Calibration test method and device of ultra-high-speed motor and motor controller

Abstract

The invention provides a calibration test method and test device for an ultra-high-speed motor and a motor controller, and belongs to the technical field of electric driving of new energy automobiles. The method comprises the following steps: operating a tested motor within a first rotating speed range, measuring electrical operation parameters of the tested motor, and determining flux linkage parameters; setting a target rotating speed higher than the upper limit of the first rotating speed range, and determining a voltage limiting condition based on the flux linkage parameter and the target rotating speed; under the operation condition of being lower than the target rotating speed, different driving current combinations are scanned, screening is carried out according to voltage limiting conditions, and driving parameter mapping of the tested motor under the target rotating speed is obtained; and in an independent test environment, carrying out a full-rotation-speed-section performance test based on the driving parameter mapping, and comparing the driving parameter mapping with expected performance to confirm or correct the driving parameter mapping so as to obtain a final calibration parameter. According to the method, the existing low-speed test resources are utilized, the calibration and verification test of the ultra-high-speed motor can be efficiently and accurately completed, and the development period is shortened.

Description

Calibration test methods, test equipment and motor controller for ultra-high speed motors Technical Field

[0001] This application belongs to the field of electric drive technology for new energy vehicles, specifically relating to a calibration test method, test device, and motor controller for an ultra-high speed motor. Background Technology

[0002] As the automotive industry continues its rapid shift towards new energy vehicles, improving the performance of automotive drive motors has become crucial. Among these advancements, the trend towards ultra-high-speed motors is becoming increasingly prominent. As the core module of new energy vehicles, the electric drive system directly determines the overall vehicle's power performance. Ultra-high-speed motor technology reduces the demand for instantaneous torque by operating at higher speeds while maintaining the same output power. This reduces motor size and weight, lowers material usage and costs, and improves energy efficiency, providing strong support for the development of new energy vehicles. Simultaneously, vehicles equipped with ultra-high-speed motors can achieve stronger power output and longer driving range. Leveraging their high power density, ultra-high-speed motors can output greater power in a smaller volume and effectively reduce energy loss during high-efficiency operation, contributing to improved driving range and power performance of new energy vehicles and meeting market demand for high-performance vehicles.

[0003] In terms of technological advancements, breakthroughs in materials technology and improvements in manufacturing processes have laid the physical foundation for the stable operation of electric motors at ultra-high speeds. Correspondingly, the control technology of electric drive systems also faces the need for upgrades to achieve more precise and efficient control of the motor's magnetic field, current, and voltage under ultra-high-speed conditions, thereby adapting to the complex operating conditions brought about by ultra-high-speed operation. However, these technological advancements are limited by bottlenecks in testing capabilities when they are put into practical application and verification.

[0004] Currently, there are relatively few test benches in the industry suitable for ultra-high-speed motors (e.g., speeds exceeding 20,000 r / min). Most companies only have conventional single-motor test benches for testing speeds below 20,000 r / min. This leads to severe challenges in bench calibration and performance testing of ultra-high-speed motors during electric drive system development: either it cannot be directly implemented at the target high speed, or the scarcity of high-speed testing equipment results in long waiting periods and high testing costs. This problem seriously restricts the R&D progress, product verification efficiency, and iteration speed of ultra-high-speed motor technology.

[0005] Therefore, developing a testing method and device that can efficiently and accurately complete the calibration and verification of ultra-high speed motors using existing low-speed testing resources has become an urgent technical problem to be solved in this field. Summary of the Invention

[0006] The purpose of this application is to solve the problems existing in the prior art and provide a calibration and testing method, testing device and motor controller for ultra-high speed motors, which can efficiently and accurately complete the calibration and verification of ultra-high speed motors by utilizing existing low-speed testing resources, and greatly reduce equipment investment costs and technical barriers.

[0007] This application is achieved through the following technical solution:

[0008] The first aspect of this application provides a calibration test method for an ultra-high-speed motor, the calibration test method comprising:

[0009] The motor under test is operated within a first speed range, the electrical operating parameters of the motor under test are measured, and the flux linkage parameters of the motor under test are determined based on the electrical operating parameters.

[0010] Set a target speed higher than the upper limit of the first speed range, and determine voltage limiting conditions based on the flux linkage parameters and the target speed;

[0011] Under operating conditions below the target speed, by scanning different combinations of drive currents and filtering them according to the voltage limit conditions, the drive parameter mapping of the motor under test at the target speed is obtained.

