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Drive motor system for electric vehicles – Part 2: Test methods
This part of GB / T 18488 specifies the instrumentation, test preparation and test methods for the test of drive motor systems for electric vehicles.
This part applies to electric vehicle drive motor system, drive motor, drive motor controller. For a motor vehicle with a power generation function and its controller, refer to this section.
2 normative reference documents
The following documents are indispensable for the application of this document. For dated references, the only dated edition applies to this document. For undated references, the latest edition (including all modifications) applies to this document.
Rotating motor quota and performance GB 755-2008
GB / T 2423.1-2008 Environmental test for electric and electronic products – Part 2: Test methods – Test A: Low temperature GB / T 2423.2-2008 Environmental testing of electric and electronic products – Part 2: Test methods – Test B: High temperature GB / T 2423.10-2008 Electrical and electronic Product environmental testing – Part 2: Test methods – Test Fc: Vibration (sine)
GB / T 2423.17-2008 Environmental testing for electric and electronic products – Part 2: Test methods – Test Ka: Salt mist GB / T 2900.25 Electrotechnical terms Rotating electrical machines GB / T 2900.33 Electrotechnical terms Power electronics technology
GB / T 3859.1-2013 General requirements for semiconductor converters and commutation converters for power grids – Part 1-1: Basic requirements GB / T 4208-2008 Enclosure protection class (IP code)
GB / T 13424-2013 Electrical test methods for semiconductor power converters GB / T 18488.1-2015 Motorized motor drive systems for electric vehicles – Part 1: Technical conditions GB / T 4942.1-2006 Protection of the overall structure of the rotating electrical machinery (IP code) GB / T 19596 Glossary of Electric Vehicles
GB / T 22719.1-2008 Interchange insulation of alternating current for low voltage motors – Part 1: Test methods
GB / T 28046.3-2011 Road vehicles – Environmental conditions and tests for electrical and electronic equipment – Part 3: Mechanical load
Test method for reliability of drive motor systems for electric vehicles GB / T
The terms and definitions defined in GB / T 2900.25, GB / T 2900.33, GB / T 19596 and GB / T 18488.1 apply to this document.
4 Test preparation 4.1 Test environmental conditions
Unless otherwise specified, all tests shall be carried out under the following environmental conditions:
A) Temperature: 18 ° C to 28 ° C;
B) relative humidity: 45% ~ 75%;
C) air pressure: 86 kPa ~ 106 kPa;
D) altitude: not more than 1 000 m, if more than 1 000 m, according to the relevant provisions of GB 755-2008. 4.2 Test equipment selection
4.2.1 Instrument Accuracy
The accuracy or error of the instrument shall not be less than the requirements of Table 1 and meet the accuracy requirements of the actual measurement parameters. In particular, the instrumentation for electrical parameter measurement shall meet the accuracy and waveform requirements of the corresponding DC parameters and AC parameters.
Table 1 Accuracy of test equipment
4.2.2 measuring required
resistance should be if the current measurement, the measuring line shunt matching with the measuring instrument.
When measured, the reading of each instrument to be read simultaneously.
4.3 Experimental power
4.3.1 test, the test power supply is provided by a DC power supply, or (energy) provided by the system of devices and other energy storage power direct current power source; voltage test DC power supply operation is not more than 250 V,during which voltage regulator error should not exceed ± 2.5 V;voltage test DC power supply operation is greater than 250 V,during which regulator error should not exceed the motor drive system be tested DC voltage of ± 1%.
4.3.2 Test subjects were able to meet the power driven motor system power requirements, and can operate in a respective state of the working voltage.
4.4wiring
4.4.1 Experimental specifications of the wiring of the vehicle should be consistent with the actual wiring, the wiring length of the wiring should be identical with the actual vehicle.
4.4.2 If the wiring test is a substantial effect on the measurement results, adjust respective outer line impedance, so equal as possible to the vehicle wiring impedance.
4.5apparatus cooling
a drive motor and a cooling a drive motor controller conditions should simulate actual use conditions in a vehicle, the drive motor and controller type cooling apparatus driving motor, the kind of coolant, the flow rate and temperature should be recorded in the test report .
4.6 shielding the signal
For to ensure the motor drive system is able to test properly, if necessary, the manufacturer, or to deal with associated analog signal by other
Masked methods.
5 – Test it emgeneral
5.1appearance
visually oriented, having the technical parameters for the specific strength requirements, such as connection strength fasteners and the like, should be accompanied by the necessary torque wrench like tool.
5.2shape and dimensions
Theof the test machine system requirements shape and dimensions, and the size range, satisfying a required measurement accuracy vernier caliper, micrometer screw gauge, meter stick measuring tool is measured.
5.3 mass
Weighing an amount of satisfied using required measurement accuracy taken driven mass and a drive motor of the motor controller, the measurement instrument error should not exceed the nominal mass of the test sample to be ± 2%.
a drive motor controller housing mechanical strength
5.4test, respectively, in the three directions of the drive motor controller housing in with/ T 18488.1-2015 accordance GB5.2.4, the pressure was slowly applied to the respective weight, wherein the weight a drive motor controller housing and the contact area of at least not less than cmX 5 5 cm,to check whether the housing obvious plastic deformation.
Cooling loop liquid cooling system 5.5sealing performance
5.5.1 of this test should be measured separately after the separation of the drive motor and the motor controller drives the cooling circuit.
5.5.2 Test, do not allow the drive motor or drive motor controller may be coated with a surface coating to prevent leakage, but allow the sealing action without chemical preservatives.
5.5.3 Test medium used may be a liquid or a gas, a liquid medium may be water containing a rust inhibitor, a viscosity of not higher than kerosene or water, non-corrosive liquids, gaseous medium may be air, nitrogen or inert gas.
5.5.4 precision measuring instruments for measuring the pressure of test medium is not lower than 1.5, the range should be 1.5~3 times the test pressure.
