WO2022016691A1 - 一种电机功率密度测试装置及方法 - Google Patents

一种电机功率密度测试装置及方法 Download PDF

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WO2022016691A1
WO2022016691A1 PCT/CN2020/115036 CN2020115036W WO2022016691A1 WO 2022016691 A1 WO2022016691 A1 WO 2022016691A1 CN 2020115036 W CN2020115036 W CN 2020115036W WO 2022016691 A1 WO2022016691 A1 WO 2022016691A1
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motor
power
load
test
speed sensor
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French (fr)
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张强
马英
田莹
张坤
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Shandong University of Science and Technology
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Shandong University of Science and Technology
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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
    • G01R31/343—Testing dynamo-electric machines in operation
    • 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
    • G01L3/26—Devices for measuring efficiency, i.e. the ratio of power output to power input
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R21/00—Arrangements for measuring electric power or power factor
    • G01R21/001—Measuring real or reactive component; Measuring apparent energy
    • G01R21/002—Measuring real component
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R21/00—Arrangements for measuring electric power or power factor
    • G01R21/06—Arrangements for measuring electric power or power factor by measuring current and voltage

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  • the invention relates to the technical field of motor testing, in particular to a device and method for testing the power density of a motor.
  • the test methods for the output power of the motor mainly include the direct measurement method and the energy consumption.
  • the analysis method and the direct measurement method connect the test motor and the accompanying motor or dynamometer through a coupling, and the dynamometer can directly obtain the output power of the motor.
  • the output power is measured by the torque speed sensor, and the power density of the motor is further calculated according to the output power.
  • the measurement results are intuitive and accurate, but the original installation method and space layout of the motor need to be changed, and the motor needs to be disassembled on the test bench for installation and testing.
  • Limitations: The energy consumption analysis method needs to measure various parameters of the motor during operation, including voltage, current, frequency, speed and temperature, etc., analyze and calculate various losses, and calculate the output power of the motor according to the energy consumption analysis.
  • the output torque and power density of the motor are calculated.
  • the energy consumption analysis method can monitor the power density change of the motor in real time without changing the spatial arrangement of the test motor. However, the size of the stray loss in the energy consumption analysis method is related to the design and manufacture of the motor. Process, capacity and many other factors are related, and the dispersion is very large, which affects the accuracy of the calculation results.
  • the present invention provides a motor power density testing device and method, which is beneficial to intuitively understand the working performance of the motor, analyze and adjust the working state of the motor, and improve the working efficiency of the motor.
  • the present invention provides a motor power density test device, including a comprehensive console, a test load, a motor to be tested, a support base, a torque speed sensor, an adjustable lift table, a photoelectric speed sensor and a resistance temperature sensor.
  • the integrated console includes a power quality regulator, a voltage regulator, a frequency converter, a power quality detector, an input device, a display, a converter, a rectifier and a computer; the input interface of the power quality regulator is connected to the power grid, and the output interface is connected to the power grid.
  • the input interface of the voltage regulator is connected, the output interface of the voltage regulator is respectively connected with the input interface of the frequency converter and one end of the rectifier, the other end of the rectifier is connected with the test load through a wire, and the output interface of the frequency converter is connected with the electrical energy
  • the quality detector is connected, the output interface of the power quality detector is respectively connected with the motor to be tested and the computer, the input device is connected with the computer input interface, the display is connected with the computer output interface, and the support base is connected with the integrated console ,
  • the adjustable lifting platform is fixedly connected, the motor to be tested is fixed with the upper end face of the adjustable lifting platform by bolts, the bottom end of the test load and the support base are connected by a guide rail, and the direction of the guide rail is consistent with the direction of the rotor axis when the motor to be tested is installed.
  • the torque The rotational speed sensor fixedly connects the output shaft of the motor to be measured and the input shaft of the load, and fixes the load by tightening bolts.
  • the photoelectric rotational speed sensor is fixed on the motor shell of the output end of the motor to be measured, and the resistance temperature sensor is fixedly embedded. Between the bottom slot of the motor stator and the iron core, the converter is connected to the computer through a wire, and the photoelectric speed sensor, the resistance temperature sensor and the torque speed sensor transmit the monitoring data to the converter in real time through the wire.
  • a method for testing the power density of a motor implemented based on the aforementioned device for testing the power density of a motor, includes the following steps:
  • Step 1 Before the test, disassemble the test motor, measure various parameters of the motor, install the resistance temperature sensor in the motor, and then fix the motor on the test bench;
  • the parameters of the motor include the motor stator winding resistance at the initial temperature value R, initial temperature of stator winding ⁇ 1 , number of motor pole pairs Q, stator outer diameter D and stator length L, and carry out no-load experiment;
  • Step 2 The tester inputs the measurement parameters to the computer through the input device
  • Step 3 Adjust the voltage regulator and inverter, change the voltage and frequency of the motor to be tested, and the power quality detector monitors various parameters of the AC output of the inverter in real time, including output voltage, output current, output frequency and power factor, photoelectric speed sensor
  • the actual speed of the motor is monitored in real time, and the temperature of the stator is monitored by the temperature sensor in real time. All monitoring data are transmitted to the computer.