[0012] In an independent testing environment, the full-speed range performance test of the motor under test is performed based on the drive parameter mapping. The drive parameter mapping is confirmed or corrected by comparing it with the expected performance, and the final calibration parameters are obtained.

[0013] Preferably, measuring the electrical operating parameters of the motor under test and determining the flux linkage parameters of the motor under test based on the electrical operating parameters includes:

[0014] Within the first speed range, the back electromotive force of the motor under test is measured at different speeds;

[0015] The flux linkage parameters are calculated based on the ratio of the back electromotive force to the corresponding rotational speed.

[0016] Preferably, the voltage limiting condition is a preset line voltage threshold, which is determined by the following formula:

[0017] Umax=Urated / 1.414×Speed / Speed-T

[0018] Where Umax is the line voltage threshold, Urated is the rated voltage, speed is the calibrated speed, and speed-T is the target speed.

[0019] Preferably, the step of scanning different combinations of drive currents and filtering them according to the voltage limiting conditions is executed by an automated calibration script, including:

[0020] Different combinations of d-axis and q-axis currents are requested sequentially with a preset step size;

[0021] For each requested current combination, the terminal voltage of the motor under test is acquired in real time.

[0022] Record the current combination and the corresponding operating status data only when the terminal voltage meets the voltage limit condition.

[0023] Preferably, the independent testing environment includes a verification test bench, which is equipped with:

[0024] A speed reducer connected to the output shaft of the motor under test;

[0025] A first dynamometer and a second dynamometer are connected to the output end of the reducer. The first dynamometer and the second dynamometer are used to measure the load torque.

[0026] Preferably, confirming or correcting the drive parameter mapping by comparing it with expected performance includes:

[0027] On the verification test bench, the actual output torque of the motor under test is obtained by the first dynamometer and the second dynamometer at the full speed range;

[0028] The actual output torque is compared with the expected torque based on the drive parameter mapping request;

[0029] The torque compensation coefficient is calculated based on the comparison difference, and the torque compensation coefficient is used to linearly correct the driving parameter mapping to generate the final calibration parameters.

[0030] A second aspect of this application provides a calibration and testing apparatus for an ultra-high-speed motor, used to implement the calibration and testing method for the ultra-high-speed motor described in any of the above-mentioned methods, comprising:

[0031] A calibration unit is used to generate a mapping of drive parameters for the motor under test at the target speed.

[0032] The verification unit is used to perform a full-speed range load test on the motor under test based on the drive parameter mapping, and to collect measured performance data.

[0033] The control and processing unit, communicatively connected to the calibration unit and the verification unit, is used for:

[0034] The calibration unit is controlled to execute an automated calibration process;

[0035] Receive the measured data from the verification unit;

[0036] The final calibration parameters are obtained by comparing the driving parameter mapping with the expected performance to confirm or correct it.

[0037] Preferably, the calibration unit includes a bench dynamometer, a motor controller, voltage and current sensors, and a first data acquisition system for collecting electrical and speed parameters of the motor under test; the verification unit includes a reducer, two dynamometers connected in parallel, and a second data acquisition system for collecting load-side torque and speed parameters of the motor under test.

[0038] Preferably, the control and processing unit includes an automatic calibration module, which is used to perform the automatic scanning and filtering operation as described in claim 4 or 5 to generate the driving parameter mapping.

[0039] A third aspect of this application provides a motor controller that internally stores final calibration parameters obtained by the calibration test method for an ultra-high-speed motor as described in any of the preceding claims, and the motor controller is configured to drive the ultra-high-speed motor to operate based on the final calibration parameters.

[0040] Compared with existing technologies, the beneficial effects of this application are as follows: This application transforms the high-speed physical constraints, which are difficult to measure directly, into calculable voltage thresholds by measuring flux linkage parameters at low speeds and performing virtual high-speed simulation calibration based on target speed and voltage limitations. Equivalent testing is then conducted at low speeds through automated scanning. This allows for efficient and accurate calibration and verification of ultra-high-speed motors using existing low-speed testing resources, significantly reducing equipment investment costs and technical barriers, and accelerating technology adoption and product development. Attached Figure Description

[0041] The above and other objects, features, and advantages of this application will become more apparent from the more detailed description of the embodiments of this application in conjunction with the accompanying drawings. The accompanying drawings are used to provide a further understanding of the embodiments of this application and form part of the specification. They are used together with the embodiments of this application to explain this application and do not constitute a limitation thereof.

