CN115754708A - Method for testing no-load loss of motor - Google Patents
Method for testing no-load loss of motor Download PDFInfo
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- CN115754708A CN115754708A CN202211337311.8A CN202211337311A CN115754708A CN 115754708 A CN115754708 A CN 115754708A CN 202211337311 A CN202211337311 A CN 202211337311A CN 115754708 A CN115754708 A CN 115754708A
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Abstract
The invention discloses a method for testing no-load loss of a motor, and the method comprises the following steps of S1, motor zero position calibration, including no-load torque test and motor zero position calibration; s2, calibrating a zero-torque ammeter: the dynamometer controls the rotating speed of the motor, the upper computer of the controller selects a current control mode, and zero-torque ammeter calibration is carried out at the corresponding rotating speed according to the calibrated zero position of the motor; s3, carrying out no-load loss test: the dynamometer controls the rotating speed of the motor, the upper computer of the controller selects a torque control mode, the given motor torque command is zero, no-load loss test is carried out, the bench records test data, and a no-load loss value is calculated; and S4, analyzing the measured no-load loss data, and performing motor zero calibration and no-load ammeter calibration according to specific data expression and input no-load loss indexes to reduce no-load loss. The invention can obtain the control parameters of the motor in no-load through calibration, thereby carrying out the test and calculation of the no-load loss of the motor.
Description
Technical Field
The invention relates to the technical field of motor control, in particular to a method for testing no-load loss of a motor.
Background
Because the new energy automobile has the advantages of small pollution, low energy consumption and the like which are incomparable with the traditional fuel oil automobile, the government of China starts to greatly promote the development of the new energy automobile in recent years. The permanent magnet synchronous motor is used as an important component in a new energy automobile, has the characteristics of high efficiency, high power factor, high power density and the like, and is widely applied to an electric drive system of the new energy automobile in recent years. For a new energy automobile, the existence of the motor can bring energy loss to the whole automobile, particularly for a hybrid electric automobile, a power source of the hybrid electric automobile consists of an engine and the motor, when torque output is not performed, the motor and an output shaft are in a hard connection mechanical structure, the motor rotates along with the output shaft of the whole automobile and is in a no-load running state, the existence of the no-load loss of the motor is equivalent to a part of load carried by the running automobile, extra energy is consumed, and the method is unfavorable for the dynamic property and the economical efficiency of the electric automobile, so that a method for calibrating, testing and reducing the no-load loss of the permanent magnet synchronous motor is needed to be researched.
Disclosure of Invention
The invention provides a method for testing the no-load loss of a motor, which can obtain the control parameters of the motor during no-load through calibration so as to test and calculate the no-load loss of the motor, can effectively reduce the no-load loss value of the motor according to the system input and the measured no-load data, and improve the dynamic property and the economical efficiency of a new energy automobile.
The technical scheme for solving the problems is as follows:
the method for testing the no-load loss of the motor comprises the following steps:
s1, motor zero calibration, including no-load torque test and motor zero calibration;
s2, calibrating a zero-torque ammeter: the dynamometer controls the rotation speed of the motor, the upper computer of the controller selects a current control mode, and zero-torque ammeter calibration is carried out at a corresponding rotation speed according to a calibrated zero position of the motor;
s3, carrying out no-load loss test: the dynamometer controls the rotation speed of the motor, the upper computer of the controller selects a torque control mode, the given motor torque command is zero, no-load loss test is carried out, the bench records test data, and a no-load loss value is calculated;
and S4, analyzing the measured no-load loss data, and performing motor zero calibration and no-load ammeter calibration according to specific data performance and input no-load loss indexes to reduce no-load loss.
Further, the no-load torque test in step S1 includes: and (3) disconnecting a three-phase connecting line between the motor and the controller, dragging the motor to rotate at a set rotating speed step by the dynamometer bench until the maximum rotating speed of the motor is reached, and measuring the torque of the motor in a no-load state at the corresponding rotating speed.
