Reluctance Machine Winding Quality Testing via Vibration Response

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Solution Overview

Problem

Conventional methods for electrical functional testing of reluctance machines in motor vehicles are inefficient, as they require disassembly and cannot accurately assess winding quality in the installed state, leading to potential damage and increased costs due to the need for manual handling and testing outside the vehicle.

Innovation Solution

A method involving a surge voltage test is performed on the reluctance machine while it is installed in the powertrain, with the rotor set to a predefined state, allowing for the evaluation of vibration responses to determine defects without disassembly, using predetermined comparison criteria to assess the machine's condition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the reluctance machine is tested by disassembly and surge voltage test outside the vehicle, then the winding quality can be measured, but the machine is exposed to damage risk and handling costs increase

Engineering Contradiction:

Improvewinding quality measurementVSAvoidmachine integrity

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The reluctance machine tests itself while installed in the vehicle by utilizing the vehicle's existing battery and control units to perform surge voltage tests and evaluate winding quality, eliminating the need for external testing equipment and disassembly operations

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The control unit of the reluctance machine is designed to perform multiple functions including both operational control and diagnostic testing, enabling it to conduct self-tests and evaluate winding quality without requiring separate dedicated testing equipment

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If the reluctance machine is tested in the installed state, then the testing efficiency is improved, but the measurement accuracy is insufficient without rotor disassembly

Engineering Contradiction:

Improvetesting efficiencyVSAvoidwinding quality measurement

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The mechanical disassembly process is replaced by an electrical testing method that uses surge voltage applied through the control unit to detect winding defects, substituting physical intervention with electrical measurement while the machine remains installed

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The testing method utilizes changes in electrical parameters (surge voltage, current response, impedance) that occur when the rotor is in different angular positions to accurately measure winding quality without requiring the rotor to be disassembled, extracting diagnostic information from parameter variations during normal installed operation

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If conventional surge voltage test methods are used without predefined rotor state, then the testing process is simple, but the measurement results are unreliable due to rotor position variability

Engineering Contradiction:

Improvetesting process simplicityVSAvoidmeasurement reliability

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The control unit pre-establishes a predefined rotor state (such as a specific angular position or rotational speed) before conducting the surge voltage test, ensuring that measurements are taken under controlled and repeatable conditions that guarantee reliable results

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The control unit monitors the actual rotor state during testing and uses feedback mechanisms to ensure the rotor reaches and maintains the predefined state, adjusting test parameters as needed to compensate for any deviations and ensuring measurement accuracy

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables efficient, accurate, and non-destructive testing of reluctance machines in their installed state, reducing the risk of damage and enabling reliable end-of-line testing, thereby improving the testing process and reducing costs.

Implementation Method 1

a procedure for a surge voltage test is provided on a reluctance machine installed in the powertrain of a motor vehicle

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3855195A1Method for functional electrical testing of a reluctance electric machine of a motor vehicle

Publication Date: 2021.07.28 MAN TRUCK & BUS SE

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AI summary

The invention relates to a method (700) for electrical functional testing, preferably for winding quality testing, of an electric reluctance machine of a motor vehicle. The method (700) comprises providing (701) the reluctance machine, comprising a rotor and a stator, in a state installed in the drive train of the motor vehicle, and setting (702) at least one predefined rotor state relative to the stator of the reluctance machine. The method further comprises performing (703) an impulse voltage test on the reluctance machine while the at least one predefined rotor state is set, wherein at least one vibration response (1, 2, 3, 4) of the reluctance machine generated during the impulse voltage test is recorded and evaluated on the basis of predetermined comparison criteria (31, 51) to determine whether or not a defect of the reluctance machine is present.