CN111380635A - Motor torque ripple test bench and test method - Google Patents
Motor torque ripple test bench and test method Download PDFInfo
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- CN111380635A CN111380635A CN201911081706.4A CN201911081706A CN111380635A CN 111380635 A CN111380635 A CN 111380635A CN 201911081706 A CN201911081706 A CN 201911081706A CN 111380635 A CN111380635 A CN 111380635A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L3/00—Measuring torque, work, mechanical power, or mechanical efficiency, in general
- G01L3/16—Rotary-absorption dynamometers, e.g. of brake type
- G01L3/22—Rotary-absorption dynamometers, e.g. of brake type electrically or magnetically actuated
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/34—Testing dynamo-electric machines
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Abstract
The application relates to a motor torque ripple test bench and a test method, wherein a synchronous belt transmission structure is arranged, and the precision of the rotation position of a rotor is accurately controlled through a large belt wheel. Through multi-position locked rotor, the torque fluctuation condition in one circle of the rotor movement can be obtained; the torque sensor is used in a low-frequency area, and the angular acceleration sensor is used in a high-frequency area, so that the measurement range of the cogging torque is expanded; the method is suitable for measuring the cogging torque of the full-frequency region of the motor. The test bench combines locked rotor and inertial loading, and the torque fluctuation condition of the motor in a rotation period can be represented by a locked rotor method on one test bench, and the cogging torque fluctuation condition of the motor can also be directly tested. The influence of the torque fluctuation of the dynamometer can be reduced as much as possible by the large-inertia flywheel. In addition, the elastic coupling is adopted to eliminate the influence of coaxiality, eccentricity and vibration on the sensor side in the transmission chain and prevent the sensor from being damaged due to vibration.
Description
Technical Field
The application relates to the field of motor testing, in particular to a torque ripple testing bench and a testing method combining locked rotor and inertia loading.
Background
In an electric drive system, torque ripple is an important source of motor vibration noise, and is one of the key issues for improving the quality of the electric drive system. The torque pulsation can also cause torque vibration, possibly cause the motor to resonate, increase various losses, shorten the service life of the motor and reduce the working reliability and stability. Therefore, it is very important to accurately test the design of the motor torque ripple along with the electric drive system and the optimization of the motor body and the control system. The motor torque ripple is mainly caused by the cogging torque of the motor and the unbalanced magnetic pull force generated on the rotor shaft due to the machining error.
The existing torque testing methods have defects, and the direct measurement method directly takes the torque as a measurement object. The method is simple to operate, but the consideration factor is too few, the method is easily influenced by load fluctuation and mechanical structure resonance in the measuring process, and the error is large. And because the rigidity of the torsion bar can not be changed in a large range, the torsion bar can only be used at a low speed, and the test range is narrow. Although the balance method overcomes the torque fluctuation in the transmission process compared with the direct method, the balance method still uses a load, the fluctuation of the load cannot be avoided, and the tested motor needs to extend out of two ends and is not suitable for testing of a common motor. Although the stator and rotor separation method has breakthrough and innovation in avoiding non-measured torque fluctuation, the method still cannot be widely applied to measurement of motor torque pulsation.
Therefore, it is desirable to establish a universal testing stand and method for testing motor torque ripple in order to directly and accurately test motor torque ripple over a wider range.
Disclosure of Invention
Aiming at the technical problems in the field, the invention provides a test bench for a motor torque ripple test.
A motor torque ripple test rig, comprising: the device comprises a tested motor, a torque sensor, a synchronous belt transmission structure, a brake, a stepping motor and a dynamometer;
the synchronous belt transmission structure comprises a large belt wheel, a small belt wheel and a synchronous belt, and the synchronous belt is in transmission connection with the large belt wheel and the small belt wheel; the output shaft of the stepping motor is coaxially and fixedly connected with the small belt wheel, the large belt wheel is coaxially fixed on a rotor shaft of the tested motor, and the large belt wheel is provided with scales which are equally spaced in the circumferential direction and correspond to the test intervals of the tested motor in a test period;
the braking force of the brake directly acts on the large belt wheel;
also comprises an angular acceleration sensor for measuring the angular acceleration of the rotor of the tested motor,
and after the tested motor is opened, the tested motor is reversely dragged by the constant-speed running of the dynamometer, the cogging torque of the tested motor when the tested motor rotates for one week is tested, the angular acceleration is adopted to reflect the cogging torque in a high-frequency area of the excitation current input into the dynamometer, and the torque sensor is used to reflect the cogging torque in a low-frequency area of the excitation current input into the dynamometer.