[0042] Figure 1 is a flowchart illustrating the calibration and testing method for an ultra-high-speed motor according to some embodiments of this application;

[0043] Figure 2 is a logical schematic diagram of the calibration method of an ultra-high speed motor according to some embodiments of this application;

[0044] Figure 3 is a schematic diagram of the structure of the test bench according to some embodiments of this application;

[0045] Figure 4 is a logical schematic diagram of the verification test method of ultra-high speed motor according to some embodiments of this application;

[0046] Figure 5 is a schematic diagram of the structure of a calibration and testing device for an ultra-high-speed motor according to some embodiments of this application. Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of this application more apparent, exemplary embodiments according to this application will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, and not all embodiments of this application. It should be understood that this application is not limited to the exemplary embodiments described herein. Based on the embodiments of this application described herein, all other embodiments obtained by those skilled in the art without inventive effort should fall within the protection scope of this application.

[0048] To address the limitation of conventional single-motor test benches in calibrating and verifying ultra-high-speed motors, this application proposes a calibration and testing method, testing apparatus, and motor controller for ultra-high-speed motors. This method and apparatus can efficiently and accurately complete the calibration and verification of ultra-high-speed motors using existing low-speed testing resources. The following detailed description, in conjunction with the accompanying drawings, further illustrates this application.

[0049] To facilitate understanding of this application, a calibration and testing method for an ultra-high-speed motor disclosed in the embodiment of this application will be described in detail with reference to FIG1.

[0050] Figure 1 is a flowchart illustrating the calibration test method for an ultra-high speed motor according to some embodiments of this application. As shown in Figure 1, the calibration test method for an ultra-high speed motor in this application includes at least the following steps S100 to S400.

[0051] Step S100: Run the motor under test within the first speed range, measure the electrical operating parameters of the motor under test, and determine the flux linkage parameters of the motor under test based on the electrical operating parameters.

[0052] The first speed range refers to the speed interval used for initial testing and baseline parameter acquisition. The upper limit of this range is limited by the physical speed capability of a conventional (non-ultra-high-speed) test bench. In a specific embodiment of the present invention, this upper limit is typically 20,000 revolutions per minute (r / min) or lower, which is the typical capability range of single-motor test benches commonly used in the industry.

[0053] Electrical operating parameters refer to measurable electrical quantities that reflect the electromagnetic and mechanical state of a motor during operation. These typically include, but are not limited to: the back electromotive force generated by the motor windings, the phase voltage and phase current of the three-phase windings, the DC bus voltage, and the speed signal indirectly obtained through sensors. These parameters are the fundamental data for analyzing the intrinsic characteristics of a motor.

[0054] Step S200: Set a target speed higher than the upper limit of the first speed range, and determine the voltage limiting condition based on the flux linkage parameter and the target speed.

[0055] The target speed refers to the expected operating speed, which is higher than the upper limit of the first speed range, as defined and verified by the method of this application. It represents the high-performance speed point that the ultra-high-speed motor needs to actually operate at, such as 25,000 r / min, 30,000 r / min, or higher.

[0056] Voltage limiting conditions refer to the constraint boundaries set on the voltage amplitude of the inverter output to the motor windings at a specific target speed to ensure the safe and reliable operation of the motor drive system. In this application, it is the line voltage threshold. This condition is pre-set through theoretical calculation based on the inherent parameters of the motor (magnetic flux linkage) and the target speed, combined with the system rated voltage, and is used to simulate voltage saturation limitation at high speeds during low-speed calibration.

[0057] Step S300: Under operating conditions below the target speed, by scanning different combinations of drive currents and filtering them according to the voltage limit conditions, the drive parameter mapping of the motor under test at the target speed is obtained.

[0058] In motor vector control, the drive current combination refers to the numerical pair of the two-axis current components—d-axis current Id and q-axis current Iq—used to independently control the motor's magnetic field and torque. Drive parameter mapping refers to the set of all safe and effective operating points (Id, Iq) that meet voltage limits, selected through a scanning process at a specific target speed.

