A motor load simulation test system and test method based on current closed-loop feedback

Abstract

The application discloses a motor load simulation test system and test method based on current closed-loop feedback, which comprises a load simulation module, a current collection module and a control module. The load simulation module is associated with the output end of a motor to be tested, and is used for forming an adjustable test load acting on the motor to be tested; the current collection module is connected to the power supply circuit of the motor to be tested, and is used for acquiring real-time working current of the motor to be tested in a test process; the control module determines a current feedback reference according to a test target, compares the real-time working current with the current feedback reference to obtain a current deviation, and adjusts the load output of the load simulation module and / or the operating state of the motor to be tested according to the current deviation. The system makes the working current of the motor to be tested participate in the closed-loop control of the load simulation test, and is favorable for improving the consistency and abnormality processing timeliness of the motor load simulation test.

Description

Technical Field

[0001] This invention relates to the field of motor testing equipment technology, and in particular to a motor load simulation test system and test method based on current closed-loop feedback. Background Technology

[0002] Brushed motors, brushless motors, and other small drive motors typically undergo power-on tests, load tests, or endurance tests before leaving the factory to confirm the motor's operating current, running time, and operational stability under set voltage, set load, and continuous operation conditions. In the production environment, a common testing method involves mounting the motor on a test bench, connecting the motor's output to a loading mechanism, and then having operators observe the voltage, current, and running time to determine if the motor meets factory requirements.

[0003] While existing testing equipment can achieve basic power-on operation and timing functions, it still has shortcomings in batch testing. On the one hand, different motors have differences in winding conditions, commutation conditions, bearing friction, and assembly precision. Under the same voltage and load conditions, the actual operating current of each motor may differ. If only a fixed load or manual observation is used as the basis for judgment, it is difficult to detect current abnormalities or load-following abnormalities in a timely manner. On the other hand, multi-station test benches usually need to test multiple motors simultaneously. When one station experiences overcurrent, undercurrent, stalling, or load abnormalities, if the abnormal motor cannot be handled independently in a timely manner, it can easily cause the abnormal motor to continue running, distort test data, and even affect the testing progress of other stations in the same batch.

[0004] Furthermore, in test equipment using magnetic particle brakes, eddy current brakes, electromagnetic brakes, or other adjustable loads as load simulation modules, prolonged continuous testing may lead to problems such as load overheating, load output drift, or mutual interference between multiple load channels. If the test is conducted solely according to the initial load setting, the actual load state of the load simulation module may deviate from the set state due to temperature changes, making it difficult to maintain consistent test results.

[0005] Therefore, how to use the real-time operating current of the motor under test as a feedback quantity to participate in load adjustment, operation control and anomaly isolation during the load simulation test is a technical problem that urgently needs to be solved in motor load simulation tests. Summary of the Invention

[0006] The present invention aims to solve at least one of the following problems in existing motor load or durability testing equipment: real-time operating current is mainly used for display or manual judgment, and it is difficult to participate in the closed-loop control of the load simulation process; fixed loading or open-loop loading methods are difficult to adapt to the individual differences of different motors under test; abnormalities of a single station cannot be isolated in time during multi-station testing; and adjustable loading components are prone to load output state drift due to temperature rise and channel interference during long-term operation.

[0007] The motor load simulation test system and test method based on current closed-loop feedback provided by this invention include:

[0008] The load simulation module is associated with the output terminal of the motor under test and is used to generate an adjustable test load acting on the motor under test.

[0009] A current acquisition module is connected to the power supply circuit of the motor under test and is used to acquire the real-time operating current of the motor under test during the test.

[0010] The control module is communicatively connected to the load simulation module and the current acquisition module, respectively. It is used to determine the current feedback benchmark according to the test target, compare the real-time operating current with the current feedback benchmark to obtain the current deviation, and adjust the load output of the load simulation module and / or the operating state of the motor under test according to the current deviation.

[0011] Preferably, the test objectives include at least one of the following: product model of the motor under test, test items, target voltage, test duration, and simulated operating conditions;

[0012] The current feedback reference includes at least one of the following: target current value, target current curve, and allowable current range.

[0013] Preferably, the load simulation module includes a load executor and a load driver unit;

[0014] The loading actuator is connected to the output end of the motor under test;

[0015] The loading drive unit is communicatively connected to the control module and is used to adjust the loading state of the loading executor according to the control quantity output by the control module.

[0016] Preferably, the load simulation module further includes a load current acquisition unit;

[0017] The loading current acquisition unit is connected to the output circuit of the loading drive unit and is used to acquire the loading drive current;

[0018] The control module is also used to generate a target loading current based on the current deviation, and to adjust the output of the loading drive unit based on the deviation between the target loading current and the loading drive current.

