A testing device for a three-phase brushless DC motor

Abstract

This utility model discloses a testing device for a three-phase brushless DC motor, belonging to the field of motor testing technology. It includes a motor mounting base and a water tank. A generator is mounted on the top surface of the motor mounting base, and a motor is positioned above the generator. A coupling connects the generator and the motor. A heating tower fixing plate is installed inside the water tank. Three sets of heating towers are fixed to the top surface of the heating tower fixing plate. Each of the three sets of heating towers has a connecting rod mounted on its bottom surface, and these connecting rods penetrate the heating tower fixing plate. Resistance wires are wound around the outer sides of each of the three sets of connecting rods from top to bottom. The free ends of the three sets of resistance wires are interconnected. A motor output line connects the generator and the three sets of heating tower connecting rods. This technical solution can effectively perform long-term load testing on the motor, and the testing process is stable and efficient.

Description

Technical Field

[0001] This utility model relates to the field of motor testing technology, specifically a testing device for a three-phase brushless DC motor. Background Technology

[0002] As a core electrical component in the manufacturing industry, electric motors are widely used in various power equipment. Motor performance testing is a crucial step in the production process; however, current testing solutions on the market have significant shortcomings: most companies only conduct no-load rotation tests, relying primarily on manufacturing process precision control for core parameters such as motor torque and power, lacking quantitative testing under actual load conditions. While some testing devices simulate load by clamping the output shaft of a friction motor, they reveal a dual deficiency during prolonged high-load operation: on the one hand, they place stringent requirements on the strength and wear resistance of the clamping mechanical structure; on the other hand, operating temperature rise significantly affects the accuracy of the test data, causing test results to deviate from actual operating conditions. This crude approach to testing not only makes it difficult to ensure consistent motor quality at the factory but also hinders the research and development of high-performance motors. Utility Model Content

[0003] The purpose of this invention is to provide a testing device for a three-phase brushless DC motor to solve the problems mentioned in the background art.

[0004] In view of the above problems, the technical solution proposed by this utility model is as follows:

[0005] A testing device for a three-phase brushless DC motor includes a motor mounting base and a water tank. A generator is mounted on the top surface of the motor mounting base, and a motor is positioned above the generator. A coupling connects the generator and the motor. A heating tower fixing plate is installed inside the water tank. Three sets of heating towers are fixed to the top surface of the heating tower fixing plate. Each of the three sets of heating towers has a heating tower connecting rod mounted on its bottom surface, and the connecting rods penetrate the heating tower fixing plate. Resistance wires are wound around the outer sides of each of the three sets of heating tower connecting rods from top to bottom. The free ends of the three sets of resistance wires are interconnected. A motor output line is connected between the generator and the three sets of heating tower connecting rods. The motor drives the generator to generate electricity, and the current flows through the resistance wires to generate a load, simulating the actual load condition of the motor and achieving long-term stable load testing. The water tank dissipates heat from the resistance wires, preventing temperature rise from affecting the testing accuracy and ensuring efficient and stable testing. The three sets of heating towers form a triangular shape, evenly distributing the load and improving testing reliability.

[0006] Furthermore, a motor key is installed on the outer side of the output shaft of the motor, and a generator key is installed on the outer side of the input shaft of the generator. The motor and the generator are respectively engaged with the coupling through the motor key and the generator key. The motor key and the generator key ensure that the motor and the coupling, and the generator and the coupling are circumferentially fixed, preventing slippage when transmitting torque, ensuring stable power transmission, and improving the accuracy of test data.

[0007] Furthermore, bearings are embedded at both ends of the coupling. The inner rings of a pair of bearings are respectively installed on the outer side of the output shaft of the motor and the outer side of the input shaft of the generator. The bearings support the coupling, reduce the radial runout and friction of the connecting shaft between the motor and the generator, reduce mechanical loss, make the rotation smoother, and ensure the stability of the load during the testing process.

[0008] Furthermore, a first temperature sensor is installed inside the motor, and a second temperature sensor and a liquid level sensor are installed inside the water tank. The first temperature sensor monitors the temperature rise of the motor to prevent overload damage; the second temperature sensor monitors the water temperature in the water tank to ensure heat dissipation; and the liquid level sensor detects the water level to prevent water shortage from causing heat dissipation failure and to ensure detection safety.

[0009] Furthermore, an electrical control cabinet is provided on the side of the motor mounting base. The electrical control cabinet supplies power to the motor and receives monitoring data from the first temperature sensor, the second temperature sensor, and the liquid level sensor. The electrical control cabinet integrates power supply, data acquisition, and control functions to achieve automated detection, real-time monitoring of equipment status, and adjustment of detection parameters based on sensor data, ensuring that the detection process is intelligent and controllable.

