Test system for surface magnet of driving motor rotor

Abstract

This application proposes a testing system for the surface magnetic properties of a drive motor rotor, comprising: a testing device, a data acquisition module, a data processing and analysis module, and a drive module. The testing device is connected to both the data acquisition module and the drive module, and the data processing and analysis module is also connected to both. The testing device includes: an adjustable positioning platform, a rotating assembly, and two sets of support sensing assemblies. The rotating assembly is mounted on the adjustable positioning platform, and the two sets of support sensing assemblies are respectively positioned on both sides of the adjustable positioning platform. The adjustable mechanical positioning platform is connected to the drive module. Therefore, this system not only possesses broad compatibility and rapid clamping capability, overcoming the limitations of traditional methods in terms of versatility, but also achieves multi-dimensional collaborative evaluation and judgment of magnetic field distribution, uniformity, and dynamic performance, significantly improving the comprehensiveness and reliability of the test.

Description

Technical Field

[0001] This application relates to the field of motor rotor testing technology, and in particular to a testing system for the surface magnetism of a drive motor rotor. Background Technology

[0002] The performance of the drive motor, a core component of new energy vehicles, directly affects the vehicle's power, energy efficiency, and reliability. Permanent magnet synchronous motors (PMSMs) have become the mainstream choice due to their small size, high power density, and high efficiency. The magnetic characteristics of the rotor surface (such as surface magnetic distribution and magnetic pole uniformity) play a crucial role in the motor's torque output, noise and vibration, and thermal stability. The surface magnetic characteristics of the rotor (i.e., "surface magnetism") directly determine the motor's key performance characteristics, such as torque, vibration noise, and thermal stability. If the rotor experiences problems such as magnetic pole misalignment, uneven magnetic field, or demagnetization, it will lead to a decline in motor performance and even pose safety hazards.

[0003] Rotor magnetic testing technology has been widely applied in fields such as new energy vehicles. Current main methods include magnetic flux density measurement and magnetic field distribution analysis. The basic principle is to use sensors to detect magnetic field strength and generate magnetic field curves. However, rotor magnetic testing technology has two major limitations: first, existing methods are usually designed only for specific types of motors, making it difficult to adapt to new and complex electromagnetic structures, resulting in insufficient versatility; second, the testing dimensions are relatively limited, often only measuring individual parameters, failing to comprehensively evaluate magnetic field distribution, uniformity, and dynamic performance, easily overlooking potential problems. Summary of the Invention

[0004] This application provides a test system for the surface magnetism of a drive motor rotor to address two major limitations of existing rotor magnetism testing techniques: first, existing methods are usually designed only for specific types of motors and are difficult to adapt to new and complex electromagnetic structures, resulting in insufficient versatility; second, the test dimensions are relatively singular, often only able to measure individual parameters, and cannot comprehensively evaluate magnetic field distribution, uniformity, and dynamic performance, easily overlooking potential problems.

[0005] A first aspect of this application provides a testing system for the surface magnetism of a drive motor rotor, comprising: a testing device, a data acquisition module, a data processing and analysis module, and a drive module. The testing device is connected to both the data acquisition module and the drive module, and the data processing and analysis module is also connected to both the data acquisition module and the drive module. The testing device includes: an adjustable positioning platform, a rotating assembly, and two sets of support sensing assemblies. The rotating assembly is disposed on the adjustable positioning platform, and the two sets of support sensing assemblies are respectively disposed on both sides of the adjustable positioning platform. A mechanical positioning platform is connected to the drive module, wherein the drive module controls the rotating component and the support sensing component respectively through the adjustable mechanical positioning platform, wherein the rotor to be tested is mounted on the rotating component; the support sensing component includes a support structure and a sensing structure, wherein the support structure is connected to the sensing structure, and a data acquisition module is connected to the sensing structure, wherein the data acquisition module is used to acquire the detection data of the rotor to be tested through the sensing structure; a data processing and analysis module is used to process and analyze the detection data to generate the test results of the rotor to be tested.

[0006] In addition, the test system for the surface magnetism of the drive motor rotor proposed in the above embodiments of this application may also have the following additional technical features:

[0007] In one embodiment of this application, the adjustable positioning platform includes a base, multiple dual-drive lifting motors, a rotating engagement gear, multiple lifting transmission chains, two lifting support columns, and a stepper motor. The stepper motor is mounted on the base, the rotating engagement gear is connected to the output shaft of the stepper motor, and the rotating engagement gear is connected to the rotating assembly. The stepper motor is connected to the drive module via a wire. The two lifting support columns are respectively mounted on the base, and the multiple lifting transmission chains are respectively disposed inside the corresponding lifting support columns. The lifting transmission chains are connected to the corresponding support sensing components. The dual-drive lifting motors are drive-connected to the corresponding lifting transmission chains, and the multiple dual-drive lifting motors are located on one side of each of the two lifting support columns. Two circular tracks with their center points as the center are provided on the base. These circular tracks are used to limit the movement trajectory of the rotating assembly.

[0008] In one embodiment of this application, the rotating assembly includes a rotating disk and a plurality of fixed buckles, wherein the rotating disk is connected to the rotating engagement gear, and the plurality of fixed buckles are arranged in a circular array on the rotating disk; the bottom of the rotating disk is provided with two movable bead protrusions, and the two movable bead protrusions are respectively engaged with the corresponding circular tracks.

[0009] In one embodiment of this application, the sensing structure includes an axial array sensing component, a radial array sensing component, and two sensing movable joints, wherein one end of each of the two sensing movable joints is connected to the support structure, and the other end of each of the two sensing movable joints is connected to the axial array sensing component and the radial array sensing component, respectively; the axial array sensing component and the radial array sensing component are respectively connected to the data acquisition module.