Further, the calibrating the zero position of the motor in the step S1 includes:
the method comprises the steps that the bench feedback torque is measured motor no-load torque, three-phase lines between a motor and a controller low-voltage wiring harness are connected, 12V low voltage and high-voltage rated voltage are arranged on the controller, a current mode is selected by an upper computer of the controller, a dynamometer drags the motor to rotate to a set rotating speed, the measured no-load torque is used as reference, d-axis current is given, and the torque measured by the bench in the current state is more than 90% of the no-load torque by adjusting an initial zero value under the condition that the flux weakening allowance of the motor is sufficient;
after the calibration under one rotating speed is finished, the dynamometer continues to drag the motor to rotate by the set rotating speed step length, and the steps are repeated until the rotating speed of the motor is the maximum rotating speed, so that the torque of the motor measured by the dynamometer under the zero position of the motor in the full rotating speed range is the no-load torque.
Further, the zero-torque ammeter calibration in the step S2 is that on the basis of completing the zero calibration of the motor, the dynamometer bench drags the motor to rotate to a set rotating speed, the upper computer of the controller selects a current mode, under the condition of ensuring sufficient flux weakening allowance of the motor, the torque of the bench feedback motor fluctuates around zero by calibrating d-axis and q-axis currents, and corresponding rotating speed, d-axis and q-axis currents are recorded;
and after the calibration is finished under one rotating speed, the dynamometer continues to drag the motor to rotate by a set rotating speed step length, the steps are repeated until the rotating speed of the motor is the maximum rotating speed, and the current data of the corresponding rotating speed, the d axis and the q axis are summarized.
Further, in the step S3, the empty load loss is tested, after the given motor torque command is zero, the dynamometer drags the motor to rotate by the set rotating speed step length, and the rack records the motor rotating speed, the motor torque, the bus voltage and the bus current when the observation torque range is about zero;
and (3) calculating to obtain the no-load loss of the motor according to the data recorded by the rack:
motor speed x motor torque/9550 = motor mechanical power;
bus voltage × bus current = electric power;
motor no-load loss = motor mechanical power + electrical power.
Further, in step S4, the no-load loss of the motor is reduced by calibration, and the measured no-load loss data is analyzed: and (3) evaluating whether the test result meets the requirements according to the no-load loss standard input by a client when the motor torque, the motor power, the bus current and the bus power at different motor rotating speeds, and if the test result does not meet the requirements, carrying out zero calibration and no-load ammeter calibration on the motor from two aspects of reducing the actual torque of the motor during a zero torque command and reducing the bus current so as to reduce the no-load loss.
Further, the process of reducing no-load loss through motor zero calibration is as follows: the dynamometer is started to drag the motor to rotate, the zero position of the motor is readjusted by referring to the measured zero-load torque, so that the motor is accurate, the error is reduced, the current component and extra torque on a d axis or a q axis caused by the zero position error are avoided, and the zero-load loss is reduced in the aspect of motor torque.
Further, the process of reducing the no-load loss through the calibration of the no-load ammeter comprises the following steps: and observing the real-time flux weakening voltage margin, firstly reducing d-axis current as much as possible under the condition of ensuring that the flux weakening voltage margin is sufficient, adjusting q-axis current and observing whether the torque of the motor is zero or not, and avoiding excessive extra current loss, thereby achieving the purpose of reducing the direct current of the bus and further reducing the no-load loss of the motor.
Further, the motor is a permanent magnet synchronous motor.
Compared with the prior art, the invention has the following advantages:
the invention describes a set of complete methods for reducing the no-load loss of the motor in detail by testing the no-load torque, calibrating the zero position of the motor in the no-load state and calibrating the control current in the zero torque state, how to test the no-load loss and combine the data expression of the no-load loss test to carry out targeted reduction. The method uses the motor no-load torque as a basic reference value in principle, teaches how to test and reduce the motor control loss, is simple and convenient to understand, and shows the result that the motor no-load loss can be fundamentally reduced, thereby reducing the unnecessary energy consumption of the motor on the new energy vehicle and improving the dynamic property and the economical efficiency of the vehicle.
