1-1．safety instructions

Warning!When the system malfunctions, only professional technicians are allowed to repair it.

Warning!During the motor testing process, do not insert your body or other objects into the testing bench.

Warning!The tested load should maintain good electrical isolation from the ground and surrounding objects.

Warning!The testing system cabinet must be safely and properly grounded.

1-2．maintenance

1. Use cotton dipped in anhydrous alcohol to clean and control the cotton pad to avoid damaging the panel.

2. Keep the fan running normally, usually replace the fan every 3 years.

3. The system cabinet needs to be kept clean and should not accumulate a large amount of dust inside.

4. Regularly check the working status of photoelectric switches and light curtain sensors. The inspection cycle is 3-5 days.

5. It is not advisable to vigorously strike the cabinet or use sharp hard objects to knock any components inside the system cabinet.

1-3．precautions

1. Environmental temperature conditions to ensure measurement accuracy: 20 ℃± 5 ℃

2. Environmental temperature range: 0 ℃~40 ℃

3. Relative humidity of the air: not exceeding 85%;

4. No corrosive, flammable, or explosive gases indoors;

5. System power supply: AC380V/50Hz; Three phase four wire system;

6. During normal testing, the air pressure source should be maintained between 0.4Mpa and 0.6Mpa. If the air pressure is too low, normal testing cannot be carried out. If it is too high, it will cause excessive impact force during the clamping and unloading process of the travel seat.

This system is mainly used for performance testing of tubular motors, including grounding resistance testing, electrical strength testing, insulation resistance testing, leakage testing, manual testing, start-up testing, performance testing, limit switch testing, and braking force testing. This system adopts a communication mode between PC and lower computer, which can monitor the data of lower computer in real time. This testing system software has a friendly interface, stable operation, and the advantages of easy and fast operation.

IIITECHNICAL INDEX

1. Grounding resistanceMeasure the resistance value between the grounding terminal and the metal casing of the motor.

Output current: AC 10A/25A

Output current error: ± (set value ´ 5%) A

Grounding resistance measurement range: (5~250) m Ω

Grounding resistance accuracy: ± 5%

2. electric strengthMeasure the leakage current value between the common terminal of the motor winding and the casing.

Test voltage range: (0~3000) V AC

Voltage withstand accuracy: ± 5.0%

Leakage current measurement range: (0~20) mA

Leakage current accuracy: ± 5.0%

3. insulation resistanceMeasure the insulation resistance between the common terminal of the motor winding and the casing.

Test voltage: 500V DC

Test voltage accuracy: ± (5% of set value) V

Insulation resistance measurement range: (5~500) M Ω

Insulation resistance accuracy: ± 5.0%

4. Leakage currentTest the leakage current between the L terminal of the power supply and GND when the tubular motor is operated at 1.06 times the rated voltage.

Test range (0-20) mA

Voltage range (0-300) VAC

Accuracy ± 2%

5. Manual forward rotation:When the tubular motor is driven forward by an external DC motor without power, measure the current of the DC motor and the on/off limit of the tubular motor.

Test range (50mA-3A)

Accuracy ± 5%

6. Manual reversal:When the tubular motor is driven in reverse by an external DC motor without power, measure the current of the DC motor and the on/off limit of the tubular motor.

Test range (50mA-3A)

Accuracy ± 5%

7. Limit switch experimentTest the quality of the limit switch for the tubular motor.

Judgment method: The motor limit switch automatically completes the action process of "turning in the forward direction to the end - turning in the reverse direction to the end - turning to the middle position" within the set time under the drive of the pulley.

Limit switch travel time range: 1.0s ≤ t ≤ 10000s

8. Braking force test:Test the ability of the motor to stop moving under load force. Judging based on the size of the slip angle.

Test scope:

(3~25) N.m, n ≤ 100r/min Accuracy: 360/1024 degrees

(25~60) N.m, n ≤ 100r/min Accuracy: 360/1024 degrees

9. priming experimentTest the motor's ability to start with a load at 0.85 times the rated voltage, including starting up and starting down tests.

