Motor load simulation device

Abstract

The utility model discloses a motor load simulation device. The device comprises a shielding darkroom; the torque rotating speed sensor is arranged in the shielding darkroom; the left half coupling and the right half coupling are respectively provided with a through hole, the left half coupling is connected with the torque rotating speed sensor, and the right half coupling is used for connecting a power shaft of a motor to be tested; column bodies are arranged on the two sides of the disc-shaped transmission part, and the column bodies are inserted into the through holes of the left half coupling and the right half coupling respectively; the dynamometer is arranged in the shielding darkroom; the dynamometer and the torque rotating speed sensor are connected through a second coupler. And the torque rotating speed power measuring instrument is connected with the torque rotating speed sensor and is arranged outside the shielding darkroom. In the device, a disc-shaped transmission part is arranged between the left half coupling and the right half coupling of the first coupling, so that electromagnetic signals generated by the dynamometer and the torque rotating speed sensor are physically isolated from the motor to be tested, and the electromagnetic compatibility test result of the motor is prevented from being influenced.

Description

Motor load simulation device Technical Field

[0001] This utility model relates to the field of motor testing technology, specifically a motor load simulation device. Background Technology

[0002] Based on the operating principle of motor products, it is known that the presence or absence of a load at the output terminal has a significant impact on electromagnetic compatibility (EMC) performance. Generally, the interference generated by a motor under load is greater than that under no load. In EMC testing, when the sample under test is a motor, considering factors such as size and mechanical installation, it is difficult to place the actual load of the motor in the test environment. Therefore, a device needs to be designed to load the motor under test to simulate an actual load. Summary of the Invention

[0003] To overcome the shortcomings of the prior art, this utility model provides a motor load simulation device. The device uses a dynamometer to load the motor to simulate the actual load. The motor under test and the torque and speed sensor are connected by a first coupling. A disc-shaped transmission component is provided between the left and right halves of the first coupling, thereby physically isolating the electromagnetic signals generated by the dynamometer and the torque and speed sensor from the motor under test and avoiding affecting the electromagnetic compatibility test results of the motor.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is: a motor load simulation device, comprising:

[0005] Shielded anechoic chamber;

[0006] A torque-speed sensor, wherein the torque-speed sensor is disposed in the shielded dark chamber;

[0007] The first coupling includes a left half coupling and a right half coupling, each having a through hole. The left half coupling is connected to the torque and speed sensor, and the right half coupling is used to connect to the power shaft of the motor under test.

[0008] The transmission component is disc-shaped, and has columns on both sides, which are respectively inserted into the through holes of the left half coupling and the right half coupling.

[0009] The second coupling is connected to the end of the torque and speed sensor that is away from the first coupling;

[0010] A dynamometer is provided in the shielded dark room, and the dynamometer is connected to the end of the second coupling away from the torque and speed sensor.

[0011] A torque, speed and power measuring instrument is installed outside the shielded dark room. The torque, speed and power measuring instrument is connected to the torque and speed sensor and is used to read the measurement data of the torque and speed sensor.

[0012] The above technical solution connects the power shaft of the motor under test to the flexible connection device. The load on the motor under test is increased by adjusting the excitation current of the dynamometer until the torque displayed by the torque-speed-power measuring instrument reaches a preset value, thus completing the loading process. A first coupling connects the motor under test and the torque-speed sensor. A disc-shaped transmission component is installed between the left and right halves of the first coupling, thereby physically isolating the electromagnetic signals generated by the dynamometer and the torque-speed sensor from the motor under test, preventing any impact on the electromagnetic compatibility test results.

[0013] Furthermore, a DC constant voltage and constant current power supply is included. This power supply is located outside the shielded anechoic chamber and is connected to the dynamometer, providing power to the dynamometer. The DC constant voltage and constant current power supply employs dual closed-loop control technology, with a load switching transient response time of <5ms and voltage fluctuation of <5%FS, adapting to the dynamometer's testing requirements for scenarios such as motor start-up and shutdown, and sudden load increases.

[0014] Furthermore, the second coupling includes a brake coupling, which is equipped with a brake. In motor EMC testing, a sudden load change scenario can be simulated through braking operation to verify the EMC performance of the motor under test under dynamic braking.