Drawings
Fig. 1 is a flow chart of a method for calibrating, testing and reducing no-load loss of a permanent magnet synchronous motor according to the invention.
Fig. 2 is a flow chart of the motor no-load torque testing method of the invention.
FIG. 3 is a flow chart of zero no-load calibration of the motor of the present invention.
FIG. 4 is a flow chart of zero torque ammeter calibration for the motor of the present invention.
Fig. 5 is a flow chart of the invention for reducing motor no-load loss.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention clearer, the technical solutions in the embodiments of the present invention are described in more detail with reference to the drawings in the embodiments of the present invention. The described embodiments are only some, but not all embodiments of the invention. The embodiments described by referring to the drawings are exemplary intended for explaining the present invention and should not be simply construed as limiting the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the invention without making creative efforts, shall fall within the protection scope of the invention.
The present invention will be described in detail with reference to the accompanying drawings.
The method for testing the no-load loss of the motor is a permanent magnet synchronous motor and comprises the following steps:
s1, motor zero calibration, including no-load torque test and motor zero calibration;
and (3) testing no-load torque: and testing to obtain control torque of the motor at each rotating speed, and using the control torque for reference torque during subsequent zero calibration of the motor. The no-load torque test in the step S1 comprises the following steps: and (3) disconnecting a three-phase connecting line between the motor and the controller, dragging the motor to rotate at a set rotating speed step by the dynamometer bench until the maximum rotating speed of the motor is reached, and measuring the torque of the motor in an idle state at the corresponding rotating speed.
Referring to fig. 2, before the dynamometer is used for dragging the motor to rotate, the three-phase line connection between the motor and the controller is disconnected, so that the controller hardware is prevented from being damaged due to overhigh counter electromotive force when the motor rotates at a high speed; setting a maximum dragging rotation speed protection threshold value and a rotation speed dragging step length of the dynamometer; starting a dynamometer and entering a rack rotating speed mode; the dynamometer drags the motor to rotate according to the set rotating speed step length, and the rotating speed reaches the set rotating speed and is stable for about 2 s; the dynamometer continues to drag the motor to rotate at a set rotating speed step length until the maximum rotating speed threshold value of the motor is reached; the dynamometer reduces the rotating speed to zero; the idle torque at each rotational speed recorded by the gantry is looked up and derived.
Calibrating the zero position of the motor: the feedback torque of the rack is measured no-load torque of the motor, three phase lines between the motor and the controller and a low-voltage wire harness of the controller are connected, the controller is provided with a low voltage of 12V and a high-voltage rated voltage, a host computer of the controller selects a current mode, the dynamometer drags the motor to rotate to a set rotating speed, the measured no-load torque is used as a reference, d-axis current is given, and the torque measured by the rack is more than 90% of the no-load torque by adjusting an initial zero value under the condition that the flux weakening allowance of the motor is sufficient.
After the calibration under one rotating speed is finished, the dynamometer continues to drag the motor to rotate by the set rotating speed step length, and the steps are repeated until the rotating speed of the motor is the maximum rotating speed, so that the torque of the motor measured by the dynamometer under the zero position of the motor in the full rotating speed range is the no-load torque.
Calibrating the zero position of the motor to the no-load torque, and calibrating the zero position of the motor by taking the no-load torque of the motor measured in the single-motor state in the step S1 as a reference value, so that the zero position of the motor is accurate and error-free, and the zero position is not accurate to be an excessive current component in the no-load state, so that the no-load loss is influenced by overlarge torque. Referring to fig. 3, the method comprises the following steps:
the first step is as follows: three phase lines between the motor and the controller, a related sensor and a power analyzer are connected, and the normal connection of a wire harness between the motor and the controller is ensured; the controller is provided with low voltage (generally 12V) and corresponding control software in a flash mode, and an upper computer is used for checking whether the communication of the controller is normal or not and whether the motor and each motor body and control parameter of the controller are correct or not. If the problem is normal, the next step is carried out, otherwise, the problem needs to be checked and solved and then the operation is continued.