[0019] Preferably, the load simulation module further includes a temperature acquisition unit; the temperature acquisition unit includes a first temperature detector and a second temperature detector, the first temperature detector being used to acquire the internal temperature of the loading actuator, and the second temperature detector being used to acquire the external temperature of the loading actuator; the control module is further used to correct the load output of the load simulation module according to the temperature status acquired by the temperature acquisition unit.

[0020] Preferably, it also includes a test bench;

[0021] The test bench forms multiple test stations;

[0022] Each of the aforementioned test stations is equipped with the load simulation module and the current acquisition module;

[0023] The control module includes multiple workstation control channels, each of which corresponds to one of the test workstations.

[0024] Preferably, the control module further includes an anomaly isolation unit;

[0025] The abnormal isolation unit is used to control the test station to stop, pause, or mark an abnormality when the real-time operating current of any test station meets the abnormality judgment condition, while keeping the other test stations running.

[0026] Preferably, it also includes a multi-channel isolation filter module;

[0027] The multi-channel isolation filter module is connected between the main power input terminal and multiple load simulation modules to suppress interference conducted through the power supply bus between different load simulation modules.

[0028] Preferably, it also includes a human-computer interaction module and a data recording module;

[0029] The human-machine interaction module is used to receive the test target and display the test status; the data recording module is used to associate and record the real-time operating current, the current feedback reference, the load output status of the load simulation module and the operating status of the motor under test.

[0030] The present invention also provides a method for simulating motor load based on current closed-loop feedback, comprising: associating the output terminal of the motor under test with a load simulation module;

[0031] Determine the current feedback reference based on the test objectives;

[0032] Obtain the real-time operating current of the motor under test during the test;

[0033] The real-time operating current is compared with the current feedback reference to obtain the current deviation;

[0034] Adjust the load output of the load simulation module and / or the operating status of the motor under test according to the current deviation.

[0035] Compared with the prior art, the motor load simulation test system and test method based on current closed-loop feedback provided by the present invention have the following beneficial effects:

[0036] 1. This invention uses the real-time operating current of the motor under test during the test as the feedback quantity, and compares the real-time operating current with the current feedback benchmark to adjust the load output of the load simulation module and / or the operating state of the motor under test according to the current deviation. Therefore, the current data is no longer just for display or manual observation, but participates in the closed-loop control process of the motor load simulation test.

[0037] 2. This invention can determine the current feedback benchmark according to the test objective, so that different product models, different test items or different simulated working conditions correspond to different current feedback control benchmarks, thereby improving the adaptability of motor load simulation test to different test requirements.

[0038] 3. In the embodiment where the load simulation module has load current acquisition, the present invention can form a target load current based on the real-time operating current of the motor under test, and adjust the load output through load drive current feedback, which is beneficial to improving the stability of the load output of the load simulation module.

[0039] 4. In the embodiment where the load simulation module has temperature acquisition, the present invention can correct the load output according to the temperature state of the loading actuator, which is beneficial to reduce the load drift caused by the temperature rise of the loading actuator during long-term durability tests.

[0040] 5. In multi-station testing scenarios, this invention enables independent current feedback control for each testing station. When an anomaly occurs at a single station, that station can be paused, stopped, or marked, while the remaining stations continue to operate, thereby improving the efficiency of batch testing and the timeliness of anomaly handling. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the overall structure of a motor load simulation test system provided in an embodiment of the present invention;

[0042] Figure 2 This is a schematic diagram of the structure of a single test station provided in an embodiment of the present invention;

[0043] Figure 3An electrical control block diagram provided in an embodiment of the present invention;

[0044] Figure 4 This is a flowchart of a current closed-loop feedback control according to an embodiment of the present invention;

[0045] Figure 5 This is a schematic diagram of multi-station independent control provided in an embodiment of the present invention;

[0046] Figure 6 This is a schematic diagram of load-driven feedback and temperature correction provided in an embodiment of the present invention.

[0047] Reference numerals: 100, Test system; 10, Test bench; 11, Test station; 20, Motor clamping assembly; 21, Positioning seat; 22, Clamping element; 30, Motor under test; 31, Output terminal; 40, Load simulation module; 41, Connecting element; 42, Loading actuator; 43, Loading drive unit; 44, Loading current acquisition unit; 45, Temperature acquisition unit; 451, First temperature detection element; 452, Second temperature detection element; 50, Power supply control module; 60, Current acquisition module; 61, Voltage acquisition module; 62, Speed ​​acquisition module; 63, Temperature rise acquisition module; 70, Control module; 71, Station control channel; 72, Abnormal isolation unit; 73, Temperature drift correction unit; 80, Multi-channel isolation filtering module; 90, Human-machine interaction module; 91, Data recording module. Detailed Implementation

[0048] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can understand and implement other implementation methods and technical effects of the present invention based on the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the various technical details in this specification can be adjusted, combined, or replaced according to different application needs without departing from the spirit and substance of the present invention. It should be noted that, without technical contradictions, the following embodiments and the technical features in the embodiments can be combined with each other. It should also be understood that the terminology used in the embodiments of the present invention is only used to describe specific implementation schemes and is not intended to limit the scope of protection of the present invention.