Preferably, the ① stepping motor rotates by a first specific angle after receiving a pulse, the synchronous belt transmission structure drives the rotor of the tested motor to rotate by a second specific angle, and a locked rotor test is performed, wherein the locked rotor test content comprises a locked rotor torque output value of the tested motor;
②, repeating the step ① until the rotor of the tested motor rotates for a period, and obtaining the locked-rotor torque output value corresponding to each rotation of the second specific angle in the period, thereby obtaining the torque fluctuation condition of the tested motor for one period.
Preferably, the first specific angle is a step angle of the selected stepping motor, which is 1.8 °; the second specific angle is 1 °, and the timing belt structure transmission ratio is a ratio of the first angle to the second angle.
Preferably, the one period is one rotation of the rotor shaft of the measured motor.
Preferably, the method further comprises the following steps: the device comprises a rotating disc provided with angular acceleration sensors, the rotating disc is arranged between a tested motor and a torque sensor, the rotating disc is perpendicular to a rotor shaft of the tested motor and is coaxially fixed, and the two angular acceleration sensors are arranged on the same circumference of the same radial plane and are reversely arranged from left to right.
Preferably, the method further comprises the following steps: an elastic coupling disposed between the flywheel and the torque sensor;
preferably, the device further comprises a flywheel, and the flywheel is installed between the dynamometer and the torque sensor.
Preferably, the device further comprises two eddy current displacement sensors arranged perpendicular to each other, and the eddy current displacement sensors measure radial runout values of the rotor shaft of the measured motor in two directions perpendicular to each other, so as to obtain the eccentricity of the rotor of the measured motor, and the two eddy current displacement sensors are located in the same radial plane perpendicular to the rotor shaft.
Preferably, after the tested motor is opened, the tested motor is reversely dragged by the dynamometer in constant-speed operation, and the cogging torque of the tested motor in the process of rotating for one circle is tested.
Preferably, the angular acceleration sensor is a piezoelectric sensor, the cogging torque is equal to the output value of the torque sensor in a low frequency region of the excitation current input to the dynamometer, and the cogging torque is equal to the product of the angular acceleration of the rotor and the sum of the rotational inertia of the measured motor and the flywheel in a high frequency region of the excitation current input to the dynamometer.
The invention has the following advantages:
the rack combines locked rotor and inertial loading, and the torque fluctuation condition of the motor in a rotation period can be represented by a locked rotor method on a test rack, and the cogging torque fluctuation condition of the motor can also be directly tested.
The synchronous belt transmission structure is arranged, and the precision of the rotating position of the rotor is accurately controlled through the large belt wheel. Through multi-position locked rotor, the torque fluctuation condition in one circle of the rotor movement can be obtained; and the braking force of the brake acts on the large belt wheel; the brake is used as a locked-rotor device to fix the position of the large belt wheel so as to realize the locked-rotor working condition.
The torque sensor is used in a low-frequency area, and the angular acceleration sensor is used in a high-frequency area, so that the measurement range of the cogging torque is expanded; the method is suitable for measuring the cogging torque of the full-frequency region of the motor, enlarges the test range and meets the requirement of high-frequency region measurement.
The influence of the torque fluctuation of the dynamometer can be reduced as much as possible by the large-inertia flywheel.
The elastic coupling is adopted to eliminate the influence of coaxiality, eccentricity and vibration in a transmission chain on the sensor side and prevent the sensor from being damaged due to vibration.
Drawings
FIG. 1 is a block diagram of a torque ripple test system
FIG. 2 is a three-dimensional model of a test system
FIG. 3 is a top view of the test system
FIG. 4 is a schematic view of a scale disk of a large belt wheel
FIG. 5 is a diagram showing the mounting position of an eddy current displacement sensor
FIG. 6 is a view showing the mounting position of a piezoelectric sensor
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments. The establishment and the test process of the torque ripple test system are specifically described by taking a 3.6kW permanent magnet synchronous motor as an example.
Referring to fig. 1 to 3, the test bench for motor torque ripple test of the present invention comprises: the device comprises a motor controller, a power supply, a power analyzer, an upper computer, a signal acquisition system, a tested motor 1, an eddy current displacement sensor 2, an angular acceleration sensor 3, a torque sensor 4, a synchronous belt transmission structure 5, a stepping motor 6, an elastic coupling, a flywheel 7, a dynamometer 8, a brake 9 and an elastic coupling 10.