[0059] Step S400: In an independent test environment, perform a full-speed range performance test on the motor under test based on the drive parameter mapping, and confirm or correct the drive parameter mapping by comparing it with the expected performance to obtain the final calibration parameters.

[0060] Among them, the full-speed range performance test refers to the systematic loading test of the motor from the lowest speed to its highest design speed (including the target speed) within the entire continuous speed range to obtain comprehensive performance data such as its torque output capability, efficiency, and temperature rise.

[0061] This application provides a calibration and testing method for ultra-high-speed motors. By measuring flux linkage parameters at low speeds and performing virtual high-speed simulation calibration based on target speed and voltage constraints, the high-speed physical constraints that are difficult to measure directly are transformed into calculable voltage thresholds. Equivalent testing is then performed at low speeds through automated scanning. This allows for efficient and accurate calibration and verification of ultra-high-speed motors using existing low-speed testing resources, significantly reducing equipment investment costs and technical barriers, and accelerating technology adoption and product development.

[0062] Next, a calibration method for an ultra-high-speed motor according to an embodiment of this application will be described with reference to FIG2.

[0063] This embodiment utilizes an existing low-speed (e.g., up to 20,000 r / min) single-motor calibration bench. Through theoretical calculations and automated scripts, it calibrates the operating characteristics of the motor at higher target speeds (e.g., 30,000 r / min or above), and uses an independent verification bench to complete the performance verification across the entire speed range.

[0064] As shown in Figure 2, the calibration method of this embodiment includes the following steps:

[0065] S1. Obtaining low-speed reference parameters.

[0066] First, the ultra-high-speed motor to be calibrated was mounted on a conventional single-motor calibration bench with a maximum speed capability of 20,000 r / min. Within the safe speed range of this bench, the motor was driven to rotate, and the back electromotive force (Back-EMF) of the motor at different speeds was measured using high-precision sensors. Subsequently, the flux linkage Ψ parameter of the motor was calculated based on the following formula:

[0067] Ψ=E / ω

[0068] Where E is the measured back electromotive force, and ω is the corresponding electric angular velocity (proportional to the mechanical rotational speed). The calculated flux linkage Ψ is an inherent electromagnetic parameter of the motor, which will be recorded and used in subsequent steps.

[0069] S2, High-speed operating condition simulation and automated calibration.

[0070] This step aims to calibrate the motor's operating characteristics at a range of target speeds (e.g., 30,000 r / min) that are above the test bench's capabilities, thereby covering its high-speed operating range.

[0071] S21. Set a target speed sequence. This sequence starts from a starting value higher than the test bench's limit speed (e.g., 20000 r / min) and increases in preset speed steps (e.g., 1000 r / min) until the maximum allowable speed of the motor design, speedmax, is reached. For each target speed Speed-T in the sequence, perform the following calibration procedure.

[0072] S22. Since the physical limit speed of the test bench (denoted as the calibration speed Speed, for example, 20000 r / min) is lower than Speed-T, a virtual line voltage threshold Umax is calculated for the current Speed-T as the safe voltage boundary at that speed. The calculation formula is:

[0073] Umax=Urated / 1.414×Speed / Speed-T

[0074] Where Urated is the rated DC bus voltage of the motor system.

[0075] S23. The control rack operates at a fixed calibrated speed (Speed), and the control mode is set to current control mode. Nested cyclic scanning is performed, with the target speed (Speed-T) as the operating point. The specific process is as follows:

[0076] Initialization: Set the d-axis current idcmd to an initial value and the q-axis current iqcmd to 0.

[0077] Outer loop (d-axis scan): Increment idcmd by a preset step size (e.g., -10A). Before each increment, check if idcmd is less than or equal to the maximum d-axis current idmax designed for the motor. If yes, execute the inner loop; otherwise, end the calibration of the current target speed Speed-T.

[0078] Inner loop (q-axis scan): For the current idcmd value, calculate the maximum allowable q-axis current iqmax based on motor parameters or a preset algorithm. Increment iqcmd by a preset step size (e.g., 10A). In each step, perform the following judgment:

[0079] Condition 1: Is iqcmd ≤ iqmax?

[0080] Condition 2: Real-time line voltage ≤ Umax at the given rotational speed.

[0081] If both of the above conditions are met simultaneously, the system will automatically record the operating point data, including idcmd, iqcmd, voltage, and speed, after 1 second of stable operation. Then, iqcmd will be incremented by one step, and the inner loop will continue.

