A motor testing system
By designing a multi-motor testing system, employing multi-clamp components and a three-axis adjustable slide, and combining central control and neural network diagnostics, the testing capacity and adaptability issues of existing motor testing systems were resolved, achieving efficient and accurate motor performance evaluation.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- QINGDAO HISENSE HITACHI AIR CONDITIONING SYST
- Filing Date
- 2025-06-17
- Publication Date
- 2026-06-19
AI Technical Summary
Existing motor testing systems have limited testing capacity, allowing only one motor to be tested at a time. They also have poor adaptability, failing to accommodate different motor models and making it inconvenient to adjust test parameters. This results in extended verification cycles and limitations on product types.
Design a motor testing system, including a motor installation module, a load simulation module, a transmission coupling module, a data acquisition module, and a central control module. Employing multiple clamping assemblies, a three-axis adjusting slide, and a central control module, the system enables simultaneous testing and model matching of multiple motors. Test parameters are configured through a human-machine interface terminal, and the data acquisition module captures key performance indicators in real time, with intelligent diagnosis performed through a neural network.
It enables simultaneous testing of multiple motors, improving testing efficiency and adaptability, simplifying test parameter adjustment, shortening the verification cycle, and enhancing test accuracy and intelligent auxiliary diagnostic capabilities.
Smart Images
Figure CN224383403U_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of testing equipment technology, and more specifically, relates to a motor testing system. Background Technology
[0002] As a key actuator in air conditioning indoor units, the stepper motor's core function lies in being controlled by the main control board's microprocessor. It drives the air guide vane through precise angular displacement output, achieving accurate control of the air delivery vector parameters. In reliability verification systems, it is crucial to examine the stability of key performance parameters such as electromechanical conversion efficiency, torque-speed characteristic curve, phase current harmonic distortion rate, and dynamic response characteristics under the coupled effects of multiple physical quantities, including power supply voltage fluctuations, dynamic load disturbances, and drive frequency steps, throughout its entire lifecycle. Current motor testing systems suffer from significant technical bottlenecks: First, limited testing capacity, allowing only one motor to be tested at a time. Second, because the height between the clamping mechanism's axis and the support surface is fixed to accommodate the load simulation module's axis height, and different motor models have different diameters, the distance between the axis and the support surface varies after mounting on the clamping mechanism. This results in existing motor testing systems only being compatible with specific motor models, exhibiting poor universality. Third, the separate setup of the test input / output modules and test fixtures makes adjusting test parameters inconvenient, requiring staff to operate them repeatedly and causing delays in switching between operating conditions. These technical shortcomings directly lead to extended product verification cycles and limitations on the types of products that can be tested. Summary of the Invention
[0003] This invention addresses the technical problems of limited testing capacity and limited types of test motors in the prior art by proposing a motor testing system that can solve the above problems.
[0004] To achieve the above-mentioned objectives, the present invention employs the following technical solution:
[0005] A motor testing system includes a motor mounting module, a load simulation module, a transmission coupling module, a data acquisition module, and a central control module;
[0006] The motor mounting module includes:
[0007] The clamping mechanism includes multiple clamping assemblies, each clamping assembly capable of securing a motor under test;
[0008] A clamping device for driving the clamping assembly to clamp the motor under test;
[0009] The three-axis adjustable slide is supported by the clamping mechanism, which is used to drive the clamping mechanism to move in the three-axis direction;
[0010] The load simulation module is used to simulate the load and is coupled to the output shaft of the motor under test through the transmission coupling module;
[0011] The central control module is connected to a human-machine interface terminal and is used for receiving configured test parameters through human-machine interaction.
[0012] The data acquisition module is used to acquire the torque and / or output current of the motor under test.
[0013] In some embodiments, the load simulation module includes:
[0014] A magnetic powder brake is used to output load torque and apply it to the motor under test through the transmission coupling module.
[0015] The load torque adjustment mechanism, controlled by the central control module, generates a torque adjustment signal to adjust the output torque of the magnetic powder brake.
[0016] A dynamic balancing counterweight mechanism is used to provide different counterweights to test the torque of the motor under test under different balanced loads.