[0010] In one embodiment of this application, the support structure includes a transmission chain fixing slider, a support platform, fixing screws, and fixing and fine-tuning screws. The support platform includes a parallel moving block and a lifting slot. The lifting slot is connected to the two lifting transmission chains and is engaged with the parallel moving block. A cross-shaped slide rail is provided on the parallel moving block, and the transmission chain fixing slider is slidably connected to the cross-shaped slide rail. The fixing screws are disposed on the transmission chain fixing slider and the parallel moving block. The sensing moving joint is connected to the transmission chain fixing slider via the fixing and fine-tuning screws.

[0011] In one embodiment of this application, the drive module is specifically used to: acquire a preset test strategy and control the adjustable positioning platform according to the preset test strategy, so as to control the operation of the stepper motor and the lifting dual drive motor.

[0012] In one embodiment of this application, the data acquisition module is specifically used to acquire the magnetic field simulation signal of the rotor under test through a sensing structure, preprocess the magnetic field simulation signal to obtain the target magnetic field simulation signal, and perform analog-to-digital conversion on the target magnetic field simulation signal to obtain the detection data.

[0013] In one embodiment of this application, the data processing and analysis module is specifically used for: parsing the detection data to obtain the magnetic field data of the rotor under test; performing multi-dimensional feature extraction and analysis on the magnetic field data to obtain the surface magnetic field feature data of the rotor under test, wherein the surface magnetic field feature data includes the maximum, minimum, average, and uniformity of the magnetic field strength, as well as the magnetic pole center angle and the waveform distortion rate of the magnetic flux density; comparing the surface magnetic field feature data with preset standard template data to generate a comparison result, and generating the test result based on the comparison result, wherein the test result includes a test report containing test information, data analysis results, and judgment conclusions.

[0014] In one embodiment of this application, the data processing and analysis module is further configured to: generate a two-dimensional cloud map of the surface magnetic field of the rotor under test, a three-dimensional surface map of the surface magnetic field, and a magnetic field distribution curve of a preset rotor cross section based on the magnetic field data, and provide the two-dimensional cloud map of the surface magnetic field, the three-dimensional surface map of the surface magnetic field, and the magnetic field distribution curve of the preset rotor cross section to the user.

[0015] In one embodiment of this application, the data processing and analysis module is further configured to generate a next-step control signal for the adjustable positioning platform and the supporting sensing component based on the test results and preset requirements, and send the next-step control signal to the drive module, wherein the next-step control signal includes a rotation angle and a sensing height; the drive module is further configured to trigger an emergency stop protection mechanism if an abnormal signal is detected, wherein the emergency stop protection mechanism includes cutting off the power supply and issuing an audible and visual alarm signal.

[0016] Compared with existing technologies, the technical solution provided in this application has the following beneficial effects: This application proposes a test system for the surface magnetism of a drive motor rotor. By supporting various novel electromagnetic topologies such as axial flux motors or dual-rotor motors, and capable of precise surface magnetism measurement deep into narrow rotor gaps, it solves the problems of poor adaptability and incompatibility with various motor types in existing technologies. Combined with the coaxiality calibration and fine-tuning functions of the rotating structure, it significantly improves the rapid response and clamping accuracy for rotors of different sizes and types, effectively reducing test preparation time and enhancing overall test efficiency and adaptability to advanced electromagnetic configurations. Furthermore, the system integrates highly automated test process control, covering the entire process from parameter setting, data acquisition and analysis to report generation and defect judgment. Through intelligent closed-loop control, it achieves autonomous prediction and collaborative execution of test steps, greatly reducing manual intervention, thereby improving test consistency and reliability, and further strengthening the comprehensive testing capability for the surface magnetism of multi-form rotors.

[0017] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0018] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a schematic diagram of a test system for measuring the surface magnetism of a drive motor rotor according to an embodiment of this application; Figure 2 This is a schematic diagram of a test apparatus according to an embodiment of this application; Figure 3 This is a schematic diagram of an adjustable positioning platform structure according to an embodiment of this application; Figure 4 This is a schematic diagram of the stepper motor position structure of an adjustable positioning platform according to an embodiment of this application; Figure 5 This is a schematic diagram of a rotating disk and a fixing buckle structure of a rotating assembly according to an embodiment of this application; Figure 6 This is a schematic diagram of a sensing structure according to an embodiment of this application; Figure 7 This is a schematic diagram of a support structure according to an embodiment of this application; Figure 8 This is a schematic diagram of a parallel moving block and lifting slot structure according to an embodiment of this application.

[0019] Reference numerals: 100, Test device; 200, Data acquisition module; 300, Data processing and analysis module; 400, Drive module; 110, Adjustable positioning platform; 111, Base; 112, Lifting dual drive motor; 113, Rotating gear; 114, Lifting transmission chain; 115, Lifting support column; 116, Stepper motor; 120, Rotating component; 121, Rotating disk; 122, Fixing buckle; 130, Rotor under test; 140, Support sensing component; 141, Support structure; 1411, Transmission chain fixing slider; 1412, Support platform; 14121, Parallel moving block; 14122, Lifting slot; 1413, Fixing screw; 1414, Fixing and fine-tuning screw; 142, Axial array sensing component; 143, Radial array sensing component; 144, Sensing moving joint. Detailed Implementation