Torque: Measurement range: (3.0~60.0) N.m Accuracy: ± 0.5%

Speed: Measurement range: (2.0~300) r/min Accuracy: ± 0.5%

Voltage: Measurement range: (20.0~300.0) V Accuracy: ± (0.25% reading ± 0.25% range)

Current: Measurement range: (0.02~20.00) A Accuracy: ± (0.25% reading ± 0.25% range)

10. Performance experimentTest the various parameters of the tubular motor during load up and down operation at rated voltage.

Torque: Measurement range: (3.0~60.0) N.m Accuracy: ± 0.5%

Speed: Measurement range: (2.0~300) r/min Accuracy: ± 0.5%

Voltage: Measurement range: (20.0~300.0) V Accuracy: ± (0.25% reading ± 0.25% range)

Current: Measurement range: (0.02~20.00) A Accuracy: ± (0.25% reading ± 0.25% range)

4Hardware Description

4-1Introduction to Overall Structure

Control panel section: including display, control buttons, and micro printer.

1. Test bench section: including motor support platform, travel seat, deceleration motor, photoelectric switch, light curtain sensor, etc.

2. Variable frequency power supply panel display window: including variable frequency power supply voltage, current, and power display.

4-2Introduction to Control Panel

LCD display

1. Start button: Press this button to start the test

2. Stop button: Press this button to stop the test

3. Emergency stop button: In case of emergency, press this button to cut off the working power supply. (Note: This button cannot be automatically restored. After pressing it, you need to manually reset the button by turning it right.)

4. Sound and light alarm: emits light and sounds an alarm when the tested product is unqualified

5. Power switch: controls the connection and disconnection of the working power supply of the control system

6. Micro printer: used to print non-conforming items of the tested motor

4-3Introduction to Test Bench

Deceleration motor: used for limit switch testing.

1. Motor support platform: supports the tested motor.

2. Test line clamp

3. Tested motor

4. Light curtain sensor: a protective device used to protect the personal safety of operators.

5. Clamping air claw: Hold the tested motor tightly during the testing process to prevent the motor from swinging out of the test bench during the testing process.

6. DC motor: used for manual testing of tubular motors.

7. Manual testing button.

1. Grounding pin: During the grounding resistance test, the tested motor casing will be continuously tapped three times to ensure good contact between the pin and the metal casing of the tested motor, thereby completing the grounding test project.

2. Photoelectric switch: Sensing whether the tested motor has been placed on the testing table.

3. Pressure regulating knob of pressure regulating valve: Adjust the air pressure of the cylinder of the deceleration motor fixture seat to adjust the force of the belt pressing the limit switch of the tested motor. The adjustment method is: first lift the pressure adjustment knob of the pressure regulating valve upwards, and then adjust the knob clockwise or counterclockwise. Adjust the air pressure clockwise to increase, and counterclockwise to decrease.

4. Pressure regulating valve pressure display gauge: displays the pressure of the pressure regulating valve.

5. Unloading speed adjustment knob: Adjust this knob to adjust the clamping speed of the travel seat (counterclockwise to increase clamping speed, clockwise to decrease speed)

6. Travel seat clamping/unloading cylinder: used to control the clamping and unloading of the travel seat.

7. Install the clamp.

8. Clamping speed adjustment knob: Adjust this knob to adjust the travel seat unloading speed (counterclockwise to increase clamping speed, clockwise to decrease speed)

4-4Other parts

4-4.1Solenoid valve box

1. Electromagnetic valves 1-5 control the actions of each cylinder separately.

2. Oil water separator.

3. Air source inlet.

4-4.2Voltage regulator for withstand voltage

1. Voltage adjustment knob for withstand voltage test: Adjusting this knob can adjust the test voltage of the withstand voltage test item. Clockwise adjustment of voltage increases, counterclockwise adjustment of voltage decreases.

4-4.3Load switch

This load switch is used to control the connection and stop of the entire system's working power supply. Turn the switch to the ON position to turn on the system's working power, and to the OFF position to turn off the working power.

4-5Pre startup inspection items:

(1) Check if the photoelectric switch is working properly. Abnormal operation of the photoelectric switch can cause the entire testing system to fail to start.

explain:

(a) Description of the normal working state of the photoelectric switch: Under normal power supply (24V DC), when the tested motor is not placed, the red working indicator light of the photoelectric switch lights up. After placing the tested motor, the red indicator light goes out, indicating that the photoelectric switch is working properly.

