Shell-less Motor Test Bench with Adjustable Stator Rotor Fixtures
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Solution Overview
Problem
Existing shell-less motor testing faces challenges in compatibility with multiple motor types, visual electromagnetic performance testing, stator and rotor axis unification, complex wiring, and high test costs due to custom-made parts and lengthy design cycles.
Innovation Solution
A mechanical device for shell-less motor testing featuring a test bench with adjustable tooling fixtures, including stator and rotor fixtures, a lift mechanism, and a center adjustment device, which facilitates clamping, axis unification, and simplified wiring, enabling efficient testing across various motor types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional motor testing methods are used, then testing can be performed, but compatibility with multiple motor types is poor and custom-made parts are required for each motor size
Solution Approach 1:
The test device employs universal fixtures and positioning mechanisms that can accommodate different motor types and sizes. The stator and rotor fixtures are designed with adjustable features allowing a single device to test multiple motor configurations without requiring custom-made parts for each motor size.
Solution Approach 2:
The device incorporates adjustable and reconfigurable components that can be dynamically adapted to different motor specifications. The fixtures allow for position adjustments and reconfigurations to accommodate varying motor dimensions and types, enabling versatile testing capability.
2Productivity
If shell-less motors are tested, then development cycle is reduced, but it is difficult to unify the axis of stator and rotor
Solution Approach 1:
The device introduces intermediary positioning components and alignment mechanisms that facilitate the unification of stator and rotor axes. These intermediaries provide reference surfaces and adjustment features that make axis alignment straightforward during testing.
Solution Approach 2:
The device replaces complex mechanical alignment procedures with simplified positioning mechanisms. The fixtures incorporate built-in alignment features that automatically guide the stator and rotor into proper alignment, reducing the difficulty of axis unification.
3Ease of operation
If traditional wiring methods are used, then connections can be made, but external complex wiring is difficult to comb and security risks are high
Solution Approach 1:
The device integrates wiring channels and connection points directly into the fixture structure. Power and signal connections are incorporated into the fixture design, allowing wires to be routed internally through dedicated channels rather than externally, simplifying wiring and reducing security risks.
4Adaptability or versatility
If different types of motors are tested, then motor variety increases, but test cost increases due to extra custom-made parts
Solution Approach 1:
The test device is designed as a universal platform that can test multiple motor types using the same fixtures and positioning mechanisms. This eliminates the need for custom-made parts for each motor type, reducing test costs while maintaining the ability to test various motor configurations.
Data Source
AI summary
A mechanical test device for testing shell-less motor includes a test bench, test motor, a test pedestal, a lift column, a lift platform upper plate, a lift platform lower plate, a stator fixture, a rotor fixture, bearings, a connecting shaft, a torque sensor, a magnetic powder brake, a lift device, and a shaft center-unified device. The test motor is fixed on a sliding guide rail by a rotor vertical adjustment device and a special fixture for a motor stator. The motor fixture uses a triangle structure to prevent the deviation of a central axis of a motor shaft. After the stator is fixed, the coaxial installation can be realized by adjusting the rotor vertical lift and adjusting device.