Interface assembly with magnetorheological motor testing device

Abstract

The utility model provides a kind of interface assembly and magnetorheological motor testing device, it is related to motor performance test technical field, and the interface assembly includes power supply interface, programmable power supply port, torsion calibration communication interface, power drive module, main control module and communication interface module.The power supply interface, programmable power supply port, communication interface and power drive module are integrated in the same component in the present application, the miniaturization and modularization of testing device are realized, the measured motor can be connected to provide flexible adjustable driving power supply, and it can be quickly switched to torsion calibration equipment and provide stable working power supply, effectively reduce external equipment dependence and connection complexity.The present application aims to improve the testing efficiency and calibration accuracy of magnetorheological motor testing device.

Description

Technical Field

[0001] This utility model relates to the field of magnetorheological motor technology, and in particular to an interface component and a magnetorheological motor testing device. Background Technology

[0002] Magnetorheological motors, as a novel type of drive device based on the magnetorheological effect, have broad application potential in precision control, mechanical transmission, and automation systems. Performance testing and calibration are crucial for ensuring the motor's output accuracy, response characteristics, and reliability.

[0003] Currently, testing systems for magnetorheological motors typically rely on multiple independent devices to perform power supply, drive, data acquisition, and communication functions. This results in low system integration, complex operation, and difficulty in achieving high-precision multi-parameter coordinated control. Particularly during torque calibration, dedicated calibration equipment is often required, necessitating manual switching and configuration, which is not only inefficient but also prone to introducing human error, affecting the consistency and accuracy of the tests. Utility Model Content

[0004] The main purpose of this invention is to propose an interface component and a magnetorheological motor testing device, which aims to improve the testing efficiency and calibration accuracy of the magnetorheological motor testing device.

[0005] To achieve the above objectives, this application proposes an interface component for use in a magnetorheological motor testing device, the interface component comprising: Power supply interface, used to connect to an external power source; Programmable power supply port for connecting the motor under test or torque calibration equipment; A torque calibration communication interface is provided for connecting to the communication terminal of the torque calibration device. The power drive module has a power input terminal electrically connected to the power supply interface and a power output terminal electrically connected to the programmable power supply port. The main control module has its output terminal electrically connected to the input terminal of the power drive module. When the programmable power supply port is connected to the motor under test, the main control module controls the power drive module to provide a programmable drive power supply to the motor under test through the programmable power supply port. At least one parameter of the drive power supply, including voltage, waveform, frequency, and duty cycle, is adjustable. When the programmable power supply port is connected to a torque calibration device, the main control module controls the power drive module to provide operating power to the torque calibration device through an adjustable power supply port. The communication interface module is electrically connected to the communication terminal of the main control module and the torque calibration communication interface, and is used to realize the communication connection between the torque calibration device and the main control module.

[0006] In one embodiment, the torque calibration device includes: a torque calibration handle; And / or, torque calibrator.

[0007] In one embodiment, when the programmable power supply port is connected to the power supply terminal of the torque calibration handle, the main control module is used to control the power drive module to provide working power to the torque calibration handle through the programmable power supply port.

[0008] In one embodiment, when the torque calibration communication interface is connected to the torque calibration handle, the main control module obtains the first calibration torque value generated by the torque calibration handle through the communication interface module.

[0009] In one embodiment, when the torque calibration communication interface is connected to the torque calibrator, the main control module receives the second calibration torque value of the torque calibrator through the communication interface module, wherein the second calibration torque value is input by the user.

[0010] In one embodiment, the main control module is further configured to control the power drive module to perform a frequency sweep operation on the motor under test in order to determine the drive parameters of the motor under test.

[0011] In one embodiment, it further includes: A communication interface is electrically connected to the communication terminal of the main control module, used to enable data interaction between the main control module and an external host computer; The data storage interface is electrically connected to the main control module and is used to access the storage medium.

[0012] Furthermore, to achieve the above objectives, this application also proposes a magnetorheological motor testing device, including the interface components as described above, and case; An input shaft is rotatably mounted on the housing and is used to connect the motor under test or the torque calibration device. The mechanism is located inside the housing and is connected to the input shaft for transmission. The control board is located inside the housing, and the main control module, power drive module and communication interface module are located on the control board.