[0020] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0021] The following description, with reference to the accompanying drawings, describes a test system for the surface magnetism of a drive motor rotor according to an embodiment of this application. The rotor magnetism testing techniques mentioned in the background art have two major limitations: first, existing methods are typically designed only for specific types of motors, making them difficult to adapt to new and complex electromagnetic structures, resulting in insufficient versatility; second, the testing dimensions are relatively singular, often only measuring individual parameters, failing to comprehensively evaluate magnetic field distribution, uniformity, and dynamic performance, easily overlooking potential problems. This application provides a test system for the surface magnetism of a drive motor rotor. This system supports novel electromagnetic topologies such as axial flux motors and dual-rotor motors, and can perform precise surface magnetism measurements deep into narrow rotor gaps, directly solving the problems of poor adaptability and incompatibility with various motor types in existing technologies. Combined with the coaxiality calibration and fine-tuning functions of the rotating structure, it significantly improves the rapid response and clamping accuracy for rotors of different sizes and types, effectively reducing test preparation time and enhancing overall test efficiency and adaptability to advanced electromagnetic configurations. Thus, it solves the problems of insufficient versatility and singular testing dimensions in related rotor magnetism testing techniques.

[0022] Figure 1 This is a schematic diagram of a test system for measuring the surface magnetism of a drive motor rotor according to an embodiment of this application; Figure 2 This is a schematic diagram of a test apparatus according to an embodiment of the present application.

[0023] like Figure 1 and Figure 2 As shown, the test system 10 for the surface magnetism of a drive motor rotor includes: a test device 100, a data acquisition module 200, a data processing and analysis module 300, and a drive module 400. The test device 100 is connected to the data acquisition module 200 and the drive module 400, respectively. The data processing and analysis module 300 is connected to the data acquisition module 200 and the drive module 400, respectively. The test device 100 includes: an adjustable positioning platform 110, a rotating component 120, and two sets of support sensing components 140. The rotating component 120 is mounted on the adjustable positioning platform 110, and the two sets of support sensing components 140 are respectively mounted on both sides of the adjustable positioning platform 110. The adjustable mechanical positioning platform is connected to the drive module 400. The drive module 400 is used to control the rotating component 120 and the support sensing components 140 through the adjustable mechanical positioning platform. The rotor 130 under test is mounted on the rotating component 120.

[0024] It should be noted that the drive module 400 described in this embodiment is used to control the rotating component 120 and the support sensing component 140 respectively through the adjustable mechanical positioning platform. That is, the drive module 400 sends a signal to the adjustable mechanical positioning platform, which drives the rotating component 120 to rotate, and at the same time drives the support sensing component 140 to perform surface magnetic testing on the rotor 130 under test.

[0025] The supporting sensing component 140 includes a supporting structure 141 and a sensing structure. The supporting structure 141 is connected to the sensing structure, and the data acquisition module 200 is connected to the sensing structure. The data acquisition module 200 is used to acquire the detection data of the rotor 130 under test through the sensing structure. The data processing and analysis module 300 is used to process and analyze the detection data to generate the test results of the rotor 130 under test.

[0026] Specifically, after the test system for the magnetic properties of the drive motor rotor is started, the data processing and analysis module 300, according to the preset test plan, controls the rotating component 120 on the adjustable positioning platform 110 via the drive module 400 to fix and position the rotor 130 under test to its initial zero position. Simultaneously, the support sensing components 140 on both sides of the adjustable positioning platform 110 are positioned in three-dimensional space under the control of the drive module 400: the support structure 141 of the support sensing component 140 drives the sensing structure to move, precisely adjusting the radial distance (sensing height) and axial alignment between the sensing structure and the surface of the rotor 130 under test, ensuring the accuracy and consistency of the measurement points. It should be noted that the entire magnetic properties test process for the drive motor rotor achieves initial alignment through non-contact measurement.

[0027] After alignment, the system begins the test cycle. The data acquisition module 200 uses the precisely aligned sensing structure to scan and acquire the raw magnetic field strength signals at specific locations on the rotor surface in real time at high speed and high sampling rate. This raw data is transmitted in real time to the data processing and analysis module 300 via a dedicated interface (e.g., Ethernet or high-speed bus) to generate the test results for the rotor 130 under test.

[0028] The core algorithm of the data processing and analysis module 300 performs multi-dimensional feature extraction and analysis on the collected magnetic field data. It automatically calculates key performance indicators for the current measurement section or region, including magnetic field extrema, average value, uniformity, magnetic pole center angle, and waveform distortion rate (THD). These quantitative indicators are automatically compared with the preset qualified rotor standard templates in the database. Based on the comparison results, the system can not only preliminarily determine whether the rotor has defects such as missing magnetic poles, uneven magnetization, or material inclusions, but the data processing and analysis module 300 (e.g., the intelligent prediction unit) will also dynamically calculate the optimal test parameters for the next step based on the characteristics of the current magnetic field distribution and the test progress. For example, to fully map the magnetic field panorama of the entire rotor, the rotor needs to be rotated to the next key angle (e.g., rotated by 1°); or to detect specific abnormal areas, the sensor height needs to be finely adjusted for a more precise scan.

[0029] The data processing and analysis module 300 transforms the decision results into specific control instructions: firstly, it generates a test report containing defect judgment conclusions, key indicators, and charts; more importantly, it simultaneously generates precise drive control signals for the adjustable positioning platform 110. These instructions are sent to the drive module 400 in real time for precise execution, causing the rotating component 120 and the support sensing component 140 to adjust to a new preset state. After adjustment, the system automatically triggers a new round of data acquisition, starting the next test cycle.

[0030] Understandably, the testing device 100, as the core execution unit of the test system for the surface magnetism of the drive motor rotor, integrates a three-axis precision moving structure (positioning accuracy ≤ ±0.01 mm) and a θ-axis rotary table (angular resolution 0.01°), which can realize multi-degree-of-freedom attitude adjustment of the rotor and ensure precise control of the test point position to adapt to the test requirements of rotors of different shapes.