[0015] Furthermore, the dynamometer is equipped with a cooling system. In this application, the dynamometer is used to simulate automotive loads, requiring significant power. High-power operation generates substantial heat, leading to temperature increases. These temperature increases can cause instability in the dynamometer's function and deviations in the generated torque. Adding a cooling system effectively stabilizes the internal temperature of the dynamometer, ensuring stable power and torque output.

[0016] Furthermore, the cooling system includes:

[0017] Liquid-cooled pipes are fixed to the dynamometer.

[0018] A pump is installed outside the shielded dark room and is connected in series with the liquid cooling pipeline.

[0019] Furthermore, the transmission component is made of nylon.

[0020] Furthermore, the diameter of the column is less than or equal to the diameter of the through holes of the left and right half couplings.

[0021] Furthermore, it includes a support base for fixing the dynamometer and the motor under test. The support base can absorb and isolate high-frequency vibrations during motor operation, reducing vibrations transmitted through the shaft, thereby reducing vibration-induced electromagnetic radiation interference.

[0022] Furthermore, the support base has at least two components, and the dynamometer and the motor under test are fixed on two different support bases. Mounting the dynamometer and the motor under test on different support bases further reduces vibration interference between the dynamometer and the motor under test.

[0023] Furthermore, the support base is made of a non-conductive material. The non-metallic material can block stray current conduction between the motor shaft and the housing, reducing the impact of common-mode current on EMC test results.

[0024] Based on the above technical solution, the beneficial effects of this utility model are as follows:

[0025] The motor load simulation device disclosed in this application uses a dynamometer to load the motor to simulate the actual load. The motor under test and the torque and speed sensor are connected by a first coupling. A disc-shaped transmission component is provided between the left and right halves of the first coupling, thereby physically isolating the electromagnetic signals generated by the dynamometer and the torque and speed sensor from the motor under test and avoiding affecting the electromagnetic compatibility test results of the motor.

[0026] The dynamometer generates a lot of heat when operating at high power, which causes the temperature to rise. The temperature rise can lead to instability in the dynamometer's function and deviations in the torque it produces. This application includes a cooling system to stabilize the internal temperature of the dynamometer and ensure stable power and torque output.

[0027] To make the above and other objects, features and advantages of this utility model more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 is a schematic diagram of the motor load simulation device in an embodiment of this utility model;

[0030] Figure 2 is a schematic diagram of the structure of the first coupling and transmission component in the embodiment of this utility model;

[0031] Figure 3 is a schematic diagram of the installation structure of the torque and speed sensor, dynamometer and motor under test in an embodiment of this utility model.

[0032] The reference numerals in the above figures are as follows: 1. Shielded anechoic chamber; 2. Torque and speed sensor; 3. Motor under test; 4. Dynamometer; 5. Left half coupling; 512. Through hole; 52. Right half coupling; 6. Brake coupling; 7. High-power DC constant voltage and constant current power supply; 8. Torque, speed and power measuring instrument; 91. Liquid cooling pipe; 92. Pump; 10. Transmission component; 101. Column. Detailed Implementation

[0033] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0034] It should be noted that in the description of this utility model, the terms "first," "second," etc., are used only for descriptive purposes and to distinguish similar objects; there is no order between them, nor should they be construed as indicating or implying relative importance. Furthermore, in the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0035] Example: This example discloses a motor load simulation device, including:

[0036] A shielded anechoic chamber 1. The shielded anechoic chamber 1 is equipped with a first cement support 21, a second cement support 31, and a third cement support 41. A torque-speed sensor 2 is fixedly installed on the first cement support 21. The torque-speed sensor 2 is an instrument for measuring the torque, speed, and power of rotating components, achieving dynamic or static monitoring by converting the physical change of torsional torque into an electrical signal. In this application, the torque-speed sensor 2 is used to measure the speed of the motor 3 under test and the torque provided by the dynamometer 4. The torque-speed sensor 2 is connected to a torque-speed-power measuring instrument 8, which is located outside the shielded anechoic chamber 1. The torque-speed-power measuring instrument 8 is used to read the measurement data from the torque-speed sensor 2.