[0049] In the description of this invention, terms such as "connection," "association," and "communication connection" should be interpreted broadly. For example, the load simulation module 40 is associated with the output terminal 31 of the motor under test 30, which can be a direct coaxial connection or an indirect connection through intermediate structures such as couplings, clamps, transition shafts, pulleys, loading motors, or brakes. The communication connection between the control module 70 and other modules can be wired communication, or it can be a common industrial field bus communication, terminal connection, analog input / output connection, or other data interaction methods. These concepts are clarified here first, and will not be repeated in subsequent embodiments. The structures in the accompanying drawings are only used to illustrate one possible form of the invention. In actual equipment, the shape, installation direction, quantity, and wiring harness routing of each module can be adjusted according to the test bench space, the specifications of the motor under test, and the on-site process requirements.

[0050] Please see Figures 1 to 6 This invention provides a motor load simulation test system 100 based on current closed-loop feedback. This test system 100 is mainly used for load simulation tests, constant torque durability tests, simulated operating condition tests, or factory sampling inspections of small drive motors such as brushed motors, brushless motors, and DC motors. In production environments, motors are usually not simply judged as qualified by idling; instead, they need to run continuously under a certain load for a period of time, and the stability of current, voltage, temperature rise, speed, or operating status is observed. The idea behind this invention is based on this practical scenario: it not only displays the current but also allows the current to truly participate in the test control. In other words, the real-time operating current is not only a result data point but can also serve as feedback to judge the current load state and operating risk of the motor under test 30.

[0051] Please see Figures 1 to 3 In one specific embodiment, the test system 100 includes a load simulation module 40, a current acquisition module 60, and a control module 70. The load simulation module 40 is associated with the output terminal 31 of the motor under test 30, and is used to form an adjustable test load acting on the motor under test 30. The current acquisition module 60 is connected to the power supply circuit of the motor under test 30, and is used to acquire the real-time operating current of the motor under test 30 during the test. The control module 70 is communicatively connected to both the load simulation module 40 and the current acquisition module 60, and is used to determine the current feedback benchmark according to the test objective, and compare the real-time operating current with the current feedback benchmark to obtain the current deviation. Here, "comparison" is not limited to simple greater than or less than judgments, but can also include interval judgments, trend judgments, duration judgments, rate of change judgments, or combinations of multiple judgment methods.

[0052] In this embodiment, the motor under test 30 can obtain the test voltage through the power supply control module 50. The power supply control module 50 may include a DC power supply, a voltage regulator, a relay, an electronic switch, a drive circuit, a protection switch, or a power distribution circuit. For products with a fixed rated voltage, the power supply control module 50 can supply power to the motor under test 30 according to a preset target voltage; for products that need to simulate different power conditions, the power supply control module 50 can also adjust the output voltage under the control of the control module 70. In actual workshops, many test benches have voltage, current, and running time displays. This invention does not exclude this traditional display method, but further incorporates the collected operating current into the control closed loop.

[0053] The current feedback reference mentioned here can be flexibly set according to actual test requirements. For example, in ordinary durability testing, the current feedback reference can be an allowable current range; in tests simulating load changes, the current feedback reference can be a target current curve that changes over time; in simple screening tests, the current feedback reference can also be a target current value. In some embodiments closer to the production site, the current feedback reference can also be associated with the product model of the motor under test 30. After the operator selects the product model on the human-machine interface module 90, the control module 70 automatically calls up the target voltage, test duration, upper allowable current limit, lower allowable current limit, and abnormal duration threshold corresponding to that model. This reduces the possibility of errors in manually setting parameters and is also suitable for testing scenarios involving multiple models and small batches of alternating production.

[0054] In a more intuitive working mode, when the real-time operating current is lower than the current feedback reference, it indicates that the actual load on the motor under test (30) may be too light. The control module 70 can control the load simulation module 40 to increase the load output, allowing the motor under test (30) to enter a running state closer to the target operating condition. When the real-time operating current is higher than the current feedback reference, it indicates that the current load on the motor under test (30) is too heavy or that the motor itself has an abnormality. The control module 70 can reduce the load output, or it can pause, stop, reduce the load, or mark the abnormality on the motor under test (30). In actual equipment operation, not every situation requires the same handling strategy. Companies can choose according to the product model and test procedures. For example, for motors that allow short-term impact, the load can be reduced and observed during short-term overcurrent; for motors with a high risk of winding temperature rise, the station can be stopped directly after the overcurrent continues for more than a preset time.