[0031] Furthermore, the X, Y, Z three-axis precision movement structure may include a transmission chain fixed slider 1411 moving within a cross-shaped slide, and a vertical movement between the support sensing component 140 and the lifting support column 115; the θ-axis rotary table may include a rotary component 120.

[0032] In the embodiments of this application, the test system for the surface magnetism of the drive motor rotor achieves precise motion control of the test device 100 through the drive module 400, acquires high-quality raw data using the support sensing component 140 and the data acquisition module 200, performs real-time insight and intelligent decision-making based on the data processing and analysis module 300, and immediately feeds the decision results back to the drive module 400 to optimize subsequent measurement actions. This complete closed-loop process realizes a leap from "passive measurement" to "active detection," greatly improving the automation level, measurement efficiency, and diagnostic accuracy of rotor surface magnetism testing.

[0033] Therefore, the embodiments of this application not only have broad compatibility and quick clamping capability, and can be adapted to various new electromagnetic topologies such as axial flux motors and dual rotor motors, breaking through the limitation of insufficient universality of traditional methods, but also achieve multi-dimensional collaborative evaluation and judgment of magnetic field distribution, uniformity and dynamic performance through highly automated comprehensive testing and intelligent closed-loop control, significantly improving the comprehensiveness and reliability of the test.

[0034] In one embodiment of this application, such as Figure 3 and Figure 4 As shown, the adjustable positioning platform 110 includes a base 111, multiple lifting dual-drive motors 112, a rotating engagement gear 113, multiple lifting transmission chains 114, two lifting support columns 115, and a stepper motor 116. The stepper motor 116 is mounted on the base 111. The rotating engagement gear 113 is connected to the output shaft of the stepper motor 116 and is connected to the rotating assembly 120. The stepper motor 116 is connected to the drive module 400 via wires. The two lifting support columns 115 are respectively mounted on the base 111. The multiple lifting transmission chains 114 are respectively mounted inside the corresponding lifting support columns 115, and are connected to the corresponding support sensing assembly 140. The lifting dual-drive motors 112 are connected to the corresponding lifting transmission chains 114. The multiple lifting dual-drive motors 112 are located on one side of each of the two lifting support columns 115. The base 111 has two circular tracks centered on their center points, which limit the movement trajectory of the rotating assembly 120.

[0035] It should be noted that the number of multiple lifting transmission chains 114 described in this embodiment can be four, and the number of lifting dual drive motors 112 can be the same as the number of lifting transmission chains 114. One lifting dual drive motor 112 is used to drive one lifting transmission chain 114 embedded in the lifting support column 115.

[0036] Furthermore, the two lifting dual drive motors 112 on one side of a lifting support column 115 rotate in opposite directions to enable the lifting transmission chain 114 to drive the lifting of the support sensing structure.

[0037] Optionally, in an embodiment of this application, the base 111 has two circular tracks with its center point as the center, which are used to limit the movement trajectory of the rotating component 120.

[0038] It is understandable that setting a circular track can maintain the stability of the rotating component 120 driving the rotor 130 under test during rotation, thereby ensuring the accuracy of the test data.

[0039] Specifically, the drive module 400 sends a running signal to the stepper motor 116. The stepper motor 116 drives the upper rotating component 120 and the rotor under test 130 for precise rotational positioning through the rotational engagement gear 113. The circular track on the base 111 ensures smooth rotation and accurate trajectory. Each of the two lifting support columns 115 has a lifting mechanism. The two lifting dual drive motors 112 of each lifting support column 115 control the lifting and lowering of the supporting sensing component 140 by driving the embedded lifting transmission chain 114. The two lifting dual drive motors 112 on the same side rotate in opposite directions, thereby working together to achieve rapid and smooth vertical lifting and lowering of the supporting sensing component 140.

[0040] In one embodiment of this application, such as Figure 5 As shown, the rotating assembly 120 includes a rotating disk 121 and multiple fixing buckles 122. The rotating disk 121 is connected to a rotating engagement gear 113, and the multiple fixing buckles 122 are arranged in a circular array on the rotating disk 121. The bottom of the rotating disk 121 is provided with two movable ball bosses, which are respectively engaged with corresponding circular tracks.

[0041] It should be noted that the multiple fixing buckles 122 described in this embodiment are arranged in a circular array on the rotating disk 121. The fixing buckles 122 and the rotating disk 121 can be locked together by a fastener. The specific structure described above has been disclosed in the prior art, so it will not be described in detail here.

[0042] In addition, the rotating disk 121 and the rotating gear 113 described in this embodiment are connected by a mating manner. It should be noted that this connection method facilitates the replacement of the rotor 130 under test by relevant technicians.

[0043] In the embodiments of this application, the rotor 130 to be tested is placed on the rotating disk 121 and is clamped and fixed by the fixing buckle 122. The movable ball boss and the circular track on the base 111 are matched in position, which can ensure that the rotating disk 121 rotates smoothly.

[0044] As a possible scenario, in order to quickly achieve accurate positioning and calibration of the rotor 130 under test, a scale can be set on the sliding rail of the fixed buckle 122 to facilitate position calibration.

[0045] In one embodiment of this application, such as Figure 6As shown, the sensing structure includes an axial array sensing component 142, a radial array sensing component 143, and two sensing moving joints 144. One end of each of the two sensing moving joints 144 is connected to the support structure 141, and the other end of each of the two sensing moving joints 144 is connected to the axial array sensing component 142 and the radial array sensing component 143, respectively. The axial array sensing component 142 and the radial array sensing component 143 are respectively connected to the data acquisition module 200.