(b) Inspection method: Check the working condition of the photoelectric switch according to the above phenomenon. When the photoelectric switch is found to be malfunctioning, please first confirm whether the power supply of the photoelectric switch is normal. If the power supply is normal, adjust the position of the photoelectric switch appropriately until the status change of the red working indicator light of the photoelectric switch can reach the normal working state.

(2) Check if the light curtain sensor is working properly.

explain:

(a) Description of the normal working status of the light curtain sensor: Under normal power supply (24V DC), the yellow indicator light on the projector (left side) lights up, indicating that the power supply is normal. If there are no obstructions within the protected area, the yellow and green indicator lights on the light receiver (right side) will light up. After confirming that the above situation is normal, insert an object into the tubular motor test bench. When the light curtain sensor senses a beam interruption, the yellow and red indicator lights of the light receiver will light up, and the green indicator light will turn off.

(b) Testing method: Follow the above description to test the working condition of the light curtain sensor. If it is found that the light curtain sensor is not working properly, please first confirm whether the power supply of the light curtain sensor is normal. When the power supply is normal and the light curtain sensor cannot work properly, a new light curtain sensor needs to be replaced.

(3) Selection of motor rear seat fixing head: Please choose the corresponding rear seat fixing head according to the type of motor rear seat being tested and fix it properly.

(4) Clamping adjustment: Before conducting the test, the position of the tested motor must be adjusted to ensure that the testing system can smoothly complete the clamping and testing.

1. Install the clamp.

2. Quick handle 1, used for fixing and loosening travel stops.

3. Quick handle 2, which is used for fixing and loosening the servo travel seat and cylinder.

Clamping adjustment steps:

(a) Release the quick handle 1 and quick handle 2 first, so that the entire servo travel seat and cylinder can move freely along the guide rail.

(b) Place the tested motor on the motor support base.

(c) Pull the servo travel seat closer to ensure that the clamping head is fully connected to the tested motor.

(d) After docking, adjust the height of the motor support seat in the test bench to align the center height of the tested motor with the mounting chuck, and fix the motor support seat. Adjust the quick handle 1 and fix the position of the travel stop block.

(e) Open the servo stroke seat and separate the clamping head from the motor by a certain distance (usually 30cm), and adjust the quick handle 2 to fix the servo stroke seat in place with the cylinder.

(f) The clamping adjustment is completed.

(5) Replacement of large and small pulleys

For different models of tested motors, the system has two pulley options with different outer diameters to ensure the testing accuracy of the system. Small pulleys are suitable for testing small torque motors (3 N.m-25 N.m), while large pulleys are suitable for testing large torque motors (10 N.m-60 N.m). Before starting the test, it is necessary to select the corresponding pulley based on the model of the tested motor. This section provides corresponding instructions for the replacement of pulleys.

1. Large pulley

2. End cap

3. The servo end is connected to the gear.

4. Fixed nut, used to secure servo motor.

5. Belt

6. Tighten the nut, used to tighten the servo motor.

7. The servo end is connected to the gear position adjustment nut.

Replacement steps:

(1) Loosen the four fixing nuts so that the servo motor can slide left and right in the slot after loosening the tightening nut.

(2) Unscrew the tight nut.

(3) Push the servo motor forward to the detachable position of the belt.

(4) Unscrew the end cap and remove the pulley.

(5) Install the pulleys and belts that need to be replaced.

(6) Tighten the tightening nut to bring the belt to the taut position. Tighten the four fixing nuts again to secure the servo motor.

be careful:Please pay attention to the operation sequence of fixing nuts and tightening nuts during disassembly and installation. When disassembling, first loosen the fixing nut, and then tighten the nut. During installation, tighten the tightening nut and then tighten the fixing nut. When installing the pulley, please ensure that the pulley is level with the servo end connecting gear, and do not cause the belt to twist, so as not to damage the belt. During adjustment, the position adjustment nut of the servo end connecting gear can be loosened to adjust the position of the servo end connecting gear, ensuring that both are level.