[0013] In one embodiment of a magnetorheological motor testing device, the core includes a magnetorheological sensor and a torque sensor, and the main control module is electrically connected to the magnetorheological fluid brake and the torque sensor.

[0014] In one embodiment of a magnetorheological motor testing device, the main control module is also used to generate a test report based on the data output by the magnetorheological fluid brake and the torque sensor, and output it through the communication interface or save it to the storage medium through the data storage interface.

[0015] This application integrates the power supply interface, programmable power supply port, communication interface, and power drive module into a single component, achieving miniaturization and modularization of the testing device. It can connect to the motor under test to provide a flexible and adjustable drive power supply, and can also quickly switch to torque calibration equipment to provide a stable operating power supply, effectively reducing reliance on external equipment and connection complexity. The main control module can precisely control the power drive module, allowing key parameters such as the output drive power supply voltage, waveform, frequency, and duty cycle to be flexibly adjusted according to testing requirements. This meets the refined testing requirements for motor drive characteristics under different operating conditions, improving the applicability and accuracy of the test. Simultaneously, through a dedicated torque calibration communication interface and communication interface module, real-time data interaction between the calibration equipment and the main control module is achieved, supporting automated calibration processes, reducing manual intervention, improving calibration efficiency, and reducing human error. Attached Figure Description

[0016] 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 the structures shown in these drawings without creative effort.

[0017] Figure 1 This is a structural framework diagram of an interface component according to the present invention; Figure 2 This is a structural diagram of an interface component according to the present invention; Figure 3 This is a structural diagram of a magnetorheological motor testing device according to the present invention.

[0018] Reference numerals: Power supply interface 01, Programmable power supply port 02, Torque calibration communication interface 03, Main control module 04, Power drive module 05, Communication interface module 06, Communication interface 07, Data storage interface 08, Housing 11, Input shaft 12, Mechanism 13, Control board 14.

[0019] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] 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.

[0021] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0022] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, if the word "and / or" appears throughout the text, it means including three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies A and B. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0023] This application proposes an interface component, such as Figure 1 As shown, the interface components of the magnetorheological motor testing device include: a power supply interface 01 for connecting to an external power source; a programmable power supply port 02 for connecting to the motor under test or a torque calibration device; a torque calibration communication interface 03 for connecting to the communication terminal of the torque calibration device; and a power drive module 05, whose power input terminal is electrically connected to the power supply interface 01 and whose power output terminal is electrically connected to the programmable power supply port 02. The main control module 04 is electrically connected to the input of the power drive module 05 at its output. When the programmable power supply port 02 is connected to the motor under test, the main control module 04 controls the power drive module 05 to provide a programmable drive power supply to the motor under test through the programmable power supply port 02. At least one parameter of the drive power supply, including voltage, waveform, frequency, and duty cycle, is adjustable. When the programmable power supply port 02 is connected to the torque calibration device, the main control module 04 controls the power drive module 05 to provide working power to the torque calibration device through the adjustable power supply port. The communication interface module 06 is electrically connected to the communication terminal of the main control module 04 and the torque calibration communication interface 03, and is used to realize the communication connection between the torque calibration device and the main control module 04.

[0024] Specifically, a magnetorheological motor is a novel drive device that achieves power transmission and motion control based on the rheological properties of a magnetorheological fluid under the influence of an external magnetic field. This type of motor exhibits broad potential in high-precision applications such as precision control, mechanical transmission systems, industrial automation, and robotics due to its advantages of rapid response, wide adjustable output torque range, and high control precision. The performance testing and calibration process of this motor directly affects its output torque accuracy, dynamic response characteristics, and long-term operational reliability; therefore, constructing an efficient and accurate testing system is crucial.

