Method and device for intelligently testing torque of high-speed motor of new energy automobile

Abstract

The invention relates to the technical field of motor testing, in particular to an intelligent torque testing method and device for a high-speed motor of a new energy automobile, and the device comprises a testing rack, a motor positioning assembly, a detection assembly, and an intelligent testing analysis system. The testing rack is of a T-shaped structure, a servo linear sliding table is arranged in the middle inside the testing rack, a testing conveying frame is arranged at the top of the servo linear sliding table in a sliding mode, a normal discharging frame and an abnormal discharging frame are arranged on the two sides inside the testing rack respectively, and the upper end faces of the normal discharging frame and the abnormal discharging frame are flush with the upper end face of the testing conveying frame. According to the invention, torque sensors and couplings of different specifications can be accommodated through a plurality of mounting grooves of a rotating frame in the detection assembly, adaptive parts can be rapidly switched by cooperating with a rotation control motor, and the testing efficiency of motors of different specifications is improved; the annular magnetorheological dampers are connected in series, so that shafting vibration is effectively attenuated, and the torque measurement precision is improved; the whole device realizes automatic, high-precision and multi-specification compatible test, and meets the test requirements of the high-speed motor of the new energy automobile.

Description

Technical Field

[0001] This invention relates to the field of motor testing technology, specifically to an intelligent torque testing method and device for high-speed motors in new energy vehicles. Background Technology

[0002] As a core component of the drive system, the high-speed motor of a new energy vehicle directly affects the vehicle's power performance, energy efficiency, and operational safety due to its torque output characteristics. Therefore, accurate testing of its torque parameters is a crucial step in the motor's production and R&D process. With the rapid development of the new energy vehicle industry, high-speed motors are evolving towards higher speeds, wider torque ranges, and more standardized specifications, placing higher demands on the adaptability, testing accuracy, and automation of torque testing devices.

[0003] Existing torque testing devices have several limitations: First, they lack adaptability, as they are mostly designed for single-specification motors. Changing the test object requires manual adjustment of the mechanical structure, which is cumbersome and time-consuming, making it difficult to meet the batch testing needs of multiple motor specifications. Second, they have poor testing stability. Factors such as shaft vibration and signal interference during high-speed operation can easily lead to increased torque measurement errors, affecting the reliability of test data. Third, they have low automation. Motor positioning and post-test sorting and unloading rely heavily on manual operation, which is not only inefficient but may also further affect the test results due to human error.

[0004] To this end, we propose an intelligent torque testing method and device for high-speed motors in new energy vehicles. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an intelligent torque testing method and device for high-speed motors in new energy vehicles, thereby resolving the aforementioned technical deficiencies.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an intelligent torque testing device for a high-speed motor of a new energy vehicle, comprising a test frame, a motor positioning component, a detection component, and an intelligent test analysis system; the test frame is a T-shaped structure, with a servo linear slide table in the center and a test conveyor frame slidably mounted on the top of the servo linear slide table; normal discharge racks and abnormal discharge racks are respectively located on both sides inside the test frame, with their upper surfaces flush with the upper surface of the test conveyor frame; guide rails are provided on both the front and rear sides inside the test frame, and the bottom of the test conveyor frame is slidably connected to the guide rails; the motor positioning component is located on the test conveyor frame and is used to fix the test motor; the detection component is located on the right side of the test frame and is used to perform torque testing on the test motor; the intelligent test analysis system is used to collect and analyze test parameters and evaluate the state of the test motor.

[0007] Preferably, the motor positioning assembly includes a vertical adjustment slide, a horizontal adjustment slide, and a positioning servo cylinder; the test conveyor frame is symmetrically provided with vertical adjustment slides on the upper left and right sides, and horizontal adjustment slides are slidably provided on the front and rear sides of the top of the vertical adjustment slides; a positioning servo cylinder is slidably provided on the top of the horizontal adjustment slides, and a positioning block is provided at the top of the drive shaft of the positioning servo cylinder; the bottom of the test motor is provided with positioning holes around the perimeter that cooperate with the positioning blocks.

[0008] Preferably, the right side of the inner wall of the test frame is provided with a discharge control slide, and two magnetic sliders are slidably provided on the left side of the discharge control slide; the magnetic sliders can be energized to attract the bottom right side of the test motor, and are used to transfer the test motor after the test is completed to the normal discharge rack or the abnormal discharge rack.

[0009] Preferably, the detection assembly includes a fixed frame, a rotating frame, a support frame, a hysteresis dynamometer, and an adjusting electric cylinder; the fixed frame is fixed to the right side of the test frame, and a rotating frame is rotatably mounted inside it; the support frame is fixed to the right side of the fixed frame, and a rotation control motor is mounted on its right side, with the output shaft of the rotation control motor connected to the right end of the rotating frame via a coupling; the rotating frame has several mounting slots inside, and a torque sensor and a coupling are mounted in each mounting slot, with the coupling connected to the detection end of the torque sensor.

[0010] Preferably, a ring-shaped magnetorheological damper is connected in series between the coupling and the torque sensor. The inner ring of the magnetorheological damper is fixed to the transition shaft by a key connection, and the outer ring is fixed inside the mounting groove by an elastic bracket. A limit ring is threadedly connected to the right side of the mounting groove, and the left side of the limit ring is in movable contact with the right side of the torque sensor.