The second step: the bench is provided with a dynamometer maximum dragging rotating speed protection threshold value, a rotating speed dragging step length, rated voltage on a controller, the dynamometer is started, the bench enters a bench rotating speed mode, and the bench is in a free state (the rotating speed of the motor is not controlled to be zero by the bench, and the motor can rotate freely).
The third step: when the original motor zero value in the upper computer is cleared, the upper computer is used for giving d-axis current (the current is determined according to the actual condition) when the motor is in a static state, the upper computer can read the motor zero value, and the initial zero value of the motor at the data position needs to be continuously adjusted according to the rotating speed.
The fourth step: under the condition of ensuring that the flux weakening voltage margin of the motor is sufficient (generally about 5% of the bus voltage of the motor, the value is taken according to the actual algorithm requirement), the power machine drags the motor to rotate at a set rotating speed step length, when the rotating speed reaches a set rotating speed and is stable for about 2s, the feedback torque value of the rack can be read, the electric no-load torque data measured before the opening can be read, and the zero value is adjusted until the no-load torque is similar under the corresponding rotating speed.
The fifth step: and the dynamometer continues to drag the motor to rotate according to the set rotating speed step length, the fourth step is repeated to adjust the zero value until the maximum rotating speed threshold value of the motor, at the moment, an accurate zero value is obtained, and the rotating speed of the dynamometer is reduced to zero.
S2, calibrating a zero-torque ammeter: the dynamometer controls the rotation speed of the motor, the upper computer of the controller selects a current control mode, and zero-torque ammeter calibration is carried out at a corresponding rotation speed according to a calibrated zero position of the motor;
step S2, zero-torque ammeter calibration is carried out, wherein on the basis of completion of zero calibration of the motor, a dynamometer bench drags the motor to rotate to a set rotating speed, a controller upper computer selects a current mode, under the condition that flux weakening allowance of the motor is sufficient, the d-axis current and the q-axis current are calibrated to enable the torque of the bench fed back by the motor to fluctuate around zero, and corresponding rotating speed, d-axis current and q-axis current are recorded; and after the calibration is finished under one rotating speed, the dynamometer continues to drag the motor to rotate by a set rotating speed step length, the steps are repeated until the rotating speed of the motor is the maximum rotating speed, and the current data of the corresponding rotating speed, the d axis and the q axis are summarized.
Namely, the zero-torque ammeter calibration keeps the initial states of the motor and the rack on the basis of the zero position of the motor obtained by the calibration in the step S1, and performs the ammeter calibration at the time of zero torque at the corresponding rotating speed, so that the feedback torque of the rack can be zero when the controller sends a zero-torque command. Referring to fig. 4, the stage apparatus state is maintained in accordance with the above-described steps, which will not be described here. Under the condition of ensuring that the flux weakening voltage margin of the motor is sufficient (given the d current in the opposite direction, the voltage margin is generally about 5% of the bus voltage of the motor, and the value is taken according to the actual algorithm requirement), the dynamometer drags the motor to rotate to the set rotating speed by the set rotating speed step length, and the bench feedback torque is a negative value. And selecting a current mode in the calibration upper computer, sending d-axis and q-axis current commands according to the actual torque, enabling the feedback torque of the rack to be zero, recording the given d-axis and q-axis currents and the rotating speed, and finishing the calibration work at the rotating speed. And the step length of the rotating speed of the dynamometer continuously drags the motor to rotate to a set rotating speed, the calibration steps are repeated until the motor reaches the maximum rotating speed, and the recorded rotating speed, d-axis current set values and q-axis current set values are summarized.
S3, carrying out no-load loss test: the dynamometer controls the rotating speed of the motor, the upper computer of the controller selects a torque control mode, the given motor torque command is zero, no-load loss test is carried out, the bench records test data, and a no-load loss value is calculated.