[0082] If condition 2 is not met (i.e., the voltage exceeds Umax), then skip the current iqcmd value (do not record it), directly increase the iqcmd step size, and continue to try.

[0083] If iqcmd > iqmax, then exit the inner loop.

[0084] After exiting the inner loop, return to the outer loop, increment idcmd by one step, and start a new round of q-axis scanning.

[0085] S24. Through the above automated scanning, explore all (id, iq) operating points that meet the voltage safety boundary and current limit at the target speed Speed-T. Organize all recorded valid operating points to generate a subset of drive parameter mappings for the target speed.

[0086] Then, the target rotational speed is increased by one step, updated to the next Speed-T value, and the following is determined:

[0087] If the new Speed-T ≤ speedmax, then repeat steps S22 and S23 to calculate the new Umax and perform a new round of scanning.

[0088] If the new Speed-T > speedmax, it signifies that the calibration work for the entire high-speed range is complete.

[0089] Finally, by integrating the operating points calibrated at all target speeds, a complete drive parameter map (current MAP) covering the high-speed operating range is formed.

[0090] The above calibration can be achieved through automated calibration scripts. Automated calibration scripts can perform calibration scanning at multiple speeds, eliminating the need for repetitive manual operations, greatly reducing the workload of calibration and testing, improving work efficiency, and minimizing calibration data errors caused by human sampling preferences, thus improving data accuracy.

[0091] In this embodiment, by using a single-motor calibration bench, the line voltage threshold at the ultra-high speed target speed is calculated using a formula. The current MAP of the ultra-high speed motor is then calibrated, thus completing the motor bench calibration. This enables the calibration of the ultra-high speed motor's current MAP at low speeds, solving the problem of calibration being impossible due to limited bench resources, shortening the development cycle, and reducing wasted time and costs.

[0092] Next, a verification test method for an ultra-high-speed motor according to an embodiment of this application will be described with reference to Figures 3 and 4.

[0093] In the calibration test method for ultra-high-speed motors in this application, the verification test process is completed through an independent verification test bench. The unique structural design of this verification bench is designed to solve the challenges of high-speed motor load testing.

[0094] Verification bench structure:

[0095] As shown in Figure 3, the core structure of the verification test bench is as follows: the output shaft of the motor under test is directly connected to the input end of a reducer. The output end of the reducer is simultaneously connected to the first and second dynamometers via a transmission mechanism (such as a coupling or gear set). The function of the reducer is to reduce the high speed (potentially exceeding 20,000 r / min) of the motor under test to a fixed speed ratio i (e.g., i = 3), allowing the two conventional dynamometers at the rear to operate within their safe and efficient speed range and accurately measure torque.

[0096] The verification test process is explained in detail below with reference to Figure 4.

[0097] After obtaining the preliminary drive parameter mapping (current MAP) through the aforementioned calibration method, it is integrated into control parameters and written into the controller corresponding to the motor under test. Subsequently, systematic verification and accuracy correction are performed according to the following steps:

[0098] S31. Perform low-speed benchmark verification on the calibration bench.

[0099] The motor with the controller, already calibrated, is reinstalled on the original calibration bench (low-speed bench) for direct torque verification using a conventional dynamometer. Load tests are performed within the dynamometer's capability range (i.e., multiple speed points below 20,000 r / min). The actual output torque T is recorded at different requested torques Tcmd, thus obtaining the measured torque MAP in the low-speed range. Simultaneously, the system's friction torque can be isolated and recorded. The initial torque accuracy at the low-speed point is calculated to determine if it meets design requirements. Torque accuracy is the difference between the requested torque Tcmd and the measured torque T, calculated using the formula: absolute error T - Tcmd or relative error (T - Tcmd) / Tcmd*100%.

[0100] S32. Perform full-speed range verification on the verification bench.

[0101] The entire motor system (motor + controller) was transferred to the aforementioned verification test bench. On this bench, a full-speed range loading test was conducted, from low speed to the target ultra-high speed. During the test, two dynamometers operated synchronously, measuring torque values ​​T1 and T2 respectively through their torque sensors, and simultaneously recording the corresponding requested motor torque Tcmd and speed. Through system testing at numerous operating points across the entire speed range, raw test datasets were obtained for subsequent analysis.

[0102] S33, Data comparison and linear correction for high-speed friction torque compensation.

