limiting post 406 away from the detection box 403. The limiting posts 406 fixed on the detection box 403 and the limiting blocks 407 fixed on the base 401 form a precision sliding guide pair. This structure ensures that the detection box 403 driven by the first cylinder 402 can move forward and backward smoothly along a strictly defined straight trajectory without shaking or deviation during its movement, thereby ensuring the positioning accuracy of the multi-probe module 404 and the connector 602. The limiting plate 408, fixed to the end of the limiting post 406, cooperates with the limiting block 407 to reliably limit and buffer the end of the mechanical stroke, preventing the detection box 403 from overshooting and protecting the equipment structure. The multi-probe module 404 is electrically connected to the internal electrical components of the controller 10 through the wires inside the detection box 403. The multi-probe module 404 establishes a direct and reliable electrical connection channel with the data acquisition and processing electrical components inside the controller 10 through the wires laid inside the detection box 403. This integrated wiring method enables the original electrical signal collected by the multi-probe module 404 from the connector 602 to be stably transmitted to the controller 10, ensuring the authenticity and integrity of the signal acquisition and laying a solid foundation for the controller 10 to perform accurate signal logic analysis, timing calculation and performance judgment.

[0051] Reference Figure 2 , Figure 3 and Figure 7The simulation component 5 includes a vertical plate 501 fixedly connected to the upper surface of the machine base 1. A fixed plate 502 is fixedly connected to the outer surface of the vertical plate 501. A second cylinder 503 is fixedly connected to the upper surface of the fixed plate 502. A slider 504 is fixedly connected to the output end of the second cylinder 503. A rectangular plate 507 is fixedly connected to the outer surface of the slider 504. A bracket 509 is fixedly connected to the upper surface of the rectangular plate 507. A servo motor 510 is fixedly connected to the upper surface of the bracket 509. A motor encoder 511 is integrated at the tail end of the servo motor 510. A connecting rod 512 is installed below the rectangular plate 507. A Hall effect magnetic ring 513 is fixedly connected to the bottom end of the connecting rod 512. A rotatable coupling 508 is installed inside the rectangular plate 507. The top end of the connecting rod 512 is connected to the output shaft end of the servo motor 510 through the coupling 508. The Hall effect magnetic ring 513 is located directly above the brushless motor body 601. Ring 513 is a multi-pole magnetized permanent magnet. Two symmetrical slide rails 505 are fixedly connected to the outer surface of the vertical plate 501. The two sides of the slider 504 are respectively slidably sleeved on the outer surface of the two slide rails 505. Limiting plates 506 are fixedly connected to both ends of each slide rail 505. The two slide rails 505 fixed on the vertical plate 501 and the corresponding sliding parts installed on the slider 504 provide high-rigidity dual guidance for the vertical movement of the simulation component 5. This makes the entire simulation component 5 driven by the second cylinder 503 move in a stable and unhindered trajectory when it drives the Hall magnetic ring 513 to rise and fall. The limiting plates 506 fixed to both ends of the slide rails 505 physically and precisely limit the upper and lower limit positions of the slider 504 and the Hall magnetic ring 513 connected to it, ensuring that the Hall magnetic ring 513 can be fully inserted into the brushless motor body 601 for testing, and can also be safely retracted when not in operation to avoid collision interference.

[0052] Reference Figure 1 , Figure 2 and Figure 6The inner side of the inner magnetic bottom ring 301 is made of a high magnetic permeability material, while the outer side is made of a non-magnetic material. The magnetic inner ring 303 and the high magnetic permeability inner part of the inner magnetic bottom ring 301 form the main body of the closed magnetic circuit. The excitation coil 304 is connected to the external power supply component through wires. The closed magnetic circuit formed by the high magnetic permeability material on the inner side of the inner magnetic bottom ring 301 and the magnetic inner ring 303, combined with the excitation coil 304, can form a stable and controllable external magnetic field auxiliary environment for the brushless motor assembly 6. In conjunction with the internal magnetic field of the Hall magnetic ring 513, it can more comprehensively simulate the magnetic field situation when the brushless motor is actually working. At the same time, the non-magnetic material on the outer side can reduce external magnetic field interference and further improve the test accuracy. Support legs 7 are fixedly connected to the four corners of the bottom surface of the machine base 1, and uprights 8 are fixedly connected to the four corners of the top surface of the machine base 1. The tops of the four uprights 8 are fixedly connected to the bottom surface of the controller 10. The support legs 7 installed at the corners of the bottom surface of the machine base 1 provide stable support for the entire testing equipment, ensuring the overall stability of the equipment during operation. The uprights 8 installed at the corners of the top surface of the machine base 1 serve as sturdy frame supports, steadily raising and fixing the controller 10 above the working area. This layout makes reasonable use of three-dimensional space, keeping the controller 10 away from the mechanical moving parts below. The top surface of the machine base 1 is equipped with three protective plates 9, which are installed between the four uprights 8. The multiple protective plates 9 arranged on the top surface of the machine base 1 and located between the uprights 8 form an effective physical isolation barrier between the machine base 1 and the controller 10. This can protect the core components such as the positioning component 3, the detection component 4, and the simulation component 5, reduce the impact of external debris on the components, and also prevent accidental contact by personnel during equipment operation, thus improving the safety of equipment use.