  • the core loss power and wind power consumption are obtained from the no-load experiment, and the test motor is connected to the test load. By changing the torque of the test load , carry out the load experiment;
  • Step 4 When the motor to be tested is stable, the computer obtains the power density under different load torques according to the energy consumption analysis method, the torque and speed sensor monitors the output power of the motor, and the measurement result of the torque and speed sensor direct measurement method is used as the accurate value , analyze the error of the energy consumption method, and make corrections by adjusting the proportion of the stray loss power to the total loss power, so that the mean square error of the revised two sets of data is minimized, and the revised energy consumption analysis method is stored;
  • Step 5 When the test motor is out of the actual work of the test bench, according to the energy consumption analysis method, the motor power density change is monitored in real time by monitoring the motor input voltage, input current, input frequency, the actual speed of the motor and the temperature of the stator.
  • the present invention proposes a motor power density testing device and method.
  • the direct measurement method is used to measure the motor power density, which is intuitive and accurate, but cannot monitor the motor power density change in real time.
  • the energy consumption analysis method can monitor the motor power density change in real time, but the calculation results are not The accuracy is affected by multiple factors.
  • Two measurement methods are used to test the motor power density on the motor test bench at the same time.
  • the measurement result of the direct measurement method is used as the accurate value to analyze the error between the energy consumption analysis method and the accurate value.
  • the ratio of the dissipated power to the total power loss makes the mean square error of the two groups of values measured by the direct measurement method and the energy consumption analysis method to be the smallest, thereby improving the accuracy of the measurement results of the energy consumption analysis method.
  • the algorithm only needs to monitor the voltage, frequency, current, speed and temperature changes of the motor during actual operation, and then the motor power density can be further calculated to realize real-time monitoring.
  • This measurement method avoids the complexity of real-time torque measurement and avoids adding sensors.
  • the required measurement parameters are simple and easy to implement, and the real-time monitoring of the motor power density can be quickly realized, and the measurement accuracy can be met. Rising test, stall temperature measurement, torque, efficiency, power factor measurement, life test, etc.
  • FIG. 1 is a schematic diagram of a power density testing device of the present invention
  • 1-test load 2-torque speed sensor; 3-photoelectric speed sensor; 4-motor to be tested; 5-integrated console; 6-support base; 7-adjustable lifting platform;
  • Fig. 2 is the schematic diagram of the embedded position of the temperature sensor of the present invention.
  • 8-resistance temperature sensor 8-resistance temperature sensor
  • FIG. 3 is a schematic diagram of the input and output of the integrated console of the present invention.
  • Fig. 5 is the schematic diagram of solving the wind power consumption P FW of the present invention.
  • FIG. 6 is a flow chart of the power density testing method of the present invention.
  • the present invention provides a motor power density testing device, as shown in FIG. 1 and FIG. 2 , including an integrated console 5, a test load 1, a motor to be tested 4, a support base 6, a torque and rotational speed sensor 2, an adjustable Lifting platform 7 , photoelectric rotational speed sensor 3 and resistance temperature sensor 8 .
  • the integrated console 5, as shown in FIG. 3, includes a power quality regulator, a voltage regulator, a frequency converter, a power quality detector, an input device, a display, a converter, a rectifier and a computer; the power quality regulator input interface connected to the power grid, the output interface is connected to the input interface of the voltage regulator, the output interface of the voltage regulator is respectively connected to the input interface of the frequency converter and one end of the rectifier, and the other end of the rectifier is connected to the test load 1 through a wire,
  • the output interface of the frequency converter is connected with the power quality detector, the output interface of the power quality detector is respectively connected with the motor to be tested 4 and the computer, the input device is connected with the computer input interface, and the display is connected with the computer output interface
  • the supporting base 6 is fixedly connected with the integrated console 5 and the adjustable lifting platform 7, the motor 4 to be tested is fixed with the upper end face of the adjustable lifting platform 7 by bolts, and the bottom end of the test load 1 is connected with the supporting base 6 through the guide rails.
  • the direction is the same as the direction of the rotor axis when the motor 4 to be tested is installed.
  • the torque and speed sensor 2 connects the output shaft of the motor 4 to be tested and the input shaft of the load, and the load is fixed by tightening bolts.