[0103] The results of the two tests were compared and analyzed to establish a correction relationship between the verification bench measurement results and the actual torque:

[0104] Verification bench torque calculation: On the verification bench, the actual torque output by the motor to the load end (T_verification) cannot be directly measured, but it can be calculated by summing the torques measured by two dynamometers and considering the speed ratio of the reducer. The preliminary calculation is as follows:

[0105] (T1+T2) / i.

[0106] Difference Analysis and Correction: Comparing the relatively accurate torque value (T_calibration) measured by the calibration bench with the converted value from the verification bench at the same speed and torque request point:

[0107] (T1+T2) / i.

[0108] A systematic deviation was found between the two, which was mainly caused by the inherent friction and loss of the verification bench drive chain and measurement system errors.

[0109] Calculate the torque compensation coefficient (Kcomp): In the low-speed overlap region, the original equivalent torque (T1+T2) / i measured on the validation bench is compared with the reliable reference torque (measured torque MAP from S31) measured on the calibration bench. A torque compensation coefficient Kcomp is calculated based on the comparison data from multiple operating points using mathematical fitting methods (such as linear regression).

[0110] This coefficient is used to linearly correct the equivalent torque of the verification bench, making it closer to the true value. The corrected torque estimate is calculated using the following formula:

[0111] (T1+T2) / i+Kcomp.

[0112] By associating the requested torque Tcmd, speed, and corrected torque value at each operating point across the entire speed range, a complete verification torque MAP with system error correction is generated.

[0113] S34. Final accuracy assessment and parameter confirmation.

[0114] The corrected torque estimate is used to evaluate the final torque accuracy of the motor across the entire speed range (especially at high speeds). The formula for calculating the final torque accuracy is:

[0115] Absolute precision:

[0116] [(T1+T2) / i+Kcomp]–Tcmd

[0117] Or relative accuracy:

[0118] {[(T1+T2) / i+Kcomp]-Tcmd} / Tcmd*100%

[0119] The calibration is performed based on torque accuracy. Specifically, if this accuracy meets the design requirements, the calibration parameters are confirmed to be valid; if not, this system error can be fed back and used to fine-tune and optimize the drive parameter mapping, thereby iteratively generating the final calibration parameters.

[0120] This embodiment verifies torque accuracy and system efficiency using a motor verification test bench, thereby completing the motor bench verification test.

[0121] This application embodiment also provides a calibration and testing device for an ultra-high speed motor, used to implement the calibration and testing method for an ultra-high speed motor as described in any of the above embodiments. As shown in FIG5, the calibration and testing device 100 includes a calibration unit 110, a verification unit 120, and a control and processing unit 130.

[0122] The calibration unit 110 is used to generate a drive parameter mapping of the motor under test at the target speed in a test environment limited by speed capability.

[0123] The verification unit 120 is a test environment independent of the calibration unit 110, used to perform full-speed range loading tests on the motor under test based on the drive parameter mapping, and to collect measured performance data.

[0124] Control and processing unit 130, communicatively connected to calibration unit 110 and verification unit 120, is used for:

[0125] The calibration unit is controlled to execute an automated calibration process;

[0126] Receive the measured data from the verification unit;

[0127] The final calibration parameters are obtained by comparing the driving parameter mapping with the expected performance to confirm or correct it.

[0128] Specifically, the control and processing unit 130 can perform the following functions:

[0129] Process control: Send instructions to the motor controller of calibration unit 110 to control it to execute the automated calibration process described in the aforementioned method, including startup, scan step size setting, loop control, etc.

[0130] Data processing: Receives raw data from the first data acquisition system and performs magnetic flux calculation, voltage threshold calculation, etc.; receives measured torque data from the second data acquisition system.

[0131] Performance Comparison and Parameter Optimization: Its internal algorithm compares the measured performance data (such as actual output torque) obtained by the verification unit 120 with the expected performance based on the drive parameter mapping request. Based on the comparison results, the unit directly confirms the validity of the mapping, or automatically calculates corrections such as torque compensation coefficients, iteratively corrects the drive parameter mapping, and finally outputs a high-confidence final calibration parameter set that can be used for the product's electronic control.

[0132] Through the coordinated operation of the calibration unit 110, the verification unit 120, and the control and processing unit 130, the device of this application can systematically complete the entire process of calibration, verification, and parameter optimization of ultra-high speed motors without the need for a dedicated ultra-high speed test bench, effectively solving the bottleneck problem of industry testing resources.