[0025] Currently, in the testing and calibration of magnetorheological motors, most systems still consist of multiple independently functioning devices, each responsible for tasks such as motor drive, power supply, data acquisition, and communication. This discrete architecture results in low integration of the entire testing platform, complex physical connections, and frequent device switching and cable plugging / unplugging during use. This not only increases operational difficulty and time costs but also makes it difficult to automate the testing process. More importantly, the lack of a unified coordination mechanism between the devices makes it difficult to implement coordinated control of multiple parameters such as drive voltage, current waveform, frequency, and duty cycle, limiting test accuracy and repeatability. Torque calibration currently relies heavily on external dedicated torque calibration equipment, with manual connection switching and parameter settings. This operating mode not only significantly reduces testing efficiency but also easily introduces operator subjectivity errors during calibration, such as loose wiring, configuration errors, or reading deviations, ultimately affecting the accuracy of torque data and the consistency of test results.

[0026] To address the problems of low system integration, cumbersome operation, and difficulty in guaranteeing calibration accuracy in the existing technologies, this application proposes a highly integrated interface component, aiming to achieve unified management of power supply, drive, communication, and control through modular design. This interface component first includes a power supply interface 01, establishing an electrical connection with an external power source and introducing raw electrical energy into the entire test system. It is the energy starting point for system operation, requiring good compatibility and stability to adapt to different external power supply environments and provide a foundation for subsequent power conversion. The power drive module 05 is the key actuator in the interface component. Its power input terminal is directly connected to the aforementioned power supply interface 01, responsible for receiving externally input electrical energy; while its power output terminal is connected to the programmable power supply port 02. The core function of this module is that, under the command control of the main control module 04, it can precisely transform and regulate the input electrical energy to generate a programmable drive power supply that meets specific requirements. It typically contains switching circuits, filtering and protection units, etc. By adjusting the on and off states of the switching devices, it can flexibly control parameters such as output voltage, current, waveform, frequency and duty cycle, thereby providing precise and adjustable drive conditions for the motor under test.

[0027] The programmable power supply port 02 is a multifunctional, reconfigurable physical interface with a dual role: Firstly, when connected to the magnetorheological motor under test, it serves as the output port of the programmable drive power supply, delivering high-quality, adjustable power generated by the power drive module 05 to the motor to simulate various actual operating conditions for performance testing. Secondly, when calibration is required, this interface can switch to connect to a torque calibration device, acting as its power input port to provide a stable and reliable power supply. This design eliminates the inconvenience and errors caused by frequent cable and equipment changes in traditional testing. Furthermore, a dedicated torque calibration communication interface 03 establishes a dedicated link with the torque calibration device. Its function extends far beyond simple power supply; it constructs a bidirectional data transmission channel, enabling the torque calibration device to upload key data such as collected torque and speed to the system's main control module 04, while also receiving commands and control parameters from the main control module 04, laying the foundation for a fully automated, closed-loop feedback calibration process.

[0028] In summary, these interfaces and modules, through meticulous electrical design and logical connections, form a collaborative and organic whole. They not only achieve unified management and flexible output of power supply and drive, but also enhance the automation, efficiency, and reliability of the magnetorheological motor testing and calibration process through communication integration. This application integrates the power supply interface 01, programmable power supply port 02, communication interface, and power drive module 05 into a single component, achieving miniaturization and modularization of the testing device. It can connect to the motor under test to provide a flexible and adjustable drive power supply, and can quickly switch to torque calibration equipment to provide a stable operating power supply, effectively reducing reliance on external equipment and connection complexity. The main control module 04 can precisely control the power drive module 05, allowing key parameters such as the voltage, waveform, frequency, and duty cycle of the output drive power supply to be flexibly adjusted according to testing requirements. This meets the refined testing requirements for motor drive characteristics under different operating conditions, improving the applicability and accuracy of the test. Meanwhile, through the dedicated torque calibration communication interface 03 and communication interface module 06, real-time data interaction between the calibration equipment and the main control module 04 is realized, supporting automated calibration processes, reducing manual intervention, improving calibration efficiency and reducing human error.

[0029] In one embodiment, the torque calibration device includes: a torque calibration handle; and / or, a torque calibrator. In this embodiment, the torque calibration device mainly includes two types of devices: a torque calibration handle and / or a torque calibrator. The two differ in their functional focus and application, but both serve the purpose of accurate calibration of torque parameters and system verification.