  • the photoelectric speed sensor 3 is fixed On the motor shell at the output end of the motor 4 to be tested, the resistance temperature sensor 8 is fixedly embedded between the bottom slot of the motor stator and the iron core, the converter is connected to the computer through wires, the photoelectric speed sensor 3, the resistance temperature sensor 8 and the torque speed sensor 2 transmit various monitoring data to the converter in real time through wires.
  • YE2-90L-4 type 1.5kw three-phase asynchronous motor is selected as the motor 4 to be tested
  • CZF-1.2 flanged magnetic powder brake is selected as the test load 4 to ensure that the rated torque of the test load is similar to the rated torque of the motor to be tested.
  • a rectifier is used to convert the AC power to DC power.
  • the input end of the power quality regulator is connected to the power grid, and the output end is connected to the test system to ensure that the power quality of the test system is stable and good.
  • the voltage regulator and inverter are manually controlled by the tester, and the input voltage and frequency of the motor to be tested are adjusted according to the test needs.
  • the voltage regulator uses TSGC2-6KVA type contact three-phase auto-coupling voltage regulator, the voltage regulator realizes 0-430V voltage regulation, the selection of the voltage regulator needs to ensure that the voltage regulation range meets the voltage requirements of the test motor, and the power quality detector is real-time Monitor and input the electrical parameters of the motor to be tested, and transmit the monitored electrical parameters to the computer in real time, so that the computer can grasp the electrical parameters of the motor to be tested in real time, and various sensors transmit the monitoring data to the computer through the converter in real time.
  • the converter selects RS485 type signal converter. As shown in Figure 4, the sensors that transmit data to the converter specifically include the photoelectric speed sensor 3, the resistance temperature sensor 8 and the torque speed sensor 2.
  • Torque speed sensor 2 when the load experiment is performed, the motor to be tested is connected to the test load 1 through the torque speed sensor 2, the output power of the motor to be tested can be calculated through the torque speed sensor, and the input voltage of the brake can be controlled by controlling the brake input voltage. Adjust the torque of the magnetic powder brake to change the load of the motor to be tested.
  • a method for testing the power density of a motor implemented based on the aforementioned device for testing the power density of a motor, as shown in FIG. 6 , includes the following steps:
  • Step 1 Before the test, disassemble the test motor, measure various parameters of the motor, install the resistance temperature sensor 8 in the motor, and then fix the motor on the test bench;
  • the parameters of the motor include the stator winding of the motor at the initial temperature Resistance value R, initial temperature of stator winding ⁇ 1 , number of motor pole pairs Q, stator outer diameter D and stator length L, and carry out no-load experiment;
  • the total volume of the conductive and magnetic conductive materials of the motor is calculated:
  • V ⁇ (D/2) 2 ⁇ L
  • the inspector adjusts the voltage regulator and the frequency converter by controlling the integrated console 5, so that the voltage input to the test motor is the rated voltage and the frequency is the rated frequency.
  • the instrument monitors the input electrical parameters of the motor to be measured in real time, and transmits the monitored electrical parameters to the computer in real time.
  • the electrical parameters include three-phase voltage RMS U 0 , three-phase current RMS I 0 , frequency f and power factor Etc., the data obtained by the computer can calculate the total loss power of the motor no-load stable operation, that is, the no-load input power of the motor
  • the total no-load power loss of the motor includes the stator loss power P CU1 , the iron core loss power P FE and the wind wear power P FW . It can be considered that the no-load input power P 0 minus the stator loss power P CU1 at the no-load experimental temperature is a constant power,
  • the power loss of the stator is related to the stator winding resistance and current.
  • the stator winding resistance changes with temperature. The temperature change of the stator is monitored in real time by the temperature sensor, and the maximum temperature ⁇ 0 of the stator is measured according to the load experiment, so as to obtain the stator winding resistance value at the corresponding temperature.
  • R 0 R[(235+ ⁇ 0 )/(235+ ⁇ 1 )]
  • the effective value of the three-phase current I 0 can be used to obtain the stator power loss
  • the tester keeps the output frequency unchanged by adjusting the voltage regulator, and sequentially reduces the voltage from 50% of the rated voltage U N to the lowest voltage of the motor, that is, the motor does not run the critical voltage, and no-load experiments are carried out each time the voltage is reduced, and the computer calculation is different.
  • no-load voltage U 0 the motor iron core loss power and wind power consumption and P′ 0 , as well as the corresponding power and the value of (U 0 /U N ) 2 under P′ 0 , and store the calculated data, when the voltage is reduced to Stop the no-load experiment at the lowest voltage of the motor, as shown in Figure 5.
  • the computer draws a curve diagram of P' 0 - (U 0 /U N ) 2 by the method of plotting according to the calculation results.