[0055] Please continue reading. Figure 2 In one embodiment of the present invention, the load simulation module 40 includes a connector 41, a load execution component 42, a load driving unit 43, a load current acquisition unit 44, and a temperature acquisition unit 45. Figure 2In the diagram, the load simulation module 40 is shown with a dashed box or a summary label to illustrate that the load actuator 42, load drive unit 43, load current acquisition unit 44, and temperature acquisition unit 45 can be components of the load simulation module 40. That is to say, Figure 2 The 40 in the text does not refer only to the loading actuator 42 itself, but to a set of structures that can form an adjustable test load on the motor under test 30 and perform related acquisition, driving or correction.

[0056] One end of the connecting member 41 is connected to the output end 31 of the motor under test 30, and the other end is connected to the loading actuator 42. The connecting member 41 can be a coupling, a collet, a sleeve, a transition shaft, a flexible connecting member, or other structures that can achieve power transmission. For small DC motors, the output end 31 is usually the output shaft, and the connecting member 41 can be a clamping coupling to facilitate quick replacement of motor shafts of different diameters; for scenarios where it is necessary to reduce the impact of installation deviations, the connecting member 41 can be a flexible coupling to absorb a small amount of coaxiality error. It should be noted that the connecting member 41 is not limited to the cylindrical structure shown in the figure, as long as it can establish a transmission relationship between the motor under test 30 and the loading actuator 42.

[0057] The loading actuator 42 is used to apply an adjustable test load to the motor under test 30. The loading actuator 42 can be a magnetic powder brake, an eddy current brake, an electromagnetic brake, a loading motor, a controllable friction loading mechanism, or other components capable of generating adjustable resistance. For example, when the loading actuator 42 uses a magnetic powder brake, the loading drive unit 43 can change the braking torque by adjusting the excitation current; when the loading actuator 42 uses an eddy current brake, the damping can be changed by adjusting the excitation intensity or control parameters; when the loading actuator 42 uses a loading motor, the load can be formed through reverse drag control, generator braking, or current control. Each of these forms has its own characteristics, but in this invention, they can all be uniformly understood as follows: the loading actuator 42 can change the load state of the motor under test 30 under the control of the control module 70.

[0058] The loading drive unit 43 is communicatively connected to the control module 70 and is used to adjust the loading state of the loading actuator 42 according to the control quantity output by the control module 70. The loading drive unit 43 can be configured as an independent drive box, an electronic control board, a power driver, or an integrated drive circuit. Figure 2 The load drive unit 43 is drawn as an electrical control box to avoid it being mistaken for another motor under test. The load drive unit 43 can receive digital control quantities, analog control quantities, pulse width modulation signals or communication commands output by the control module 70, and convert them into drive current, drive voltage or execution control quantities suitable for the load actuator 42.

[0059] Please see Figure 3 and Figure 6 In another embodiment, the load simulation module 40 further includes a load current acquisition unit 44. The load current acquisition unit 44 is connected to the output circuit of the load drive unit 43 and is used to acquire the load drive current. The load drive current referred to here mainly refers to the current used to drive the load actuator 42 to generate resistance or braking force, rather than the operating current of the motor under test 30 itself. The control module 70 generates a target load current based on the current deviation between the real-time operating current and the current feedback reference, and then adjusts the output of the load drive unit 43 based on the deviation between the target load current and the load drive current. The advantage of this approach is that the operating current of the motor under test 30 serves as the outer layer feedback, while the load drive current serves as the inner layer feedback on the load execution side. When combined, the output of the load simulation module 40 is less likely to remain in an open-loop setting state.

[0060] Specifically, assuming the target for the motor under test 30 during a certain test phase is to maintain operation near a predetermined current, but the actual real-time operating current is lower than expected, the control module 70 can increase the target loading current. The loading drive unit 43 then increases its output based on the target loading current, increasing the resistance of the loading actuator 42. Conversely, if the real-time operating current is higher than expected, the control module 70 can decrease the target loading current or directly output control commands such as load reduction or shutdown. This is not about making the control algorithm overly complex, but rather about making the load simulation process more controllable through the coordination between the motor-side current and the loading-side current. For review and understanding, this at least forms a control chain of "real-time operating current feedback of the motor under test—target loading current generation—loading drive current feedback—load output correction," rather than a simple list of several detection modules.

[0061] In some implementations, the control module 70 can execute the above control process according to a preset control cycle. Within each control cycle, the current acquisition module 60 acquires the real-time operating current of the motor under test 30. The control module 70 calculates the current deviation based on this real-time operating current and the current feedback reference, and determines the load correction direction based on this current deviation. Subsequently, the loading drive unit 43 adjusts the loading state of the loading actuator 42 according to the control quantity output by the control module 70, and the loading current acquisition unit 44 acquires the actual loading drive current and feeds it back to the control module 70. If there is a deviation between the actual loading drive current and the target loading current, the control module 70 corrects the output of the loading drive unit 43. This process can be repeated to gradually bring the load output closer to the target state during the test.