[0011] Preferably, the torque sensors are of different specifications to adapt to test motors of different specifications; the hysteresis dynamometer is fixed to the top of the support frame, its output shaft is equipped with an adjusting electric cylinder, the driving end of the adjusting electric cylinder is equipped with a mounting frame, the mounting frame is equipped with a pneumatic gripper on the side near the rotating frame, the right side of the torque sensor is equipped with a positioning groove, and the pneumatic gripper is adapted to the positioning groove.

[0012] Preferably, the intelligent test and analysis system includes a test parameter acquisition module, a shaft system dynamic response analysis module, and an energy loss analysis module; the test parameter acquisition module is used to acquire shaft system dynamic response parameters, signal quality parameters, and energy loss parameters; the shaft system dynamic response analysis module is used to analyze shaft system stability.

[0013] Preferably, the dynamic response parameters of the shaft system include the torque fluctuation coefficient, the natural frequency of the shaft system, the excitation frequency, and the maximum deflection of the shaft system; the energy loss parameters include mechanical loss and system efficiency, and the mechanical loss includes bearing friction loss and air resistance loss.

[0014] Preferably, the intelligent test analysis system can generate fault codes based on test results; when the system efficiency deviates... And the motor bearing temperature When this happens, a fault warning will be automatically triggered.

[0015] Preferably, a test method for an intelligent torque testing device for a high-speed motor of a new energy vehicle, applied to such an intelligent torque testing device, includes the following steps:

[0016] Step 1, Motor Loading and Positioning: Place the test motor to be tested on top of the test conveyor frame and start the motor positioning assembly: Adjust the position of the positioning servo cylinder by adjusting the vertical and horizontal adjustment slides so that the positioning block is aligned with the positioning hole at the bottom of the test motor; the positioning servo cylinder drives the positioning block to insert upward into the positioning hole, and the telescopic blocks on both sides of the positioning block automatically pop into the positioning slots on the inner wall of the positioning hole to achieve rigid fixation of the test motor;

[0017] Step 2: Transport to the testing station: The servo linear slide is started, which drives the test conveyor to slide along the guide rail, transporting the test motor to the testing area on the right side inside the test frame, close to the fixed frame and the rotating frame; at this time, the bottom right side of the test motor contacts the magnetic slider on the discharge control slide.

[0018] Step 3: Sensor and Coupling Matching Selection: The intelligent test and analysis system automatically matches the corresponding coupling and torque sensor according to the specifications of the test motor; the rotation control motor drives the rotating frame to rotate, rotating the matched coupling and torque sensor from the mounting slot to the test position aligned with the test motor, and the limit ring ensures that the torque sensor is fixed in the mounting slot;

[0019] Step 4: Connection of testing components: The adjusting electric cylinder of the hysteresis dynamometer is activated, pushing the mounting frame to move towards the rotating frame, so that the pneumatic gripper on the mounting frame engages with the positioning slot on the right side of the torque sensor, completing the rigid connection between the hysteresis dynamometer and the torque sensor; the output shaft of the test motor is inserted into the left interface of the coupling, and the right side of the coupling is connected to the detection end of the torque sensor, and the series-connected annular magnetorheological damper enters the working state to attenuate the vibration of the shaft system;

[0020] Step 5, Torque Testing and Parameter Acquisition: The hysteresis dynamometer is started, and the actual operating conditions of the test motor are simulated by adjusting the load; the torque sensor acquires the instantaneous torque value of the test motor in real time. Simultaneously collect speed and motor bearing temperature Parameters such as voltage and current; the test parameter acquisition module of the intelligent test and analysis system receives the data, and the shaft dynamic response analysis module calculates the torque fluctuation coefficient. Resonance frequency deviation The energy loss analysis module calculates mechanical losses. System efficiency ;

[0021] Step Six: Data Analysis and Condition Assessment: The comprehensive condition assessment module integrates the analysis results of shaft dynamic response, energy loss, etc., to quantitatively evaluate and test the motor performance. , and If it is determined to be a normal part; It automatically generates fault codes and identifies the component as faulty;

[0022] Step 7, Automatic Sorting and Discharge: For normal parts: The discharge control slide drives the magnetic slider to be energized, adsorbing the bottom right side of the test motor. The positioning servo cylinder drives the positioning block to move down and disengage from the positioning hole. The magnetic slider drives the test motor to transfer to the normal discharge rack. Then the magnetic slider is de-energized, completing the discharge of normal parts. For abnormal parts: Similarly, the magnetic slider transfers the test motor to the abnormal discharge rack, completing the discharge of abnormal parts. The test conveyor rack is reset to the initial position, ready for the next test.

