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Development Test Stands for Electric Motors

Development test stands from imc are characterized by high flexibility in electric motor trials. A comprehensive variety of motor types can be tested and a complete range of tests carried out. The mechanical configuration consists of a test bed with a load machine and a torque measuring shaft. The load machine and torque sensor shaft are mounted on a linear guide and precisely aligned axially by means of laser. It can be moved towards the test object on ball bearings, as a complete unit. Especially time-saving: no need to realign the load machine assembly when changing the torque sensor.

 

Configuration with an active drive machine (depending on the testing task: PMSM synchronous motor or asynchronous machine) as load unit, increases the possibilities for testing:

  • Determining electromotive force (EMF), also known as back EMF
  • Cogging torque measurement for creeping speed of 0.5 ... 10 RPM
  • Towing the test object and compensate to a 0 Nm torque range
  • Determining the torque ripple at defined RPMs
  • Dynamic loading of the test object and effect of disturbance quantities on test object

The configuration of a passive brake (eddy current brake, magnetic particle brake, etc.) is also possible which is useful for special applications, such as acoustic measurements or very high RPMs.

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The Advantages of imc Electric Motor Test Stands:

  • Single-source: from components through to turnkey electric motor test stands
  • Flexible: complete range of motor types supported
  • Expandable: modular system design
  • Advanced: own software platform for configuration, automatized testing and evaluation
  • Open: Interfaces for connecting third-party devices and software components
  • Innovative: test procedures developed in-house and supported scientifically
  • Calibrated: complete measurement chain from sensor to data acquisition, traceable including calibration document
  • High precision: laser-based shaft alignment
  • No open questions: comprehensive documentation
  • Experienced: 30  years expertise in testing electric motors

Characteristics of imc Test Stands

Test stand mechanics

  • Load machine for active and passive operation of the test object in the range of 0.5 to over 20,000 RPM
  • Operation of the load machine can be controlled by RPM as well as by torque and position. Mode of operation is set by parameters in imc STUDIO user software without any need for programming
  • Load machine assembly consists of a load machine, transmission if required, torque measuring shaft, and couplings and can be simply moved on a linear guide
  • Exchange of torque measuring shaft without the need to realign
  • Test object holders aligned to the load machine assembly, simple and fast change of DUT via a centred adapter flange without realigning
  • Documented alignment of the load machine assembly listing alignment error in a protocol
  • Test space accessible across its entire width, large test objects can be placed using lifting equipment
  • Service life of > 20 years: evidence by proven references

Measurement Equipment and Data Acquisition

  • Sampling rate of up to 100 kHz and analog bandwidth of up to 48 kHz for fast measurement channels
  • Number of measurement channels can be easily extended  any time with EtherCAT- and CAN interfaces in the test space
  • Expected service life of measurement equipment can be  backed up by appropriate options for service and calibration

Electromechanical Components and Sensor Technology

  • Test object control
    • Integration of various schemes for test object control (DC, AC, EC)
    • Integration of control components (power converter) specific to application
  • Sensor technology
    • Selected according to the specific demands  in terms of required sensor accuracy
    • Equipped with all  sensor technology necessary for carrying out testing
    • Integration and connection of sensors to data acquisition system

Test Software

  • Integration platform imc OMEGA for managing test configuration, test objects and test results
  • Test stand automation based on imc STUDIO and imc Online FAMOS
  • Evaluation and reporting based on imc FAMOS
  • Integration of third-party devices
  • Continuous development, refinement and extension of supported test types
  • Scientific support for development

Calibration

  • Calibration of the entire measurement chain with traceability of results to national standards
  • If required, equipment for annual calibration on-site is available as an option. System revision that involves shipping the data acquisition equipment back to imc site (thus resulting in the decommissioning of a test stand for substancial periods of time) is only required every three to five years.

Integration of Third-Party Devices

  • Complete integration of temperature and climatic chambers
  • High voltage and protective conductor test systems
  • Isolation test systems
  • Power measurement systems and oscilloscopes

Machinery Directive, CE and Safety

  • Commissioning

Commissioning

Test stands are always offered with factory acceptance test (FAT) in Berlin, commissioning on-site and user training. The test stand is delivered and commissioned as a turnkey solution.

24/7 Continuous Operation

All imc electric motor test stands are configured for continuous operation. However, because purely continuous operation often places high demands on test stand structure and design, imc also offers tailored test stands, specifically designed for endurance testing. These, for instance, perform a few test tasks only, that however run  over a period of weeks or months. In order to maintain test efficiency, two, three or six load machine assemblies operate in parallel, whereby operation in a temperature or climate chamber is also possible. The actual test procedure is established in close coordination with the customer including the desired reactions upon possible test object failures or with early detection of drift in characteristic values.

 

Production Test Stands for Electric Motors

Electric drives such as DC and EC motors are more and more extensively deployed in the automotive industry. At the same time there is an increasing requirement for a 100% analysis of motors for fault detection and error analysis as well as statistics on quality, without increasing production cycles times. The model-based Parameter Identification method (PI method) from imc allows testing to be performed under load, yet without an “explicit” separate load machine. Instead, the motor is loaded dynamically by exploiting its own inherent inertia. This allows motor parameters such as resistance, inductivity and friction to be determined within a few seconds. A mathematical model and its parameters reflect motor behaviour in its completeness and make it possible to monitor motor production based on limit values and trend statistics. The identified parameters of the model equation can then be used to calculate derived key performance indicators of the motor characteristic curve.

Find out more about Production Test Stands for Electric Motors

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