[0017] In some embodiments, the clamp assembly includes:
[0018] The lower clamping part is fixed on the three-axis adjusting slide, and a lower clamping notch is provided on the upper surface of the lower clamping part;
[0019] The upper clamping part has an upper clamping notch on its lower surface that matches the lower clamping notch. The upper clamping part is connected to the clamping device and is used to move the upper clamping part toward the lower clamping part to clamp the motor under test, or to move the upper clamping part away from the lower clamping part to release the motor under test.
[0020] In some embodiments, the upper surface of the lower clamping part is provided with a guide mechanism, and the upper clamping part is provided with a guide hole, through which the guide mechanism passes and connects to the upper clamping part.
[0021] In some embodiments, a limiting mechanism is provided on the upper part of the guide mechanism, and the limiting mechanism is located above the upper clamping part.
[0022] In some embodiments, the lower clamping notch is V-shaped, and the upper clamping notch is an inverted V-shape.
[0023] In some embodiments, the clamping device is a pneumatic clamping device.
[0024] In some embodiments, the load simulation module is mounted on a support platform, which is a shock-resistant granite platform, and the bottom of the support platform is equipped with vibration-damping pads.
[0025] In some embodiments, the motor testing system further includes:
[0026] An electrical assembly cabinet is mounted on the support platform, located behind the motor mounting module. The electrical assembly cabinet has a cavity for accommodating electrical components. The human-machine interface terminal is mounted on the front panel of the electrical assembly cabinet.
[0027] In some embodiments, the motor testing system further includes:
[0028] A safety cover is installed on the support platform and covers the outside of the motor mounting module and the load simulation module. A door is provided in front of the safety cover.
[0029] Compared with the prior art, the advantages and positive effects of the present invention are:
[0030] The motor testing system of this invention, by setting up multiple clamping assemblies, each clamping assembly can fix one motor under test, supporting simultaneous testing of multiple motors and improving testing efficiency. By setting up a three-axis adjusting slide, the position of the motor under test can be adjusted by driving the clamping mechanism to move in three directions. This allows different models of motors to be coupled to the load simulation module through a transmission coupling module, making this solution more versatile.
[0031] Other features and advantages of the present invention will become clearer after reading the detailed embodiments of the invention in conjunction with the accompanying drawings. Attached Figure Description
[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0033] Figure 1 This is a schematic diagram of one embodiment of the motor testing system proposed in this application;
[0034] Figure 2 This is a schematic diagram of the load simulation module in one embodiment of the motor testing system proposed in this application;
[0035] Figure 3 This is a schematic diagram of the clamp assembly in one embodiment of the motor testing system proposed in this application;
[0036] Figure 4 This is a schematic diagram of another embodiment of the motor testing system proposed in this application;
[0037] Figure 5 yes Figure 1 Side view. Detailed Implementation
[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0039] It should be noted that in the description of this invention, the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," which indicate directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.
[0040] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.
[0041] This embodiment proposes a motor testing system, including a motor mounting module, a load simulation module, a transmission coupling module, a data acquisition module, and a central control module. The motor under test is fixedly mounted on the motor mounting module. The load simulation module simulates the load and outputs load torque, which is then transmitted to the motor under test via the transmission coupling module. Data from the motor under test, such as torque and key performance indicators for computer-controlled electrical conversion efficiency and total harmonic distortion (THD), are synchronously captured by the data acquisition module and sent to the central control module.
[0042] The central control module can be configured locally or remotely. When the central control module is configured remotely, the data acquisition module transmits the acquired data to the central control module via deterministic Ethernet (time jitter < 1μs). The central control module can generate a set of dynamic characteristic curves in real time, including torque-speed characteristic curves, efficiency cloud diagrams, and harmonic spectra.
[0043] In some embodiments, the motor mounting module includes a clamping mechanism for holding and fixing the motor under test, such as... Figure 1 As shown, the clamping mechanism includes multiple clamping assemblies 11, each of which can fix a motor 30 under test.
[0044] In some embodiments, the motor mounting module further includes a clamping device 12 for providing a clamping driving force to the clamp assembly 11. The clamping device 12 is connected to the clamp assembly 11 and is used to drive the clamp assembly 11 to clamp the motor 30 under test for testing, or to release the clamp on the motor 30 under test after the test is completed.