[0053] Reference Figure 1 , Figure 2 and Figure 3 The controller 10 integrates a display screen 11 and buttons 12 on its front side. Together, these components form an intuitive human-machine interface. The display screen 11 can show the test status, step prompts, the acquired Hall signal waveform, and the final performance judgment result. The buttons 12 provide operators with a convenient way to operate the machine. The upper surface of the machine 1 is equipped with a first switch 13 electrically connected to the first cylinder 402, a second switch 14 electrically connected to the servo motor 510, and a third switch 15 electrically connected to the second cylinder 503. The first switch 13 allows for easy control of the first cylinder 402 to move at a preset distance. The second switch 14 allows for control of the servo motor 510 to rotate at a preset speed. The third switch 15 allows for control of the second cylinder 503 to move at a preset distance.

[0054] It should be noted that the brushless motor body 601 typically houses three Hall sensors, which are mounted on the stator of the motor and arranged in a circle around the central rotor. Each Hall sensor has its own independent power, ground, and signal output pins. Therefore, the motor will have at least five wires leading out to connect to these three sensors. The voltage changes output by these three independent signal lines are called the three Hall signals. The connector 602 mounted on the outer surface of the brushless motor body 601 contains the pins of these three Hall sensors, and the multi-probe module 404 is a module consisting of three pairs of probes to ensure simultaneous and reliable contact with all necessary pins.

[0055] Working principle: Before operation, the operator first places the brushless motor body 601 to be tested vertically in the annular space of the positioning component 3 and manually adjusts its orientation so that the connector 602 on its side is roughly facing the location of the test box 403. Then, the first cylinder 402 is activated, driving the test box 403 to move smoothly forward along the precision guide pair composed of the limiting post 406 and the limiting block 407. During this process, the auxiliary guide plates 405 fixed on both sides of the test box 403, according to their set spacing, first contact the two side edges of the connector 602, and use mechanical force to finely adjust and guide the circumferential angle of the brushless motor body 601, so that the interface of the connector 602 and the multi-probe module 404 achieve preliminary axial alignment. After completing this mechanical pre-positioning, the controller 10 supplies power to the excitation coil 304, generating a strong radial focusing magnetic field in the closed magnetic circuit formed by the high magnetic permeability inner part of the inner magnetic bottom ring 301 and the magnetic inner ring 303. This magnetic field firmly attracts the metal shell of the brushless motor body 601 and automatically centers it at the center position of the non-magnetic upper ring 302, achieving a non-destructive and high-precision final fixation. At the same time, the non-magnetic material components effectively shield the positioning magnetic field from interference to the internal test area of ​​the motor. Then, the detection box 403 is returned to its initial position. Then, the second cylinder 503 starts to move, pushing the entire analog assembly 5 to descend vertically along the slide rail 505, causing the Hall magnetic ring 513 to be inserted. The sensor is inserted into the central cavity of the fixed motor. Simultaneously, the detection box 403 advances again. Based on the previous alignment, the multi-probe module 404 can be vertically inserted into the connector 602 to establish a reliable connection with the electrical pins of the Hall sensor. Then, the servo motor 510 starts and drives the multi-pole magnetized Hall magnetic ring 513 to rotate precisely at a preset speed inside the brushless motor body 601 through the coupling 508 and connecting rod 512, simulating the dynamic rotating magnetic field generated by the real rotor, thereby stimulating the Hall sensor built into the motor to output a signal. The detection box 403 and the multi-probe module 404 transmit the collected Hall signal to the controller 10 through internal integrated wiring. The controller 10 synchronously receives the precise angular position information from the motor encoder 511 and compares and analyzes it with the timing characteristics such as the transition edges and high and low levels of the three Hall signals. Finally, it calculates the installation phase angle error, signal logic relationship and electrical characteristics of the Hall sensor, and displays detailed test results and judgments on the display screen 11. The entire workflow is fully automated, from clamping, positioning, magnetic field simulation to signal acquisition and analysis. The testing process is safe, pure, and the results are reliable.