[0062] Please continue reading. Figure 6In some continuous endurance test scenarios, the loading actuator 42 will generate heat after prolonged operation. For magnetic particle brakes, eddy current brakes, or electromagnetic brakes, temperature changes may alter the actual loading effect under the same drive current. Therefore, the load simulation module 40 may also include a temperature acquisition unit 45. The temperature acquisition unit 45 is used to acquire the temperature status of the loading actuator 42, and the control module 70 corrects the load output of the load simulation module 40 based on this temperature status. This embodiment primarily considers long-term operation scenarios, especially in endurance tests where a single station may operate continuously for several hours or even longer. If the thermal state of the loading actuator 42 continues to change, relying solely on the initial loading parameters is insufficient for stability.

[0063] In a more specific embodiment, the temperature acquisition unit 45 includes a first temperature detection element 451 and a second temperature detection element 452. The first temperature detection element 451 is used to acquire the internal temperature of the loading actuator 42, such as the temperature of the coil region, magnetic medium region, or other internal heat-generating regions; the second temperature detection element 452 is used to acquire the external temperature of the loading actuator 42, such as the temperature of the casing, heat sink, or peripheral heat-generating region. In the accompanying drawings, the first temperature detection element 451 corresponds to the internal region of the loading actuator 42, and the second temperature detection element 452 corresponds to the casing or peripheral region of the loading actuator 42. The internal temperature can reflect the instantaneous thermal state near the heat source in the loading actuator 42, while the external temperature can reflect the overall temperature state of the loading actuator 42 after heat dissipation. Viewing both types of temperatures together provides a closer picture of the actual operating state than viewing only a single point temperature.

[0064] In use, the control module 70 can determine the temperature drift correction amount based on the internal and external temperatures, and use this correction amount to adjust the target loading current or the output of the loading drive unit 43. For example, if the actual resistance decreases under the same loading drive current after the loading actuator 42 heats up, the control module 70 can appropriately increase the target loading current; if the temperature change causes the load output to be too large, it can also be corrected in the opposite direction. Such temperature drift correction does not require the use of a fixed formula; it can be implemented using calibration tables, empirical models, piecewise functions, or software algorithms. In practical terms, as long as it can compensate for the load output based on the thermal state of the loading actuator 42, the technical objective of this embodiment can be achieved.

[0065] In one optional calibration method, load tests can be performed with the load actuator 42 under different temperature conditions to establish a correspondence between the temperature state and the load output deviation. This correspondence can be stored in the control module 70, the data recording module 91, or a storage unit communicating with the control module 70. During the formal test, the control module 70 queries the corresponding correction amount based on the temperature state collected by the temperature acquisition unit 45 and corrects the target load current accordingly. In this way, the load simulation module 40 can maintain a relatively consistent output state in the cold state, the temperature rise state, and the thermal stability state, and is less likely to experience significant load level drift before and after the test.

[0066] Please see Figure 1 and Figure 5 In an embodiment suitable for batch testing in a production workshop, the testing system 100 further includes a test bench 10. The test bench 10 forms multiple test stations 11, each of which is equipped with a load simulation module 40 and a current acquisition module 60. The control module 70 includes multiple station control channels 71, each corresponding to one test station 11. In this way, multiple motors under test 30 can be tested simultaneously, but each test station 11 does not simply share the same control logic; instead, each station performs feedback control based on the real-time operating current of its corresponding motor.

[0067] In some embodiments, the test station 11 is further equipped with a motor clamping assembly 20. The motor clamping assembly 20 may include a positioning seat 21 and a clamping member 22. The positioning seat 21 is used to support the housing of the motor under test 30, and the clamping member 22 is used to restrict the movement of the motor under test 30 relative to the positioning seat 21. After the motor under test 30 is installed, its output end 31 faces the load simulation module 40. Although this part is not the most critical control point of the present invention, it is very necessary in actual equipment, because if the motor is not clamped stably, it is meaningless to discuss current feedback and load stability later. The positioning seat 21 can be set as a V-shaped seat, an arc-shaped support seat, a flat positioning seat, or an interchangeable positioning seat according to the housing shape of the motor under test 30, and the clamping member 22 can be a pressure plate, a quick clamp, a pneumatic gripper, an elastic clamping member, or other clamping structures.