[0045] To address the issue that existing motor testing systems suffer from poor versatility due to their fixed height between the clamping mechanism's axis and the support surface, which is necessary to match the axis height of the load simulation module, and the varying diameters and shaft lengths of different motor models, the motor testing system can only test specific motor models. In some embodiments, the motor mounting module includes a three-axis adjusting slide 13. The clamping mechanism is supported on the three-axis adjusting slide 13, which moves the clamping mechanism along three axes. This allows for adjustment of the tested motor 30 along three axes, regardless of its diameter or shaft length. The three-axis adjusting slide 13 adjusts the motor's position in both height and horizontal plane to achieve compatibility with the load simulation module.
[0046] The three-axis adjusting slide 13 shall have sliding rails for the horizontal XY axes and a sliding rail for the vertical Y axis. A drive motor shall be correspondingly provided on each axis.
[0047] In some embodiments, the load simulation module is used to simulate the load and is coupled to the output shaft of the motor under test through the transmission coupling module.
[0048] When simulating the operating conditions of the motor under test 30, the central control module needs to input the normal operating parameters of the simulated load into the load simulation module. The load simulation module calculates the load size and displacement required at different times, and then converts them into the torque and speed required by the servo motor and magnetic powder brake.
[0049] The central control module is connected to the human-machine interface terminal 14 for receiving and configuring test parameters through human-machine interaction.
[0050] Operators can configure a set of multi-dimensional physical quantity test parameters through the human-machine interface terminal 14, including but not limited to: dynamic load gradient (0-300 N·m / s programmable), drive voltage vector (0-24 V, accuracy ±0.1 V), and drive frequency (0-1000 Hz, accuracy ±1 Hz). The central control module establishes a dynamic coupling relationship with the load simulation unit and power drive unit through the RTU protocol to construct a composite operating condition matrix of operating characteristics.
[0051] The data acquisition module is used to acquire the torque and / or output current of the motor under test 30.
[0052] The data acquisition module may include, but is not limited to, torque sensors and angle sensors. The torque sensor can be connected to the motor under test through a transmission coupling module.
[0053] In some embodiments, the data acquisition module synchronously captures key performance indicators of the tested object, such as torque, electromechanical conversion efficiency, and total harmonic distortion (THD), and transmits them to the central control module via deterministic Ethernet (time jitter < 1 μs). This generates a dynamic characteristic curve cluster in real time, including torque-speed characteristic curves, efficiency cloud maps, and harmonic spectra. The communication interface unit, based on the MQTT protocol, transmits test data to a cloud server. The cloud computing deployment utilizes a hybrid architecture of neural networks and long short-term memory networks. It trains a BP neural network on the transmitted key characteristic data (including operating condition simulation data and the performance indicators of the tested motor) to obtain key coefficients and construct a correlation model. Intelligent auxiliary diagnosis is implemented for the tested sample motor. Simultaneously, based on prior self-learning and the input of typical fault data, an FTA fault tree is established for auxiliary judgment.
[0054] In some embodiments, such as Figure 2 As shown, the load simulation module includes a magnetic powder brake 15, which is used to output load torque and act on the tested motor 30 through the transmission coupling module.
[0055] In some embodiments, the motor shaft of the motor under test 30 is finally connected to the magnetic powder brake 15 through the transmission coupling module 16. The magnetic powder brake 15 is used to simulate the working conditions of the motor under test. The output torque of the magnetic powder brake is set according to the actual situation to simulate the operation of the motor under test under load. The output values such as current, voltage and power of the motor under test under load are simulated through the load simulation output.
[0056] The test results can also be displayed on the human-computer interaction terminal 14, and compared with the actual design data requirements to perform motor testing.
[0057] In some embodiments, the load simulation module further includes a load torque adjustment mechanism (not shown in the figure), which is controlled by the central control module to generate a torque adjustment signal for adjusting the output torque of the magnetic powder brake 15.
[0058] In some embodiments, the load simulation module also includes a dynamic balancing counterweight mechanism 18, which is used to provide different counterweights to test the torque of the motor under test 30 under different balancing loads.
[0059] In some embodiments, such as Figure 3 As shown, the clamp assembly includes a lower clamping part 191 and an upper clamping part 192. The lower clamping part 191 is fixed on the three-axis adjusting slide 13, and a lower clamping notch 1911 is provided on the upper surface of the lower clamping part 191.