The tested motor 1 comprises a rotor shaft A;
the synchronous belt transmission structure comprises a large belt wheel, a small belt wheel and a synchronous belt, and the synchronous belt is in transmission connection with the large belt wheel and the small belt wheel; an output shaft of the stepping motor is coaxially and fixedly connected with the small belt wheel, and the large belt wheel is coaxially fixed on a rotor shaft of the motor to be measured; preferably, the large belt wheel and the small belt wheel are toothed wheels, and the synchronous belt is a toothed belt;
determining the transmission ratio of a large belt wheel and a small belt wheel according to the test requirement by combining with the stepping angle of a stepping motor, wherein in the locked-rotor test process, the stepping motor rotates by a first specific angle after receiving a pulse, and drives the rotor of the tested motor to rotate by a second specific angle through the synchronous belt transmission structure to perform a locked-rotor test; preferably, to ensure a certain accuracy, the first specific angle is 1.8 °, and the stepper motor drives the rotor shaft to rotate 1 ° under one pulse by using a synchronous belt transmission structure with a transmission ratio i equal to 1.8, that is, the second specific angle is 1 °.
In order to simplify the overall structure of the test bench and facilitate the installation of the brake, a large belt wheel with a larger radius is designed, so that the large belt wheel can be used as a component of synchronous belt transmission and also can be used as a brake disc in the bench, and in view of the consideration of a mechanical design manual, a groove type can be selected to be an H type, and a pitch p is selectedb12.7mm, the number of teeth z of the small pulley is determined by trial and error120, large pulley tooth number z236. Meanwhile, as shown in fig. 4, the large belt wheel is provided with scales at equal intervals in the circumferential direction, so that the accuracy of the rotating position of the rotor is further ensured;
the braking force of the brake acts on the large belt wheel; the brake is used as a locked-rotor device to fix the position of the large belt wheel so as to realize the locked-rotor working condition.
The elastic coupling is arranged between the flywheel and the torque sensor; the problem of rotor eccentricity caused by the assembly process is inevitably caused because the shafting of the test bench is longer, and in order to compensate the problems of the rotor eccentricity and the bench vibration, the flywheel and the torque sensor are connected by adopting the diaphragm coupling. Meanwhile, due to the adoption of the elastic coupling, preferably the double-diaphragm coupling, the misalignment of input and output axes is compensated, the clockwise and anticlockwise rotation characteristics of the input and output shafts are the same, and the zero rotation clearance and the accurate transmission of the torque and the rotation speed can be realized.
The mechanical equation of the whole rotating shaft system is as follows:
wherein, TeElectromagnetic torque generated for the motor, J1、J2Respectively, the rotational inertia, omega, of the motor to be measured and the flywheelrIs the angular velocity of the system, C1、C2The damping coefficients of the transfer system and the flywheel are respectively.
Selecting two eddy current displacement sensors which are arranged vertically to each other, wherein the arrangement mode is shown in figure 5 and is used for measuring radial runout values of a motor rotor in two directions which are vertical to each other, and the two eddy current displacement sensors are in the same radial plane and are vertical to a rotor shaft A; to analyze the eccentricity of the motor rotor during one revolution of the motor rotor. Therefore, subsequent analysis work of unbalanced magnetic tension can be carried out, and effective prediction of the electromagnetic property and the mechanical property of the motor under the condition of rotor eccentricity is realized;
the HBM high-precision sensor selected by the torque sensor adopts non-contact measurement signal transmission and is connected with the rotor shaft of the tested motor through a flange, so that the torque and speed signal measurement of the motor can be realized, the test precision is 0.05 percent, and the torque and torque fluctuation of the motor can be effectively captured.
When the torque sensor is used, if the angular speed of a connecting shaft of the torque sensor is too large, the torque value output by the torque sensor is inaccurate, namely, the frequency band of a signal directly tested by the torque sensor has a certain range, and because the rotating speed of the dynamometer is in direct proportion to the frequency of an input current, the torque sensor can only directly test the torque when the frequency of an excitation current input by a tested system is less than one tenth of the resonant frequency of the tested system, and cannot meet the cogging torque test of the full rotating speed range of the motor.
In the process of testing the cogging torque, the cogging torque measures the angular acceleration of a rotor of a tested motor by adopting an angular acceleration sensor in a high-frequency region of an excitation current input into a dynamometer, and measures the torque of the rotor by adopting a torque sensor in a low-frequency region of the excitation current input into the dynamometer; the high and low frequencies are determined by those skilled in the art from the actual test rig resonant frequency, and are preferably considered high frequency excitation currents when the excitation current frequency is one tenth and above the test rig and low frequency excitation currents when the excitation current frequency is below one tenth of the test rig.