[0030] A torque calibration handle is a portable torque calibration tool that typically incorporates a high-precision strain gauge or magnetoelastic torque sensor, signal conditioning circuitry, and a microprocessor unit. Its working principle is as follows: when mechanically connected to the output shaft of the magnetorheological motor under test, the handle senses the torsional deformation caused by the actual torque, converts the mechanical quantity into an electrical signal, and after amplification, filtering, and analog-to-digital conversion, outputs the torque reading in digital form. This type of device is lightweight and flexible, suitable for rapid on-site calibration and real-time torque monitoring during installation and commissioning, and has strong engineering applicability.

[0031] Torque calibrators are typically benchtop or integrated high-precision measuring instruments. In addition to torque detection, they integrate multi-channel data acquisition, real-time graphical display, data storage and analysis, and communication interfaces. They can perform static torque calibration and simultaneously measure multiple parameters such as dynamic torque, speed, and power. Calibrators usually connect to a host computer or main control system via standard communication protocols, supporting automated calibration processes and remote control. They are suitable for applications requiring high measurement accuracy and functional completeness, such as laboratories, quality inspection departments, and production line off-line testing.

[0032] In the interface component system of this embodiment, when the programmable power supply port 02 is connected to any of the aforementioned torque calibration devices, the main control module 04 can automatically identify the device type and power requirements, and control the power drive module 05 to output an appropriate operating voltage and current, thereby providing a stable power supply for the built-in circuits, sensors, and display units of the calibration device. Simultaneously, through a dedicated torque calibration communication interface 03, bidirectional data interaction between the calibration device and the main control module 04 is achieved, completing functions such as parameter configuration, command issuance, and torque data feedback, constructing an integrated torque calibration and testing environment, and improving the reliability, automation, and system integration of the calibration process.

[0033] In one embodiment, when the programmable power supply port 02 is connected to the power supply terminal of the torque calibration handle, the main control module 04 controls the power drive module 05 to provide working power to the torque calibration handle through the programmable power supply port 02.

[0034] In this embodiment, when the programmable power supply port 02 is connected to the power supply terminal of the torque calibration handle, the system enters the torque calibration working mode. At this time, the main control module 04 first automatically identifies the external load as the torque calibration handle through the device detection mechanism, and then starts the preset power supply control protocol. Based on the electrical characteristics and power requirements of different connected devices, it generates corresponding control commands and sends them to the power drive module 05. After receiving the control signal from the main control module 04, the power drive module 05 performs chopping, modulation, and filtering on the original power supply to convert the unstable input power supply into a set of highly stable, clean, and parameter-adjustable DC working power supplies. This precisely regulated working power supply is delivered to the power supply terminal of the torque calibration handle through the programmable power supply port 02, providing a stable and reliable energy supply for all electronic components inside the torque calibration handle, such as precision sensors, signal conditioning chips, microprocessors, and display units, ensuring that it can start normally and enter a high-precision measurement state.

[0035] Meanwhile, the main control module 04 establishes a bidirectional data connection with the handle through an independent torque calibration communication interface 03. This not only enables the main control module 04 to monitor the power supply status and power quality in real time, but more importantly, it can receive the digital torque data collected and converted by the handle in real time, and can send commands to the handle, such as starting measurement, setting the sampling rate, or selecting the range, thereby realizing a complete closed-loop calibration process from power supply to data acquisition.

[0036] In one embodiment, when the torque calibration communication interface 03 is connected to the torque calibration handle, the main control module 04 obtains the first calibration torque value generated by the torque calibration handle through the communication interface module 06.

[0037] In this embodiment, once the torque calibration communication interface 03 establishes a connection with the communication terminal of the torque calibration handle, the system enters the torque data interaction phase. The torque calibration communication interface 03 establishes a stable and reliable bidirectional communication link between the main control module 04 and the external calibration equipment. It typically supports one or more standard industrial communication protocols to adapt to the interface specifications of calibration handles from different manufacturers and models. Under normal operating conditions, the high-precision torque sensor inside the torque calibration handle senses the mechanical torque applied to it in real time and converts this mechanical quantity into a weak electrical signal. This signal is amplified, filtered, and temperature drift eliminated by the handle's built-in signal conditioning circuit before being converted into a digital quantity by an analog-to-digital converter. The handle's core processing unit then processes this raw digital data, potentially including numerical conversion, unit conversion, linear compensation, and filtered averaging based on a pre-calibration curve, ultimately generating a first calibration torque value representing the current torque measurement result. This value is standardized data that can be directly read and used by the upper-level system.