[0060] The lower surface of the upper clamping part 192 is provided with an upper clamping notch 1921 that matches the lower clamping notch 1911. The upper clamping notch 1921 and the lower clamping notch 1911 form a space for accommodating the motor 30 under test. The upper clamping part 192 is connected to the clamping device 12 and is used to move the upper clamping part 192 toward the lower clamping part 191 to clamp the motor 30 under test, or to move the upper clamping part 192 away from the lower clamping part 191 to release the motor 30 under test.
[0061] To ensure that the upper clamping notch 1921 and the lower clamping notch 1911 remain aligned each time the lower clamping part 191 approaches the lower clamping part 191, and to reliably clamp the motor 30 under test, in some embodiments, a guide mechanism 193 is provided on the upper surface of the lower clamping part 191, and a guide hole (not shown in the figure due to angle) is provided on the upper clamping part 192. The guide mechanism 193 passes through the guide hole and connects to the upper clamping part 192. By providing the guide mechanism 193, it can be ensured that the upper clamping notch 1921 and the lower clamping notch 1911 remain aligned each time the lower clamping part 191 approaches the lower clamping part 191.
[0062] In some embodiments, the guide mechanism 193 can be implemented using a guide rod.
[0063] In some embodiments, there may be one or more guide rods.
[0064] When releasing the clamp on the motor 30 under test, the upper clamping part 192 needs to be controlled to move away from the lower clamping part 191. It doesn't need to move too far; just enough space is needed to remove the motor 30. Therefore, in some embodiments, a limiting mechanism 194 is provided on the upper part of the guide mechanism 193, and the limiting mechanism 194 is located above the upper clamping part 192. It is only necessary to control the movement of the upper clamping part 192 to the position of the limiting mechanism 194.
[0065] To ensure stable clamping of the motor under test 30, in some embodiments, the lower clamping notch 1911 is V-shaped, and the upper clamping notch 1921 is an inverted V-shape. The V-shaped triangular structure is the most stable, and when the motor under test 30 is clamped in it, it can contact the four inner sidewalls of the lower clamping notch 1911 and the upper clamping notch 1921 respectively, further improving stability.
[0066] In some embodiments, the clamping device 12 may be implemented using, but is not limited to, a pneumatic clamping device.
[0067] In some embodiments, the motor testing system also includes a support platform 20, on which the load simulation module is mounted.
[0068] In some embodiments, the support platform 20 is a shock-resistant granite platform to reduce the impact of external vibrations on motor testing.
[0069] In some embodiments, the bottom of the support platform 20 is provided with vibration isolation pads 21, which can further reduce vibration transmission.
[0070] In some embodiments, the motor testing system also includes an electrical assembly cabinet 22, such as... Figure 4 , Figure 5 As shown, the electrical assembly cabinet 22 is mounted on the support platform 20 and located behind the motor mounting module. The electrical assembly cabinet 22 has a cabinet cavity for accommodating electrical components. The human-machine interface terminal 14 is mounted on the front panel of the electrical assembly cabinet, which allows users to view output results and input test parameters.
[0071] In some embodiments, the motor testing system also includes a safety cover 23, which is mounted on the support platform 20 and covers the outside of the motor mounting module and the load simulation module. A door 231 is provided in front of the safety cover 23. During testing, the door 231 can be closed to reduce the transmission of vibrations generated during motor testing through the air, thus reducing noise. When the operator needs to operate the system, the door 231 can be opened for convenient operation.
[0072] In some embodiments, the electrical assembly cabinet 22 is equipped with a power module 24 for providing power to various electrical components.
[0073] In some embodiments, the specific implementation is as follows: the default range of the load simulation module is 200 m N·m, the resolution is 0.1 μN·m, and the common operating range is 0-200 m N·m; the default range of the power supply module is 0-24 V, the resolution is 0.1 V, and the common operating range is 12 V ± 15%; the default range of the power drive module is 0-1000 Hz, the resolution is ± 1 Hz, and the common operating range is 500-800 Hz.
[0074] The criteria for judging the tested product are whether the torque, efficiency, and distortion rate exceed the preset range and whether there are obvious abnormal fluctuations. The equipment assists in the judgment, and the final result is based on the conclusion drawn by the human judge of the operating curve.