[0037] As shown in Figures 1 and 2, one end of the torque-speed sensor 2 is connected to a first coupling, which includes a left half coupling 51 and a right half coupling 52. Each of the left half coupling 51 and the right half coupling 52 has a through hole 512. The right half coupling 52 is connected to the torque-speed sensor 2, and the left half coupling 51 is used to connect to the motor 3 under test. In this application, the left half coupling 51 and the right half coupling 52 are driven by a disc-shaped transmission device 10. The transmission device 10 has columns 101 on both sides, which are inserted into the through holes of the left half coupling 51 and the right half coupling 52. It should be noted that the diameter of the column is less than or equal to the diameter of the through holes of the left half coupling 51 and the right half coupling 52. The end of the torque-speed sensor 2 facing away from the first coupling is connected to a brake coupling 6.

[0038] The end of the first coupling opposite to the torque and speed sensor 2 is used to connect the motor under test 3, which is fixedly mounted on the second cement support 31. The variety of motors under test 3 and the inherent gear clearances on the motor shafts make it difficult to ensure that the power shaft of the motor under test 3 remains coaxial with the shaft of the torque and speed sensor 2 during actual operation. The first coupling provides a certain degree of redundancy to the connection between the two shafts, effectively eliminating misalignment caused by motor shaft vibration during rotation, avoiding sudden changes in torque and speed, and ensuring stable operation of the motor under test 3. It also reduces shaft wear caused by abnormal operating conditions of the motor under test 3 due to shaft asymmetry.

[0039] The brake coupling 6 is connected to a dynamometer 4 at the end opposite to the torque and speed sensor 2. The dynamometer 4 is fixedly mounted on the third cement support 41. The dynamometer 4 is connected to a high-power DC constant voltage and constant current power supply 7. The high-power DC constant voltage and constant current power supply 7 is located outside the shielded anechoic chamber 1. The high-power DC constant voltage and constant current power supply 7 adopts dual closed-loop control technology, with a load switching transient response time of <5ms and voltage fluctuation of <5%FS, adapting to the testing requirements of the dynamometer for scenarios such as motor start-up and shutdown and sudden load increases. In this application, an EVWB series bidirectional DC power supply is used to power the dynamometer 4. By adjusting the output current of the EVWB series bidirectional DC power supply, the output torque of the dynamometer 4 can be adjusted. To simulate automotive load, the dynamometer 4 used in this application has a rated power of 110KW, a rated torque of 400Nm, a maximum torque speed of 2600 rpm, and a maximum speed of 8000 rpm.

[0040] The first, second, and third cement supports are configured such that, after the torque-speed sensor 2, the motor under test 3, and the dynamometer 4 are fixed, their axes are aligned on the same center line. The cement supports can absorb and isolate high-frequency vibrations during motor operation, reducing vibrations transmitted through the shaft and thus lowering vibration-induced electromagnetic interference. They can also block stray current conduction between the motor shaft and the housing, reducing the impact of common-mode current on EMC test results.

[0041] In some feasible embodiments, the first cement support, the second cement support, and the third cement support can also be replaced with non-conductive engineering plastic material.

[0042] The brake coupling 6 is equipped with a brake. In motor EMC testing, the braking operation can simulate a sudden load change scenario to verify the EMC performance of the motor under test 3 under dynamic braking.

[0043] In this application, the dynamometer 4 is used to simulate a vehicle load, requiring a large amount of power. High-power operation generates significant heat, leading to a temperature rise. This temperature rise causes instability in the dynamometer 4, resulting in torque deviations. Therefore, this application includes a cooling system to stabilize the internal temperature of the dynamometer, ensuring stable power and torque output. The cooling system includes a liquid-cooled pipe 91 fixed to the dynamometer 4, with a pump 92 connected in series on the pipe. The pump 92 is located outside the shielded anechoic chamber 1 and provides power for the flow of condensate within the liquid-cooled pipe 91. A cooling tower is also connected in series to the liquid-cooled pipe 91, with its inner cavity communicating with the pipe. The condensate in the pipe absorbs heat emitted by the dynamometer 4 and then transfers the heat through the cooling tower. It is understood that during the construction of the shielded anechoic chamber 1, the floor level is higher than the actual ground level, allowing the liquid-cooled pipe 91 and other wiring harnesses and pipes to be arranged below the metal floor level, entering and exiting through pre-reserved pipe openings.