And S3, testing the air load loss, wherein after the torque command of the given motor is zero, the dynamometer drags the motor to rotate at a set rotating speed step length, and the rack records the rotating speed of the motor, the torque of the motor, the voltage of a bus and the current of the bus when the torque range is observed to be about zero. Namely: and selecting a torque mode in the calibration upper computer or the bench upper computer, sending a zero torque command, dragging the motor to rotate to a set rotating speed by the dynamometer at a set rotating speed step length, and observing the bench feedback torque after the bench is stabilized for 2 s. And (4) continuously dragging the motor to rotate to a set rotating speed by the rotating speed step length of the dynamometer, repeating the calibration steps until the motor reaches the maximum rotating speed, and summarizing the recorded rotating speed, torque, bus voltage and bus current value.
And (3) calculating according to the data recorded by the rack to obtain the no-load loss of the motor:
motor speed x motor torque/9550 = motor mechanical power;
bus voltage x bus current = electrical power;
motor no-load loss = motor mechanical power + electrical power.
According to the calculation method, two main influence factors of the no-load loss of the motor can be seen: motor torque and bus current. Under the condition that the rotating speed of the motor is constant, the larger the output torque of the motor is, the larger the bus current is, and the larger the no-load loss of the motor is.
And S4, analyzing the measured no-load loss data, and performing motor zero calibration and no-load ammeter calibration according to specific data expression and input no-load loss indexes to reduce no-load loss.
And S4, reducing the no-load loss of the motor through calibration, and analyzing the measured no-load loss data: and (3) evaluating whether the test result meets the requirements according to the no-load loss standard input by a client when the motor torque, the motor power, the bus current and the bus power at different motor rotating speeds, and if the test result does not meet the requirements, carrying out zero calibration and no-load ammeter calibration on the motor from two aspects of reducing the actual torque of the motor during a zero torque command and reducing the bus current so as to reduce the no-load loss. Namely: and (4) observing a curve of the motor power and the bus power according to the no-load loss data obtained by the test in the step (S3), analyzing the performance of the no-load loss in a full rotating speed range, evaluating whether the actual torque (whether the torque is about zero) and the bus power (whether the numerical value is large and the trend is not smooth) of the motor are abnormal, and further performing reduction measures.
The first measure is that the process of reducing no-load loss through motor zero calibration is as follows: the dynamometer is started to drag the motor to rotate, the zero position of the motor is readjusted by referring to the measured zero-load torque, so that the motor is accurate, the error is reduced, the current component and extra torque on a d axis or a q axis caused by the zero position error are avoided, and the zero-load loss is reduced in the aspect of motor torque.
The second measure is that the process of reducing the no-load loss through the calibration of the no-load ammeter is as follows: and observing the real-time flux weakening voltage margin, firstly reducing d-axis current as much as possible under the condition of ensuring that the flux weakening voltage margin is sufficient, adjusting q-axis current and observing whether the torque of the motor is zero or not, and avoiding excessive extra current loss, thereby achieving the purpose of reducing the direct current of the bus and further reducing the no-load loss of the motor.
Claims (9)
1. The method for testing the no-load loss of the motor is characterized by comprising the following steps of:
s1, motor zero calibration, including no-load torque test and motor zero calibration;
s2, calibrating a zero-torque ammeter: the dynamometer controls the rotating speed of the motor, the upper computer of the controller selects a current control mode, and zero-torque ammeter calibration is carried out at the corresponding rotating speed according to the calibrated zero position of the motor;
s3, carrying out no-load loss test: the dynamometer controls the rotation speed of the motor, the upper computer of the controller selects a torque control mode, the given motor torque command is zero, no-load loss test is carried out, the bench records test data, and a no-load loss value is calculated;
and S4, analyzing the measured no-load loss data, and performing motor zero calibration and no-load ammeter calibration according to specific data expression and input no-load loss indexes to reduce no-load loss.
2. The method for testing the no-load loss of the motor according to claim 1, wherein the no-load torque test in the step S1 comprises: and (3) disconnecting a three-phase connecting line between the motor and the controller, dragging the motor to rotate at a set rotating speed step by the dynamometer bench until the maximum rotating speed of the motor is reached, and measuring the torque of the motor in an idle state at the corresponding rotating speed.