[0075] This method addresses the technical bottlenecks of traditional testing systems and proposes a deep learning-based full-dimensional performance evaluation system for stepper motors. It innovatively constructs a modular clamping mechanism to achieve a 10-channel parallel testing matrix. The system integrates: ① a load simulation module; ② a power drive module; ③ an analog quantity acquisition system; and ④ a signal conditioning unit for real-time stepless adjustment of multiple physical quantities. Dynamic closed-loop control of test parameters is achieved through an industrial IoT architecture, and a distributed data platform is built based on the MQTT protocol to achieve joint time-domain analysis of time-domain waveforms and characteristic parameters. The core innovation lies in deploying a local IoT gateway with a human-machine interface and using a hybrid architecture of neural networks and long short-term memory networks to establish a multi-dimensional parameter correlation model. Transfer learning algorithms are used to achieve: ① automatic calibration of dynamic performance envelopes; ② abnormal operating condition pattern recognition; and ③ fault tree analysis (FTA) model. This system successfully constructs a digital twin of the motor's dynamic characteristics, enabling predictive maintenance capabilities throughout the product lifecycle and improving testing efficiency and accuracy.
[0076] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions claimed by the present invention.
[0077] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.
[0078] For ease of explanation, the above description has been provided in conjunction with specific embodiments. However, the above exemplary discussion is not intended to be exhaustive or to limit the embodiments to the specific forms disclosed above. Various modifications and variations can be obtained based on the above teachings. The selection and description of the above embodiments are for the purpose of better explaining the principles and practical applications, thereby enabling those skilled in the art to better utilize the described embodiments and various different variations of embodiments suitable for specific use considerations.
Claims
1. An electrical machine testing system, characterized by, It includes a motor mounting module, a load simulation module, a transmission coupling module, a data acquisition module, and a central control module; The motor mounting module includes: The clamping mechanism includes multiple clamping assemblies, each clamping assembly capable of securing a motor under test; A clamping device for driving the clamping assembly to clamp the motor under test; The three-axis adjustable slide is supported by the clamping mechanism, which is used to drive the clamping mechanism to move in the three-axis direction; The load simulation module is used to simulate the load and is coupled to the output shaft of the motor under test through the transmission coupling module; The central control module is connected to a human-machine interface terminal and is used for receiving configured test parameters through human-machine interaction. The data acquisition module is used to acquire the torque and / or output current of the motor under test.
2. The motor testing system according to claim 1, characterized in that, The load simulation module includes: A magnetic powder brake is used to output load torque and apply it to the motor under test through the transmission coupling module. The load torque adjustment mechanism, controlled by the central control module, generates a torque adjustment signal to adjust the output torque of the magnetic powder brake. A dynamic balancing counterweight mechanism is used to provide different counterweights to test the torque of the motor under test under different balanced loads.
3. The motor testing system of claim 1, wherein, The clamp assembly includes: The lower clamping part is fixed on the three-axis adjusting slide, and a lower clamping notch is provided on the upper surface of the lower clamping part; The upper clamping part has an upper clamping notch on its lower surface that matches the lower clamping notch. The upper clamping part is connected to the clamping device and is used to move the upper clamping part toward the lower clamping part to clamp the motor under test, or to move the upper clamping part away from the lower clamping part to release the motor under test.
4. The motor testing system of claim 3, wherein, The upper surface of the lower clamping part is provided with a guide mechanism, and the upper clamping part is provided with a guide hole. The guide mechanism passes through the guide hole and is connected to the upper clamping part.
5. The motor testing system of claim 4, wherein, The guide mechanism is provided with a limiting mechanism, which is located above the upper clamping part.
6. The motor testing system of claim 3, wherein, The lower clamping notch is V-shaped, and the upper clamping notch is an inverted V-shape.
7. The motor testing system of any one of claims 1-6, wherein, The clamping device is a pneumatic clamping device.
8. The motor testing system of any one of claims 1-6, wherein, The load simulation module is mounted on a support platform, which is a shock-resistant granite platform, and the bottom of the support platform is equipped with vibration-damping pads.
9. The motor testing system of claim 8, wherein, The motor testing system also includes: An electrical assembly cabinet is mounted on the support platform, located behind the motor mounting module. The electrical assembly cabinet has a cavity for accommodating electrical components. The human-machine interface terminal is mounted on the front panel of the electrical assembly cabinet.
10. The motor testing system of claim 9, wherein, The motor testing system also includes: A safety cover is installed on the support platform and covers the outside of the motor mounting module and the load simulation module. A door is provided in front of the safety cover.