  • This curve is approximately a straight line.
  • the curve is fitted into a straight line, and the corresponding value of the fitted straight line is calculated when (U 0 /U N ) 2 is zero, which is the wind wear power P FW , because the sum of the loss power of the motor iron core and the wind wear is the constant loss power, so calculate get core power loss
  • Step 2 The tester inputs the measurement parameters to the computer through the input device
  • Step 3 Adjust the voltage regulator and the inverter, change the voltage and frequency of the motor 4 to be tested, and the power quality detector monitors various parameters of the AC output of the inverter in real time, including output voltage, output current, output frequency and power factor, and photoelectric speed. Sensor 3 monitors the actual speed of the motor in real time, and the temperature sensor monitors the temperature of the stator in real time. All monitoring data are transmitted to the computer. The no-load experiment obtains the core loss power and wind power consumption, and the test motor is connected to the test load 1. By changing the test load 1 torque, carry out the load test;
  • the computer torque and speed sensor 2 can be calculated.
  • the real-time output power of the motor to be tested is obtained.
  • the power quality detector monitors the input electrical parameters of the motor to be tested in real time, and transmits the monitored electrical parameters to the computer in real time.
  • the electrical parameters include three-phase voltage RMS U, three-phase Current effective value I, frequency f and power factor etc., by adjusting the voltage regulator to change the torque of the test load 1 for many times, calculate the input power of the motor 4 to be tested under different loads
  • the computer can obtain the synchronous speed of the motor
  • the computer can obtain the motor slip
  • the computer can obtain the slip when converted to the specified temperature ⁇ S
  • the computer calculates the rotor power loss
  • P CU2 (P 1 -P CU1 -P FE ) ⁇ Ss
  • the size of the motor stray loss Ps is related to many factors such as the design, manufacturing process, and capacity of the motor. According to the empirical formula, the motor stray loss is related to the motor rated power P N and the motor rated current I N.
  • the motor stray loss power empirical formula is
  • the computer can obtain the output power of the motor under the load torque
  • the computer monitors the actual output power of the motor in real time through the torque and speed sensor 2, and retains the average value P' of the motor output power calculated by the torque and speed sensor 2 within a certain time period under different loads after the motor is stabilized and the actual motor output power derived from the computer formula. Average output power P.
  • the computer corrects the ratio of the stray power loss Ps to the total power loss in the energy consumption analysis method. Correction with coefficient C
  • Step 4 When the motor 4 to be tested is stable, the computer obtains the power density under different load torques according to the energy consumption analysis method, the torque and speed sensor 2 monitors the motor output power, and the torque and speed sensor 2 directly measures the results. As an accurate value, analyze the error of the energy consumption method, and make corrections by adjusting the proportion of stray loss power to the total loss power, so as to minimize the mean square error of the two groups of data after correction, and store the corrected energy consumption analysis method;
  • Step 5 When the test motor is out of the actual work of the test bench, according to the energy consumption analysis method, the motor power density change is monitored in real time by monitoring the motor input voltage, input current, input frequency, the actual speed of the motor and the temperature of the stator.
  • the tester removes the motor 4 to be tested from the test bench.
  • the motor When the motor is actually working, it is only necessary to monitor the motor input voltage, input frequency, input current, stator temperature and the actual speed of the motor in real time to monitor the change of motor power density in real time.
  • the required monitoring variables are simple and easy to implement.