[0133] The following section provides a detailed description of the test bench for the ultra-high-speed motor described in this application, using three examples.

[0134] As shown in Figure 3, the calibration and testing device for ultra-high-speed motors includes:

[0135] Analog power supply: Used to provide initial electrical energy input to the system.

[0136] Bench dynamometer: Used to provide a controllable mechanical load and accurately measure or control the speed of the motor M1 under test, ensuring that it operates within the first speed range (e.g., below 20,000 r / min).

[0137] Motor controller: Works in conjunction with the bench dynamometer to apply controllable drive current (including d-axis current and q-axis current) to the motor under test M1.

[0138] DC current and voltage sensors: installed at the input terminal of the motor under test M1, used to collect electrical parameters such as DC bus voltage in real time.

[0139] AC current and voltage sensors: installed at the output of the motor controller to collect electrical parameters such as three-phase voltage and three-phase current of the motor in real time.

[0140] Reducer: Its input end is directly connected to the output shaft of the ultra-high-speed motor being tested. The function of this reducer is to reduce the high output speed of the motor (which may exceed 20,000 r / min) to a lower speed range that the downstream dynamometer can reliably withstand and measure at a fixed speed ratio (e.g., i = 3).

[0141] Two low-speed load dynamometers are connected in parallel to the output of the reducer via a transmission mechanism (such as a coupling or gearbox). This parallel dual dynamometer design can jointly handle high-power loads and accurately measure torques T1 and T2 separately using torque sensors.

[0142] Torque sensor: Located between the output end of the reducer and the input end of the low-speed load dynamometer, it is used to collect the torque signal of the branch circuit and transmit it to the power analyzer.

[0143] Power analyzer: It accurately measures the electrical parameters of the motor through current and voltage sensors, evaluates the motor's performance parameters, and transmits the data to the bench console for control.

[0144] Bench control unit: Electrically connected to the motor controller and power analyzer respectively, serving as the core control unit of the system, receiving signals from various sensors and the power analyzer, and sending control commands to the motor controller to achieve automated control of the testing process.

[0145] This embodiment solves the problem of directly loading and testing ultra-high-speed motors by using a verification bench consisting of a motor, a reducer, and two parallel dynamometers. The reducer reduces the motor's high speed to the safe range of the dynamometer, while the two dynamometers share the high torque and achieve data cross-verification. This structure cleverly transforms ultra-high speed into a test condition of high torque and appropriate speed, making it possible to conduct full-speed and full-load performance tests on ultra-high-speed motors using existing mature medium- and low-speed high-torque dynamometers, filling the gap in the inability to directly load and test ultra-high-speed motors. Based on this structure, by comparing the benchmark data of the calibration bench, the torque compensation coefficient can be calculated, and the system can correct errors such as transmission chain losses. Thus, even under non-direct measurement conditions, high-confidence full-speed range (including ultra-high speed) performance verification results can still be obtained, ensuring the final validity and reliability of the calibration parameters.

[0146] In one embodiment of this application, the control and processing unit includes an automated calibration module, which is used to perform automated scanning and filtering operations to generate the driving parameter mapping.

[0147] Specifically, the automated calibration module can be configured to execute nested loop logic: in the outer loop, the d-axis current request value is incremented by a step size; for each d-axis current value, the q-axis current request value is incremented by a step size in the inner loop; and in each inner loop, it is determined in real time whether the motor terminal voltage exceeds the calculated voltage limit condition, thereby automatically filtering and recording all safe and valid operating points, thus generating the drive parameter mapping efficiently and without human error.

[0148] This application also provides a motor controller, which internally stores the final calibration parameters obtained by the calibration test method of the ultra-high speed motor as described in any of the above embodiments, and the motor controller is configured to drive the ultra-high speed motor to operate based on the final calibration parameters.

[0149] The motor controllers provided in the embodiments of this application are all used to execute the corresponding methods provided above. Therefore, the beneficial effects they can achieve can be referred to the beneficial effects in the corresponding methods provided above, and will not be repeated here.

[0150] Finally, it should be noted that the above technical solution is only one implementation method of this application. For those skilled in the art, based on the application methods and principles disclosed in this application, it is easy to make various types of improvements or modifications, and not limited to the methods described in the specific implementation methods above. Therefore, the methods described above are only preferred and have no limiting significance.