[0038] At this point, the main control module 04 sends a data request command to the torque calibration handle according to the predetermined communication protocol. Upon receiving a valid command, the handle sends out the encapsulated first calibration torque value data packet through the torque calibration communication interface 03. The communication interface module 06 of the main control module 04 is responsible for receiving these raw data byte streams, performing verification, decoding, and parsing, restoring them to accurate torque values, and sending them to the core processor of the main control module 04. After obtaining the first calibration torque value, the main control module 04 can compare and analyze it with the current theoretical output torque of the magnetorheological motor or readings from other sensors to obtain the motor's output accuracy, perform closed-loop control adjustments, or record the data for generating calibration reports and performance analysis.

[0039] In one embodiment, when the torque calibration communication interface 03 is connected to the torque calibrator, the main control module 04 receives the second calibration torque value from the torque calibrator through the communication interface module 06, wherein the second calibration torque value is input by the user.

[0040] In this embodiment, when the torque calibration communication interface 03 establishes a connection with the torque calibrator, the system enters a high-precision, multi-functional torque calibration and data management process. The torque calibration communication interface 03 establishes a stable, reliable, and industry-standard bidirectional communication link, ensuring seamless access and efficient interaction for various calibration instruments. The torque calibrator is a highly integrated desktop or rack-mounted professional device. In addition to torque measurement functions, it typically provides rich human-machine interfaces, such as touchscreens, physical buttons, or knobs. Users can manually input or select specific torque settings, calibration points, or threshold parameters based on actual operating conditions or calibration specifications through these interfaces. The instrument's internal high-performance processor recognizes this manually set torque value as a standard reference value, i.e., the second calibration torque value, and may further encapsulate it in format, standardize units, or convert protocols for transmission.

[0041] The main control module 04 continuously monitors the data stream on the torque calibration communication interface 03 through its built-in communication interface module 06. When the user completes input and triggers the send command, the torque calibrator sends the encapsulated second calibration torque value data packet through the communication interface. The communication interface module 06 of the main control module 04 accurately receives the data packet and, after confirming its accuracy, transmits it to the core processing unit of the main control module 04. After obtaining the second calibration torque value, the main control module 04 can immediately use it as the target benchmark or judgment standard for system execution. For example, the main control module 04 can control the power drive module 05 to adjust the current or voltage output to the magnetorheological motor under test, so that the actual torque generated by the motor dynamically approaches the calibration value set by the user; simultaneously, the system can collect the actual output torque of the motor in real time and compare and analyze it with the second calibration torque value, thereby automatically completing calibration accuracy verification, generating error curves, or determining whether the product is qualified.

[0042] In one embodiment, the main control module 04 is also used to control the power drive module 05 to perform a frequency sweep operation on the motor under test in order to determine the drive parameters of the motor under test.

[0043] In this embodiment, the main control module 04 controls the power drive module 05 to perform an automatic frequency sweep operation on the motor under test to accurately acquire its dynamic response characteristics and determine the optimal drive parameters. This process is particularly important for devices such as magnetorheological motors that rely on the nonlinear relationship between current and torque and dynamic response, and is a prerequisite for achieving high-precision control. The main control module 04 first generates a frequency sweep control command sequence, which defines the start frequency, end frequency, frequency change step size, dwell time at each frequency point, and applied current or voltage amplitude, etc. This command sequence is sent to the power drive module 05 in real time. According to the frequency sweep command issued by the main control module 04, the power drive module 05 dynamically adjusts the drive signal output to the windings of the motor under test. It generates an AC or pulse drive voltage / current with constant amplitude and continuously changing frequency according to a preset law through its internal high-speed power switching devices and closed-loop control circuit, and applies it to the two ends of the motor under test.