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Abstract

一种电机功率密度测试装置及方法，涉及电机测试技术领域，包括综合控制台（5）、测试负载（1）、待测电机（4）、支撑底座（6）、转矩转速传感器（2）、可调节升降台（7）、光电转速传感器（3）与电阻式温度传感器（8），根据负载关系协调设备运行速度，始终保持不过载稳定运行，在发生过载时自动停机，实现过载保护，保证了设备运行安全，避免负载过大设备损坏，并针对各种存在安全隐患的情况快速做出反应，以便满足传输要求，提高运输效率，提升运行安全系数，降低人工参与程度，减少运营成本，实现设备更加安全可靠运行。

Description

一种电机功率密度测试装置及方法 技术领域
本发明涉及电机测试技术领域，尤其涉及一种电机功率密度测试装置及方法。
背景技术
目前，功率密度已成电机性能中的一个重要指标，实时监测电机功率密度有利于直观了解电机工作性能，便于分析调整电机工作状态以提高电机工作效率，电机功率密度和电机输出功率与电机的导电、导磁材料的体积的有关，实际测量中电能质量不仅会影响测量精度，还会影响用电设备的稳定性与使用寿命，现阶段，电机输出功率的测试方法主要有直测法与能耗分析法，直测法将测试电机与陪测电机或测功机通过联轴器连接，测功机可直接得到电机输出功率，陪测电机与测试电机间需通过转矩转速传感器同轴连接，通过转矩转速传感器测量输出功率，根据输出功率进一步计算得到电机功率密度，测量结果直观准确，但需要改变电机原有安装方式与空间布置，需要将电机拆卸在测试台上安装测试，存在很大局限性；能耗分析法需要测量电动机运行时的各项参数，包括电压、电流、频率、转速及温度等，分析计算各项损耗，根据能耗分析计算得到电机的输出功率，由输出功率进一步计算得到电机输出转矩与功率密度，能耗分析法能够在不改变测试电机空间布置的前提下实时监测电机的功率密度变化，但能耗分析法中杂散损耗的大小与电机的设计、制造工艺、容量等许多因素有关，并且分散性很大，影响计算结果的准确性。
发明内容
针对现有技术的不足，本发明提供一种电机功率密度测试装置及方法，有利于直观了解电机工作性能，便于分析调整电机工作状态，提高电机工作效率。
本发明所采取的技术方案是：
一方面，本发明提供一种电机功率密度测试装置，包括综合控制台、测试负载、待测电机、支撑底座、转矩转速传感器、可调节升降台、光电转速传感器与电阻式温度传感器。
所述综合控制台包括电能质量调节器、调压器、变频器、电能质量检测仪、输入设备、显示器、转换器、整流器以及计算机；所述电能质量调节器输入接口接入电网，输出接口与所述调压器输入接口相连接，调压器输出接口分别与所述变频器输入接口以及所述整流器一端相连，整流器另一端通过导线与所述测试负载相连，变频器输出接口与所述电能质量检测仪相连接，电能质量检测仪输出接口分别与待测电机以及计算机相连，所述输入设备与计算机输入接口相连接，所述显示器与计算机输出接口相连接，所述支撑底座与综合控制台、可 调节升降台固定连接，待测电机通过螺栓与可调节升降台上端面固定，测试负载底端与支撑底座通过导轨连接，导轨方向与待测电机安装时转子轴线方向一致，所述转矩转速传感器将待测电机输出轴与负载输入轴固定连接，并通过紧固螺栓将负载固定，所述光电转速传感器固定在待测电机输出端电机壳上，所述电阻式温度传感器固定埋置于电机定子底槽与铁芯之间，转换器通过导线与计算机相连，光电转速传感器、电阻式温度传感器与转矩转速传感器通过导线将监测数据实时传递给转换器。
另一方面，一种电机功率密度测试方法，基于前述一种电机功率密度测试装置实现，包括以下步骤：
步骤1：测试前将测试电机拆卸，测量电机各项参数，并将电阻式温度传感器装在电机内，再将电机固定安装在测试台；所述电机各项参数包括初始温度下电机定子绕组电阻值R、定子绕组初始温度θ 1、电机极对数Q、定子外径直径D与定子长度L，并进行空载实验；
步骤2：测试人员通过输入设备将测量参数输入至计算机；
步骤3：调节调压器与变频器，改变待测电机电压与频率，电能质量检测仪实时监测变频器输出交流电的各项参数，包括输出电压、输出电流、输出频率与功率因数，光电转速传感器实时监测电机实际转速，温度传感器实时监测定子温度，各项监测数据均传输给计算机，空载实验得到铁芯损耗功率与风摩耗功率，将测试电机与测试负载连接，通过改变测试负载的转矩，进行负载实验；
步骤4：当待测电机稳定后，计算机根据能耗分析法，得到不同负载转矩下的功率密度，转矩转速传感器对电机输出功率监测，以转矩转速传感器直测法测量结果作为准确值，分析能耗法误差大小，通过调整杂散损耗功率所占总损耗功率的比例进行修正，使修正后的两组数据均方差最小，将该修正后的能耗分析法储存；
