Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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AT4000—New Energy Vehicle Motor Performance Test System

Case Presentation

  AT4000—New Energy Vehicle Motor Performance Test System—Product Background

  Overview:

  New energy vehicle motors are increasingly widely used in passenger cars, commercial vehicles, logistics vehicles, and heavy trucks in the automotive industry. The motor must ensure product performance and product quality in product development and factory inspection, so the performance of the motor is strictly The testing and analysis of this is particularly important. This system is based on the national standard GB/T 18488.1-2015 "Electric Vehicle Motors and Controllers Part One Technical Conditions" GB/T 18488.2-2015 "Electric Vehicle Motors and Controllers Part Two Test Methods" and refer to other national standard requirements In accordance with various motor test standards, type verification tests are carried out on motor test purposes, test procedures and test methods.

Bench picture

 

 

  Reference standard:

  ● GB/T 18488.1-2015 "Electric Vehicle Motor and Its Controller Part One Technical Conditions"

  ● GB/T 18488.2-2015 "Electric Vehicle Motors and Controllers Part 2 Test Methods"

  ● GB/T 18385-2005 "Electric Vehicle Power Performance Test Method"

  ● GB/T 18386-2005 "Electric Vehicle Energy Consumption Rate and Driving Range Test Method"

  ● GB/T 755-2008 "Rating and performance test methods for rotating electrical machines"

  ● GB/T 29307-2012 "Reliability Test Method of Drive Motor System for Electric Vehicles"

  ● GB/T 22669-2008 "Three-phase permanent magnet synchronous motor test method"

  ● GB/T 1032-2005 "Three-phase asynchronous motor test method"

  ● GB/T 50054-95 "Code for Low Voltage Power Distribution Design"

  ● GB/T 50055-93 "General Electric Equipment Power Distribution Design Code"

  ● Machinery manufacturing system according to GB9061-85

  ● The electrical system is in accordance with GB5226-85

  AT4000—New Energy Vehicle Motor Performance Test System—Topological Structure

  AT4000—new energy vehicle motor test system adopts modular and integrated design, the operating part is ergonomically designed, and can complete manual/automatic mode control. It consists of three parts: mechanical system, simulation guarantee system, electrical system and upper computer software system.

  ● Mechanical system: cast iron platform, loading equipment, quick clamping system, shaft connection part and other equipment.

  ● Simulation guarantee system: Environmental warehouse, temperature control system and other equipment components.

  ● Electrical system: two-way drive DC power supply, loading control, sensors (torque, speed, current, voltage, vibration, temperature) real-time data acquisition system, data acquisition, current sensor acquisition, electrical parameter measurement equipment, alarm system and other equipment components.

  ● Software system: The upper computer test software is divided into data acquisition communication module, data acquisition setting module, data real-time exchange control module, and data processing module according to the system. The upper computer completes the functions of test control, data analysis and display, data recording and export according to the test items.

  AT4000—New Energy Vehicle Motor Performance Test System—System Function

  The basic scope and accuracy of the performance bench test of passenger car motors:

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

  ● Recommended measuring range of speed: 0~15000~20000 r/min;

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

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

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

  ● Electric basic power measurement accuracy: ±0.03%;

  ● Speed ​​measurement accuracy: ±1r/min;

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

  The basic scope and accuracy of commercial vehicle motor performance bench test:

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

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

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

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

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

  ● Electric basic power measurement accuracy: ±0.03%;

  ● Speed ​​measurement accuracy: ±1r/min;

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

  The basic scope and accuracy of the motor performance bench test for logistics vehicles:

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

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

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

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

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

  ● Electric basic power measurement accuracy: ±0.03%;

  ● Speed ​​measurement accuracy: ±1r/min;

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

  The basic scope and accuracy of heavy-duty truck motor performance bench test:

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

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

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

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

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

  ● Electric basic power measurement accuracy: ±0.03%;

  ● Speed ​​measurement accuracy: ±1r/min;

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

  Test items:

  Locked rotor test, load test, no-load test, temperature rise test, load characteristic test, efficiency characteristic test (torque-speed characteristic), no-load loss of drive motor, steady-state short-circuit current limit, overspeed test, reliability test (Durability test) Short-term increased voltage test, electric operating conditions, power generation conditions, efficiency MAP diagrams, etc.

  Working conditions: NEDC, WLTP, FTP72, FTP75, JC08, etc.

  AT4000—New Energy Vehicle Motor Performance Test System—Main Features

  01 Functional modularity

  All the benches are built using functional modularity, and are combined into one test system in the form of a combination of modules. Customers can add or remove test modules according to different test objects.

  02 Advanced measurement methods

  Adopting advanced real-time measurement and control system, including input electrical parameter test, speed and torque test, etc., the torque and speed sampling rate is up to 1000Hz, which meets the high precision and fast response requirements of the test system, and provides transient data and characteristic value data, which is convenient for the software to test Comprehensive analysis of process data.

  03 Complete test items

  According to the test requirements specified in the national standard, test items can be added or removed according to the configuration module, which can meet the test items for various types of tests

  04 Motor load

  Using asynchronous motor/permanent magnet motor as the test motor load, changing the traditional load mode, improving the system's dynamic measurement range and accuracy of torque and speed, improving the loading performance (forward/reverse, reverse drag), and shortening the load response Time, can realize the loading of any load curve, highly simulating the real-time operating conditions of the motor/drive.

  05Environmental simulation equipment

  Using compressor refrigeration and heating mode as the test piece environmental simulation equipment and temperature control system, the high temperature, low temperature, high humidity, low humidity environment of the test piece is simulated, which shortens the aging durability test time of the test piece, thereby increasing The entire R&D efficiency reduces the R&D cycle.

  06Humanized design

  It adopts a professional motor test bench, the fixture has a quick docking function, and is convenient for loading and unloading, which can be adapted to the installation of different test pieces. The system operation adopts the piano table/standing cabinet + computer table control mode, which can complete the entire test operation layout in a single position.

  07 Customized testing software

  The motor test system test software developed by the Sichuan Chengbang Software R&D team, according to the national standard requirements test items, classifies the software interface and process, reduces repeated tests, and greatly improves the work efficiency of testers. And it has the functions of real-time curve drawing, transient value capture, trend curve drawing and analysis, multi-parameter combination display, qualified judgment, report export and so on.

  AT4000—New Energy Vehicle Motor Performance Test System—Main Application

  ● Passenger car drive motor and control system

  ● Commercial vehicle drive motor and control system

  ● Logistic vehicle drive motor and control system

  ● Heavy truck drive motor and control system

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