[0023] Compared with existing technologies, it has the following advantages:

[0024] 1. By adopting a T-shaped structure for the test frame, combined with a servo linear slide, guide rail, and test conveyor, stable conveying of the test motors is achieved. The inclusion of normal and abnormal discharge racks allows for rapid motor classification after testing, improving the continuity of the testing process. In the motor positioning assembly, the cooperation of vertical and horizontal adjusting slides and positioning servo cylinders allows for the adaptation of test motors of different specifications. The design of positioning blocks, positioning holes, telescopic blocks, and positioning slots ensures motor stability during testing and reduces vibration interference. Multiple mounting slots in the rotating frame of the testing assembly can accommodate… Different specifications of torque sensors and couplings, combined with rotary control motors, enable rapid switching of compatible components, improving testing efficiency for motors of different specifications. The series connection of toroidal magnetorheological dampers effectively attenuates shaft vibration and improves torque measurement accuracy. The hysteresis dynamometer, in conjunction with the torque sensor, accurately simulates the load and measures parameters. Adjustable electric cylinders and pneumatic grippers ensure reliable connection, while limit rings fix the torque sensor. The mounting bracket and other structures enhance the ease of operation and stability of the equipment. The overall device achieves automated, high-precision, and multi-specification compatible testing, meeting the testing needs of high-speed motors for new energy vehicles.

[0025] 2. The test parameter acquisition module comprehensively acquires key parameters such as shaft dynamic response, signal quality, and energy loss. The shaft dynamic response analysis module provides a basis for optimizing shaft stability and adapting to different motor specifications. The energy loss analysis module enables accurate simulation of motor load and early fault warning, providing decision support for maintenance, adjustment, and full life cycle management. The collaborative work of these modules improves the automation level, measurement accuracy, and adaptability to different motor specifications of the test device, enabling timely warning of motor faults, ensuring efficient and accurate testing, and meeting the testing needs of high-speed motors for new energy vehicles.

[0026] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description and the drawings. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of an intelligent torque testing device for a high-speed motor of a new energy vehicle according to an embodiment of the present invention;

[0028] Figure 2 This is a schematic diagram of the test conveyor and test motor structure according to an embodiment of the present invention;

[0029] Figure 3 This is a schematic diagram of the material discharge control slide and magnetic slider structure according to an embodiment of the present invention;

[0030] Figure 4 This is a schematic diagram of the fixed frame and rotating frame structure according to an embodiment of the present invention;

[0031] Figure 5 This is a schematic diagram of the rotating frame, support frame, and hysteresis dynamometer structure according to an embodiment of the present invention;

[0032] Figure 6 This is a schematic diagram of the intelligent test and analysis system according to an embodiment of the present invention.

[0033] In the diagram, 1. Test frame; 2. Normal discharge frame; 3. Abnormal discharge frame; 4. Servo linear slide; 5. Guide rail; 6. Test conveyor frame; 7. Test motor; 8. Vertical adjustment slide; 9. Horizontal adjustment slide; 10. Positioning servo cylinder; 11. Discharge control slide; 12. Magnetic slider; 13. Fixed frame; 14. Rotating frame; 15. Mounting slot; 16. Coupling; 17. Torque sensor; 18. Limit ring; 19. Support frame; 20. Rotation control motor; 21. Hysteresis dynamometer; 22. Adjustment cylinder; 23. Mounting frame; 24. Pneumatic gripper; 25. Positioning slot. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Example 1

[0036] Please see Figures 1 to 5 As shown, a torque intelligent testing device for a high-speed motor of a new energy vehicle includes:

[0037] The test frame 1 has a T-shaped structure. A servo linear slide 4 is fixedly installed in the middle of the test frame 1, and a test conveyor 6 is slidably installed on the top of the servo linear slide 4. A normal discharge rack 2 and an abnormal discharge rack 3 are respectively installed on both sides of the test frame 1, and the upper end surfaces of the normal discharge rack 2 and the abnormal discharge rack 3 are on the same horizontal plane as the upper end surface of the test conveyor 6. Guide rails 5 are fixedly installed on the front and rear sides of the test frame 1, and the front and rear sides of the bottom of the test conveyor 6 are slidably connected to the top of the two guide rails 5 respectively.

[0038] The motor positioning assembly includes a vertical adjustment slide 8, a horizontal adjustment slide 9, and a positioning servo cylinder 10. Vertical adjustment slides 8 are symmetrically fixedly arranged on the upper left and right sides inside the test conveyor frame 6. Horizontal adjustment slides 9 are slidably arranged on the front and rear sides of the top of the two vertical adjustment slides 8. Two positioning servo cylinders 10 are slidably arranged on the top of the two horizontal adjustment slides 9, and a positioning block is fixedly arranged at the top of the drive shaft of the positioning servo cylinder 10. A test motor 7 is placed on the top of the test conveyor frame 6, and positioning holes that cooperate with the positioning blocks are provided around the bottom of the test motor 7.

[0039] It should be noted that during the intelligent torque test of the high-speed motor, the test motor 7 is placed on top of the test conveyor frame 6, and the positioning holes and positioning blocks around the bottom of the test motor 7 are used for connection to ensure the positioning stability of the test motor 7 on top of the test conveyor frame 6. The vertical adjustment slide 8 drives the two horizontal adjustment slides 9 to slide relative to each other. At the same time, the positioning servo cylinders 10 on the top of the two horizontal adjustment slides 9 are moved to below the positioning holes at the bottom of the test motor 7. The driving end of the positioning servo cylinder 10 controls the positioning block to move upward, inserting the top of the positioning block into the positioning hole at the bottom of the test motor 7. Both sides of the surface of the positioning block are provided with telescopic blocks, and both sides of the inner wall of the positioning hole are provided with positioning slots. After the positioning block is inserted into the positioning hole, the telescopic blocks automatically insert into the positioning slots to ensure the connection stability between the positioning block and the positioning hole. The positions of the vertical adjustment slide 8 and the horizontal adjustment slide 9 are adjusted according to the different specifications of the test motor 7, so that the positioning block can be used to position and fix test motors 7 of different specifications, ensuring the stability of the test motor 7 during the test.