[0068] For multi-station testing, the control module 70 can assign an independent station control channel 71 to each test station 11. Each station control channel 71 can collect the real-time operating current of the corresponding test station 11 and independently control the corresponding load simulation module 40 based on the current deviation of the corresponding test station 11. Therefore, even if multiple test stations 11 perform the same test, adjustments can be made according to the actual current of each motor 30 under test, preventing individual differences in one motor from affecting other stations. This may seem like a small improvement in control logic, but it is significant for batch testing.

[0069] The control module 70 may also include an anomaly isolation unit 72. The anomaly isolation unit 72 is used to control the test station 11 to stop, pause, or mark an anomaly when the real-time operating current of any test station 11 meets the anomaly determination condition, while allowing the remaining test stations 11 to continue operating. Anomaly determination conditions may include real-time operating current exceeding the upper limit for a preset time, real-time operating current falling below the lower limit for a preset time, real-time operating current change rate exceeding a preset threshold, or current suddenly disappearing or fluctuating during operation. It is important to note that anomaly isolation does not simply stop all stations together, but rather handles the abnormal station individually, which is very useful for batch testing.

[0070] Please see Figure 5 , Figure 5 This illustrates a schematic relationship for independent control of multiple workstations. The control module 70 controls multiple test workstations 11 through multiple workstation control channels 71. For ease of explanation, Figure 5 The diagram shows three test stations 11-1, 11-2, and 11-3, with 11-2 corresponding to the anomaly isolation unit 72. The main point of this diagram is that when a test station meets the anomaly detection criteria, the anomaly isolation unit 72 can perform isolation processing on that test station without requiring the other test stations to stop. In practical applications, it is not limited to only intermediate stations being able to trigger the anomaly isolation unit 72. Figure 5 This is only used to illustrate the control relationship when an anomaly occurs at one of the test stations. When an anomaly occurs at any other test station, it can also be handled by the anomaly isolation unit 72 according to the same logic.

[0071] The handling method of the anomaly isolation unit 72 can vary depending on the equipment configuration. For example, the anomaly isolation unit 72 can control the power supply control module 50 of the corresponding workstation to disconnect the power; it can also control the load simulation module 40 of the corresponding workstation to unload; or it can mark the corresponding workstation as abnormal and stop the running timer. In some embodiments, the anomaly isolation unit 72 can also output alarm information to the human-machine interaction module 90, so that the operator can know which workstation has an anomaly. For minor anomalies that do not require immediate shutdown, the anomaly isolation unit 72 can also first perform load reduction or pause, and then wait for manual review or secondary judgment.

[0072] Please see Figure 3In another embodiment, the test system 100 further includes a multi-channel isolation filter module 80. The multi-channel isolation filter module 80 is connected between the main power input and multiple load simulation modules 40 to suppress interference conducted between different load simulation modules 40 via the power supply bus. The multi-channel isolation filter module 80 may include a common-mode inductor, a differential-mode inductor, an LC filter unit, an absorption circuit, an isolation power supply unit, or other electromagnetic interference suppression structures. This part is designed primarily to address the possibility of switching noise, back electromotive force, or high-frequency ripple in each loading channel during simultaneous operation of multiple stations. Without processing, these issues can easily affect the stability of current acquisition and the accuracy of control judgment.

[0073] In some embodiments, the multi-channel isolation filter module 80 can be located between the power supply control module 50 and the multiple load simulation modules 40, or it can be located at the input terminal of the load drive unit 43 corresponding to each station. For a multi-station test system using centralized power supply, the multi-channel isolation filter module 80 can perform branch filtering on the load drive circuit of each station; for a test system with independent power supply to each station, the multi-channel isolation filter module 80 can also be located on the power supply branch of each station. Through this setting, the impact of load drive changes in one station on the current sampling results of other stations can be reduced.

[0074] In some embodiments, the test system 100 may further include at least one of a power supply control module 50, a voltage acquisition module 61, a speed acquisition module 62, and a temperature rise acquisition module 63. The power supply control module 50 provides a test voltage to the motor under test 30. The voltage acquisition module 61 acquires the real-time power supply voltage of the motor under test 30. The speed acquisition module 62 acquires the real-time speed of the motor under test 30. The temperature rise acquisition module 63 acquires the temperature or temperature rise status of the motor under test 30. The control module 70 can determine the control quantity corresponding to the current deviation based on the real-time operating current and at least one of the real-time power supply voltage, real-time speed, and real-time temperature. This is to avoid simply attributing all current changes to load changes, since power fluctuations, speed changes, or motor temperature rises may also affect the current.

[0075] For example, when the real-time operating current increases and the real-time speed decreases, the control module 70 can determine that the load on the motor under test 30 may be too large, and thus reduce the load output of the load simulation module 40 or enter the abnormal judgment process; when the real-time operating current increases but the real-time supply voltage also increases synchronously, the control module 70 can combine the voltage change to correct the current deviation and avoid misjudgment due to power fluctuations; when the temperature rise of the motor under test 30 continues to increase and the current gradually deviates from the current feedback reference, the control module 70 can reduce the load output in advance or shorten the continued running time of the station. Such joint judgment is not required in every embodiment, but can be used as an extension to improve control stability.