The torque sensor is used in the low-frequency area, and the angular acceleration sensor is used in the high-frequency area, so that the measuring range of the cogging torque can be expanded;
the relationship between the angular acceleration and the output torque of the motor is as follows:
Te＝J1αm(2)
wherein, αmIs the measured angular acceleration of the rotor.
Therefore, the cogging torque is equal to the output value of the torque sensor in the low-frequency region of the excitation current input into the dynamometer, and the cogging torque is equal to the product of the angular acceleration of the rotor and the sum of the rotational inertia of the tested motor and the flywheel in the high-frequency region of the excitation current input into the dynamometer.
Preferably, the angular acceleration sensor is a piezoelectric sensor 3, the piezoelectric sensor 3 is arranged between the measured motor and the torque sensor, the piezoelectric sensor is mounted on a disc B coaxial with the rotor shaft a, the two piezoelectric sensors are arranged on the same circumference of the same radial plane and are arranged in left-right opposite directions to measure the angular acceleration of the rotor during the rotation of the motor, and the arrangement positions of the two piezoelectric sensors on the disc are shown in fig. 6;
the angular acceleration of the rotor shaft of the measured motor is:
wherein, αt1、αt2Respectively are the measured values of the two angular acceleration sensors, and d is the vertical distance between the two angular acceleration sensors.
In order to eliminate the influence of torque fluctuation of the dynamometer on a tested motor in dynamic test, a flywheel with large inertia is arranged between the dynamometer and a torque sensor.
The testing method specifically comprises the following steps:
for locked rotor torque testing:
①, when the stepping motor receives a pulse and rotates a first specific angle, the synchronous belt transmission structure drives the rotor of the tested motor to rotate a second specific angle to perform a locked rotor test, wherein the locked rotor test content comprises the locked rotor torque output value and the rotor radial runout value of the tested motor;
preferably, the second specific angle is 1 °
②, repeating the step ① until the rotor of the tested motor rotates for a period, obtaining the locked-rotor torque output value corresponding to each rotation of the second specific angle in the period, and further obtaining the torque fluctuation condition of the tested motor for a period and the eccentricity condition of the rotor of the tested motor.
Preferably, the one period is one rotation of the rotor of the tested motor;
for cogging torque testing:
and after the tested motor is opened, the tested motor is reversely dragged by the dynamometer in constant-speed operation, and the cogging torque condition of the tested motor is tested when the tested motor rotates for one circle. At the moment, the motor to be measured is disconnected with a power supply, and the cogging torque of the motor to be measured can be measured according to national standards.
Claims (10)
1. A motor torque ripple test rig, comprising: the device comprises a tested motor, a torque sensor, a synchronous belt transmission structure, a brake, a stepping motor and a dynamometer;
the method is characterized in that:
the synchronous belt transmission structure comprises a large belt wheel, a small belt wheel and a synchronous belt, and the synchronous belt is in transmission connection with the large belt wheel and the small belt wheel; the output shaft of the stepping motor is coaxially and fixedly connected with the small belt wheel, the large belt wheel is coaxially fixed on a rotor shaft of the tested motor, and the large belt wheel is provided with scales which are equally spaced in the circumferential direction and correspond to the test intervals of the tested motor in a test period;
the braking force of the brake directly acts on the large belt wheel;
also comprises an angular acceleration sensor for measuring the angular acceleration of the rotor of the tested motor,
and after the tested motor is opened, the tested motor is reversely dragged by the constant-speed running of the dynamometer, the cogging torque of the tested motor when the tested motor rotates for one week is tested, the angular acceleration is adopted to reflect the cogging torque in a high-frequency area of the excitation current input into the dynamometer, and the torque sensor is used to reflect the cogging torque in a low-frequency area of the excitation current input into the dynamometer.
2. The gantry of claim 1, further comprising:
① the step motor rotates a first specific angle after receiving a pulse, the synchronous belt drive structure drives the rotor of the tested motor to rotate a second specific angle, and a locked rotor test is carried out, the locked rotor test content includes the locked rotor torque output value of the tested motor;
②, repeating the step ① until the rotor of the tested motor rotates for a period, and obtaining the locked-rotor torque output value corresponding to each rotation of the second specific angle in the period, thereby obtaining the torque fluctuation condition of the tested motor for one period.