5.5.5the test, the test temperature and the temperature of the test medium to be consistent and stable environment; the test sample is blocked end of the cooling circuit, but does not affect the sealing performance is deformed, the charging circuit test medium, using a medium pressure measurement instruments applied when the liquid test medium, air cooling circuit cavity needs to be drained. Then, gradually pressurized to aGB/ T 18488.1-2015 test pressure 5.2.5, and the pressure is maintained at least 15 min.
5.5.6 pressure holding process, the pressure meter display value should not drop, leakage No visible during the test by the casing wall and any fixed connection. If the test medium is a liquid, it may not have visible droplets or moist surface.
5.6 Cold stator winding driving resistance ofDC
the driving coil resistance of the DC motor stator cold should be measured in an actual cold state, the ambient temperature and the record time of measurement values.
5.6.1 measuring the ambient temperature
of the drive motor placed at a time in a spatially uniform temperature, the drive motor and the internal and external ambient temperature is uniform, the temperature values recorded. Analyzing the same standard temperature conditions to satisfy one of the following:
measuring the motor windings, the core and ambient temperature with a thermometer (or ETD), the difference between the measured temperature and the ambient temperature should not exceed 2 K,if necessary, thermometer measures should be insulated with the outside world, and the time placed the thermometer is not less than 15 Measuring the winding
5.7.1.3 if desired, measuring the insulation resistance or the cooling circuit through the cooling liquid in the hot state, the temperature of the surrounding medium, refers to the temperature of the space where the temperature of the test sample or the test coolant.
5.7.2 Selection megger
5.7.2.1 megger should be selected according to the measured winding (or measuring point) of the maximum working voltage.
5.7.2.2 When does not exceed the maximum operating voltage of 250V,the time 500 should be Vm egger used, the maximum operating voltage exceeds 250 V,but not more than 1 000 V,when 1 000 should be used Vm egger.
5.7.2.3 When measured values to be read pointer or megger stable after the displayed value.
5.7.3 drive motor stator winding insulation resistance housing 5.7.3.1if the whole story of each winding end lead alone, should the winding insulation resistance were measured for each of the cabinet and the other winding element embedded sample temperature does not participate in the trial or the like should be connected to the core for an electrical cabinet, the cabinet should be grounded.
5.7.3.2 the neutral point connected together while not easy to separate, then the measurement of all together on the chassis of the winding insulation resistance.
5.7.3.3 After measurement, each housing an electrical circuit for discharging it to deal with the ground connection.
5.7.4 drive motor stator winding insulation resistance of the temperature sensor the
5.7.4.1 If driving motor embedded with a temperature sensor, respectively, shall measure the insulation resistance between the stator windings and the temperature sensor. 5.7.4.2 If the beginning and end of each winding end lead alone, should the winding insulation resistance were measured for each of the temperature sensor, other windings, and other temperature detecting element or the like embedded not participate in the trial should be electrically connected to the core or the casing, chassis should be grounded.
5.7.4.3 When a neutral point of the winding is not easy to separate and connected together, connected together all the measurement winding insulation resistance of the temperature sensor.
5.7.4.4 After measurement, each housing an electrical circuit for discharging it to deal with the ground connection.
A drive motor controller
5.7.5 insulation resistance
Before 5.7.5.1 test, the controller and the external power supply and a load to be separated, can not withstand the electrical components (e.g., semiconductor rectifiers, semiconductor capacitors, and the like) is suitably a high pressure impact megger measurement prior to or remove it from the short circuit.
5.7.5.2 When the test were measured power terminal and the controller housing, the insulation resistance between the signal terminals and the controller housing, the controller control signal terminal and a power terminal, do not participate in the test portion should be connected to ground.
5.7.5.3 After measurement, each circuit portion being electrically connected to the ground so as to deal with the discharge.
5.8 resistance voltage
5.8.1 interturn driving motor winding voltage impact resistance
Between 5.8.1.1 drive motor armature winding turn impulse withstand voltage (DC brushed driving motor armature windings excluded)
according to/ T 18488.1-2015 GB5.2. 8.1 predetermined setting test parameters, and according to/ T 22719.1-2008 GB5.2.1, 5.2.2 or 5.2.3 predetermined connection and its corresponding test methods were tested.
5.8.1.2 drive motor field winding inter turn impact resistance the voltage
in with GB/ T 18488.1-2015 accordance setting test parameters in 5.2.8.1, and the impact test voltage is directly applied to the field winding between the lead associated with the test winding No test coil winding or lead wire side should be shorted to ground together with the core.
5.8.1.3 has interturn brushed DC drive motor armature winding voltage impact resistance
in with/ T 18488.1-2015 test parameters provided accordance GB in 5.2.8.1, and using inter-span test method or sheet method.test,
When the an impact test voltage is directly applied between the commutator segments, the armature shaft should be grounded.
Span Method:
Select the number of spans commutator windings should be determined according to the type and specific test equipment,generally recommend 5to7.To make each room are subjected to a voltage of a same test conditions recommended by experiments sheet (the number of tests can be reduced in accordance with the pressure equalizing line connection).
Inter-chip method:
sequentially changing a pair of adjacent commutator segments tested. During the test, if no test coil to produce a high induced voltage, means should be provided to the on-chip ground subjects both sides of the sheet commutated commutation, and good contact.
5.8.2 drive motor windings and the chassis power frequency withstand voltage test 5.8.2.1 Preparation
5.8.2.1.1 The test shall be performed on the power frequency voltage tester, should make the necessary safety precautions prior to the test, and the measurement winding insulation resistance. Unless otherwise specified, the tests shall be performed at the drive motor standstill.