3. The method for testing the no-load loss of the motor according to claim 1, wherein the motor zero calibration in the step S1 comprises:
the method comprises the steps that the bench feedback torque is measured motor no-load torque, three-phase lines between a motor and a controller low-voltage wiring harness are connected, 12V low voltage and high-voltage rated voltage are arranged on the controller, a current mode is selected by an upper computer of the controller, a dynamometer drags the motor to rotate to a set rotating speed, the measured no-load torque is used as reference, d-axis current is given, and the torque measured by the bench in the current state is more than 90% of the no-load torque by adjusting an initial zero value under the condition that the flux weakening allowance of the motor is sufficient;
after the calibration under one rotating speed is finished, the dynamometer continues to drag the motor to rotate by the set rotating speed step length, and the steps are repeated until the rotating speed of the motor is the maximum rotating speed, so that the torque of the motor measured by the dynamometer under the zero position of the motor in the full rotating speed range is the no-load torque.
4. The method for testing the no-load loss of the motor according to claim 1, wherein the zero-torque ammeter calibration in the step S2 is that a dynamometer bench drags the motor to rotate to a set rotating speed on the basis of completing the zero calibration of the motor, an upper computer of a controller selects a current mode, under the condition that the flux weakening allowance of the motor is sufficient, the currents of a d axis and a q axis are calibrated to enable the torque of the bench fed back by the motor to fluctuate around zero, and the corresponding rotating speed, the currents of the d axis and the q axis are recorded;
and after the calibration is finished under one rotating speed, the dynamometer continues to drag the motor to rotate by a set rotating speed step length, the steps are repeated until the rotating speed of the motor is the maximum rotating speed, and the current data of the corresponding rotating speed, the d axis and the q axis are summarized.
5. The method for testing the no-load loss of the motor according to claim 1, wherein in the step S3, the no-load loss is tested, after the given motor torque command is zero, the dynamometer drags the motor to rotate in a set rotating speed step, and the rack records the motor rotating speed, the motor torque, the bus voltage and the bus current when the observation torque range is about zero;
and (3) calculating according to the data recorded by the rack to obtain the no-load loss of the motor:
motor speed x motor torque/9550 = motor mechanical power;
bus voltage x bus current = electrical power;
motor no-load loss = motor mechanical power + electrical power.
6. The method for testing the no-load loss of the motor according to claim 1, wherein the step S4 is to reduce the no-load loss of the motor by calibration, and analyze the measured no-load loss data: and (3) evaluating whether the test result meets the requirements according to the no-load loss standard input by a client when the motor torque, the motor power, the bus current and the bus power at different motor rotating speeds, and if the test result does not meet the requirements, carrying out zero calibration and no-load ammeter calibration on the motor from two aspects of reducing the actual torque of the motor during a zero torque command and reducing the bus current so as to reduce the no-load loss.
7. The method for testing the no-load loss of the motor according to claim 6, wherein the process of reducing the no-load loss through the zero calibration of the motor comprises the following steps: the dynamometer is started to drag the motor to rotate, the zero position of the motor is readjusted by referring to the measured no-load torque, so that the motor is accurate, the error is reduced, current components and extra torque are avoided from being generated on a d axis or a q axis due to the zero position error, and no-load loss is reduced in the aspect of motor torque.
8. The method for testing the no-load loss of the motor according to claim 6, wherein the process of reducing the no-load loss through the calibration of the no-load ammeter comprises the following steps: and observing the real-time flux weakening voltage margin, firstly reducing d-axis current as much as possible under the condition of ensuring that the flux weakening voltage margin is sufficient, adjusting q-axis current and observing whether the torque of the motor is zero or not, and avoiding excessive extra current loss, thereby achieving the purpose of reducing the direct current of the bus and further reducing the no-load loss of the motor.
9. The method for testing the no-load loss of the motor according to any one of claims 1 to 8, wherein the motor is a permanent magnet synchronous motor.
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