[0046] It should be noted that the axial array sensing component 142 and the radial array sensing component 143 described in this embodiment can each be equipped with a miniature triaxial magnetic field Hall sensor (e.g., Texas Instruments TMAG5170-Q1), and the number of such sensors can be at least four (using high-precision Hall elements with linearity better than 0.1%FS). The axial array sensing component 142 or the radial array sensing component 143 can be replaced according to the electromagnetic configuration of the rotor 130 under test. The types of the axial array sensing component 142 or the radial array sensing component 143 include single-point type, linear type, and surface type.

[0047] This allows for flexible adaptation to magnetic field measurements of different parts of radial and inner rotors, such as the outer circle, end face, and inner hole, as well as complex magnetic pole topologies such as V-shaped, U-shaped, double-layer, and skewed poles. It is also suitable for surface magnetic field measurements of the flat rotor structure of axial flux motors, and even more suitable for surface magnetic field measurements of narrow rotor gaps in new dual-rotor motors.

[0048] In addition, the sensing moving joint 144 described in this embodiment is mainly composed of multiple segments connected end to end. Its shape and number of segments can be adjusted according to the actual situation of the rotor 130 under test. The sensing moving joint 144 can be manually and finely adjusted by fixing and fine-tuning screws 1414 to compensate for the small errors that may occur during lifting or position adjustment, and to ensure that the test gap between the Hall sensor probe and the rotor surface (usually set to 1mm±0.02mm) remains constant, so that the sensing position is adapted.

[0049] As a possible approach, in order to improve the efficiency of changing the rotor 130 under test, a quick-change rotor fixture system (not shown in the figure) can be arranged on one side of the testing device 100. It is equipped with rotating disks 121 of various specifications and fixing buckles 122, which can be compatible with various permanent magnet rotors of different sizes. The fixture change time is ≤ 3 minutes, which significantly improves the equipment's rapid response capability to rotors of different specifications.

[0050] In one embodiment of this application, such as Figure 7 and Figure 8As shown, the support structure 141 includes a transmission chain fixing slider 1411, a support platform 1412, fixing screws 1413, and fixing and fine-tuning screws 1414. The support platform 1412 includes a parallel moving block 14121 and a lifting slot 14122. The lifting slot 14122 is connected to two lifting transmission chains 114 and is engaged with the parallel moving block 14121. A cross-shaped slide is provided on the parallel moving block 14121, and the transmission chain fixing slider 1411 is slidably connected to the cross-shaped slide. The fixing screws 1413 are provided on the transmission chain fixing slider 1411 and the parallel moving block 14121. The sensing moving joint 144 is connected to the transmission chain fixing slider 1411 through the fixing and fine-tuning screws 1414.

[0051] In the embodiments of this application, the length of the lifting slot 14122 can be flexibly changed according to the shape and size of the rotor 130 to be tested, so that the movable path of the sensing structure can be adapted to the measurement position. At the same time, different parallel moving blocks 14121 can be flexibly changed according to the actual measurement size range requirements, so as to obtain cross-shaped slides of different specifications to meet different testing requirements.

[0052] Specifically, the fixed slider 1411 of the transmission chain changes position via a cross-shaped slide rail on the parallel moving block 14121 to adjust the relative position between the actual shape of the rotor 130 under test and the axial array sensing component 142 and the radial array sensing component 143. The vertical movement of the overall structure supporting the sensing assembly 140 is achieved by the lifting dual drive motor 112 of the adjustable positioning platform 110 driving the lifting transmission chain 114 and the lifting slot 14122.

[0053] As a possible alternative, the support structure 141 may be made of a non-magnetic metallic material (e.g., aluminum) and its exterior may be oxidized to avoid electromagnetic interference during actual testing.

[0054] As another possible scenario, in order to further avoid electromagnetic interference during the test, in this embodiment of the application, the rotating disk 121 and the fixing buckle 122 are respectively made of alumina ceramic material, wherein the alumina ceramic material has a built-in heating resistance wire to realize the heating operation of the rotor 130 under test.

[0055] Understandably, many rotors (especially precision motors and aerospace motors) require performance parameter testing within a specific temperature range (e.g., -40℃ to 150℃). Temperature affects the magnetism, electrical resistance, and dimensions of materials. Ceramic materials typically have good thermal conductivity. The built-in heating resistance wire allows for active and precise temperature control of the test fixture and the rotor under test 130, stabilizing them at the preset test temperature point. This ensures the consistency and accuracy of the test conditions.

[0056] In one embodiment of this application, such as Figure 1 As shown, the drive module 400 is specifically used to: acquire a preset test strategy and control the adjustable positioning platform 110 according to the preset test strategy, so as to control the stepper motor 116 and the lifting dual drive motor 112 to run.

[0057] It should be noted that the preset test strategy described in this embodiment may include the rotation angle of the output shaft of the stepper motor 116 and the stroke of the lifting transmission chain 114 driven by the lifting dual drive motor 112, so that the rotor 130 under test is adjusted to the reference zero position and one end of the sensing structure is in the initial position.

[0058] Additionally, the drive module 400 described in this embodiment includes a motion controller, which may employ a Delta ASDA-A2 series servo drive.

[0059] Understandably, the motion controller receives motor operation commands from the data processing and analysis module 300, drives the stepper motor 116 of the θ-axis rotation platform through pulse signals, and sends operation signals to the lifting dual drive motor 112 to achieve precise positioning of the test point.