5.8.2.1.2 labor frequency pressure test instrument transformer shall have sufficient capacity, if the motor winding is driven again large capacitance, its rated capacity SN(kVA)should be greater than the formula(7)Calcd. zfCUU
SN= 27:NTXl~billion3 (7)
/ – power frequency in hertz(Hz);
C- capacitance of the motor windings is driven again, the process unit(F);
U– – test voltage, in volts(V);
UNT– test high side of the transformer rated voltage, in volts(V).
Test Method 5.8.2.2
5.8.2.2.1 TestWhen the voltage to be applied between the windings and the housing, the frequency of power frequency test voltage, the voltage waveform should be as close to the sinusoidal waveform. At this time, the temperature detection and the other winding element or the like embedded shall not participate in the trial or the core is connected to the housing, the housing should be grounded. When the armature winding of each phase of each branch end and beginning, or lead alone, it should be tested separately. If the neutral point of three-phase windings is not easy to separate, three-phase winding a voltage to be applied simultaneously.
5.8.2.2.2 according to/ T 18488.1 GB–2015 in the full value of the test voltage 5.2.8.2.1 Table 1 loaded between the drive housing and motor windings. The loading process, the applied voltage should be no more than half the full value of the test voltage begins, then no more than 5% of the full value of the speed uniformly or stepwise increased to full value, to increase the voltage from the half-value full-time value should be less than 10 s,the full value of the test voltage should last 5.8.2.2.3 min0
1the mass 5 kW(or kVA)when and the motor routine experimentation, 1 min test may be about 5s instead of the test,test voltage should meet GB / 18488.1-2015 requirements 5.2.8.2.1 table 1T.1 may also be used Sin place of the test, but the test voltage should/ T 18488.1-2015 GB5.2.8.2.1 in Table 1 is 120%. When the test is completed, the voltage drops to be the full value of 1/3 or less, before disconnecting the power supply, and tested winding discharged.
5.8.2.2.4 during the test, or if the voltage is found dramatically increases the leakage current, sound insulation smoke or other anomalies occur, immediately reduce the voltage, disconnect the power supply, will be discharged again after the winding of the winding to be checked.
5.8.2.2.5 recorded during the test magnitude of the current leakage.
5.8.3 motor winding for driving the temperature sensor working frequency withstand voltage
5.8.3.1When the drive motor temperature sensor embedded in the stator winding, the winding should be conducted on the work driving motor temperature sensor frequency withstand voltage test.
5.8.3.2When the test, the 1 500 V withstand voltage method according to the full value of 5.8.2.2 in the drive between the motor windings and the temperature sensor, the driving motor windings and the like should be connected to other core elements or housing, the housing It should be grounded.
5.8.3.3in the case of armature windings embedded in a plurality of temperature sensors, each temperature sensor to respond in the withstand voltage test. 5.8.3.4recorded during the test magnitude of the current leakage.
Frequency withstand voltage 5.8.4drive motor
5.8.4.1test process controller,each power terminal of the drive motor controller to be short circuited, the respective signal terminals should be shorted. According to / T 18488.1-2015 GB Table 2 test voltage required to set the test voltage, in accordance with Test Method 5.8.2.2 of the driving power terminal and motor controller housing, control signal terminals and the housing, the power terminals of the controller and the controller test between the signal terminals. In the case of signals with the controller housing is shorted, the controller does not perform the withstand voltage test signal terminal of the housing.
5.8.4.2withstanding voltage test process drive motor controller housing power terminals, a signal terminal and a controller in the housing, the other terminals do not participate in the trial or components should be connected with the housing, the housing is grounded.
5.8.4.3withstanding voltage test process between a power terminal and control terminal of the drive motor control signal, the power terminal and the other elements do not participate in the trial should be connected to the housing, the housing is grounded.
5.8.4.4due to electromagnetic induction on some other circumstances caused by the high voltage into the low voltage circuit components (such as pulse transformers, transformers, etc.), can be isolated prior to testing or removal.
5.8.4.5recorded during the test magnitude of the current leakage.
5.9 speed
5.9.1 shoulddrive motor running for some time, the drive motor bearing lubrication even after the trial began speeding.
5.9.2 overspeed test before carefully check the quality of the drive motor assembly, in particular rotatable assembly quality portion, appropriate protective measures should be taken to prevent flying debris or parts when the speed increases.
5.9.3When the overspeed test, measurement and control subjects of the vibration driven motor, speed and distance parameters such as bearing temperature measurement method should be used.
5.9.4 overspeed test sample may be selected rotation drive motor load or prime mover (dynamometer) drag method depending on the circumstances.
Method subjects rotation driving motor load:
the test, the motor is again driven under the control of the drive motor controller, smooth rotation to 1.2 times the maximum operating speed, and this speed no-load operation point of not less than 2 min.
Using a prime mover (dynamometer) drag method:
test drive motor is not energized, rotates smoothly to 1.2 times the maximum operating speed of a prime mover (dynamometer) under drag, and on this point idling speed is not less than 2 min.
5.9.5 during the acceleration, when the drive motor reaches the rated speed, the motor functioning should be observed, after confirming that no anomalies, then increase the rotational speed at an appropriate speed until a predetermined rotational speed.
5.9.6After the overspeed test should check the rotating part of the drive motor is damaged or detrimental deformation, loose fasteners, and does not allow other phenomenon.
6 Temperature Rise Test
6.1drive motor winding resistance measured
6.1.1motor winding temperature is appropriate Measurement of resistance. This method is based on driving the motor windings during the test the DC resistance changes with temperature and corresponding changes in increments to determine the winding temperature rise.