Claims

1. A calibration and testing method for an ultra-high-speed motor, characterized in that, The calibration test method includes: operating the motor under test within a first speed range, measuring the electrical operating parameters of the motor under test, and determining the flux linkage parameters of the motor under test based on the electrical operating parameters; setting a target speed higher than the upper limit of the first speed range, and determining voltage limiting conditions based on the flux linkage parameters and the target speed; under operating conditions below the target speed, scanning different combinations of drive currents and filtering them according to the voltage limiting conditions to obtain the drive parameter mapping of the motor under test at the target speed; and in an independent test environment, performing a full-speed range performance test of the motor under test based on the drive parameter mapping, and confirming or correcting the drive parameter mapping by comparing it with the expected performance to obtain the final calibration parameters.

2. The calibration and testing method for ultra-high-speed motors according to claim 1, characterized in that: Measuring the electrical operating parameters of the motor under test and determining the flux linkage parameters of the motor under test based on the electrical operating parameters includes: measuring the back electromotive force of the motor under test at different speeds within a first speed range; and calculating the flux linkage parameters based on the ratio of the back electromotive force to the corresponding speed.

3. The calibration and testing method for ultra-high-speed motors according to claim 1, characterized in that: The voltage limiting condition is a preset line voltage threshold, which is determined by the following formula: Umax=Urated / 1.414×Speed / Speed-T where Umax is the line voltage threshold, Urated is the rated voltage, speed is the calibrated speed, and speed-T is the target speed.

4. The calibration and testing method for ultra-high-speed motors according to claim 1, characterized in that: The process of scanning different drive current combinations and filtering them according to the voltage limit conditions is executed by an automated calibration script. The process includes: sequentially requesting different d-axis and q-axis current combinations with a preset step size; acquiring the terminal voltage of the motor under test in real time for each requested current combination; and recording the current combination and corresponding operating status data only when the terminal voltage meets the voltage limit conditions.

5. The calibration and testing method for ultra-high-speed motors according to claim 1, characterized in that: The independent testing environment includes a verification test bench, which is equipped with: a reducer connected to the output shaft of the motor under test; a first dynamometer and a second dynamometer connected to the output end of the reducer, the first dynamometer and the second dynamometer being used to measure the load torque.

6. The calibration and testing method for ultra-high-speed motors according to claim 5, characterized in that: The process of confirming or correcting the drive parameter mapping by comparing it with expected performance includes: obtaining the actual output torque of the motor under test at full speed range, measured by the first dynamometer and the second dynamometer, on the verification test bench; comparing the actual output torque with the expected torque based on the drive parameter mapping request; calculating the torque compensation coefficient based on the comparison difference; and using the torque compensation coefficient to linearly correct the drive parameter mapping to generate the final calibration parameters.

7. A calibration and testing device for an ultra-high-speed motor, characterized in that, A calibration test method for implementing the ultra-high-speed motor according to any one of claims 1 to 6, comprising: a calibration unit for generating a drive parameter mapping of the motor under test at the target speed; a verification unit for performing a full-speed-range load test on the motor under test based on the drive parameter mapping and collecting measured performance data; and a control and processing unit communicatively connected to the calibration unit and the verification unit, for: controlling the calibration unit to execute an automated calibration process; receiving the measured data from the verification unit; and obtaining the final calibration parameters by comparing the drive parameter mapping with the expected performance to confirm or correct it.

8. The calibration and testing device for ultra-high-speed motors according to claim 7, characterized in that, The calibration unit includes a bench dynamometer, a motor controller, voltage and current sensors, and a first data acquisition system for collecting electrical and speed parameters of the motor under test; the verification unit includes a reducer, two dynamometers connected in parallel, and a second data acquisition system for collecting load-side torque and speed parameters of the motor under test.

9. The calibration and testing device for ultra-high-speed motors according to claim 7, characterized in that, The control and processing unit includes an automatic calibration module, which is used to perform the automatic scanning and filtering operation as described in claim 4 to generate the driving parameter mapping.

10. A motor controller, characterized in that, The motor controller internally stores the final calibration parameters obtained by the calibration test method of the ultra-high speed motor according to any one of claims 1 to 6, and the motor controller is configured to drive the ultra-high speed motor to operate based on the final calibration parameters.

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