[0060] In one embodiment of this application, such as Figure 1 As shown, the data acquisition module 200 is specifically used to acquire the magnetic field simulation signal of the rotor 130 under test through the sensing structure, and to preprocess the magnetic field simulation signal to obtain the target magnetic field simulation signal; and to perform analog-to-digital conversion on the target magnetic field simulation signal to obtain the detection data.

[0061] It should be noted that the detection data described in this embodiment may include the test path, sampling step size, number of sampling points, and magnetic field strength.

[0062] In the embodiments of this application, the data acquisition module 200 may employ a 16-bit high-precision A / D converter (analog-to-digital converter) with a sampling rate of up to 1 MSPS (Megasamples Per second) / channel, and is equipped with a low-noise preamplifier circuit, a filtering module and a data buffer module, thereby ensuring that high signal-to-noise ratio data can still be acquired in complex industrial environments.

[0063] The data acquisition module 200 supports 8-channel synchronous parallel acquisition, capable of simultaneously recording real-time data of the three components of magnetic induction intensity: Bx, By, and Bz (X, Y, and Z refer to the three spatial axes). The output signal from the Hall sensor is conditioned by a differential amplifier circuit (adjustable amplification from 100 to 1000 times) before being sent to an A / D converter for analog-to-digital conversion. The converted data is temporarily stored in a data cache module (capacity ≥ 1GB) and transmitted in real-time to the data processing and analysis module 300 via a high-speed data interface (e.g., USB 3.0). To reduce electromagnetic interference, the circuit design of the data acquisition module 200 employs a multi-layer PCB (Printed Circuit Board) layout and a metal shielding housing, and an EMI filter (Electromagnetic Interference filter) is added at the power input.

[0064] In one embodiment of this application, such as Figure 1 As shown, the data processing and analysis module 300 is specifically used for: parsing the detection data to obtain the magnetic field data of the rotor 130 under test; performing multi-dimensional feature extraction and analysis on the magnetic field data to obtain the surface magnetic field feature data of the rotor 130 under test, wherein the surface magnetic field feature data includes the maximum, minimum, average, and uniformity of the magnetic field strength, as well as the magnetic pole center angle and the waveform distortion rate of the magnetic flux density; comparing the surface magnetic field feature data with the preset standard template data to generate comparison results, and generating test results based on the comparison results, wherein the test results include a test report containing test information, data analysis results, and judgment conclusions.

[0065] It should be noted that the multi-dimensional feature extraction and analysis of magnetic field data described in this embodiment may include automatically calculating and displaying key indicators such as the maximum, minimum, and average values ​​of magnetic field strength, uniformity (defined as magnetic pole center angle, magnetic flux density waveform distortion rate, etc., i.e., surface magnetic field feature data).

[0066] Furthermore, this embodiment describes comparing surface magnetic field characteristic data with preset standard template data to generate comparison results, and then generating test results based on these results. In other words, it can compare the test results with preset standard template data to determine whether the rotor is qualified, and automatically generate a test report containing test information, data analysis results, and judgment conclusions. For example, it can provide judgments on typical defects such as missing magnetic poles, insufficient magnetization, magnetic material inclusions, and interlayer short circuits.

[0067] As a possible scenario, the data processing and analysis module 300 also has the function of receiving and storing data. It can receive the raw magnetic field data from the data acquisition module 200 in real time and store it on the local hard drive or network server in a preset format (e.g., CSV (comma-separated value) format).

[0068] In one embodiment of this application, such as Figure 1 As shown, the data processing and analysis module 300 is also used to: generate a two-dimensional cloud map of the surface magnetic field of the rotor 130 under test, a three-dimensional curved surface map of the surface magnetic field, and a magnetic field distribution curve of a preset rotor cross section based on the magnetic field data, and provide the two-dimensional cloud map of the surface magnetic field, the three-dimensional curved surface map of the surface magnetic field, and the magnetic field distribution curve of the preset rotor cross section to the user.

[0069] Understandably, the data processing and analysis module 300 can dynamically draw two-dimensional cloud maps, three-dimensional surface maps, and magnetic field distribution curves of a certain cross section of the rotor surface magnetic field, and supports real-time display of the coordinates of data points and magnetic field values ​​for user analysis.

[0070] In one embodiment of this application, such as Figure 1 As shown, the data processing and analysis module 300 is also used to generate the next control signal for the adjustable positioning platform 110 and the supporting sensing component 140 according to the test results and preset requirements, and send the next control signal to the drive module 400. The next control signal includes the rotation angle and the sensing height.

[0071] Specifically, the data processing and analysis module 300 can make a preliminary judgment on the test requirements based on the current test status and data information, obtain the preset status of the next rotation angle and sensing height, generate drive control signals for the stepper motor 116 and the lifting dual drive motor 112, and then send the stepper motor 116 rotation angle command to the drive module 400.

[0072] The drive module 400 is also used to trigger an emergency stop protection mechanism if an abnormal signal is detected, wherein the emergency stop protection mechanism includes cutting off the power supply and issuing an audible and visual alarm signal.

[0073] It should be noted that the abnormal signals described in this embodiment can be detected by a variety of sensors, such as: an infrared grating sensor for monitoring whether someone has entered the test area, a current and voltage sensor for detecting overcurrent and overheating of the drive motor, and a laser displacement sensor for monitoring the distance between the Hall sensor probe and the rotor.

[0074] Specifically, during the magnetic field test of the drive motor rotor, when any of the above sensors detects an abnormal signal, the system immediately triggers the emergency stop protection mechanism, cuts off the motor power supply, and issues an audible and visual alarm signal.