6.1.2 Test before, according to the method of measuring 5.6 Cold actual driving a DC resistance of the motor windings (or winding DC resistance at the start of the test), if the respective phase winding is connected within the motor, it can be measured in a two outlet ends between the DC resistance and to record winding
6.1.3 test, the motor drive system operates in a certain operating state, immediately after stopping the motor-energized, to minimize on stopping during
The impact the drive motor winding temperature changes. In the off time can start recording time, and record the temperature of the cooling medium. Measuring the resistance of the motor windings of the drive as soon as changes over time, the winding resistance measurement point and winding resistance measured before the test the same point. Recording a first time point in time should not exceed 30 s-energized,starting from the first recording spot, the longest every 30 s,record data once until a smooth change in the winding resistance, the record time is preferably not less than the total length of 5 min.
6.2 Calculations drive motor winding temperature rise
6.2.1is to the drive motor windings of copper windings, the motor temperature can be instantly broken is obtained from the formula (8) is
calculated: = – (235 – | –6〇 (8)
feetc
– driving the motor winding temperature rise, units of Kelvin(K);
Rsquare– the driving resistance of the motor winding-off time can be in units of milliohms (mn);
Rc– start the drive motor the actual cold DC resistance before the test, expressed in milliohms(Mn);
thousand and – the drive motor can always off the cooling medium temperature, in degrees Celsius (°c);
Square c– corresponding to the actual cold resistance measurement time winding temperature, in degrees Celsius (°C).
6.2.2For the armature windings are materials other than copper, the material should be0 °C the reciprocal of the temperature coefficient of resistance at instead of 235 numerical formula (8), for winding aluminum, unless otherwise specified , 225 should be used.
6.3 Determination of the coolant temperature
6.3.1 of the drive motor using ambient air or gas cooling (cooler without opening motor or motor closed), the temperature of the ambient air or gas shall be less than four pyrometer measuring, thermometer should be distributed around the motor drive different locations, the measuring point from the driving motor 1 m,~2 ma height measurement point located 1/2 of the height position of the drive motor, and to prevent the impact of all of the radiation and gas flow. A plurality of average temperature as the current temperature readings.
6.3.2 forced air or with a closed cycle air cooling system for driving the motor, the motor driving the air inlet cool ant measured.
6.3.3using liquid-cooled drive motor, to be taken as a coolant inlet temperature of the windings of the cooling medium.
6.3.4,Coolant temperature at the end of the test should be able to take off time of the temperature of the cooling medium.
6.4 extrapolation off the drive motor can always the winding resistance
6.4.1use6.1 measured after driving off the motor when the winding resistance can change over time of the data plotted versus time curve resistance, plotted, recommended semilogarithmic coordinates, the resistance marked on the logarithmic scale, and the graph of this curve extrapolated to time-energized drive motor, the driving resistance is the resistance of the obtained time-energized motor.
6.4.2 If the measured resistance after continuous rise in the drive motor to stop rotating, the highest value should be measured as the resistance of the resistance-energized time.
6.4.3 obtain the resistance value of the driving motor-off time can by extrapolation, using formula (8) driving the motor winding temperature to obtain the time-energized. 6.4.4If the first driving motor-energized winding resistance measurement obtained after reading-off time can always exceeds 30 s,the predetermined portion of the present method can be employed only after the user to reach agreement with the manufacturer.
7 7.1 Test input-output characteristics operating voltage
7.1.1 benchrange,the motor drive system DC link voltage were set at the maximum operating voltage and the minimum operating voltage at, at different operating voltages, at different operating speed test the maximum torque at work, stable recording speed and torque values.
7.1.2 measurement points within the system, the drive motor speed range of less than 10, the drawing speed – torque characteristic curve, to check whether the torque output of products capable of complying with the technical documentation.
Torque 7.2 – Characteristics of rotation speed and efficiency of
the test point selection 7.2.1 7.2.1.1speed selected test
The Test point,the motor drive system operates in the speed range of the rotational speed generally take less than 10 points, preferably not greater than the minimum speed point 10% of the maximum operating speed, spacing between adjacent speed point of not more than 10% of the maximum operating speed. Test point selecting feature points to be included when necessary, such as:
– rated operating speed point;
– the maximum operating speed point;
– the continuous power operating speed corresponding to the lowest point;
– defined operating other special points.
7.2.1.2 selected test point torque
in the drive system of the electric motor or fed state, the rotational speed at each point of the torque generally take less than 10 points, for high-speed operation state, the selected rotational speed at each point points torque may be suitably reduced, but not less than 5. Test point selecting feature points to be included when necessary, such as:
at the continuous torque point value;
at the peak torque point value (or maximum torque);
point on the continuous power curve;
the peak power (or maximum power) curve point on:
the definition of other special work points.
7.2.2 selecting measurement
When testparameters,in accordance with the purpose of the test, all or part of the associated measured at selected test points following data:
a drive motor controller DC bus voltage and current;
voltage, current, frequency and power of the drive motor;
driving torque, speed and mechanical power of the motor;
a drive motor, the drive efficiency of the motor controller or the motor drive system;
drive armature winding resistance and the temperature of the motor;
flow rate and temperature of the coolant;
other measurement parameters specially defined.
7.2.3 Test Method
7.2.3.1measuring instrument should be of sufficient accuracy, but can not be less than the requirements of 4.2.1.
7.2.3.2Non-specific instructions, using appropriate equipment or dynamometer dynamometer includes functions as a load, the motor drive system should be tested in a hot operating state, the drive motor controller operating voltage of the DC bus rated voltage.
7.2.3.3When the test, the test conditions can be set according to the test object, the motor drive system may be tested under the actual conditions of the cold state or hot state, the drive motor controller may be provided to the DC link voltage maximum operating voltage, the minimum operating voltage, rated at voltage or other operating voltage, the test may be a speed and torque operating point, may be a work area or all of the characteristic curve, if necessary, appropriate test conditions to be recorded in the test report.
7.2.3.4 When the test, the drive motor controller can drive the input voltage and the output current of the motor controller inputs or outputs by the measurement obtained by calculation, measurement, voltage and current measurement points should be close to the driving terminals of the motor controller. The controller input power and output power may be measured directly using a power meter.