[0044] Using the above technical solution, the power shaft of the motor 3 under test is connected to the first coupling, and the coaxiality is adjusted using a laser alignment instrument to ensure that the error is less than or equal to 0.05mm. The torque, speed and power measuring instrument 8 and the EVWB series bidirectional DC power supply are turned on, and it is confirmed that the power output is zero and the torque, speed and power measuring instrument 8 can receive the signal. At this time, the torque, speed and power measuring instrument 8 displays zero values.

[0045] When the motor under test 3 is turned on, its power shaft drives the first coupling and the brake coupling 6 to rotate synchronously. Once the speed of the motor under test 3 reaches the rated speed, the torque-speed-power measuring instrument 8 displays that the EVWB series bidirectional DC power supply provides excitation loading to the dynamometer 4, and monitors the torque and speed displayed by the torque-speed-power measuring instrument 8 in real time until the test requirements are met.

[0046] The motor load simulation device disclosed in this application is installed entirely inside the shielded anechoic chamber 1, eliminating the need to drill holes in the wall of the shielded anechoic chamber 1 and thus avoiding damage to the stability of the shielding effectiveness.

[0047] Tests have shown that the radiated emission noise floor of this device is more than 6 dB below the CISPR 25 Level 5 limit, fully meeting the requirements of international and domestic standards for laboratory noise floor.

[0048] This utility model uses specific embodiments to illustrate the principle and implementation of the utility model. The above description of the embodiments is only for the purpose of helping to understand the method and core idea of ​​the utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​the utility model. Therefore, the content of this specification should not be construed as a limitation of the utility model.

Claims

1. A motor load simulation device, characterized in that, include: A shielded anechoic chamber; a torque and speed sensor disposed within the shielded anechoic chamber; a first coupling comprising a left half coupling and a right half coupling each having through holes, the left half coupling being connected to the torque and speed sensor, and the right half coupling being used to connect to the power shaft of the motor under test; a transmission component, the transmission component being disc-shaped, with columns on both sides of the transmission component, the columns being respectively inserted into the through holes of the left half coupling and the right half coupling; a second coupling, the second coupling being connected to the end of the torque and speed sensor opposite to the first coupling; a dynamometer, the dynamometer being disposed within the shielded anechoic chamber, the dynamometer being connected to the end of the second coupling opposite to the torque and speed sensor; and a torque, speed, and power measuring instrument, the torque, speed, and power measuring instrument being disposed outside the shielded anechoic chamber, the torque, speed, and power measuring instrument being connected to the torque and speed sensor, and used to read the measurement data from the torque and speed sensor.

2. The motor load simulation device as described in claim 1, characterized in that, It includes a DC constant voltage and constant current power supply, which is located outside the shielded dark room and is connected to the dynamometer to supply power to the dynamometer.

3. The motor load simulation device as described in claim 1, characterized in that, The transmission component is made of nylon.

4. The motor load simulation device as described in claim 1, characterized in that, The diameter of the column is less than or equal to the diameter of the through holes of the left and right half couplings.

5. The motor load simulation device as described in claim 1, characterized in that, The second coupling includes a brake coupling, wherein the brake coupling is provided with a brake.

6. The motor load simulation device as described in claim 1, characterized in that, The dynamometer is equipped with a cooling system.

7. The motor load simulation device as described in claim 6, characterized in that, The cooling system includes: a liquid cooling pipe fixed to the dynamometer; and a pump located outside the shielded dark room, connected in series with the liquid cooling pipe.

8. The motor load simulation device as described in claim 1, characterized in that, It includes support bases, of which there are at least two, and the dynamometer and the motor under test are fixed on two different support bases.

9. The motor load simulation device as described in claim 8, characterized in that, The support base is made of a non-conductive material.

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