[0040] Furthermore, to achieve automatic classification of high-speed motors after torque detection, a discharge control slide 11 is fixedly installed on the right side of the inner wall of the test frame 1, and two magnetic sliders 12 are slidably installed on the left side of the discharge control slide 11. When the torque of the test motor 7 is tested, the test conveyor 6 is slid to the right side of the test frame 1 by the servo linear slide 4. At this time, the right side of the bottom of the test motor 7 contacts the left side of the two magnetic sliders 12. The two magnetic sliders 12 are energized, and the left side of the two magnetic sliders 12 magnetically attracts the right side of the bottom of the test motor 7, realizing the magnetic connection between the magnetic sliders 12 and the test motor 7. After the test operation of the test motor 7 is completed, the test motor 7 is divided into normal parts and abnormal parts according to the test results. The material control slide 11, in conjunction with the magnetic slider 12, conveys the test motor 7 of normal parts to the normal discharge rack 2 at the rear. Through the limiting connection between the contact positioning block and the positioning hole, and utilizing the magnetic attraction relationship between the magnetic slider 12 and the bottom right side of the test motor 7, the two magnetic sliders 12 drive the test motor 7 from the top of the test conveyor 6 to the top of the normal discharge rack 2. Then, the power to the magnetic slider 12 is turned off, so that the magnetic attraction relationship between the magnetic slider 12 and the test motor 7 is released. Conversely, the test motor 7 of abnormal parts is sent to the abnormal discharge rack 3 located at the front. The normal discharge rack 2 and the abnormal discharge rack 3 are used to classify and send out normal parts and abnormal parts respectively, realizing the automatic classification of the test motor 7, which facilitates subsequent testing of normal parts and timely repair of abnormal parts.

[0041] As a further explanation of the scheme in this embodiment, a detection component is also provided on the right side of the test frame 1. The detection component includes a fixed frame 13 and a rotating frame 14. The fixed frame 13 is fixedly provided on the right side of the test frame 1, and the rotating frame 14 is rotatably provided inside the fixed frame 13. A support frame 19 is fixedly provided on the right side of the fixed frame 13, and a rotation control motor 20 is fixedly provided on the right side of the support frame 19. One end of the output shaft of the rotation control motor 20 is fixedly connected to the right end of the rotating frame 14 through a coupling. The rotating frame 14 has a plurality of mounting slots 15 inside, and a torque sensor 17 is movably provided in the middle of each of the mounting slots 15. A coupling 16 is also movably provided on the left side of each of the mounting slots 15, and the inside of the coupling 16 is connected to the detection end of the torque sensor 17. A ring-shaped magnetic flux is also connected in series between the coupling 16 and the torque sensor 17. Specifically, the inner ring of the magnetorheological damper is fixed to the transition shaft via a key connection, and the outer ring is fixed inside the mounting groove 15 via an elastic bracket. A limit ring 18 is also threadedly connected to the right side of the mounting groove 15, and the left side of the limit ring 18 is in active contact with the right side of the torque sensor 17. The torque sensors 17 have different specifications, and the appropriate torque sensor 17 is selected for testing according to the different specifications of the test motor 7. A hysteresis dynamometer 21 is also fixedly installed on the top of the support frame 19, and an adjusting electric cylinder 22 is fixedly installed on the output shaft of the hysteresis dynamometer 21. A mounting frame 23 is fixedly installed on the drive end of the adjusting electric cylinder 22, and a pneumatic gripper 24 is provided on the side of the mounting frame 23 near the rotating frame 14. A positioning groove 25 is provided on the right side of the torque sensor 17, and one side of the pneumatic gripper 24 is in active contact with the inside of the positioning groove 25.

[0042] It should be noted that when conducting torque testing on the test motor 7, after the test motor 7 is placed on the left side of the rotating frame 14, a matching coupling 16 and torque sensor 17 are selected in advance according to the specifications of the test motor 7. The output shaft of the rotation control motor 20 controls the rotation of the rotating frame 14 to rotate the selected coupling 16 and torque sensor 17 to the top. At this time, the adjusting cylinder 22 at one end of the output shaft of the hysteresis dynamometer 21 pushes the mounting frame 23 closer to the positioning groove 25 on the side of the torque sensor 17. The pneumatic gripper 24 on one side of the mounting frame 23 and the positioning groove 25 on the side of the torque sensor 17 are connected to complete the limiting connection between the hysteresis dynamometer 21 and the torque sensor 17. Then, one end of the output shaft of the test motor 7 is inserted into the coupling 16 for connection. The load of the torque sensor 17 is adjusted by the hysteresis dynamometer 21 to simulate the actual operating conditions of the test motor 7, and the torque sensor is used to accurately measure the output torque, speed and power of the motor.