[0076] The human-machine interface module 90 receives test targets and displays test status. Test targets may include the product model of the motor under test 30, test items, target voltage, test duration, target current value, target current curve, or allowable current range. The human-machine interface module 90 can also display real-time operating current, real-time supply voltage, load output status, operating status, operating time, and abnormal information. The data recording module 91 is used to correlate and record real-time operating current, current feedback reference, load output status, and the operating status of the motor under test 30 to form test traceability data. This part is also crucial for the production workshop, because test data often needs to be mapped to batches, models, or even individual motors.

[0077] In some embodiments, the data recording module 91 can record test data according to a fixed sampling period, or record test data at key nodes such as when an anomaly occurs, load adjustment occurs, test starts, or test ends. The recorded content may include product model, workstation number, test start time, test end time, real-time operating current, target current value or allowable current range, load drive current, load correction amount, temperature status, anomaly type, and processing result. Using this data, it is possible to subsequently trace whether a specific motor under test 30 experienced overcurrent deviation, load correction, abnormal shutdown, or other issues during the test.

[0078] Please see Figure 4 The test method provided by this invention can be implemented according to the following process. First, the output terminal 31 of the motor under test 30 is associated with the load simulation module 40. Specifically, the motor under test 30 can be installed at the test station 11, and the output terminal 31 can be connected to the load actuator 42 through the connector 41. Then, the current feedback reference is determined according to the test target. The test target can be input by the operator through the human-machine interaction module 90, or it can be automatically called by the control module 70 according to the product model.

[0079] Next, the motor under test (DUT) 30 is started, and the current acquisition module 60 acquires the real-time operating current of the DUT 30 during the test. The control module 70 compares the real-time operating current with the current feedback reference to obtain the current deviation. Subsequently, the control module 70 adjusts the load output of the load simulation module 40 and / or the operating state of the DUT 30 according to the current deviation. For example, when the real-time operating current is lower than the current feedback reference, the load output can be increased; when the real-time operating current is higher than the current feedback reference, the load output can be decreased, or the DUT 30 can be paused, stopped, deloaded, or flagged as abnormal.

[0080] In one specific test procedure, the operator can first select the product model of the motor under test (30) through the human-machine interface module 90 and confirm the test items. The control module 70 calls the corresponding test target and current feedback benchmark according to the product model. After the motor under test (30) is installed in the test station 11, the control module 70 controls the power supply control module 50 to supply power to the motor under test (30), and at the same time, the load simulation module 40 applies an initial test load to the motor under test (30). The current acquisition module 60 starts to acquire the real-time operating current, and the control module 70 determines whether the current load meets the test requirements based on the real-time operating current. If the current deviation is small, the current load output is maintained; if the current deviation exceeds the preset range, the load adjustment or abnormal handling process is initiated.

[0081] In the embodiment where the load simulation module 40 has a load current acquisition unit 44, the control module 70 can generate a target load current based on the current deviation. The load current acquisition unit 44 acquires the load drive current output by the load drive unit 43, and then the control module 70 adjusts the output of the load drive unit 43 based on the deviation between the target load current and the load drive current. This process is equivalent to adding another layer of feedback on the load execution side, not only telling the loading mechanism "how much should be loaded," but also checking whether the load drive is actually keeping up.

[0082] In the embodiment where the load simulation module 40 includes a temperature acquisition unit 45, the temperature acquisition unit 45 acquires the temperature status of the loading actuator 42, and the control module 70 corrects the target loading current or load output based on the temperature status. For long-term endurance tests, this step can reduce the impact of the temperature rise of the loading actuator 42 on the load simulation status. Even if the test lasts for a long time, the system will not continuously control according to the initial cold-state parameters.

[0083] In a multi-station test scenario, each test station 11 performs real-time operating current acquisition, current deviation calculation, and load output control. When any test station 11 meets the abnormality judgment condition, the abnormality isolation unit 72 controls that test station 11 to stop, pause, or mark an abnormality, while keeping the remaining test stations 11 running. In this way, an abnormality in one motor will not affect the entire test group, nor will it allow the abnormal motor to remain in a risky operating state.

[0084] In some embodiments, the test method may further include a test completion judgment step. When the running time of the motor under test 30 reaches the test duration, and the real-time operating current, temperature status, or other operating parameters do not meet the abnormal judgment conditions, the control module 70 can mark the test result corresponding to the motor under test 30 as qualified or completed; when an abnormal shutdown, continuous overcurrent, continuous undercurrent, or load following failure occurs during the test, the control module 70 can mark the test result corresponding to the motor under test 30 as abnormal. The above test results can be displayed through the human-machine interaction module 90 or saved by the data recording module 91.

