Installation site of motor test bench

The motor test bench is a specialized benchmark platform designed for motor performance testing, parameter calibration, and reliability verification. It is a core auxiliary equipment in the motor research and development, production, and quality inspection processes. Its core function is to provide a stable, flat, and rigid installation benchmark for the motor, ensuring stable operation of the motor during testing, reducing interference from factors such as vibration and displacement on test data, and thus ensuring the accuracy and repeatability of test results. The following is an introduction from the aspects of structural characteristics, core functions, application scenarios, and technical requirements:

1、 Core Structure and Design Features

The motor test platform is usually made of high-strength cast iron (such as HT200-HT300 gray cast iron) or ductile iron, and some high-precision scenarios may use alloy cast iron. The structural design must meet the following requirements:

High rigidity: The thickness of the platform is usually 1/10-1/15 of its own length (such as a 2-meter-long platform with a thickness of ≥ 200mm), and the bottom is reinforced with ribs (grid or cross shaped) to resist the torque and vibration during motor operation and avoid deformation of the platform itself.

Stability: After aging treatment (natural aging for 2-3 years or artificial aging), internal stress is eliminated to prevent a decrease in flatness due to stress release after long-term use.

Surface treatment: The working surface undergoes precision machining (milling, grinding, or scraping), and the flatness error is controlled at level 1 (≤ 24 μ m/m) to level 0 (≤ 12 μ m/m) according to the testing accuracy requirements. Some high-precision testing platforms need to reach level 00 (≤ 8 μ m/m).

Functional accessories: T-shaped slots, threaded holes, or positioning pin holes can be reserved on the surface for fixing motors, dynamometers, sensors, and other equipment, achieving quick clamping and positioning; Large platforms can also integrate shock absorbers (such as rubber pads and spring dampers) to further reduce external vibration interference.

2、 Core role

The motor testing platform is the "reference carrier" of the motor testing system, and its role is reflected in the following aspects:

Ensure installation coaxiality: The motor and dynamometer (or load equipment) need to be connected coaxially through a platform. The flatness and rigidity of the platform can reduce the axis deviation caused by installation deviation, avoid additional torque or vibration during testing, and ensure accurate measurement of parameters such as speed and torque.

Suppressing vibration conduction: Motor operation (especially high-speed and high-power motors) will generate vibration, and the weight of the platform (usually 1-5 tons, large platforms can reach more than 10 tons) and rigidity can absorb some of the vibration, preventing the vibration from being transmitted to sensors (such as torque sensors and vibration sensors) and causing data distortion.

Provide stable support: For heavy-duty motors (such as megawatt level wind turbines and industrial drive motors), the platform needs to withstand a weight of several tons to tens of tons. Its structural strength can prevent the motor from tilting due to unstable support, ensuring the safety and stability of the testing process.

3、 Application scenarios

The application of the motor testing platform runs through the entire lifecycle of the motor, with core scenarios including:

R&D testing: During the motor design phase, it is used to test the performance parameters of the prototype (such as efficiency, power factor, temperature rise curve, vibration noise). The high precision of the platform ensures the repeatability of the test data, providing reliable basis for design optimization (such as efficiency map testing of new energy vehicle drive motors).

Production quality inspection: In the mass production of motors, it is used for performance sampling before leaving the factory (such as locked rotor test and no-load test for small and medium-sized asynchronous motors), quickly fixing the motor and testing equipment through a platform to improve detection efficiency.

Type test: Conduct comprehensive performance verification of the motor according to national standards (such as GB/T 1032-2012 "Test Methods for Three phase Asynchronous Motors"), which needs to be completed on a high-precision platform to ensure that the test results comply with industry standards and can be used as a basis for product certification.

Fault diagnosis: For motors with abnormal operation (such as excessive vibration and decreased efficiency), simulate working conditions on the platform for testing, and analyze the cause of the fault (such as rotor imbalance and bearing wear) based on sensor data.