7.2.3.5 – Under normal circumstances, the drive power transmission cable between the motor controller and the drive motor does not have a significant effect on the measurement results, if the length or the impedance of the cable is seriously affect the operating characteristics of the test system, it is necessary adjust the cable, or be amended on the measurement results, in order to avoid or reduce the impact.
7.2.3.6 during the test, in order to ensure accuracy of measurement, the work drive motor torque and speed should be measured directly on the driving motor shaft, at this time, and the torque between the drive motor shaft speed measuring apparatus should be a rigid connection; If the transmission efficiency can be ignored and the intermediate coupling device of the wind mill loss, may be placed in the drive coupling link between the motor shaft and the torque and speed measuring apparatus, this time, the reading speed of a torque measuring device is the drive motor value of the output shaft.
7.2.3.7 need for taking into account the transmission efficiency and the coupling device during the test in the wind friction loss,with reference to Appendix A,the test results were corrected Method.
7.2.3.8 During the test, the test should prevent overheating of the driving motor system affect measurement accuracy, when necessary, the torque – speed characteristics can be measured segment.
Efficiency measurements 7.2.4
efficiency of the motor controller
7.2.4.1 drive
7.2.4.1.1 driving efficiently into the motor controller when the motor driving system of the electric state of the controller and the drive efficiency of the motor system efficiency of feed state controller, which value should be determined according to the ratio of the driving motor controller input power and output power calculations.
7.2.4.1.2 driving efficiency of the motor controller according to formula (9) is calculated:
7c= &Xlthousand and (9):
deadci%
– a drive motor controller Efficiency (%);
Pc driving motor 〇– controller output power in kilowatts(kw);
Pci- a drive motor controller input power in kilowatts(kW).
the driving motor efficiency
7.2.4.2
Feeding efficiency when state of the 7.2.4.2.1 efficiency of the driving motor into the driving system of the electric motor and the driving state of the motor system efficiency, the value should be determined in accordance with the ratio of input power and output power of the driving motor.
7.2.4.2.2 driving motor efficiency according to equation (10) calculated:
Vm = ^ Xlthousandand% (10)
^ mi
7m- driving motor efficiency (%);
Pm〇– output power of the driving motor , in kilowatts(kW);
Pmi– driving motor input power in kilowatts(kW).
7.2.4.3drive motor system efficiency
7.2.4.3.1motor drive system be tested together in the test bench, the input and output parameters of the motor driving system according to the measurement and calculation to obtain a drive motor system efficiency.
7.2.4.3.2 When the electric drive motor system is working state, the input power of the driving power of the motor controller DC bus input and an output of mechanical power drive shaft of the motor, the motor driving efficiency under the operating state of an electric system according to formula (11 ) is obtained:
when the system is in the drive motor 7.2.4.3.3 feeding operation state, the input power to mechanical power, the output power of the driving motor shaft for the drive power output from the motor controller DC bus, the drive motor feeding system working state efficiency according to equation (12) is
obtained: 9.55 I / XI xlQQ% (
V– drive motor system efficiency (%);
n drive motor speed, in revolutions per minute(r/min);
T- a drive motor shaft torque, in units of Nm(N • m);
U– a drive motor controller average DC link voltage, in volts(V);
I– a drive motor controller average DC-bus current, in amperes(A).
7.2.5 key characteristic parameters
7.2.5.1.1 unless otherwise noted during the test, the drive motor controller is set to the rated voltage of the DC bus voltage, the motor drive system can operate the electric power feeding, or status.
7.2.5.1.2When the test, the drive motor system operates to/ T 18488.1 GB–the torque and speed conditions specified in 2015 5.4.3, 7.2.3 using the method in the test and measurement, the motor drive system should be able to grow time work, and no more than drive the motor insulation class and temperature rise limits specified.
7.2.5.2 continuous power
7.2.5.1in accordance with the obtained continuous torque and a corresponding operating speed, continuous power can be obtained by calculation at the respective operating point of the drive motor by the formula (13).
Pm– continuous driving motor shaft power in kilowatts(kW).
7.2.5.3 peak torque
7.2.5.3.1 peak torque can be driven by the motor test system is actually cold. Unless otherwise noted, during the test, the drive motor controller is set to the rated voltage of the DC bus voltage, the motor drive system can operate the electric power feeding or state.
7.2.5.3.2When the test, the drive motor system to work GB / intheat peak torque 18488.1-2015 5.4.5 predetermined value, rotation speed and duration conditions T,using the method 7.2.3 in the test and measurement, At the same time recording the duration of the test. Driving motor temperature rise limit system should be able to work properly, and the driving motor does not exceed a predetermined level and the insulation.
7.2.5.3.3 When If multiple times in the measurement of peak torque, drive motor should be restored to the actual cold, then a second test measurements.
7.2.5.3.4 If the manufacturer or the user agrees to be reduced without the strength test, the driving motor is not allowed to return to begin a second cold test measurements. If this adjustment, the test measured temperature and the temperature rise value is large, or exceeds the relevant threshold requirements, such an adjustment should not be made to ensure the accuracy of test results.
7.2.5.3.5 Torque Peak Test duration can be performed according to user requirements or manufacturer, the manufacturer recommends that the motor drive system can continue to 1 min30or sPeak work as a reference, and the test measurements.7.2.5.3.6 As a special case of peak torque, the motor drive system can test the maximum torque at each rotational speed operating point, during the test, the test duration at maximum torque can be very short, generally well below 30 s.Based on test data, the rendering speed drive motor system – the maximum torque curve.
the peak power
7.2.5.3 according to and peak torque corresponding to the obtained operating speed can be obtained using the calculation formula (13) in the driving motor corresponding to system
the peak power operating point, the peak power should correspond to the duration of the test.