[0044] Throughout the frequency sweep process, the main control module 04 synchronously and in real-time acquires the motor's response signals at each frequency excitation point using a high-precision current sensor and voltage detection circuit. This includes the input current, voltage, phase, and the actual output torque and speed fed back from the torque sensor. The core processor of the main control module 04 rapidly processes this massive amount of time-domain response data, typically converting it to the frequency domain using algorithms such as Fourier transform. This allows it to obtain the motor's impedance characteristics, gain, and phase hysteresis at different frequencies, and subsequently plot the system's frequency response characteristic curve. By analyzing this curve, the main control module 04 can automatically identify the key dynamic drive parameters of the motor under test, such as the motor's electrical time constant, mechanical time constant, resonant frequency point, and optimal operating frequency band.

[0045] In one embodiment, such as Figure 1 and Figure 2 As shown, it also includes: Communication interface 07 is electrically connected to the communication terminal of the main control module 04 and is used to enable data interaction between the main control module 04 and an external host computer; data storage interface 08 is electrically connected to the main control module 04 and is used to connect to a storage medium.

[0046] In this embodiment, the system further integrates a communication interface and a data storage interface 08 to enhance data interaction capabilities and the independence of offline operation. The communication interface is directly electrically connected to the communication terminal of the main control module 04 and can adopt various physical forms and protocol standards. For example, it can support wired communication methods such as USB, Ethernet, RS-232, and CAN bus, or integrate wireless communication modules such as Wi-Fi and Bluetooth to achieve wireless communication functions. This establishes a stable and reliable bidirectional data link between the main control module 04 and the external host computer.

[0047] During operation, the main control module 04 uses this communication interface to continuously upload all process data, calibration results, and system status information—including real-time collected torque, speed, current, and voltage—to the host computer software according to the agreed application layer protocol. The host computer software then performs in-depth processing and visualization of this massive amount of data, generating multi-dimensional dynamic test curves, detailed data tables, and standardized test reports, providing users with intuitive and in-depth analysis. Simultaneously, the host computer can also send complex control commands, parameter configurations, or firmware upgrade programs to the main control module 04 through this interface, enabling remote monitoring and advanced control of the entire testing process.

[0048] To ensure full functionality even when the device cannot connect to a host computer or requires mobile applications, the system is also equipped with a data storage interface 08, such as an SD card slot, which is also electrically connected to the main control module 04. Users can insert external storage media such as SD cards. The main control module 04 can control its internal file system, automatically writing complete test sequence data, calibration configurations, and results into the storage medium for long-term storage. This allows the device to operate completely "bare-metal," independently completing all testing tasks and recording data without an external computer. Afterwards, users can either remove the memory card and analyze the data on a computer using a card reader, or wirelessly read historical data files directly on the device via a connected mobile app.

[0049] This application also proposes a magnetorheological motor testing device, such as... Figure 3 As shown, it includes the interface components as described above, and a housing 11; an input shaft 12, rotatably mounted on the housing 11, for connecting the motor under test or a torque calibration device; a mechanism 13, located inside the housing 11, and connected to the input shaft 12 in a transmission manner; and a control board 14, located inside the housing 11, on which the main control module 04, the power drive module 05, and the communication interface module 06 are located.

[0050] The housing 11 serves as the mechanical foundation and physical protection structure of the entire system. Its interior forms a sealed or semi-sealed space to accommodate all core components, effectively shielding against external electromagnetic interference and protecting the internal precision mechanism 13 and circuitry from physical damage and environmental dust. The input shaft 12, as a crucial power and torque transmission interface, is rotatably mounted on the housing 11 via a high-precision bearing system. This shaft is highly adaptable; one end extends outside the housing 11, allowing for flexible connection to the output shafts of different models and sizes of motors under test via specific adapter fixtures. Alternatively, it can be connected to the input interface of a torque calibration device when calibration is required. To ensure testing accuracy, when connecting the motor, its body must be rigidly fixed using a dedicated fixture to effectively suppress vibration and jitter during motor operation, preventing interference with high-precision torque measurement.

[0051] The core of the device is the mechanism 13 located within the housing 11, which houses a magnetorheological sensor unit. This sensor is mechanically coupled to an internal torsion shaft. A high-precision torque sensor is integrated onto the torsion shaft. During motor testing, the magnetorheological sensor, based on instructions from the main control module 04, precisely controls the magnetic field strength by adjusting the current in its internal coil, thereby altering the viscous damping and shear strength of the magnetorheological fluid within it. This applies a dynamically adjustable fixed load to the torsion shaft. When the motor under test drives the input shaft 12 to rotate, the torque is transmitted to the torsion shaft through the transmission mechanism. At this time, the torsion shaft undergoes a slight deformation due to the torque. The torque sensor on it detects this deformation in real time and converts it into an electrical signal. The torque value obtained after processing this signal is the actual output torque of the motor under test.