步骤5：当测试电机脱离测试台实际工作时，根据该能耗分析法通过监测电机输入电压、输入电流、输入频率、电机实际转速与定子温度，从而实时监测电机功率密度变化。
采用上述技术方案所产生的有益效果在于：
本发明提出一种电机功率密度测试装置及方法，使用直测法测量电机功率密度直观准确，但不能实时监测电机功率密度变化，能耗分析法可实时监测电机功率密度变化，但其计算结果的准确性受多因素共同影响，在电机测试台上同时使用两种测量方法对电机功率密度进行测试，将直测法测量结果作为准确值，分析能耗分析法与准确值的误差，通过修正杂散损耗功率占总损耗功率的比值，使得直测法与能耗分析法所测得两组数值均方差最小，从而提高能耗分析法测量结果的准确性，使用该电机修正后的能耗分析算法，仅需监测该电机实际工 作时电压、频率、电流、转速及温度变化，就可进一步计算得到电机功率密度，实现实时监测，该测量方法避免转矩实时测量的复杂性，避免因添加传感器而改动电机原有布置，所需测量参数简单易实现，能够快速实现电机功率密度的实时监测，且满足一定测量精度，测量装置能够对多种类型电机功率密度进行测试，根据需要可进行电机温升实验、堵转温度测定、转矩、效率、功率因素测定、寿命实验等。
附图说明
图1为本发明功率密度测试装置示意图；
其中，1-测试负载；2-转矩转速传感器；3-光电转速传感器；4-待测电机；5-综合控制台；6-支撑底座；7-可调节升降台；
图2为本发明温度传感器埋置位置示意图；
其中，8-电阻式温度传感器；
图3为本发明综合控制台输入输出示意图；
图4为本发明数据流向示意图；
图5为本发明风摩耗功率P FW求解示意图；
图6为本发明功率密度测试方法流程图。
具体实施方式
下面结合附图对本发明具体实施方式加以详细的说明。
一方面，本发明提供一种电机功率密度测试装置，如图1，图2所示，包括综合控制台5、测试负载1、待测电机4、支撑底座6、转矩转速传感器2、可调节升降台7、光电转速传感器3与电阻式温度传感器8。
所述综合控制台5如图3所示，包括电能质量调节器、调压器、变频器、电能质量检测仪、输入设备、显示器、转换器、整流器以及计算机；所述电能质量调节器输入接口接入电网，输出接口与所述调压器输入接口相连接，调压器输出接口分别与所述变频器输入接口以及所述整流器一端相连，整流器另一端通过导线与所述测试负载1相连，变频器输出接口与所述电能质量检测仪相连接，电能质量检测仪输出接口分别与待测电机4以及计算机相连，所述输入设备与计算机输入接口相连接，所述显示器与计算机输出接口相连接，所述支撑底座6与综合控制台5、可调节升降台7固定连接，待测电机4通过螺栓与可调节升降台7上端面固定，测试负载1底端与支撑底座6通过导轨连接，导轨方向与待测电机4安装时转子轴线方向一致，所述转矩转速传感器2将待测电机4输出轴与负载输入轴固定连接，并通过紧固螺栓将负载固定，所述光电转速传感器3固定在待测电机4输出端电机壳上，所述电阻式温度传感器8固定埋置于电机定子底槽与铁芯之间，转换器通过导线与计算机相连，光电 转速传感器3、电阻式温度传感器8与转矩转速传感器2通过导线将各项监测数据实时传递给转换器。
本实施例中待测电机4选用YE2-90L-4型1.5kw三相异步电机，测试负载4选用CZF-1.2法兰式磁粉制动器，保证测试负载额定转矩与待测电机额定转矩大小相近，因为该制动器需接直流电源，故使用整流器将交流电转换为直流电。
电能质量调节器输入端连接电网，输出端接入测试系统，保证测试系统电源质量稳定良好，调压器与变频器由测试人员手动控制，根据测试需要对输入待测电机的电压、频率进行调整，调压器选用TSGC2-6KVA型接触式三相自耦调压器，该调压器实现0-430V电压调节，调压器选择需保证调压范围满足测试电机电压需求，电能质量检测仪实时监测输入待测电机的电参数，并实时将所监测的电参数传输给计算机，计算机从而实时掌握输入待测电机的各项电参数，各类传感器实时将监测数据通过转换器传输给计算机，其中转换器选用RS485型信号转换器。如图4，传递给转换器数据的传感器具体包括光电转速传感器3、电阻式温度传感器8与转矩转速传感器2，当进行空载实验时不需要连接测试负载1，故此时不安装接入转矩转速传感器2，当进行负载实验时，通过转矩转速传感器2将待测电机与测试负载1相连接，通过转矩转速传感器可计算得出待测电机输出功率，通过控制制动器输入电压，从而调节磁粉制动器的转矩，实现改变待测电机负载大小。
另一方面，一种电机功率密度测试方法，基于前述一种电机功率密度测试装置实现，如图6所示，包括以下步骤：