7.2.5.5 stall torque
7.2.5.5.1 unless otherwise noted during the test, the drive motor controller is set to the rated voltage of the DC bus voltage.
7.2.5.5.2 When the test, the drive motor rotor should be blocked, the motor drive system operates at the actual cold state, to apply the required torque to stall the drive motor by the drive motor controller, recording and blocking stall torque transfer time.
7.2.5.5.3 changing the relative position of the driving motor stator and rotor, equally divided in the circumferential direction of the stall to take five points, respectively, above experiment was repeated, repeated before each test should be restored to the actual motor driving the cold state. Each stall the stall time test should be the same.
7.2.5.5.4 takes the minimum value of five measurements result in a stall torque of the motor stall torque of the drive system.
7.2.5.6 maximum operating speed
7.2.5.6.1 during the test, the drive motor controller is set to the rated voltage of the DC bus voltage, the motor drive system should work in a hot state.
When 7.2.5.6.2 test, uniform adjustment test bench, the drive motor speed was raised to the maximum operating speed, and a predetermined load is applied not lower than the product technical documents, the drive motor system is stable, continued in this state, working time should be less than 3 min.
7.2.5.6.3 measured according to the test method 7.2.3,every 30s recorded once and the driving torque of the motor output speed. If necessary,can with reference to Appendix.A the torque be amended the results of Test Methodof
7.2.5.7 efficient workspace
7.2.5.7.1 in the drive torque of the motor operating speed range of the system, according to the test point 7.2.1 test, test points should be evenly distributed, and the number of not less than 100.
7.2.5.7.2 7.2.3 The method of the motor drive system be tested should achieve thermal operating state, the driving motor controller operating voltage of the DC bus rated voltage, the motor drive system can operate the electric power feeding or state.
7.2.5.7.3 tested at different speeds and different torque points need to record the driving speed, torque, and a drive motor controller DC bus voltage and current, alternating voltage and current and other parameters according to the motor shaft, if necessary,method can with reference to Appendix a the be amended torque.
7.2.5.7.4 efficiency of each test point is calculated in accordance with the method of 7.2.4.
7.2.5.7.5 accordance with GB/ T 18488.1-2015 the requirements in 5.4.9.2 for efficient work area, the number of test points in line with statistical criteria, and the total value of the ratio of the number of test points test, a percentage that efficient workspace .
7.2.5.7.6 encourage driving motor obtained by fitting the experimental and calculated data, etc., to efficiently drive the motor controller or the working area of the drive motor system.
7.2.5.8 most efficient
7.2.5.8.1 can follow the choice test point one of two ways:
the most efficient operating point provided by the manufacturer or product technical documentation for testing;
2.5.7 combined with efficient workspace trials, select all the most efficient test point value that is considered the highest efficiency.
7.2.5.8.2 accordance with the test method 7.2.3, the test system should achieve thermal drive motor operating state, the drive motor controller operating voltage of the DC bus rated voltage, the motor drive system can operate the electric power feeding or state.
7.2.5.8.3 drive motor test system operates in the test point, the recording parameter speed, torque, and voltage, current, and cooling conditions and the like, if necessary,can be with reference to Appendix A relevant data corrected of the method.
7.2.5.8.4 efficiency test point calculation method according to 7.2.4.
control accuracy 7.3
7.3.1 precision control
7.3.1.1in the test, the drive motor controller DC link voltage should be set to the rated voltage, the motor drive system should be in an unloaded, hot, the electric operating state.
7.3.1.2drive motor speed control system having a function, in 10% ~ 90% of the maximum operating speed range, even taking 10 points at different speeds as a target value. Setting a target speed according to the drive motor controller or the PC software, the direct drive motor rotational acceleration from standstill, a steady state and to speed this process should not drive motor controller or the PC software to make any adjustments, the recording driving the motor actual speed after stabilization, and calculates the difference between the actual speed and the target speed, the deviation of the actual rotational speed or the rotational speed target value of the percentage of the target rotational speed, the rotational speed target value is the value corresponding to the speed control accuracy.
7.3.1.3rotational speed target value for each of the above test were performed, select the error maximum precision in speed control, the speed of the drive motor as the system control accuracy.
7.3.1.4the drive motor speed control system does not function, the test is not carried out.
precision torque
7.3.2.17.3.2 test control,the motor driving DC link voltage controller should set rated voltage, the motor drive system is hot should electric operating state.
7.3.2.2drive motor torque control system having a function, in 10% ~ 90% peak torque speed range in the setting conditions, a uniform take 10 different torque point as a target value. A torque target value is set according to the drive motor controller or the PC software, the drive motor output torque and speed by the steady-state zero torque directly to the work, this process should not drive motor controller or the PC software to do any adjustment, the actual torque value of the motor driving the recording system, and calculates the difference between the actual torque value and the target torque, or the deviation of the actual torque and the target torque percentage of the target torque value, this value is the specific in under conditions of rotational speed, the torque target value corresponding to the torque control accuracy.
7.3.2.3torque target value for each of the above test were performed, select the error maximum torque control precision of the driving torque of the motor control system is the accuracy of the particular rotational speed conditions.
7.3.2.4loading process, the drive motor speed will change the work, for setting the rotational speed may be set and controlled by the dynamometer.
7.3.2.5system for driving the motor without torque control function, the test is not carried out.
7.4.1speed response
7.4.1.1 time test time,the drive motor controller DC link voltage should be set to the rated voltage, the motor drive system should be in an unloaded, hot, the electric operating state.
7.4.1.2drive motor having a speed control system, in accordance with the rotational speed of the drive motor controller or a desired value setting PC software, direct drive motor rotational acceleration from standstill, this process should not drive motor controller or the PC software to do any adjustment, the recording speed of the drive motor from the controller receives the desired information start instruction to the first predetermined desired value tolerance range of elapsed time.