[0043] In one specific embodiment, the present invention employs a T-shaped structure for the test frame 1, combined with a servo linear slide 4, guide rail 5, and test conveyor 6, to achieve stable conveying of the test motor 7. Furthermore, the inclusion of a normal discharge rack 2 and an abnormal discharge rack 3 allows for rapid motor classification after testing, improving the continuity of the testing process. In the motor positioning assembly, the cooperation of a vertical adjusting slide 8, a horizontal adjusting slide 9, and a positioning servo cylinder 10 allows for the adaptation of test motors 7 of different specifications. The design of the positioning block and positioning hole, as well as the telescopic locking block and positioning slot, ensures motor stability during testing and reduces vibration interference. Multiple mounting slots in the rotating frame 14 of the detection assembly further enhance the stability of the motor. The 15 unit can accommodate torque sensors 17 and couplings 16 of different specifications. With the help of the rotary control motor 20, it can quickly switch between compatible components, improving the testing efficiency for motors of different specifications. The series connection of the toroidal magnetorheological damper effectively attenuates shaft vibration and improves torque measurement accuracy. The hysteresis dynamometer 21 works in conjunction with the torque sensor 17 to accurately simulate the load and measure parameters. The adjusting electric cylinder 22 and pneumatic gripper 24 ensure reliable connection. The limit ring 18 can fix the torque sensor 17. The mounting bracket 23 and other structures enhance the ease of operation and stability of the equipment. The overall device realizes automated, high-precision, and multi-specification compatible testing, meeting the testing needs of high-speed motors for new energy vehicles.

[0044] Example 2

[0045] Please see Figure 6 As shown, specifically, the intelligent torque testing device also includes an intelligent testing and analysis system, which comprises a test parameter acquisition module, a shaft system dynamic response analysis module, and an energy loss analysis module. The test parameter acquisition module collects and acquires shaft system dynamic response parameters, signal quality parameters, and energy loss parameters. The shaft system dynamic response analysis module analyzes these parameters to provide a basis for optimizing shaft system stability and adapting to different motor specifications. The energy loss analysis module analyzes energy loss parameters to achieve accurate simulation of motor load and early fault warning.

[0046] The dynamic response parameters of the shaft system include torque fluctuation coefficient, shaft system natural frequency, excitation frequency, and maximum shaft system deflection. The torque fluctuation coefficient is obtained by collecting the instantaneous torque value of the motor output shaft from a torque sensor and statistically analyzing the instantaneous torque value within the sampling period using testing software. The shaft system natural frequency is obtained by spectrum analysis software. The excitation frequency is obtained by collecting the motor speed from a speed sensor installed on the motor output shaft and dividing the speed by sixty. The maximum shaft system deflection is calculated by installing a laser displacement sensor at the midpoint of the shaft system span to measure the radial displacement of the shaft in real time, while simultaneously measuring the radial force using a force sensor, and combining the shaft system span, material elastic modulus, and moment of inertia.

[0047] Energy loss parameters include mechanical losses and system efficiency. Mechanical losses include bearing friction losses and air resistance losses. Bearing friction losses are calculated by measuring the bearing friction torque using a torque sensor and combining it with the rotational speed. Air resistance losses are calculated by obtaining the drag coefficient through wind tunnel experiments and combining it with the frontal area, air density, and peripheral velocity. System efficiency is calculated by obtaining the output torque and rotational speed using a torque sensor and a rotational speed sensor, respectively. The input power is calculated by collecting voltage, current, and power factor data using a power analyzer. The input power is the product of the voltage, current, and power factor parameters. Finally, the system efficiency is obtained by dividing the output power by the input power.

[0048] The analysis process of the shaft system dynamic response analysis module for the shaft system dynamic response parameters is as follows:

[0049] According to the formula The torque fluctuation coefficient is calculated. Specifically, the torque fluctuation coefficient is an indicator used to measure the degree of fluctuation in the output torque of a high-speed motor during testing. It reflects the stability of the torque output; the larger the value, the more severe the torque fluctuation. The torque is the average torque, and n represents the total number of times torque data was collected during the test. The instantaneous torque value is obtained from the i-th acquisition.

[0050] The absolute value of the difference between the shaft system's natural frequency and the excitation frequency is used as the resonant frequency deviation. The value is used to measure the deviation between the excitation frequency of the actual vibration of the shaft system and the natural frequency of the shaft system, reflecting the resonance risk of the shaft system vibration. The unit is Hertz. When the value is small, the shaft system is more likely to resonate, which may affect the stability of the test device and the measurement accuracy.

[0051] when At that time, adjust the excitation current of the magnetorheological damper to increase the shaft damping ratio until... Ensure that the torque measurement accuracy of the motor is ≤ ±0.5%FS within the speed range of 15000-25000r / min.