[0075] The test system for the surface magnetism of the drive motor rotor proposed in this application will be described in detail below with reference to the accompanying drawings. After the rotor magnetic surface testing system is started, it first enters the initialization and clamping stage. The operator places the rotor 130 to be tested on the rotating disk 121 of the rotating assembly 120 and secures it firmly using the fixed buckles 122 arranged in a circular array. Subsequently, under the command of the preset program of the data processing and analysis module 300, the system performs precise initial alignment of the testing device 100 through the drive module 400. The drive module 400 controls the stepper motor 116 on the adjustable positioning platform 110 to operate. The stepper motor 116 drives the entire rotating assembly 120 through the rotating engagement gear 113, adjusting the rotor to the reference zero position. At the same time, the drive module 400 also controls the lifting dual drive motor 112 located next to the lifting support columns 115 on both sides of the base 111 to operate. The lifting dual drive motor 112 drives the lifting transmission chain 114 embedded in the lifting support column 115 to run, thereby adjusting the initial height of the support sensing assembly 140 connected to the chain.

[0076] The support structure 141 of each supporting sensing component 140 begins fine positioning. The lifting slot 14122 of its support platform 1412 moves with the lifting transmission chain 114, while the operator can manually slide the transmission chain fixing slider 1411 on the support platform 1412 according to the rotor size, moving and locking it on the cross-shaped slide of the parallel moving block 14121. Subsequently, by adjusting the sensing moving joint 144 connected to the slider and the fixing and fine-tuning screws 1414, the final angle and position fine-tuning of the sensing structure is performed, ensuring that the probes of the axial array sensing component 142 and the radial array sensing component 143 maintain a precise and constant measurement gap with the rotor surface, completing the initial alignment for non-contact measurement.

[0077] After alignment, the system enters an automated testing loop. The data acquisition module 200 immediately acquires multi-component raw analog signals of the rotor surface magnetic field at a high sampling rate using the precisely positioned axial array sensing component 142 and radial array sensing component 143, and converts them into digital signals for real-time uploading. The data processing and analysis module 300 receives this data, performs real-time visualization and multi-dimensional analysis, automatically calculates key indicators such as magnetic field strength, uniformity, and waveform distortion rate at the current measurement point, and compares them with a standard template to diagnose potential defects. Simultaneously, the intelligent prediction unit in the data processing and analysis module 300 dynamically calculates the optimal test parameters for the next step based on existing data and the analysis progress.

[0078] Next, the data processing and analysis module 300 translates the decision into specific instructions and issues them to the drive module 400. The motion controller of the drive module 400 then executes precisely: controlling the stepper motor 116 to rotate the rotating disk 121 and the rotor by a slight angle (e.g., 1°) through the rotational engagement gear 113. Simultaneously, it may coordinate the control of the dual lifting drive motors 112 on both sides, using the lifting transmission chain 114 and the support platform 1412 to perform micro-motion compensation on the height of the supporting sensing component 140, so that the sensing structure reaches the next preset measurement position. After the movement is completed, the system automatically triggers a new round of data acquisition and analysis, starting the next test cycle. This process repeats until a panoramic scan and evaluation of the magnetic field on the entire rotor surface is completed. Finally, the data processing and analysis module 300 integrates all the cycle data to generate a test report containing complete test results, defect judgments, and detailed charts, marking the completion of this test task.

[0079] Understandably, through the mechanical cooperation between the parallel moving block 14121 in the support platform 1412 and the interchangeable length lifting slot 14122, as well as the displacement of the sensor chain fixed slider in the cross-shaped slide, and in conjunction with the multi-segment adjustable sensor moving joint 144, a high degree of flexibility and adaptability in spatial position of the sensing structure is achieved. This allows the system to not only flexibly adapt to different parts such as the outer circle, end face, and inner hole of radial inner and outer rotors, as well as complex magnetic pole topologies such as V-shaped, U-shaped, double-layer, and oblique pole, but also to the flat rotor structure of axial flux motors. Furthermore, it can perform precise surface magnetic field measurements in the narrow rotor gaps of novel dual-rotor motors, effectively solving the problem of poor adaptability and inability to be applied to various novel electromagnetic topologies in existing technologies.

[0080] Furthermore, the system integrates automated test process control, achieving a high degree of automation from test parameter setting, probe path planning, data acquisition and analysis to automatic report generation and determination of typical defects in non-conforming products (such as missing magnetic poles, insufficient magnetization, etc.). In particular, the data processing and analysis module 300 can predict the next test requirements based on the current test status, driving the stepper motor 116 and the lifting dual drive motor 112 to work together, realizing intelligent closed-loop control of the test process, greatly reducing manual intervention, improving the consistency and reliability of the test, and further consolidating the multi-form rotor surface magnetization test capability based on dual positioning.

[0081] Therefore, the test system for the surface magnetism of drive motor rotors proposed in this application, by supporting various novel electromagnetic topologies such as axial flux motors or dual-rotor motors, and capable of performing precise surface magnetism measurements deep into narrow rotor gaps, directly solves the problems of poor adaptability and incompatibility with various motor types in existing technologies. Combined with the coaxiality calibration and fine-tuning functions of the rotating structure, it significantly improves the rapid response and clamping accuracy for rotors of different sizes and types, effectively reducing test preparation time and enhancing overall test efficiency and adaptability to advanced electromagnetic configurations. Furthermore, the system integrates highly automated test process control, covering the entire process from parameter setting, data acquisition and analysis to report generation and defect judgment. Through intelligent closed-loop control, it achieves autonomous prediction and collaborative execution of test steps, greatly reducing manual intervention, thereby improving test consistency and reliability, and further strengthening the comprehensive test capability for the surface magnetism of multi-form rotors.