步骤1：测试前将测试电机拆卸，测量电机各项参数，并将电阻式温度传感器8装在电机内，再将电机固定安装在测试台；所述电机各项参数包括初始温度下电机定子绕组电阻值R、定子绕组初始温度θ 1、电机极对数Q、定子外径直径D与定子长度L，并进行空载实验；
通过初始温度下电机定子绕组电阻R、定子绕组初始温度θ 1、电机极对数Q、定子外径直径D与定子长度L，计算得到电机的导电、导磁材料的总体积：
V＝π·(D/2) 2·L
将电机组装安装到可调升降台7上，此时不连接测试负载，进行电机空载实验，通过输入设备将所测量电机定子绕组电阻R、定子绕组初始温度θ 1、电机极对数Q、定子外径直径D与定子长度L传输给计算机进行数据储存，检测人员通过控制综合控制台5调节调压器与变频器，使输入测试电机的电压为额定电压，频率为额定频率，电能质量检测仪对待测电机输入电参数实时监测，将监测的各项电参数实时传输给计算机，其中各项电参数包括三相电 压有效值U 0、三相电流有效值I 0、频率f与功率因数
Figure PCTCN2020115036-appb-000001
等，计算机根具所得数据计算得到电机空载稳定运行的总损耗功率，即电机空载输入功率
Figure PCTCN2020115036-appb-000002
电机空载总损耗功率包括定子损耗功率P CU1、铁芯损耗功率P FE与风摩耗功率P FW，可认为空载输入功率P 0减去空载实验温度下定子损耗功率P CU1为恒定功率，定子损耗功率与定子绕组电阻、电流有关，定子绕组电阻随温度发生变化，通过温度传感器实时监测定子温度变化，根据负载实验测量定子最高温度θ 0，从而得出对应温度下定子绕组电阻值
R 0＝R[(235+θ 0)/(235+θ 1)]
进一步，根据负载实验，三相电流有效值I 0可得出定子损耗功率
Figure PCTCN2020115036-appb-000003
电机铁芯损耗功率与风摩耗功率和为
P′ 0＝P FE+P FW＝P 0-P CU1
测试人员通过调节调压器保持输出频率不变，依次将电压从50％额定电压U N降至电机最低电压，即电机不运转临界电压，每次降低电压时均进行空载实验，计算机计算不同空载电压U 0下，电机铁芯损耗功率与风摩耗功率和P′ 0，以及对应功率和P′ 0下(U 0/U N) 2的数值，并将计算数据储存，当电压降低到电机最低电压时停止空载实验，如图5，计算机根据计算结果通过描点法绘制P′ 0——(U 0/U N) 2的曲线图，此曲线近似为一条直线，通过最小二乘法将曲线拟合成直线，计算(U 0/U N) 2为零时拟合直线对应数值，即为风摩耗功率P FW，因为电机铁芯与风摩耗的损耗功率和为恒定损耗功率，故计算得到铁芯损耗功率
P FE＝P 0-P CU1-P FW
步骤2：测试人员通过输入设备将测量参数输入至计算机；
步骤3：调节调压器与变频器，改变待测电机4电压与频率，电能质量检测仪实时监测变频器输出交流电的各项参数，包括输出电压、输出电流、输出频率与功率因数，光电转速传感器3实时监测电机实际转速，温度传感器实时监测定子温度，各项监测数据均传输给计算机，空载实验得到铁芯损耗功率与风摩耗功率，将测试电机与测试负载1连接，通过改变测试负载1的转矩，进行负载实验；
将电机铁芯损耗功率P FE与风摩耗功率P FW储存于计算机，将待测电机4通过转矩转速传感器2与测试负载1同轴连接，进行负载实验，计算机转矩转速传感器2可计算得出待测 电机实时输出功率，同理电能质量检测仪对待测电机输入电参数实时监测，将监测的各项电参数实时传输给计算机，其中各项电参数包括三相电压有效值U、三相电流有效值I、频率f与功率因数
Figure PCTCN2020115036-appb-000004
等，通过调整调压器多次改变测试负载1转矩，计算不同负载下待测电机4的输入功率
Figure PCTCN2020115036-appb-000005
根据电机频率f与极对数Q，计算机可得出电机同步转速
Ns＝(60·f)/Q
根据光电转速传感器3实时监测电机实际转速N，计算机可得到电机转差率
S＝(Ns-N)/Ns
根据测试电机定子温度θ T，计算机可得到换算至规定温度θ S时的转差率
Ss＝S[(235+θ s)/(235+θ T)]
进一步，计算机计算得到转子损耗功率
P CU2＝(P 1-P CU1-P FE)·Ss
电机杂散损耗Ps的大小与电机的设计、制造工艺、容量等许多因素有关，根据经验公式电机杂散损耗与电机额定功率P N，电机额定电流I N有关，电机杂散损耗功率经验公式为
Ps＝0.5％P N·(I/I N) 2
根据各项计算功率，计算机可得到该负载转矩下电机输出功率
P＝P 1-(P CU1+P CU2+P FE+P FW+Ps)
计算机通过转矩转速传感器2实时监测电机实际输出功率，保留电机稳定后不同负载下某相同时间段内，由转矩转速传感器2计算所得电机输出功率平均值P’与由计算机公式推导所得电机实际输出功率平均值P。