[0052] The energy loss analysis module analyzes energy loss parameters as follows:

[0053] Through formula The compensation torque is calculated. This represents the compensation torque, used to compensate for the mechanical losses generated by the motor and related transmission components (such as connecting shafts) during the test, ensuring the hysteresis dynamometer accurately simulates the motor's applied torque. The unit is Newton-meter. By compensating for this torque, the testing device can more accurately simulate the actual load conditions of the motor during operation. Mechanical power loss refers to the total power loss of the motor shaft system during operation due to various mechanical frictions and resistances, measured in watts; it consists of bearing friction power loss. and air resistance loss power It consists of two parts, namely ; Bearing friction loss power is the power loss generated by the internal friction of the motor bearing during rotation (such as the friction between the rolling elements and the raceway), and the unit is watt. Air resistance power loss refers to the power loss caused by air resistance when rotating parts such as motor shafts rotate in the air, due to the resistance of the air (friction between the air and the surface of the rotating parts, air eddies, etc.). The unit is watt.

[0054] The control module of the hysteresis dynamometer pre-stores data at different speeds. and Database, based on Accurate load simulation of the test motor under rated operating conditions, including This represents the actual applied torque, which is the torque that the hysteresis dynamometer ultimately applies to the motor, used to simulate the load torque of the motor during actual operation. The loading torque command for a hysteresis dynamometer is the target loading torque value set by the tester or test program according to test requirements (such as simulating the load of a motor under a certain operating condition); when , This refers to the actual efficiency of the motor, which is the ratio of the mechanical power output by the motor to the electrical power input; here it is expressed as system efficiency. The set efficiency anomaly threshold is a predetermined efficiency critical value based on the motor's design standards, performance requirements, or industry specifications; when At that time, fault codes are automatically generated to provide early warnings of motor malfunctions during the testing process; among them This represents the temperature parameters of the motor bearing during the testing process, which are obtained by using an infrared temperature sensor on the motor bearing area.

[0055] In one specific embodiment, the present invention comprehensively acquires key parameters such as shaft dynamic response, signal quality, and energy loss through a test parameter acquisition module. The shaft dynamic response analysis module provides a basis for optimizing shaft stability and adapting to motors of different specifications. The energy loss analysis module enables accurate simulation of motor load and early fault warning, providing decision support for maintenance, adjustment, and full life cycle management. The collaborative work of these modules improves the automation level, measurement accuracy, and adaptability to motors of different specifications of the testing device, enabling timely warning of motor faults, ensuring efficient and accurate testing, and meeting the testing needs of high-speed motors for new energy vehicles.

[0056] Example 3

[0057] A testing method for an intelligent torque testing device for high-speed motors in new energy vehicles includes the following steps:

[0058] Step 1, Motor Loading and Positioning: Place the test motor 7 to be tested on top of the test conveyor 6 and start the motor positioning assembly: Adjust the position of the positioning servo cylinder 10 by adjusting the vertical adjustment slide 8 and the horizontal adjustment slide 9 so that the positioning block is aligned with the positioning hole at the bottom of the test motor 7; the positioning servo cylinder 10 drives the positioning block to insert upward into the positioning hole, and the telescopic blocks on both sides of the positioning block automatically pop into the positioning slots on the inner wall of the positioning hole, so as to achieve rigid fixation of the test motor 7 and ensure that there is no loosening or vibration during the test.

[0059] Step 2: Transport to the testing station: The servo linear slide 4 is started, which drives the test conveyor 6 to slide along the guide rail 5, transporting the test motor 7 to the testing area on the right side inside the test frame 1, close to the fixed frame 13 and the rotating frame 14; at this time, the bottom right side of the test motor 7 contacts the magnetic slider 12 on the discharge control slide 11, preparing for subsequent sorting and discharge.

[0060] Step 3: Sensor and Coupling Matching Selection: The intelligent test and analysis system automatically matches the corresponding coupling 16 and torque sensor 17 according to the specifications, torque range, shaft diameter, and speed range of the test motor 7; the rotation control motor 20 drives the rotating frame 14 to rotate, rotating the matched coupling 16 and torque sensor 17 from the mounting slot 15 to the test position aligned with the test motor 7, and the limiting ring 18 ensures that the torque sensor 17 is fixed in the mounting slot 15.

[0061] Step 4, Component Connection: The adjusting cylinder 22 of the hysteresis dynamometer 21 is activated, pushing the mounting frame 23 to move towards the rotating frame 14, so that the pneumatic gripper 24 on the mounting frame 23 engages in the positioning groove 25 on the right side of the torque sensor 17, completing the rigid connection between the hysteresis dynamometer 21 and the torque sensor 17; the output shaft of the test motor 7 is inserted into the left interface of the coupling 16, and the right side of the coupling 16 is connected to the detection end of the torque sensor 17. The inner ring of the series-connected annular magnetorheological damper is fixed to the transition shaft, and the outer ring is fixed to the mounting groove 15, entering the working state to attenuate shaft vibration.

[0062] Step 5, Torque Testing and Parameter Acquisition: The hysteresis dynamometer 21 is started, and the actual operating conditions of the test motor 7 are simulated by adjusting the load; the torque sensor 17 acquires the instantaneous torque value of the test motor 7 in real time. Simultaneously collect speed and motor bearing temperature Parameters such as voltage and current; the test parameter acquisition module of the intelligent test and analysis system receives the data, and the shaft dynamic response analysis module calculates the torque fluctuation coefficient. Resonance frequency deviation The energy loss analysis module calculates mechanical losses. System efficiency .