[0082] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0083] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0084] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0085] It should be understood that the various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (FPGAs), field-programmable gate arrays (FPGAs), etc.

[0086] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

Claims

1. A testing system for the surface magnetism of a drive motor rotor, characterized in that, include: The system comprises a testing device, a data acquisition module, a data processing and analysis module, and a driver module. The testing device is connected to both the data acquisition module and the driver module. The data processing and analysis module is also connected to both the data acquisition module and the driver module. The testing device includes: an adjustable positioning platform, a rotating assembly, and two sets of support sensing assemblies. The rotating assembly is disposed on the adjustable positioning platform, and the two sets of support sensing assemblies are respectively disposed on both sides of the adjustable positioning platform. The adjustable mechanical positioning platform is connected to the drive module, wherein the drive module is used to control the rotating component and the support sensing component respectively through the adjustable mechanical positioning platform, wherein the rotor to be tested is disposed on the rotating component; The supporting sensing component includes a supporting structure and a sensing structure, wherein the supporting structure is connected to the sensing structure, the data acquisition module is connected to the sensing structure, and the data acquisition module is used to acquire the detection data of the rotor under test through the sensing structure. The data processing and analysis module is used to process and analyze the detection data to generate test results for the rotor under test.

2. The system according to claim 1, characterized in that, The adjustable positioning platform includes a base, multiple dual-drive lifting motors, rotating gears, multiple lifting transmission chains, two lifting support columns, and a stepper motor. The stepper motor is mounted on the base, the rotary engagement gear is connected to the output shaft of the stepper motor, the rotary engagement gear is connected to the rotary assembly, and the stepper motor is connected to the drive module via wires; Two lifting support columns are respectively disposed on the base, and the plurality of lifting transmission chains are respectively disposed inside the corresponding lifting support columns, wherein the lifting transmission chains are connected to the corresponding support sensing components; The lifting dual drive motor is connected to the corresponding lifting transmission chain, wherein the plurality of lifting dual drive motors are respectively located on one side of the two lifting support columns; The base has two circular tracks centered on its center point, which are used to limit the movement trajectory of the rotating component.

3. The system according to claim 2, characterized in that, The rotating assembly includes a rotating disk and multiple fixing buckles, wherein, The rotating disk is connected to the rotating engagement gear, and a plurality of the fixing buckles are arranged in a circular array on the rotating disk; The bottom of the rotating disk is provided with two movable bead protrusions, which are respectively configured to cooperate with the corresponding circular track.

4. The system according to claim 2, characterized in that, The sensing structure includes an axial array sensing component, a radial array sensing component, and two sensing movement joints, wherein... One end of each of the two sensing movable joints is connected to the support structure, and the other end of each of the two sensing movable joints is connected to the axial array sensing component and the radial array sensing component, respectively. The axial array sensing component and the radial array sensing component are respectively connected to the data acquisition module.

5. The system according to claim 4, characterized in that, The support structure includes a transmission chain fixing slider, a support platform, fixing screws, and fixing and fine-tuning screws, wherein... The support platform includes a parallel moving block and a lifting slot, wherein the lifting slot is connected to the two lifting transmission chains and is connected in cooperation with the parallel moving block; The parallel moving block is provided with a cross-shaped slide rail, and the transmission chain fixed slider is slidably connected to the cross-shaped slide rail; The fixing screw is disposed on the transmission chain fixing slider and the parallel moving block; The sensing moving joint is connected to the transmission chain fixing slider via the fixing and fine-tuning screws.

6. The system according to claim 2, characterized in that, The driving module is specifically used for: A preset test strategy is obtained, and the adjustable positioning platform is controlled according to the preset test strategy to control the operation of the stepper motor and the lifting dual drive motor.

7. The system according to claim 1, characterized in that, The data acquisition module is specifically used for, The magnetic field simulation signal of the rotor under test is acquired by the sensing structure, and the magnetic field simulation signal is preprocessed to obtain the target magnetic field simulation signal. The target magnetic field simulation signal is converted from analog to digital to obtain the detection data.

8. The system according to claim 7, characterized in that, The data processing and analysis module is specifically used for: The detection data is analyzed to obtain the magnetic field data of the rotor under test; Multi-dimensional feature extraction and analysis are performed on the magnetic field data to obtain the surface magnetic field feature data of the rotor under test. The surface magnetic field feature data includes the maximum, minimum, average, and uniformity of the magnetic field strength, as well as the magnetic pole center angle and the waveform distortion rate of the magnetic flux density. The surface magnetic field characteristic data is compared with preset standard template data to generate comparison results, and the test results are generated based on the comparison results. The test results include a test report containing test information, data analysis results, and judgment conclusions.

9. The system according to claim 8, characterized in that, The data processing and analysis module is also used for: Based on the magnetic field data, a two-dimensional cloud map of the surface magnetic field of the rotor under test, a three-dimensional surface map of the surface magnetic field, and a magnetic field distribution curve of a preset rotor cross section are generated, and the two-dimensional cloud map of the surface magnetic field, the three-dimensional surface map of the surface magnetic field, and the magnetic field distribution curve of the preset rotor cross section are provided to the user.

10. The system according to claim 8, characterized in that, The data processing and analysis module is also used to generate the next control signal for the adjustable positioning platform and the supporting sensing component based on the test results and preset requirements, and send the next control signal to the drive module, wherein the next control signal includes rotation angle and sensing height; The drive module is also used to trigger an emergency stop protection mechanism if an abnormal signal is detected, wherein the emergency stop protection mechanism includes cutting off the power supply and issuing an audible and visual alarm signal.

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