1、 Testing requirements:
1. The AC power dynamometer test bench system is suitable for performance research and assessment testing of electric vehicle motors and controllers, providing accurate and reliable test charts and data as a basis for testing the power performance, efficiency characteristics, and safety protection functions of electric drive systems, in order to evaluate the performance of electric drive system products; And conduct research on vehicle motor control strategies by simulating actual vehicle operating conditions.
2. Mainly used for testing the performance, medium temperature and temperature rise, motor torque characteristics and efficiency of electric vehicle motors and controllers. Main test contents: motor three-phase resistance, no-load test, load efficiency test, locked rotor test, motor temperature, motor temperature rise, overload capacity test, maximum working speed, overspeed test, motor controller protection test, etc.
3. The system can set a constant torque test below the rated speed of the motor; Constant power test above rated speed, displaying torque speed curve and efficiency speed curve on industrial computer
4. Testing of motor power generation performance: The testing system can set the load motor power generation efficiency for controller testing.
5. The frequency converter has good speed regulation and low-speed operation performance, with a frequency regulation accuracy of 0.1HZ and a stability of 0.5%, and has good loading characteristics.
6. Electric dynamometer can not only be used as a loading device, but also as a driving device.
7. It has protection functions such as overcurrent, overvoltage, undervoltage, phase loss, short circuit, overclocking, stall, overheating of power components, and instantaneous power outage.
8. Compared with other load (dynamometer) devices, AC power dynamometers have the following unparalleled advantages:
(1) As a dynamometer, it is necessary to complete both loading and driving functions.
(2) It can operate in four quadrants, which means it can be used as both a generator and an electric motor; It can be loaded forward or backward. This is very ideal for tests such as engine tests that require reverse towing and transmission tests that require forward and reverse loading.
(3) Energy saving: Due to the use of power generation feedback loading, the energy-saving effect of the DC bus power dynamometer system is particularly significant. Especially for fatigue life testing, the energy-saving effect is very significant. The energy-saving efficiency mainly depends on the efficiency of the test bench transmission, usually around 80%
(4) The loading characteristics are very good: constant torque loading can be maintained below the rated speed (0 speed or even reverse), and constant power loading can be achieved above the rated speed.
(5) Since the loader itself does not consume loading power (feedback to the grid or input), it does not require a device that requires a large amount of water as a medium like hydraulic dynamometers and cooling with water like eddy current dynamometers.
(6) The stability of constant torque and constant speed control is unparalleled by other loaders, as it can maintain extremely high stability (0.1% -0.3%) throughout the entire speed (even at zero speed) and torque range.
(7) There are two working modes available: constant torque (loading) and constant speed (reverse drag) to meet different testing needs.
(8) Simple structure, good stability and reliability, easy to use.
(9) It can easily achieve zero torque and zero speed starting, to achieve true impact free soft starting for the power grid and machinery.
2、 Equipment testing execution standards are based on:
1. GB/T18488.1-2015 "Technical Conditions for Test Methods of Electric Motors and Controllers for Electric Vehicles"
2. GB/T18488.1-2006 "Technical Conditions for Test Methods of Electric Motors and Controllers for Electric Vehicles"
3. GB/T18488.2-2006 "Test Methods for Motors and Controllers for Electric Vehicles"
4. GB/T755-2008 "Rating and Performance Test Methods for Rotating Electrical Machines"
5. GB/T1029-2006 Test Methods for Three phase Synchronous Motors
6. GB/T1032-2005 "Test Methods for Three phase Asynchronous Motors"
7. GB/T 18385-2005 "Test Methods for Power Performance of Electric Vehicles"
8. GB/T 19752-2005 "Test Method for Power Performance of Hybrid Electric Vehicles"
9. GB/T 18384.1-2001 "Safety Requirements for Electric Vehicles - Part 1: On Board Energy Storage Devices"
10. GB/T 18384.2-2001 "Safety Requirements for Electric Vehicles Part 2: Functional Safety and Fault Protection"
11. GB/T 18386-2005 "Test Method for Energy Consumption Rate and Range of Electric Vehicles"
12. GB/T 50054-95 "Code for Design of Low Voltage Distribution"
13. GB/T 50055-93 "Design Specification for Distribution of General Electrical Equipment"
3、 Main testing items:
1. Motor temperature rise test
2. Motor torque characteristics and efficiency testing
A stalling torque and stalling current
B torque speed curve
Calculation of C motor efficiency and control efficiency
D Voltage fluctuation and peak torque, power measurement
3. Maximum operating speed test
4 overspeed test
5. Motor no-load characteristic test
6. Motor load characteristic test
Overload test of 7 motors and their controllers
8 Motor and its controller protection test
4、 Function
1. Manual control
In order to ensure the completion of certain new special test projects and to ensure that the computer system does not have a significant impact on the test progress in the event of short-term unrecoverable faults, the bidder must provide complete manual operation control functions (control and measurement of the computer can be completed by manually reading the test items when it is not running), and the operator can complete the test through the switches, buttons, and adjustment devices on the control console.
2. Automatic control
2.1 To ensure the safety of the experiment, power switches, output voltage conversion switches, etc. are not automatic and are operated manually through buttons or buttons designed on the computer.
2.2 After inputting the rated parameters of the tested motor, select the test item. The system can be controlled by computer and PLC to automatically complete the entire process of the test item with the participation of manual labor according to the initial set test item and test plan.
3. The operation control system must have an emergency stop (power button) function.
4. Realize the collection, analysis, processing, display, printing of test reports, data storage, and partial control functions of experimental data through computer software. The entire testing system consists of an industrial computer, range gear switching device, sensors, signal conditioning module, hardware for data acquisition and measurement instruments, measurement software, and other components.
5. The data measurement system adopts two display modes: computer automatic acquisition and instrument display.
6. Automatically collect test data such as DC voltage, current, power, speed, torque, output power, temperature, etc; Automatically save and process data; Draw curves and automatically generate printed test reports; Establish a test database and product quality statistics table, and the query method should be convenient and fast.
7. The test report can be automatically generated during the testing process or manually inputted, and its format is agreed upon by both parties. The report should be prepared using the most convenient computer language currently available, which is easy for manual operation, including manual participation functions such as adjusting certain data.
8. The accuracy of measuring instruments should meet the electrical testing requirements for electric vehicle motors and controllers according to standards.
9. The accuracy of the torque speed sensor is 0.2 level, requiring high dynamic stability.
10. The measurement of input power (voltage, current, power, etc.) has an accuracy of 0.5 level.
11. The accuracy of temperature measurement is level 0.5.
12. The accuracy of resistance measurement is 0.2 level.
13. The measurement system and control system must be equipped with backup software CDs.
14. The experimental parameters are automatically collected by the computer, with modular functions. After each functional test is completed, relevant curves are generated and the test report can be printed.