[0063] Step Six: Data Analysis and Condition Assessment: The comprehensive condition assessment module integrates the analysis results of shaft dynamic response, energy loss, etc., to quantitatively evaluate and test the performance of motor 7. , and If it is determined to be a normal part; It automatically generates fault codes and identifies the component as abnormal.

[0064] Step 7, Automatic Sorting and Discharge: For normal parts: The discharge control slide 11 drives the magnetic slider 12 to be energized, adsorbing the bottom right side of the test motor 7. The positioning servo cylinder 10 drives the positioning block to move down and disengage from the positioning hole. The magnetic slider 12 drives the test motor 7 to transfer to the normal discharge rack 2. Then the magnetic slider 12 is de-energized, completing the discharge of normal parts. For abnormal parts: Similarly, the magnetic slider 12 transfers the test motor 7 to the abnormal discharge rack 3, completing the discharge of abnormal parts. The test conveyor rack 6 is reset to the initial position, ready for the next test.

[0065] In one specific embodiment, this invention achieves fully automated operation by precisely positioning and automatically transporting the test motor 7 to the test station, combining the rotating frame 14 to quickly switch between the appropriate coupling 16 and torque sensor 17, and utilizing the hysteresis dynamometer 21 in conjunction with the torque sensor 17 for testing, significantly improving testing efficiency. The toroidal magnetorheological damper effectively attenuates shaft vibration, and the intelligent test analysis system accurately analyzes parameters such as torque fluctuation coefficient and system efficiency, ensuring torque measurement accuracy ≤ ±0.5%FS. Furthermore, it can automatically generate fault codes based on efficiency deviation and temperature parameters, enabling early fault warning. After testing, the motor is automatically classified into the normal discharge rack 2 or the abnormal discharge rack 3 using the discharge control slide 11 and the magnetic slider 12, adapting to the testing needs of motors of different specifications. The overall process is coherent and efficient, meeting the high-precision and automated testing requirements of high-speed motors for new energy vehicles.

[0066] Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.

[0067] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0068] Although 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 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 torque intelligent testing device for a high-speed motor of a new energy vehicle, comprising a test frame (1), a motor positioning component, a detection component, and an intelligent testing and analysis system; characterized in that, The test frame (1) is equipped with a servo linear slide (4) in the middle, and a test conveyor (6) is slidably mounted on the top of the servo linear slide (4). The test frame (1) is equipped with a normal discharge rack (2) and an abnormal discharge rack (3) on both sides. The test frame (1) is equipped with guide rails (5) on both the front and rear sides. The bottom of the test conveyor (6) is slidably connected to the guide rails (5). The motor positioning component is located on the test conveyor (6) and is used to fix the test motor (7). The detection component is located on the right side of the test frame (1) and is used to perform torque testing on the test motor (7). The intelligent test analysis system is used to collect and analyze test parameters and evaluate the status of the test motor (7).

2. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 1, characterized in that, The motor positioning assembly includes a vertical adjustment slide (8), a horizontal adjustment slide (9), and a positioning servo cylinder (10); the test conveyor (6) is symmetrically provided with vertical adjustment slides (8) on the upper left and right sides, and horizontal adjustment slides (9) are slidably provided on the front and back sides of the top of the vertical adjustment slides (8). The positioning servo cylinder (10) is slidably provided on the top of the horizontal adjustment slides (9), and a positioning block is provided at the top of the drive shaft of the positioning servo cylinder (10); the test motor (7) is provided with positioning holes around its bottom that cooperate with the positioning blocks.

3. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 1, characterized in that, The inner wall of the test frame (1) is provided with a discharge control slide (11) on the right side, and two magnetic sliders (12) are slidably provided on the left side of the discharge control slide (11); the magnetic sliders (12) can be energized to attract the bottom right side of the test motor (7), and are used to transfer the test motor (7) after the test is completed to the normal discharge rack (2) or the abnormal discharge rack (3).

4. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 1, characterized in that, The detection assembly includes a fixed frame (13), a rotating frame (14), a support frame (19), a hysteresis dynamometer (21), and an adjusting electric cylinder (22); the fixed frame (13) is fixed to the right side of the test frame (1), and the rotating frame (14) is rotatably mounted inside it; the support frame (19) is fixed to the right side of the fixed frame (13), and a rotary control motor (20) is provided on its right side, and the output shaft of the rotary control motor (20) is connected to the right end of the rotating frame (14) through a coupling; the rotating frame (14) is provided with several mounting slots (15), and a torque sensor (17) and a coupling (16) are provided in the mounting slots (15), and the coupling (16) is connected to the detection end of the torque sensor (17).

5. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 4, characterized in that, A ring-shaped magnetorheological damper is connected in series between the coupling (16) and the torque sensor (17). The inner ring of the magnetorheological damper is fixed to the transition shaft by a key connection, and the outer ring is fixed inside the mounting groove (15) by an elastic bracket. A limit ring (18) is threadedly connected to the right side of the mounting groove (15), and the left side of the limit ring (18) is in active contact with the right side of the torque sensor (17).

6. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 4, characterized in that, Several torque sensors (17) have different specifications and are used to adapt to test motors (7) of different specifications; the hysteresis dynamometer (21) is fixed on the top of the support frame (19), and its output shaft is provided with an adjusting electric cylinder (22). The driving end of the adjusting electric cylinder (22) is provided with a mounting frame (23). The mounting frame (23) is provided with a pneumatic gripper (24) on the side near the rotating frame (14). The right side of the torque sensor (17) is provided with a positioning groove (25). The pneumatic gripper (24) is adapted to the positioning groove (25).

7. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 1, characterized in that, The intelligent test and analysis system includes a test parameter acquisition module, a shaft dynamic response analysis module, and an energy loss analysis module. The test parameter acquisition module is used to acquire shaft system dynamic response parameters, signal quality parameters, and energy loss parameters; the shaft system dynamic response analysis module is used to analyze shaft system stability.

8. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 7, characterized in that, The dynamic response parameters of the shaft system include the torque fluctuation coefficient, the natural frequency of the shaft system, the excitation frequency, and the maximum deflection of the shaft system; the energy loss parameters include mechanical loss and system efficiency, and the mechanical loss includes bearing friction loss and air resistance loss.

9. The intelligent torque testing device for a high-speed motor of a new energy vehicle according to claim 1, characterized in that, The intelligent test and analysis system can generate fault codes based on test results; when the system efficiency deviates... And the motor bearing temperature When this happens, a fault warning will be automatically triggered.

10. A method for intelligently testing the torque of a high-speed motor in a new energy vehicle, applied to the intelligent torque testing device for a high-speed motor in a new energy vehicle according to any one of claims 1-9, characterized in that, Includes the following steps: Step 1, Motor loading and positioning: Place the test motor (7) to be tested on the top of the test conveyor (6), and start the motor positioning assembly: Adjust the position of the positioning servo cylinder (10) by adjusting the vertical adjustment slide (8) and the horizontal adjustment slide (9) so that the positioning block is aligned with the positioning hole at the bottom of the test motor (7); the positioning servo cylinder (10) drives the positioning block to insert upward into the positioning hole, and the telescopic blocks on both sides of the positioning block automatically pop into the positioning slots on the inner wall of the positioning hole to achieve rigid fixation of the test motor (7); Step 2: Transport to the test station: The servo linear slide (4) is started, which drives the test conveyor (6) to slide along the guide rail (5) and transport the test motor (7) to the detection area on the right side inside the test frame (1), close to the fixed frame (13) and the rotating frame (14); at this time, the bottom right side of the test motor (7) contacts the magnetic slider (12) on the discharge control slide (11); Step 3: Sensor and Coupling Matching Selection: The intelligent test analysis system automatically matches the corresponding coupling (16) and torque sensor (17) according to the specifications of the test motor (7); the rotation control motor (20) drives the rotating frame (14) to rotate, rotating the matched coupling (16) and torque sensor (17) from the mounting slot (15) to the test position aligned with the test motor (7), and the limiting ring (18) ensures that the torque sensor (17) is fixed in the mounting slot (15); Step 4, Detection component connection: The regulating cylinder (22) of the hysteresis dynamometer (21) is activated, pushing the mounting frame (23) to move towards the rotating frame (14), so that the pneumatic gripper (24) on the mounting frame (23) is engaged in the positioning groove (25) on the right side of the torque sensor (17), completing the rigid connection between the hysteresis dynamometer (21) and the torque sensor (17); the output shaft of the test motor (7) is inserted into the left interface of the coupling (16), and the right side of the coupling (16) is connected to the detection end of the torque sensor (17), and the series-connected annular magnetorheological damper enters the working state to attenuate the vibration of the shaft system; Step 5, Torque Test and Parameter Acquisition: The hysteresis dynamometer (21) is started, and the actual operating conditions of the test motor (7) are simulated by adjusting the load; the torque sensor (17) acquires the instantaneous torque value of the test motor (7) in real time. Simultaneously collect speed and motor bearing temperature Parameters such as voltage and current; The intelligent test and analysis system's test parameter acquisition module receives data, and the shaft system dynamic response analysis module calculates the torque fluctuation coefficient. Resonance frequency deviation The energy loss analysis module calculates mechanical losses. System efficiency ; Step 6, Data Analysis and Condition Assessment: The comprehensive condition assessment module integrates the analysis results of shaft dynamic response, energy loss, etc., and quantitatively assesses the performance of the test motor (7): If , and If it is determined to be a normal part; It automatically generates fault codes and identifies the component as faulty; Step 7, Automatic Classification and Discharge: For normal parts: The discharge control slide (11) drives the magnetic slider (12) to be powered on, adsorbing the bottom right side of the test motor (7). The positioning servo cylinder (10) drives the positioning block to move down and disengage from the positioning hole. The magnetic slider (12) drives the test motor (7) to transfer to the normal discharge rack (2). Then the magnetic slider (12) is powered off, and the normal parts are discharged. For abnormal parts: Similarly, the magnetic slider (12) transfers the test motor (7) to the abnormal discharge rack (3), and the abnormal parts are discharged. The test conveyor rack (6) is reset to the initial position, ready for the next test.

Images