[0085] In summary, the motor load simulation test system 100 provided by this invention uses the real-time operating current of the motor under test 30 as the feedback quantity for the load simulation test, enabling the load output of the load simulation module 40 and the operating state of the motor under test 30 to be adjusted according to the current deviation. Furthermore, through implementation methods such as load drive current feedback, temperature state correction, multi-station independent control, anomaly isolation, multi-channel isolation filtering, and data recording, the consistency, timeliness of anomaly handling, and long-term operational stability of the motor load simulation test can be improved.

[0086] It should be understood that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions or improvements made by those skilled in the art without departing from the spirit and substance of the present invention should be included within the scope of protection of the present invention.

Claims

1. A motor load simulation test system based on current closed-loop feedback, characterized in that, include: The load simulation module (40) is associated with the output terminal (31) of the motor under test (30) and is used to form an adjustable test load acting on the motor under test (30); The current acquisition module (60) is connected to the power supply circuit of the motor under test (30) and is used to acquire the real-time operating current of the motor under test (30) during the test. The control module (70) is communicatively connected to the load simulation module (40) and the current acquisition module (60) respectively. It is used to determine the current feedback benchmark according to the test target, compare the real-time operating current with the current feedback benchmark to obtain the current deviation, and adjust the load output of the load simulation module (40) and / or the operating state of the motor under test (30) according to the current deviation.

2. The motor load simulation test system according to claim 1, characterized in that, The test objectives include at least one of the following: product model of the motor under test (30), test items, target voltage, test duration, and simulated operating conditions; The current feedback reference includes at least one of the following: target current value, target current curve, and allowable current range.

3. The motor load simulation test system according to claim 1, characterized in that, The load simulation module (40) includes a load executor (42) and a load drive unit (43). The loading actuator (42) is connected to the output end (31) of the motor under test (30) in a transmission connection; The loading drive unit (43) is communicatively connected to the control module (70) and is used to adjust the loading state of the loading executor (42) according to the control quantity output by the control module (70).

4. The motor load simulation test system according to claim 3, characterized in that, The load simulation module (40) also includes a load current acquisition unit (44). The loading current acquisition unit (44) is connected to the output circuit of the loading drive unit (43) and is used to acquire the loading drive current; The control module (70) is also used to generate a target loading current based on the current deviation, and to adjust the output of the loading drive unit (43) based on the deviation between the target loading current and the loading drive current.

5. The motor load simulation test system according to claim 3, characterized in that, The load simulation module (40) further includes a temperature acquisition unit (45); the temperature acquisition unit (45) includes a first temperature sensor (451) and a second temperature sensor (452), the first temperature sensor (451) is used to acquire the internal temperature of the loading actuator (42), and the second temperature sensor (452) is used to acquire the external temperature of the loading actuator (42); the control module (70) is also used to correct the load output of the load simulation module (40) according to the temperature status acquired by the temperature acquisition unit (45).

6. The motor load simulation test system according to claim 1, characterized in that, It also includes a test bench (10); The test bench (10) forms multiple test stations (11); Each of the test stations (11) is equipped with the load simulation module (40) and the current acquisition module (60). The control module (70) includes multiple workstation control channels (71), each of which corresponds to one of the test workstations (11).

7. The motor load simulation test system according to claim 6, characterized in that, The control module (70) also includes an abnormal isolation unit (72); The abnormal isolation unit (72) is used to control the test station (11) to stop, pause or mark abnormal when the real-time operating current of any test station (11) meets the abnormal judgment condition, and to keep the other test stations (11) running.

8. The motor load simulation test system according to claim 6, characterized in that, It also includes a multi-channel isolation filter module (80); The multi-channel isolation filter module (80) is connected between the main power input terminal and multiple load simulation modules (40) to suppress interference between different load simulation modules (40) conducted through the power supply bus.

9. The motor load simulation test system according to claim 1, characterized in that, It also includes a human-computer interaction module (90) and a data recording module (91); The human-machine interaction module (90) is used to receive the test target and display the test status; the data recording module (91) is used to associate and record the real-time working current, the current feedback reference, the load output status of the load simulation module (40) and the operating status of the motor under test (30).

10. A method for simulating motor load based on current closed-loop feedback, characterized in that, include: Connect the output terminal (31) of the motor under test (30) to the load simulation module (40); Determine the current feedback reference based on the test objectives; Obtain the real-time operating current of the motor under test (30) during the test; The real-time operating current is compared with the current feedback reference to obtain the current deviation; Adjust the load output of the load simulation module (40) and / or the operating status of the motor under test (30) according to the current deviation.

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