7.4.1.3When the test should be changed for the starting position of the driving motor stator and rotor, equally divided in the circumferential direction to take five points, respectively, above experiment was repeated under the same conditions the speed desired value, taking the maximum of 5 times the recording time measurements value as the drive motor rotation speed the response time of the speed desired value.
7.4.1.4the drive motor speed control system does not function, the test is not carried out.
torque response time of
7.4.2.17.4.2the test, the drive motor controller DC link voltage should be set to the rated voltage, the motor drive system should be in the stall, hot, the electric operating state.
7.4.2.2drive motor having a torque control system in the stall state, the desired value is set according to a torque drive motor controller or the PC software, the motor torque control, the output torque of the drive motor from zero increases rapidly, this process should not drive motor controller or the PC software to make any adjustments, the recording time of the drive motor controller receives a torque command from the beginning to the first information of a desired predetermined tolerance range of the expected value of elapsed .
7.4.2.3When the test should be changed for the starting position of the driving motor stator and rotor, equally divided in the circumferential direction to take five points, respectively, above experiment was repeated under the same conditions of torque desired value, five measurements taken in recording time Examples of the maximum response time of the drive motor torque of the torque desired value.
7.4.2.4 system for driving the motor without torque control function, the test is not carried out.
7.5.1 Test Method 7.5 operating current drive motor controller
7.5.1.1drive motor corresponding to a drive motor controller connected together after bench test, the motor drive system components can operate in an electric or fed state.
7.5.1.2When test bench provided the conditions specified by the manufacturer or product according to technical documents, such as the drive motor controller DC bus voltage, the driving torque and operating speed, the duration of the test motor, the motor drive system should be able in a predetermined normal and stable operation limits the temperature rise in the test period, and the driving motor does not exceed a predetermined level and the insulation.
7.5.1.37.2.3The method of measuring the rms value of the motor driving controller operating current.
7.5.2 drive motor controller continuously operating current
bench under certain conditions, if the drive motor system capable of stable operation for a long period while a current measured operating current for the continuous drive motor controller.
7.5.3 short-time working current drive motor controller
according to a predetermined product manufacturer or technical documents, by changing the drive motor controller bench test conditions increased operating current, so that the driving motor system to normal and stable in a shorter time work, the current measured at this time is the driving current of the motor controller in short-time work within a corresponding working time, the drive motor controller short duration of the operating current should be not less than 30 s.
7.5.4 drive motor controller the maximum operating current
according to specified product manufacturer or technical documents, a further increase in driving conditions change bench motor controller current, the test duration may be very short, generally well below 30 s,measured at this time the current maximum operating current for the drive motor controllers.
7.6 feeding characteristics
7.6.1 Chapter 6, select the calculation method of 7.2.1,7.2.2,7.2.3 temperature measurement points, the measurement parameters and test methods, the test is equally applicable to the feeding characteristics of the process.
7.6.2 test the test machine system driven by a prime mover (dynamometer) drag, feeding in a state, on measurement parameters and test
DC link voltage conditions,depending the purposes,the controller operates the driving motor set , the feeding motor driving test under the corresponding operating speed and torque load.
7.6.3A drive motor controller when feeding a recording state DC bus voltage, the DC bus current, the driving motor of each phase AC voltage, AC current, and a drive shaft of the motor parameters such as speed and torque, while the power obtained by calculation, the feed electrical efficiency values, the correlation curve plotted. 7.6.4When necessary,should with reference to Appendix the test results be corrected A.
8 8.1 Safety Test Safety Ground in spection
Ground inspection method and gage according to claim/ T 13422-2013 GB5.1.3 performed, measure the ground resistance test drive the respective motor system. Gage recommended milliohmmeter.
8.2 protection controller
According GB/ T 3859.1-2013 tothe requirements in 7.5.3.
8.3 a drive motor controller supported
8.3.1 capacitor discharge time of the discharge time of
Passive the test, the DC bus voltage should be set to the maximum operating voltage, the voltage is stabilized, immediately cut off the DC power supply, while the use of electrical measuring instruments measure taken drive motor controller supporting an open circuit voltage across the capacitor. During the test, the drive motor controller does not participate in any work. Record support from the cutting timing capacitor open-circuit voltage drops to 60 until the V elapsed time, this value is the discharge time of the drive motor controller passive support capacitance.
8.3.2 active discharge time
for a driving motor controller active discharge function, the test, the DC bus voltage should be set to the maximum operating voltage, the voltage is stabilized, immediately cut off the DC power supply, and a drive motor controller involved in the discharge process, using electrical measuring instruments measuring the open circuit voltage taken across the motor drive controller supporting capacitance capacitor recording support from the cutting time until the open circuit voltage drops to 60 V elapsed time, i.e. this value as the drive motor controller supported active capacitor discharge time.
environmental adaptability test 9.1 Low Temperature Test
9.1.1 9 low temperature storage test, the drive motor and a drive motor controller connected properly, in with GB / T accordance 2423.1-2008, and placed inside a low temperature, so that the inside temperature is lowered a 40 °C,and kept 2 h,during the test, the drive motor system is in a non-energized state, for liquid-cooled drive motor and a drive motor controller, the coolant barrier.cold storage 2 h,After at low temperatures in accordance with methods 5.7 retest tank insulation resistance, insulation resistance during the retest, the temperature should be maintained at a low temperature tank a 40 °C.
9.1.2 cold storage2 h,after the temperature of the low temperature tank maintained at a 40 °C,the motor drive system is energized at a low temperature tank to check whether the normal load start. For liquid-cooled drive motor and a drive motor controller, if required during start into coolant composition, temperature and flow rate of cooling liquid product according to technical document.
9.1.3 the end of the test,in with GB / T after the return to normality accordance 2423.1-2008, the drive motor controller is the DC bus voltage is set to the rated working voltage, the drive motor operates in continuous torque, under the condition of continuous power, the system can check No work properly.