[0010] Furthermore, the resistance wire is a nickel-chromium resistance wire, which has the characteristics of high resistivity, high temperature resistance, and strong oxidation resistance. It can maintain a stable resistance value under long-term power supply, ensuring constant load and improving detection accuracy and reliability.

[0011] Furthermore, the three sets of heating towers are arranged in a triangular shape. This triangular layout ensures that the three sets of heating towers are symmetrically distributed, and the heat generated by the resistance wire is evenly distributed into the water tank, avoiding local overheating. At the same time, the three-phase load is balanced, simulating the actual three-phase operating conditions of the motor.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: The testing device for this three-phase brushless DC motor uses a coupling to connect the motor and generator together and transmit power, thereby reducing the strength requirements of the fixed mechanism. The motor drives the generator to generate electricity, and the current flows through the resistance wire to generate a load, simulating the actual load condition of the motor and realizing long-term stable load testing. The water tank dissipates heat from the resistance wire, avoiding the impact of temperature rise on the testing accuracy and ensuring the efficient and stable testing process. The three sets of heating towers form a triangular shape, evenly distributing the load and improving the reliability of the test. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the detection device for a three-phase brushless DC motor disclosed in an embodiment of this utility model;

[0014] Figure 2 This is a cross-sectional schematic diagram of the motor mounting structure of the detection device for a three-phase brushless DC motor disclosed in this embodiment of the present invention;

[0015] Figure 3 This is a first three-dimensional structural diagram of the heating tower of the testing device for a three-phase brushless DC motor disclosed in this embodiment of the present invention;

[0016] Figure 4 This is a second three-dimensional structural diagram of the heating tower of the testing device for a three-phase brushless DC motor disclosed in this embodiment of the present invention.

[0017] In the diagram: 1. Motor; 2. Generator; 3. Coupling; 4. Bearing; 5. Motor key; 6. Generator key; 7. Motor mounting base; 8. First temperature sensor; 9. Water tank; 10. Heating tower; 11. Resistance wire; 12. Second temperature sensor; 13. Liquid level sensor; 14. Electrical control cabinet; 15. Heating tower fixing plate; 16. Heating tower connecting rod; 17. Generator output line. Detailed Implementation

[0018] 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.

[0019] Please see Figures 1-4This utility model provides a technical solution: a testing device for a three-phase brushless DC motor, including a motor mounting base 7 and a water tank 9. A generator 2 is mounted on the top surface of the motor mounting base 7, and a motor 1 is located above the generator 2. A coupling 3 connects the generator 2 and the motor 1. A heating tower fixing plate 15 is installed inside the water tank 9. Three sets of heating towers 10 are fixed on the top surface of the heating tower fixing plate 15. A heating tower connecting rod 17 is installed on the bottom surface of each of the three sets of heating towers 10, and the heating tower connecting rod 17 passes through the heating tower fixing plate 15. Resistance wires 11 are wound around the outer sides of the heating tower connecting rods 17 from top to bottom. The free ends of the three sets of resistance wires 11 are connected to each other. A motor output line 16 is connected between the generator 2 and the three sets of heating tower connecting rods 17. The motor 1 drives the generator 2 to rotate and generate electricity through the coupling 3. The current flows into the three sets of resistance wires 11 through the motor output line 16, and the resistance wires 11 heat up to form a load. The water in the water tank 9 absorbs the heat of the resistance wires 11 and dissipates heat through water circulation to maintain a stable detection environment. The electrical control cabinet 14 monitors the temperature and liquid level to ensure detection safety.

[0020] As an embodiment of this utility model, a motor key 5 is installed on the outer side of the output shaft of the motor 1, and a generator key 6 is installed on the outer side of the input shaft of the generator 2. The motor 1 and the generator 2 are respectively engaged with the coupling 3 through the motor key 5 and the generator key 6. The motor key 5 is embedded in the keyway of the output shaft of the motor 1 and the coupling 3, and the generator key 6 is embedded in the keyway of the input shaft of the generator 2 and the coupling 3, forming a rigid connection. When the motor 1 rotates, it drives the generator 2 to rotate synchronously through the coupling 3.

[0021] As an embodiment of this utility model, the coupling 3 is further provided with bearings 4 at both ends. The inner rings of a pair of bearings 4 are respectively installed on the outer side of the output shaft of the motor 1 and the outer side of the input shaft of the generator 2. The inner rings of the bearings 4 rotate with the shafts of the motor 1 and the generator 2, while the outer rings are fixed in the coupling 3. Through the rolling friction of balls or rollers, the transmission resistance is reduced and the transmission efficiency is improved.

[0022] As an embodiment of this utility model, a first temperature sensor 8 is installed inside the motor 1, and a second temperature sensor 12 and a liquid level sensor 13 are installed inside the water tank 9. The temperature sensor converts the temperature signal into an electrical signal and transmits it to the electrical control cabinet 14. When the temperature of the motor 1 is too high or the water temperature of the water tank 9 exceeds the threshold, the electrical control cabinet 14 will alarm or adjust the load. The liquid level sensor 13 detects the water level and prompts to add water when it is lower than the set value.