3. The gantry of claim 2, wherein: the first specific angle is a stepping angle of the selected stepping motor, and is 1.8 degrees; the second specific angle is 1 °, and the timing belt structure transmission ratio is a ratio of the first angle to the second angle.
4. The gantry of claim 2, wherein: the one period is one rotation of the rotor shaft of the tested motor.
5. The gantry of any one of claims 1 to 4, further comprising: the device comprises a rotating disc provided with angular acceleration sensors, the rotating disc is arranged between a tested motor and a torque sensor, the rotating disc is perpendicular to a rotor shaft of the tested motor and is coaxially fixed, and the two angular acceleration sensors are arranged on the same circumference of the same radial plane and are reversely arranged from left to right.
6. The gantry of any one of claims 1 to 4, further comprising: an elastic coupling disposed between the flywheel and the torque sensor.
7. The gantry of any one of claims 1 to 4, further comprising a flywheel mounted between the dynamometer and the torque sensor.
8. A gantry according to any one of claims 1 to 4, further comprising two eddy current displacement sensors arranged perpendicularly to each other, for measuring the radial runout of the rotor shaft of the electrical machine under test in said two directions perpendicular to each other, and thereby obtaining the eccentricity of the rotor of said electrical machine under test, both said eddy current displacement sensors being in the same radial plane perpendicular to said rotor shaft.
9. The gantry of any one of claims 1 to 4, wherein: and after the tested motor is opened, the tested motor is reversely dragged by the dynamometer in constant-speed operation, and the cogging torque of the tested motor in the process of rotating for one circle is tested.
10. The gantry of any one of claims 1 to 4, wherein: the angular acceleration sensor is a piezoelectric sensor, the cogging torque is equal to the output value of the torque sensor in the low-frequency region of the excitation current input into the dynamometer, and the cogging torque is equal to the product of the angular acceleration of the rotor and the sum of the rotational inertia of the tested motor and the flywheel in the high-frequency region of the excitation current input into the dynamometer.
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Cited By (8)
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| CN112556830A (en) * | 2020-11-27 | 2021-03-26 | 杭州大路实业有限公司 | Vibration test device and method for low-vibration motor under load working condition |
| CN112763114A (en) * | 2020-12-03 | 2021-05-07 | 北京航空航天大学宁波创新研究院 | Stalling torque testing device and method |
| CN113820055A (en) * | 2021-09-10 | 2021-12-21 | 华南理工大学 | Method for measuring cogging torque of permanent magnet motor |
| CN114252187A (en) * | 2021-12-15 | 2022-03-29 | 上海奥波智能科技有限公司 | Equipment, method, device and medium for testing motor pulsation torque |
| CN114415024A (en) * | 2022-03-21 | 2022-04-29 | 江铃汽车股份有限公司 | Motor locked-rotor testing device and method |
| CN114441078A (en) * | 2021-12-22 | 2022-05-06 | 中国航空工业集团公司北京长城计量测试技术研究所 | Online torque measurement structure and online torque measurement method of power measurement device |
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| CN114441078B (en) * | 2021-12-22 | 2023-09-15 | 中国航空工业集团公司北京长城计量测试技术研究所 | Online torque measurement structure and online torque measurement method of power measurement device |
| CN114415024A (en) * | 2022-03-21 | 2022-04-29 | 江铃汽车股份有限公司 | Motor locked-rotor testing device and method |
| CN114646463A (en) * | 2022-03-29 | 2022-06-21 | 山东中科伺易智能技术有限公司 | Tooth socket torque testing device |
| CN116465292A (en) * | 2023-05-06 | 2023-07-21 | 太原理工大学 | High-precision detection system and method for vibration displacement of inclined installation of eddy current sensor probe |
| CN116465292B (en) * | 2023-05-06 | 2023-11-07 | 太原理工大学 | High-precision detection system and method for vibration displacement of inclined installation of eddy current sensor probe |
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Effective date of registration: 20230412 Address after: No. D501, D502, and D503, Building D, Huafeng International Robot Industrial Park, Hangcheng Avenue, Nanchang Community, Xixiang Street, Bao'an District, Shenzhen City, Guangdong Province, 518100 Patentee after: SHENZHEN XILIN ELECTRICAL TECHNOLOGY Co.,Ltd. Address before: 100081 No. 5 South Main Street, Haidian District, Beijing, Zhongguancun Patentee before: BEIJING INSTITUTE OF TECHNOLOGY |