Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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EOL4000 - EM motor online performance test system

The motor system of new energy automobile in the automobile industry must ensure that each motor passes the test before leaving the factory. The manufacturers have a growing demand for the test, so they can meet the EM motor production until the test leaves the factory. According to the output demand of each motor, the time and process of the whole production beat and detection beat, the production line is directly connected with the test. According to the National standard GB/T 18488.1-2015 "Part I Technical Conditions of Motors and Controllers for Electric Vehicles" GB/T 18488.2-2015 "Part II Test Methods for Motors and Controllers for Electric Vehicles" and referring to other national standards and various motor test standards, this system determines and tests the motor qualification of the motor online mode.

Case Presentation

EOL4000 - EM motor online performance test system - Product background

Summary:

The motor system of new energy automobile in the automobile industry must ensure that each motor passes the test before leaving the factory. The manufacturers have a growing demand for the test, so they can meet the EM motor production until the test leaves the factory. According to the output demand of each motor, the time and process of the whole production beat and detection beat, the production line is directly connected with the test. According to the National standard GB/T 18488.1-2015 "Part I Technical Conditions of Motors and Controllers for Electric Vehicles" GB/T 18488.2-2015 "Part II Test Methods for Motors and Controllers for Electric Vehicles" and referring to other national standards and various motor test standards, this system determines and tests the motor qualification of the motor online mode.

Bench pictures

Reference standards:

L GB/T 18488.1-2015 Part I Technical Conditions for Electric Motors and Their Controllers for Electric Vehicles

Part II Test Methods for Electric Motors and Their Controllers for Electric Vehicles

L GB/T 18385-2005 Test Methods for Dynamic Performance of Electric Vehicles

L GB/T 18386-2005 Test Method for Energy Consumption rate and Driving Range of Electric Vehicles

L GB/T 755-2008 Rotary Motor Quota and Performance Test Methods

L GB/T 29307-2012 Reliability Test Method for Drive Motor System for Electric Vehicles

Test Methods for Three-phase Permanent Magnet Synchronous Motor (PMSM)

L GB/T 1032-2005 Three-phase Asynchronous Motor Test Methods

Low Voltage Distribution Design Specification

L GB/T 50055-93 Distribution Design Specification for General Electric Equipment

L Mechanical manufacturing system according to GB9061-85

L Electrical system according to GB5226-85

EOL4000 - EM motor on - line performance test system - Topology

Eol4000-em motor on-line performance test system adopts modular, integrated design, operation part conforms to ergonomic design, and can complete manual/automatic mode control. It is composed of mechanical system, rapid clamping system, simulation guarantee system, electrical system and upper computer software system.

Mechanical system: the whole mechanical platform, loading equipment, shafting connection part and other equipment composition.

L Quick clamping system: the clamping and positioning clamping device of the motor under test, front and back moving device and other equipment.

L Safeguard system: temperature control system and other equipment composition.

L Electrical system: bidirectional DC power supply, load control, real-time data acquisition system for sensors (torque, speed, current, voltage, vibration, temperature), data acquisition, current sensor acquisition, electrical parameter measurement equipment, alarm system, serial scanning system and other equipment.

L Software system: Upper computer test software is divided into data acquisition and communication module, data acquisition and setting module, data real-time exchange and control module, and data processing module according to the system. The whole process control program is adopted to complete the product qualification evaluation through data acquisition, control and processing, and the data link of the entire production system is complete through the matching between the EOL4000 production line workstation system and the production management system, so that the original data of the production inspection system can be traceable.

