EV motor dyno test, motor controller test




The objective of EV motor dyno test, motor controller test bed is to complete the durability test, routine performance test and road condition simulation test of the electric vehicle motor and motor controller. The test bench are mainly used for routine performance test, durability and load test as well as other customized development tests such as motor or motor controller contrast test and research and development, etc.

The EV motor dyno test, motor controller test bed can be used to test the performance of the motor for the electric vehicle. It will provide user with the hardware test support and assist user to improve the design and verify the product performance.

 

EV motor dyno test, motor controller test

 

EV motor dyno test, motor controller test bed structure

 

  1. Mechanical section

It is used to install the specimen, load motor, torque sensor and other mechanical components while ensuring that the mechanical parts coaxial less than 0.05mm

 

  1. Drive control section

It controls the load motor including AC drive, FC2013 AC Dynamometer control unit, electronic throttle drive unit, etc. Also it seamlessly integrates user or third-party motor controller, DC power supply and other equipment

 

  1. Electrical parameter measurement section

Using power analyzer to test the system electrical parameters of the motor and the controller and to convert, collect, calculate, etc.

 

  1. Temperature control section

It is used to absorb heat of the tested motor and its controller to ensure the system normal test process and to provide system reliability with its service life

 

  1. Field data acquisition section

It includes the tested motor torque and speed as well as the parameters such as temperature and pressure of the motor and its control during the test process.

 

  1. PC control section

It controls the load system to perform relevant work condition tasks and provides human-machine control interface. It includes industrial computer, test control software system, etc.

 

Electric vehicle motor test bed

 

EV motor dyno test, motor controller test content

 

  • GBT 18488.1-2015 Drive motor system for electric vehicles. Part 1: Specification
  • GBT 18488.2-2015 Drive motor system for electric vehicles – Part 2: Test methods
  • GBT 29307-2012 The reliability test methods of drive motor system for electric vehicles
  • Peak power and torque test
  • Rated power and torque test
  • Tested motor characteristic test
  • Efficiency spectroscopy test
  • Tested motor and its controller temperature rise test
  • Motor torque step response test
  • Tested motor torque control accuracy test
  • Feedback power generating test, motoring and generating switching test
  • Motor performance and strategy optimization test
  • Motor drive mode switching and energy management
  • Steady state and road load simulation
  • Driver simulation such as acceleration, braking, parking, economy, sports driving and other tests
  • Standard driving cycle tests such as ECE and NEDC

 

Electric vehicle motor test bed

 

AC dynamometer control

The AC dynamometer monitoring and control device, which is under our independent research and development, can be the perfect combination of ABB or Siemens converter for constant speed or constant torque mode control.

 

Tested motor control interface

The CAN-DBC format of motor controller protocol can be parsed to facilitate the integration of tested motor control. The change of the control protocol does not need the reprogramming.

The original file can be simply replaced. Motor control can be achieved by selecting the mode (such as power on, operation mode) or button output mode (set torque or speed).

 

Parameter monitoring interface

Automatic collection of electrical parameters, mechanical power, the tested motor parameters and related temperature parameters achieves system real-time monitoring.

 

Parameter property interface

In addition to four commonly used formula calculation, square, square root, sine, cosine, logarithm, absolute value, exponential and other functions can also be included.

In combination with FC2021C Switch module, the parameters for sound and light alarm and emergency stop protection can be achieved. Without this peripheral, when the parameter reaches the alarm value, its color will be changed.

 

Integration of electrical parameters power analyzer

  • Yokogawa power analyzer: WT1800, WT3000, WT330
  • Guangdong Zhiyuan power analyzer or power meter: PA5000, PA330 series
  • Fluke power analyzer: NORMA 4000 or 5000

 

Electric vehicle motor test bed




Production end-of-line EV motor dyno test, motor controller test

 

EV motor dyno test, motor controller test

 

  • End-of-line test

The motor factory test after the assembly

 

  • Features

A high degree of automation to meet the requirements of the test speed and mass production

 

  • System components

Mechanical test rig, DC power supply, digital converter system, motor parameter acquisition system, power analyzer and sensors, test conditioning system, FC2013 AC Dynamometer control unit, industrial computer, control software.

 

  • EOL inspection test bench system

The dynamometer, fast alignment and automatic positioning clamping part, conveying device, preloading and dismantling mechanism, PLC control system and the actuating mechanism.

 

Motor and controller production EOL test related test items

 

  • General test items
  • Temperature rise test
  • Input and output characteristic test
  • Security test
  • Reliability test
  • Others …

 


Motor and controller production end-of-line test technical standard

 

  • GBT 18488.1-2015 Drive motor system for electric vehicles. Part 1: Specification
  • GBT 18488.2-2015 Drive motor system for electric vehicles – Part 2: Test methods
  • GBT 22669-2008 Test procedures for three-phase permanent magnet synchronous machines
  • GBT 1032-2012 Test procedures for three-phase induction motors
  • GBT 1029-2005 Test procedures for three-phase synchronous machines
  • GBT 29307-2012 The reliability test methods of drive motor system for electric vehicles

..



About dynamometer

 

 

Parameter selection and curve download

 

 

Application description download