进一步可计算得到对应负载转矩下电机功率密度
S'＝P'/V
S＝P/V
多次通改变电机负载转矩，得到多组测量结果，计算机根据转矩转速传感器2所获得的功率作为准确值，对能耗分析法中杂散损耗功率Ps所占总损耗功率的比值通过修正系数C进行修正
Ps'＝C·0.5％P N·(I/I N) 2
作不同应负载下电机实际输出功率平均值P与计算电机输出功率平均值P′的均方差，其差值是关于修正系数C的函数，可求最小均方差对应修正系数C，记录该修正系数C，得到该电机输出功率计算式
P＝P 1-(P CU1+P CU2+P FE+P FW+Ps')
步骤4：当待测电机4稳定后，计算机根据能耗分析法，得到不同负载转矩下的功率密度，转矩转速传感器2对电机输出功率监测，以转矩转速传感器2直测法测量结果作为准确值，分析能耗法误差大小，通过调整杂散损耗功率所占总损耗功率的比例进行修正，使修正后的两组数据均方差最小，将该修正后的能耗分析法储存；
步骤5：当测试电机脱离测试台实际工作时，根据该能耗分析法通过监测电机输入电压、输入电流、输入频率、电机实际转速与定子温度，从而实时监测电机功率密度变化。测试人员将待测电机4从测试台拆下，当该电机实际工作时，只需要实时监测电机输入电压、输入频率、输入电流、定子温度与电机实际转速，就可实时监测电机功率密度变化，所需监测变量简单易实现。
最后应说明的是：以上各实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明权利要求所限定的范围。

Claims (4)

  1. 一种电机功率密度测试装置，其特征在于：包括综合控制台、测试负载、待测电机、支撑底座、转矩转速传感器、可调节升降台、光电转速传感器与电阻式温度传感器；
    所述综合控制台包括电能质量调节器、调压器、变频器、电能质量检测仪、输入设备、显示器、转换器、整流器以及计算机；所述电能质量调节器输入接口接入电网，输出接口与所述调压器输入接口相连接，调压器输出接口分别与所述变频器输入接口以及所述整流器一端相连，整流器另一端通过导线与所述测试负载相连，变频器输出接口与所述电能质量检测仪相连接，电能质量检测仪输出接口分别与待测电机以及计算机相连，所述输入设备与计算机输入接口相连接，所述显示器与计算机输出接口相连接，所述支撑底座与综合控制台、可调节升降台固定连接，待测电机通过螺栓与可调节升降台上端面固定，测试负载底端与支撑底座通过导轨连接，所述转矩转速传感器将待测电机输出轴与负载输入轴固定连接，并通过紧固螺栓将负载固定，所述光电转速传感器固定在待测电机输出端电机壳上，所述电阻式温度传感器固定埋置于电机定子底槽与铁芯之间，转换器通过导线与计算机相连，光电转速传感器、电阻式温度传感器与转矩转速传感器通过导线将监测数据实时传递给转换器。
  2. 根据权利要求1所述的一种电机功率密度测试装置，其特征在于，所述导轨的方向与待测电机安装时转子轴线方向一致。
  3. 一种电机功率密度测试方法，通过权利要求1所述一种电机功率密度测试装置实现，其特征在于，包括以下步骤：
    步骤1：测试前将测试电机拆卸，测量电机各项参数，并将电阻式温度传感器装在电机内，再将电机固定安装在测试台；
    步骤2：测试人员通过输入设备将测量参数输入至计算机；
    步骤3：调节调压器与变频器，改变待测电机电压与频率，电能质量检测仪实时监测变频器输出交流电的各项参数，包括输出电压、输出电流、输出频率与功率因数，光电转速传感器实时监测电机实际转速，温度传感器实时监测定子温度，各项监测数据均传输给计算机，空载实验得到铁芯损耗功率与风摩耗功率，将测试电机与测试负载连接，通过改变测试负载的转矩，进行负载实验；
    步骤4：当待测电机稳定后，计算机根据能耗分析法，得到不同负载转矩下的功率密度，转矩转速传感器对电机输出功率监测，以转矩转速传感器直测法测量结果作为准确值，分析能耗法误差大小，通过调整杂散损耗功率所占总损耗功率的比例进行修正，使修正后的两组数据均方差最小，将该修正后的能耗分析法储存；
    步骤5：当测试电机脱离测试台实际工作时，根据该能耗分析法通过监测电机输入电压、输入电流、输入频率、电机实际转速与定子温度，从而实时监测电机功率密度变化。
  4. 根据权利要求3所述的一种电机功率密度测试方法，其特征在于，步骤1中所述电机各项参数包括初始温度下电机定子绕组电阻值R、定子绕组初始温度θ1、电机极对数Q、定子外径直径D与定子长度L，并进行空载实验。
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