[0023] As an embodiment of this utility model, the side of the motor mounting base 7 is provided with an electrical control cabinet 14. The electrical control cabinet 14 supplies power to the motor 1, receives monitoring data from the first temperature sensor 8, the second temperature sensor 12 and the liquid level sensor 13, provides power to the motor 1, receives data from the temperature and liquid level sensors, analyzes and processes the data through an internal program, displays real-time data, and triggers a protection mechanism in case of an anomaly, such as cutting off the power or starting the cooling system.

[0024] Specifically, the electrical control cabinet 14 is powered by a DC power supply. The power supply circuit has a DC voltmeter and a DC ammeter to detect the voltage and current. The electrical control cabinet 14 can also set the rotation direction of the motor 1, allowing it to start and stop. The panel of the electrical control cabinet 14 is also equipped with a motor temperature gauge, receiving feedback signals from the first temperature sensor 8 to detect the operating temperature of the motor 1. The panel of the electrical control cabinet 14 is also equipped with a water tank temperature gauge, receiving feedback signals from the second temperature sensor 12 inside the water tank 9 to detect the temperature of the water tank 9. The panel of the electrical control cabinet 14 is also equipped with a liquid level alarm indicator light, receiving the liquid level signal from the water tank 9. When the liquid level switch is closed, normal testing can proceed; when the liquid level switch is open, it indicates that the water level in the tank is insufficient, automatically stopping the test, and the liquid level alarm light illuminates, prompting the user to add water.

[0025] As an embodiment of this utility model, the resistance wire 11 is further made of nickel-chromium resistance wire. Nickel-chromium resistance wire generates heat when current passes through it, and its resistance value changes little with temperature. It can work stably in high-temperature environments and provide a continuous and stable load for motor 1.

[0026] As an embodiment of this utility model, the three sets of heating towers 10 are arranged in a triangular shape, and the three sets of heating towers 10 correspond to the three-phase circuit respectively, forming a star or delta connection. The current flows evenly through the resistance wires 11 of each phase, generating a balanced load, and ensuring that the motor 1 is tested in a three-phase balanced state.

[0027] It should be noted that all standard parts used in this application can be purchased from the market, and can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art. The control method is automatic control through a control cabinet. The control circuit can be implemented by simple programming by those skilled in the art and is common knowledge in the field. Furthermore, since this application is mainly used to protect mechanical devices, this application will not explain the control method and circuit connection in detail.

Claims

1. A testing device for a three-phase brushless DC motor, characterized in that, The system includes a motor mounting base (7) and a water tank (9). A generator (2) is mounted on the top surface of the motor mounting base (7). A motor (1) is located above the generator (2). A coupling (3) connects the generator (2) and the motor (1). A heating tower fixing plate (15) is installed inside the water tank (9). Three sets of heating towers (10) are fixed on the top surface of the heating tower fixing plate (15). A heating tower connecting rod (17) is installed on the bottom surface of each of the three sets of heating towers (10). The heating tower connecting rod (17) passes through the heating tower fixing plate (15). Resistance wires (11) are wound from top to bottom on the outer side of each of the three sets of heating tower connecting rods (17). The free ends of the three sets of resistance wires (11) are connected to each other. A motor output line (16) is connected between the generator (2) and the three sets of heating tower connecting rods (17).

2. The testing device for a three-phase brushless DC motor according to claim 1, characterized in that, A motor key (5) is installed on the outside of the output shaft of the motor (1), and a generator key (6) is installed on the outside of the input shaft of the generator (2). The motor (1) and the generator (2) are engaged with the coupling (3) through the motor key (5) and the generator key (6) respectively.

3. The testing device for a three-phase brushless DC motor according to claim 1, characterized in that, Both ends of the coupling (3) are fitted with bearings (4), and the inner rings of a pair of bearings (4) are respectively installed on the outside of the output shaft of the motor (1) and the outside of the input shaft of the generator (2).

4. The testing device for a three-phase brushless DC motor according to claim 1, characterized in that, The motor (1) is equipped with a first temperature sensor (8), and the water tank (9) is equipped with a second temperature sensor (12) and a liquid level sensor (13).

5. The testing device for a three-phase brushless DC motor according to claim 4, characterized in that, The motor mounting base (7) has an electrical control cabinet (14) on its side. The electrical control cabinet (14) supplies power to the motor (1) and receives monitoring data from the first temperature sensor (8), the second temperature sensor (12), and the liquid level sensor (13).

6. The testing device for a three-phase brushless DC motor according to claim 1, characterized in that, The resistance wire (11) is a nickel-chromium resistance wire.

7. The testing device for a three-phase brushless DC motor according to claim 1, characterized in that, The three sets of heating towers (10) form a triangular shape.

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