[0052] It is important to note that, to ensure the absolute accuracy of the test results, the device mechanism 13 itself must be calibrated before using the device to test any motor for the first time. This process is performed by connecting the torque output shaft of a torque calibrator, which has undergone higher-level metrology, to the input shaft 12. The calibrator applies a series of known standard torques, which the main control module 04 uses to correct the mapping between the measured values ​​of the torque sensor inside the mechanism 13 and their true values, establishing a high-precision calibration curve and thus eliminating systematic errors.

[0053] The control board 14 is also fixedly installed inside the housing 11. The aforementioned main control module 04, power drive module 05, and communication interface module 06 are all integrated on this printed circuit board in the form of integrated circuits and electronic components. This optimizes the internal space layout, shortens the signal transmission path between modules, and improves the system's anti-interference capability and reliability.

[0054] The superior performance of this device is also reflected in its powerful dynamic load simulation capability. Through pre-programming or real-time command reception via the main control module 04, the power drive module 05 can output a current signal that varies according to a complex time-varying curve to the magnetorheological sensor. This current determines the instantaneous magnetic field strength inside the sensor, and the magnetic field strength directly determines the damping characteristics and exhibited "mechanical stiffness" of the magnetorheological fluid, i.e., the magnitude of the load torque. Therefore, the system can accurately follow the preset time-torque curve changes of the motor load torque within a single cycle. Due to the millisecond-level fast response characteristics of the magnetorheological effect itself, the entire load adjustment process is extremely rapid, realistically simulating the complex and transient load conditions faced by the motor in practical applications, providing a powerful tool for dynamic performance testing of the motor.

[0055] In one embodiment of a magnetorheological motor testing device, the core 13 includes a magnetorheological sensor and a torque sensor, and the main control module 04 is electrically connected to the magnetorheological fluid brake and the torque sensor.

[0056] The magnetorheological sensor is the active load generating component in the mechanism 13. Its interior is filled with a magnetorheological fluid, which consists of tiny magnetic particles suspended in a carrier oil. When the main control module 04 applies current to the sensor's excitation coil via the power drive module 05, an adjustable magnetic field is generated around the coil. This magnetic field causes the magnetic particles to instantaneously align into a chain-like structure along the magnetic field lines, significantly altering the fluid's viscosity and shear strength, thus creating a precisely controllable damping force. This damping force acts on the rotating component connected to the input shaft 12, converting into a load torque on the measured motor. By programming and controlling the current variation, complex dynamic load conditions can be simulated.

[0057] The torque sensor is a high-precision measuring element in the movement 13, typically designed based on strain gauges or non-contact electromagnetic principles. It is directly coupled in the mechanical path that transmits torque (e.g., through a torque shaft), detecting minute deformations or stress changes caused by torque in real time and converting them into electrical signals. This signal is transmitted to the main control module 04, where it undergoes signal conditioning, analog-to-digital conversion, and algorithm processing to ultimately calculate an accurate real-time torque value.

[0058] The main control module 04 is electrically connected to both the magnetorheological sensor and the torque sensor, forming a highly efficient closed-loop control circuit. Its working principle is as follows: Based on the user-defined target load curve, the main control module 04 outputs a corresponding control current to the excitation coil of the magnetorheological sensor via the power drive module 05 to set the initial load. Simultaneously, it continuously acquires the actual torque signal fed back from the torque sensor and compares this measured value with the target value in real time. If a deviation exists, the main control module 04 quickly adjusts the current output to the magnetorheological sensor based on its built-in control algorithm, thereby precisely adjusting the damping force generated and causing the actual torque to quickly converge to the target value. This closed-loop feedback mechanism effectively compensates for interference caused by factors such as temperature changes, mechanical wear, or speed fluctuations, ensuring stable and accurate load simulation and high-precision torque measurement across the entire operating range.