[0056] Although specific embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these specific embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A brushless motor Hall effect testing device, comprising a machine base (1), a positioning component (3), a detection component (4), a simulation component (5), and a controller (10), characterized in that: The upper surface of the machine tool (1) is fixedly connected to a base plate (2). The positioning component (3) and the detection component (4) are both installed on the upper surface of the base plate (2). The positioning component (3) has a brushless motor assembly (6) inside. The brushless motor assembly (6) includes a brushless motor body (601) and a connector (602) installed on the outer surface of the brushless motor body (601). The positioning component (3) includes an inner magnetic bottom ring (301) fixedly connected to the upper surface of the base plate (2). A non-magnetic upper ring (302) is fixedly connected to the upper surface of the inner magnetic bottom ring (301). A magnetic inner ring (303) is installed inside the inner magnetic bottom ring (301). An excitation coil (304) is installed outside the magnetic inner ring (303). The detection component (4) includes a base platform (401) fixedly connected to the upper surface of the base plate (2). A first cylinder (402) is fixedly connected to the upper surface of the base platform (401). A detection box (403) is fixedly connected to the output end of the first cylinder (402). A multi-probe module (404) is installed inside the detection box (403). Two auxiliary guide plates (405) for auxiliary positioning are fixedly connected to the outer surface of the detection box (403). The multi-probe module (404) is located between the two auxiliary guide plates (405). The simulation component (5) includes a servo motor (510) and a Hall magnetic ring (513) for detection. The inner magnetic ring (303) and the inner magnetic bottom ring (301) with high magnetic permeability inner side constitute the main body of the closed magnetic circuit.

2. The brushless motor Hall effect testing device according to claim 1, characterized in that: The inner side of the inner magnetic bottom ring (301) is made of a high magnetic permeability material, and the outer side of the inner magnetic bottom ring (301) is made of a non-magnetic material. The excitation coil (304) is connected to the external power supply component through a wire.

3. The brushless motor Hall effect testing device according to claim 1, characterized in that: The multi-probe module (404) is inserted into the inside of the connector (602), and the spacing between the two auxiliary guide plates (405) is equal to the length of the connector (602).

4. The brushless motor Hall effect testing device according to claim 1, characterized in that: Two limiting posts (406) are fixedly connected to one side of the detection box (403) near the first cylinder (402), and two limiting blocks (407) are fixedly connected to the upper surface of the base (401). The outer surfaces of the two limiting posts (406) are respectively slidably sleeved in the inner walls of the two limiting blocks (407), and a limiting plate (408) is fixedly connected to one end of each limiting post (406) away from the detection box (403).

5. The brushless motor Hall effect testing device according to claim 1, characterized in that: A vertical plate (501) is fixedly connected to the upper surface of the machine base (1). A fixed plate (502) is fixedly connected to the outer surface of the vertical plate (501). A second cylinder (503) is fixedly connected to the upper surface of the fixed plate (502). A slider (504) is fixedly connected to the output end of the second cylinder (503). Two symmetrical slide rails (505) are fixedly connected to the outer surface of the vertical plate (501). The two sides of the slider (504) are slidably sleeved on the outer surfaces of the two slide rails (505). Limit plates (506) are fixedly connected to both ends of each slide rail (505). A rectangular plate (507) is fixedly connected to the outer surface of the slider (504). The upper surface of the rectangular plate (507) is... A bracket (509) is fixedly connected to the upper surface of the bracket (509). The servo motor (510) is fixedly connected to the upper surface of the bracket (509). The tail end of the servo motor (510) is integrated with a motor encoder (511). A connecting rod (512) is installed below the rectangular plate (507). The Hall magnetic ring (513) is fixedly connected to the bottom end of the connecting rod (512). The Hall magnetic ring (513) is a multi-pole magnetized permanent magnet. A rotatable coupling (508) is installed inside the rectangular plate (507). The top end of the connecting rod (512) is connected to the output shaft end of the servo motor (510) through the coupling (508). The Hall magnetic ring (513) is located directly above the brushless motor body (601).

6. The brushless motor Hall effect testing device according to claim 1, characterized in that: The multi-probe module (404) is electrically connected to the internal electrical components of the controller (10) via wires inside the detection box (403).

7. The brushless motor Hall effect testing device according to claim 1, characterized in that: The machine base (1) has four fixed legs (7) at the four corners of its bottom surface and four fixed poles (8) at the four corners of its top surface. The tops of the four poles (8) are fixedly connected to the bottom surface of the controller (10).

8. The brushless motor Hall effect testing device according to claim 7, characterized in that: The upper surface of the machine base (1) is provided with three protective plates (9), and the three protective plates (9) are installed between four uprights (8).

9. The brushless motor Hall effect testing device according to claim 1, characterized in that: The controller (10) has a display screen (11) and buttons (12) integrated on the front.

10. The brushless motor Hall effect testing device according to claim 1, characterized in that: The upper surface of the machine tool (1) is equipped with a first switch (13) electrically connected to the first cylinder (402), a second switch (14) electrically connected to the servo motor (510) is installed on the upper surface of the machine tool (1), and a third switch (15) electrically connected to the second cylinder (503) is installed on the upper surface of the machine tool (1).

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