9.2.1 9.2high temperature storage test, the drive motor and the drive motor controller into a high temperature box, in with GB / T accordance 2423.2-2008, the inside temperature was raised to 85 °C,and kept 2h during the test, the drive motor system is in a non-energized state, for liquid-cooled drive motor and a drive motor controller, the coolant barrier.high temperature storage 2 h,After the grease within the bearing drive motor Check whether there is overflow, while the method according to retest the insulation resistance of 5.7 at a high temperature box, the insulation resistance during the retest, the temperature should be maintained at a high temperature tank 85 °C.
9.2.2 temperature storage 2 h,in with GB / T accordance 2423.2-2008 back to normal after the drive motor controller is the DC link voltage is set to the rated working voltage, the drive motor operates in continuous torque under the condition of continuous power, check The system is working.
9.2.3 When the high temperature test, the drive motor and a drive motor controller connected properly, in with GB / T accordance 2423.2-2008, the temperature into the box, according to GB / T the requirements of 5.6.2.2 in 18488.1-2015 provided ambient temperature inside the test, the drive motor controller is the DC bus voltage is set to the rated working voltage, the drive motor operates in continuous torque, under the condition of continuous power, the system checks whether the drive motor 2work h properly.For liquid-cooled drive motor and a drive motor controller, to be passed through the cooling liquid during the test, composition, temperature and flow rate of the coolant in accordance with a predetermined product technical documents.high temperature 2 h,After the 5.7 in a high temperature process according to retest tank insulation resistance, insulation resistance during the retest, the temperature of the high temperature tank should remain unchanged.
9.2.4 After high temperature test is completed, the sample should be tested in accordance with GB / T 2423.2–2008 provisions of normalcy.
9.3 damp heat test
9.3.1 drive motor and a drive motor controller is placed in a temperature (40 ± 2) °C,relative humidity of 90% ~ 95% under the conditions of the test environment, maintained 48 h,during the test, the drive motor the system is in the non-energized state, for a liquid-cooled drive motor and a drive motor controller, the coolant barrier.48 h,After 5.7 multiplexing method according to measure the insulation resistance, insulation resistance during the retest, the test environment condition should remain unchanged.
9.3.2 the end of the test back to normal, the drive motor controller is the DC bus voltage is set to the rated working voltage, the drive motor operates in continuous torque, under the condition of continuous power, the inspection system is working.
9.4.1 When the test, the test sample is secured in the vibration test table and in the normal installation position, in the tested non-operating state, while the product should be connected to a hose or other accessories mounted connector, and secure.
9.4.2 frequency sweep vibration test, as by/ T 18488.1-2015 required GB 5.6.4.1.1 provided in the severity level, and as in / T 2423.10-2008 tested specified GB of.
9.4.3 random vibration test, as by/ T 18488.1-2015 required GB5.6.4.2.1 provided in the severity level, and as in / T 28046.3-2011 tested specified GBof.
9.4.4After the vibration test is completed, to check whether the damaged parts, fasteners are loose. After returned to normal, the drive motor controller is the DC bus voltage is set to the rated working voltage, the drive motor operates in continuous torque, under the condition of continuous power, the inspection system is working.
9.5 waterproof, dust-proof
according to GB T 4942.1-2006 /and test conducted in the method 4208-2008 specified GB.
9.6 salt spray
9.6.1 in accordance with/ T 2423.17 GB–salt spray test specified in 2008. A drive motor and drive motor controller in a normal salt spray tank should be installed state, the test period should meet the GB / requirements of 5.6.6 18488.1-2015T.
9.6.2 completion of the test, the drive motor and a drive motor controller resumes 1 h,~2 h After the electric motor driving the work DC link controller 1
Voltage is set to the rated voltage, the drive motor operates in continuous torque, continuous power condition , the inspection system can work properly, but will not be examined appearance driving motor and drive motor controller.
9.7 EMC
disturbance tests of electromagnetic radiation and electromagnetic radiation immunity test shall test in accordance with the test method provided by the manufacturer or the user.
Reliability Test 10
in with/ T were tested accordance GB 29307-2012’s.
motor drive system operating torque measurement result correction method
A.1 wind abrasion torque
during the test, since the relationship between the torque and the connection position accuracy and efficiency of mechanical transmission speed measuring apparatus and the drive motor spindle Causes, air friction loss generated in the drive system of the electric motor during the test, the wear wind torque T\w by formula(a.1) calculated:
Pi:when the drive system is a drive motor test dynamometer -input electric power, in watts(W),at this time, the dynamometer is not energized, is in a free rotation state;
Psquare– the drive motor is again input electric power system load, in watts(W); nt Wind abrasion test subjects torque motor speed, in revolutions per minute
(r / min); T d to rque wind abrasion torque dynamometer test apparatus (rotational speed or torque measuring device) measurements show, units of Nm(N • m).
A.2 operating torque of
Corrected the electric motor drive system during the test, subjects the drive motor output torque correction T \ (N • m)according the formula calculated to
(A .2): T c = fw (a.2)
After the feeding system during the test drive motor, the drive motor is again corrected input to rque T \ (N • m)according to formula(a.3)
calculated: T r = T t – Tf (A.3)
Tt– dynamometer test are shown in the output torque of the driving motor, the unit of Nm(N • m).
Note that the formula(A.L), formula(A.2) and Formula(A of.3) has certain conditions. Suppose the motor drive system when air abrasion test, whether the electric power feeding state or a state, which the system loss remains unchanged, to obtain of formula(Athe results.1); the same time, the system assumes that the drive motor and at different operating speed working under torque conditions, the wind friction losses remain constant,can be obtained of formula(a.2) and formula(a.the results3) of the.
Encourage the user or the manufacturer according to the actual need for more scientific and rational correction method.
jacobcheng 2017-04-12T19:48:09+00:00
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