[0059] In one embodiment of a magnetorheological motor testing device, the main control module 04 is also used to generate a test report based on the data output by the magnetorheological fluid brake and the torque sensor, and output it through the communication interface 07 or save it to the storage medium through the data storage interface 08.

[0060] Specifically, during the testing process, the main control module 04 continuously and synchronously records control signals and status data from the magnetorheological fluid brake, as well as key performance parameters such as real-time torque, speed, and angle, fed back from the torque sensor and speed measurement unit, through its high-speed data acquisition system. After the test, or according to preset trigger conditions, the main control module 04 processes the collected raw time-series data and generates a test report. Then, it calls the driver of communication interface 07 to upload the generated complete test report data packet to the connected external host computer in real time. In addition, the main control module 04 simultaneously or independently writes the test report file to the storage medium, such as an SD card, inserted into the data storage interface 08. This ensures that the device can independently complete all tests and fully record all results even in a "bare-metal" operating mode without an external computer, greatly enhancing the portability and flexibility of on-site testing.

[0061] The above embodiments are merely preferred embodiments of this utility model and do not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the content of this utility model specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. An interface component, characterized in that, The interface component, used in a magnetorheological motor testing device, includes: Power supply interface, used to connect to an external power source; Programmable power supply port for connecting the motor under test or torque calibration equipment; A torque calibration communication interface is provided for connecting to the communication terminal of the torque calibration device. The power drive module has a power input terminal electrically connected to the power supply interface and a power output terminal electrically connected to the programmable power supply port. The main control module has its output terminal electrically connected to the input terminal of the power drive module. When the programmable power supply port is connected to the motor under test, the main control module controls the power drive module to provide a programmable drive power supply to the motor under test through the programmable power supply port. At least one parameter of the drive power supply, including voltage, waveform, frequency, and duty cycle, is adjustable. When the programmable power supply port is connected to a torque calibration device, the main control module controls the power drive module to provide operating power to the torque calibration device through an adjustable power supply port. The communication interface module is electrically connected to the communication terminal of the main control module and the torque calibration communication interface, and is used to realize the communication connection between the torque calibration device and the main control module.

2. The interface component as described in claim 1, characterized in that, The torque calibration device includes: a torque calibration handle; And / or, torque calibrator.

3. The interface component as described in claim 2, characterized in that, When the programmable power supply port is connected to the power supply terminal of the torque calibration handle, the main control module controls the power drive module to provide working power to the torque calibration handle through the programmable power supply port.

4. The interface component as described in claim 2, characterized in that, When the torque calibration communication interface is connected to the torque calibration handle, the main control module obtains the first calibration torque value generated by the torque calibration handle through the communication interface module.

5. The interface component as described in claim 2, characterized in that, When the torque calibration communication interface is connected to the torque calibrator, the main control module receives the second calibration torque value of the torque calibrator through the communication interface module, wherein the second calibration torque value is input by the user.

6. The interface component as described in claim 1, characterized in that, The main control module is also used to control the power drive module to perform a frequency sweep operation on the motor under test in order to determine the drive parameters of the motor under test.

7. The interface component as described in claim 1, characterized in that, Also includes: A communication interface is electrically connected to the communication terminal of the main control module, used to enable data interaction between the main control module and an external host computer; The data storage interface is electrically connected to the main control module and is used to access the storage medium.

8. A magnetorheological motor testing device, characterized in that, Including the interface component as described in any one of claims 1-7, and case; An input shaft is rotatably mounted on the housing and is used to connect the motor under test or the torque calibration device. The mechanism is located inside the housing and is connected to the input shaft for transmission. The control board is located inside the housing, and the main control module, power drive module and communication interface module are located on the control board.

9. The magnetorheological motor testing device as described in claim 8, characterized in that, The mechanism includes a magnetorheological sensor and a torque sensor, and the main control module is electrically connected to the magnetorheological fluid brake and the torque sensor.

10. The magnetorheological motor testing device as described in claim 8, characterized in that, The main control module is also used to generate a test report based on the data output by the magnetorheological fluid brake and the torque sensor, and output it through the communication interface or save it to the storage medium through the data storage interface.

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