4-6Specific operating steps

1. Insert the power cable plug into a three-phase (380V, three-phase four wire system) socket.

2. Turn the load switch to the ON position.

3. Turn on the power switch on the panel and activate the emergency stop button.

4. Install the tested motor according to the instructions of the test line clamp.

5. Adjust the position between the "loading and unloading clamp cylinder base" and the "travel stopper".

6. Adjust the "motor support seat" to make the motor shaft coaxial with the mounting clamp.

7. Connect the gas source.

8. Open the system testing software and select the corresponding motor model to enter the testing interface.

9. Press the 'Start' button, and the system will automatically perform testing for each item. Press the 'Stop' button during the testing process to stop the system from testing. If encountering special circumstances, you can press the "emergency stop" button to cut off the control power and stop the system being tested. The testing sequence is as follows: grounding resistance - insulation resistance - electrical strength - leakage test - manual test - limit switch test - performance increase test - performance decrease test - start up test - start down test - brake force increase test - brake force decrease test.

4-7Communication line connection method

Connect the communication line of the PLC port to COM1 (i.e. serial port 1 of the industrial computer itself), connect the communication line of the voltage resistant insulation 2-in-1 board port to COM2 (i.e. serial port 2 of the industrial computer itself), connect the communication line of the grounding leakage board port to COM3 (i.e. serial expansion card 1), connect the communication line of the GDW1200C (single-phase electrical parameter tester) port to COM4 (i.e. serial expansion card 2), connect the communication line of the GDW1206A port to COM5 (i.e. serial expansion card 3), and connect the communication line of the variable frequency power supply port to COM6 (i.e. serial port 1 of the industrial computer itself).

Explanation: Each serial port is labeled with a number. Simply connect the corresponding number on the serial port card of the industrial computer according to the number on each serial port.

5software documentation

5．1Software installation (installation environment Windows 2000)）

Open the software CD display

Double click "SETUP. EXE" to enter the installation welcome interface,

Click 'Next' to enter the following interface,

Click on the "I agree to the terms of this license agreement" checkbox to proceed to "Next",

Enter the company name, click 'Next', and enter the next interface,

The default path is C: \ \ PROGRAM FILE \ \. To change the path, click "Change Directory" to change the path. Click 'Next' to enter the following interface,

Set up the shortcut folder and shortcut type, click "Next" continuously until the installation is completed and a successful installation prompt appears. Click "Finish" to complete the software installation.

5．2Software opening operation:

i. Turn on the system power

Ii. After starting the computer, double-click the desktop icon to open the software.

iii. Execute TUBULARMOTOR.EXE to enter the initial interface.

Note: It is possible to switch between Chinese and English modes. Selecting a mode will display the corresponding Chinese and English

(1) Click the "Test" button to enter the parameter selection interface

a、 Belt pulley options: Based on the actual size of the belt pulley installed in the system, select "large pulley" or "small pulley", and the system defaults to "large pulley".

b、 Model: Click on the model dropdown menu to display the following interface, as shown in Figure (19). Select the corresponding model from the dropdown menu based on the measured motor model.

c、 Number: The number function is automatically generated by the system and consists of the test date and the number of test units.

d、 Tester: The tester enters the testing employee number in this box. When checking the box for connecting to a remote server,

The test data will be automatically saved to the remote server and the database of this testing platform. When not marked with a √, the test data is only saved in the database of this testing platform.

e、 After the above selection and settings are successful, click on "Download Data to PLC" to download all parameter settings and test employee numbers of the selected model to the PLC. (Note: When downloading parameters, please confirm that the testing system is in standby mode, that is, the system's working power is turned on and the emergency stop button is not pressed. Otherwise, the selected model's setting parameters cannot be downloaded correctly to the PLC, which poses a testing hazard to the tested motor.). ）

f、 After downloading the data, click "OK" to enter the testing interface. The 'Cancel' button is used to return to the previous interface.

(2) Click on "Parameter Settings" and a password input box will pop up. After entering the correct password, enter the parameter settings interface (factory password is admin, pay attention to case sensitivity),

(a) Nameplate selection drop-down menu: This drop-down menu contains all the parameters of the motor model that have been set. Select one of the models from the drop-down menu to enter the setting of the motor parameters for that model.

(b) Click on each test item separately to enter the corresponding parameter settings for that test item. If you click on "Insulation Resistance" and enter the insulation resistance parameter setting interface, you can set the "Test Allow/Not Allow" option, as well as the test voltage, test time, and insulation resistance measurement lower limit value.