EOL4000 - EM motor on - line performance test system - System functions

Basic range and accuracy of passenger vehicle motor performance test bench:

● Recommended power range: 0~300KW power level, supporting other customization of power, speed, torque level;

● Recommended speed measurement range: 0~ 15000-20000 r/min;

● Recommended torque measurement range: 0~ 500n. m;

● Recommended test voltage class: DC: 0~800~1200V;

● Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of measuring range;

● Electric basic power measurement accuracy: ±0.03%;

● Speed measurement accuracy: ±1r/min;

● Torque measurement accuracy: ±0.05%F.S;

Basic range and accuracy of motor performance bench test for commercial vehicles:

● Recommended power range: 0~400~500KW power level, support other other power, speed, torque level customization;

● Recommended speed measurement range: 0~3300~4500 r/min;

● Recommended torque measurement range: 0~3000~3700N.m;

● Recommended test voltage class: DC: 0~800~1200V;

● Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of measuring range;

● Electric basic power measurement accuracy: ±0.03%;

● Speed measurement accuracy: ±1r/min;

● Torque measurement accuracy: ±0.05%F.S;

Basic range and accuracy of motor performance test of logistics vehicle:

● Recommended power range: 0~200KW power level, support other other power, speed, torque level customization;

● Recommended speed measurement range: 0~6000~10000 r/min;

● Recommended torque measurement range: 0~1000~1500N.m;

● Recommended test voltage class: DC: 0~800~1200V;

● Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of measuring range;

● Electric basic power measurement accuracy: ±0.03%;

● Speed measurement accuracy: ±1r/min;

● Torque measurement accuracy: ±0.05%F.S;

Basic range and accuracy of heavy-duty truck motor performance bench Test:

● Recommended power range: 0~500~800KW power level, supporting other customization of power, speed, torque level;

● Recommended speed measurement range: 0~2800 r/min;

● Recommended torque measurement range: 0~10000N.m;

● Recommended test voltage class: DC: 0~800~1200V;

● Voltage/current measurement accuracy: ±0.01% of reading + ±0.03% of measuring range;

● Electric basic power measurement accuracy: ±0.03%;

● Speed measurement accuracy: ±1r/min;

● Torque measurement accuracy: ±0.05%F.S;

Experimental items:

No-load test, load characteristic test, electric condition, power generation condition, various custom conditions, etc.

EOL4000 - EM motor on - line performance test system - Main features

01 Functional Modularization

The whole design of the platform is adopted, and the modular component combination is adopted inside, which is convenient for the platform combination and maintenance.

02 Advanced means of measurement

Advanced real-time measurement and control system is adopted, including input electrical parameters test, rotational speed torque test, etc. The sampling rate of torque and rotational speed is up to 1000Hz, which meets the requirements of high precision and rapid response of the test system. Moreover, transient data and eigenvalue data are provided to facilitate the comprehensive analysis of test process data by software in the later stage.

The test items are complete

According to the test requirements stipulated by the national standard, the test items can be added or subtracted according to the configuration module, which can meet all kinds of ex-factory test items

04 Motor load

Using asynchronous motor/permanent magnet motor as subjects load, change the traditional way of load and improve the system of dynamic measurement of torque and rotational speed range and precision, improve load (is/reverse, the drag), shorten the response time of load, which can realize arbitrary load curve of load, high simulation of the motor/drive real-time operation condition.

System up and down flow control.

The measured parts are hoisted to the quick clamping device by the lifting device, and the measured motor is positioned by the positioning device. Pneumatic/hydraulic compression mode is adopted to install the measured parts on the support of the measured parts, and then the measured parts system is quickly connected with the test dynamometer through the rapid docking of the middle device, thus completing the docking process of the measured parts. After the test is completed, complete the offline process according to the on-line process inversion procedure.

06 Humanized design

Professional factory EDS electric drive assembly test bench, fixture has the function of quick clamping and docking, and convenient loading and unloading can be adapted to the installation of different specimens. The system operation adopts the cabinet + cantilever computer control mode, which can complete all the test operation layout.

Customized test software

The motor factory test system test software developed by Sichuan Chengbang software development team designs the software according to the test process, categorizes the software interface and control process, reduces the repetition of tests, and greatly improves the work efficiency of test personnel. It also has the functions of real-time curve drawing, transient value capture, trend curve drawing and analysis, multi-parameter combination display, qualification determination, report export and so on.

EOL4000 - EM motor on - line performance testing system - Main applications

L Passenger vehicle driving motor and control system

L Commercial vehicle driving motor and control system

L Logistics vehicle driving motor and control system

Heavy truck driving motor and control system

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