(c) After setting all the parameters, click "Save" to save the set parameters.

(d) Click 'Delete Settings' to delete the parameters of this motor model.

(e) Add leakage current and manual function parameter settings. After setting it up, click on 'Save'.

Practical Question 1How to create a new motor model?

Method 1：After entering the parameter setting interface, set the parameters of the desired motor model in the blank setting interface of each test item. After setting, click "Save As". Enter the motor model in the pop-up type interface and click "OK" to complete the parameter setting of the new motor model.

Method 2：It is also possible to create a new motor model on top of the existing one, which can improve operational efficiency and testing efficiency when different motor models have similar parameters.

The specific operation is: select a motor model from the drop-down menu on the parameter setting interface nameplate, enter the parameter change settings for that model of motor, click "Save As" after setting, enter the new motor model, and complete the parameter settings for the new motor model.

Attention: Please confirm that clicking "Save As" instead of "Store" will overwrite the original settings parameters of the motor model.

Practical Question 2How to change password?

method:Click on "Change Password" in the parameter settings interface to enter the password modification interface. Enter the new password in the password box and click "Change" to complete the setting of the new password. In the future, entering the parameter settings interface will require entering the newly changed password.

be careful:Please save the password you have set after changing it!

Practical Question 3How to connect to a remote server?

method:Click on "Connect to Remote Server" in the parameter settings interface, and the following interface will appear, as shown in Figure (21). Enter the server IP address, server database name, and corresponding database operation table name, and click "OK" to complete the remote server connection settings. When testing, check the "Connect to Remote Server" checkbox in the parameter selection interface, and the test data will be automatically saved to the database of the remote server and this testing platform.

(3) Click on "Database" to enter the data interface, as shown in Figure (22). Test data can be viewed. In the data query drop-down menu, you can select the test number for different date data to query all test data for that date. Click on the 'Import Excel' system

1. Static test item data display section: including the display of test parameters for three static test items: grounding, insulation, electrical strength, leakage current, and manual function.

2. Batch number, serial number, operator display section: displays the test batch number (i.e. test date), batch number, and operator's job number.

3. Torque and speed plotting section: During dynamic testing (including performance, start-up, and braking force), a curve graph of torque and speed will be plotted in this blank area.

4. Dynamic test data display section: During testing, clicking on each test item can view the corresponding test data for that item.

5. Test result statistics section: This section displays the total number of tests in the batch, as well as the number of qualified and unqualified tests. And the specific test item where the non-conforming products appeared will be counted, making it easier for testers to calculate the overall results and quality of the batch of products.

Leakage current data display interface

The small icon 6 represents the display area for leakage current test data

Manual function display interface

The small icon 7 indicates that clicking on the manual function test will enter the forward and reverse testing interface for manual testing

VIExplanation of Variable Frequency Power Supply

Please refer to the "User Manual for Variable Frequency Power Supply"

7Printer Description

A panel micro printer is used to print out the non-conforming items of the tested motor. When encountering non-conforming products during the testing process, the panel micro printer will immediately print out the non-conforming test items and their test parameters.

Printer precautionsPlease pay attention to regularly replacing the paper and ribbon of the panel micro printer. (Please refer to the "Printer Manual" for replacement instructions)

8Troubleshooting

1. The entire system has no working power supply. Check if the system power fuse is intact.

2. During the testing process, there was no data display or display error on the software interface. Please check if there is any looseness or detachment in the serial port wiring and make corrections.

3. The tested product is not working. Check if the input air switch is turned on, if the photoelectric switch and light curtain sensor are working properly, if the wiring is correct, and if the corresponding contactor is working.

9Supply completeness

1. 1 set of system control cabinet

2. 1 set of industrial computer and monitor

3. 1 set of motor rear seats (3, including 1 already installed on the system cabinet)

4. 1 copy of software CD

5. 1 copy of user manual

6. Fuse 10 A……………………………………………………………………… 3 individual

7. 1 copy of certificate of conformity

8. 1 copy of warranty card

9. 1 set of hexagonal tools (3mm, 4mm, 5mm, 6mm)

10. 1 set of keyboard and mouse

11. 1 synchronous belt pulley

12. Belt... 1 piece

13. One GDW1200C single-phase electrical parameter meter

14. Variable frequency power supply 1 unit