Dynamic motor test bench, high-speed motor dynamometer

The development time for electrified drivetrain systems is decreasing as technology advances, but creating and evaluating modern electric propulsion systems remains challenging. This complexity comes from the variety of technologies used, such as electrically excited synchronous motors (EESM), asynchronous motors (ASM), and permanent magnet synchronous motors (PMSM), along with different driveline designs.

To help manufacturers test and certify these electric driveline systems quickly and to high-quality standards, Dyno Equip offers a wide range of specialized electric vehicle motor dynamometers, advanced software, tools, and established procedures.

The comprehensive high-speed motor test bench covers various testing aspects, including performance, noise, vibration, and harshness (NVH), electromagnetic compatibility (EMC), and durability. These capabilities assist customers in developing electrified driveline systems that meet the strictest quality and performance requirements.

EV motor test bench for performance tests

The performance test bench is the ideal solution for validating the design of any unit under test (UUT). It provides a comprehensive platform where customers can rigorously assess their designs. With the help of advanced software tools and specialized testing equipment, users can easily adjust the UUT and evaluate all operational parameters on the motor test bench, ensuring that every aspect of the design is thoroughly examined. Additionally, thermal studies can be effectively conducted using a climate chamber, allowing for an in-depth understanding of how temperature variations impact the UUT’s performance.

To effectively test the entire speed and torque range of various e-motor types, the motor test bench must be highly adaptable. This adaptability requires precise adjustments to the motor dynamometer system, drive shaft, and overall mechanics to accommodate different configurations and operational scenarios. One of the significant challenges faced during this process is meeting the extensive validation and verification requirements within tight deadlines. The future-proof and optimized motor test bench is designed to handle UUTs with a broad range of speed and torque, making it suitable for testing any contemporary electric drivetrain, regardless of its complexity.

Moreover, numerous testing and optimization tasks are essential to ensure that the electrified driveline meets the highest standards for performance, efficiency, and drivability tailored to specific vehicles. The DynoEquip electric motor test bench is equipped with powerful software packages and ready-to-use applications. These tools enable customers to streamline the process of building, testing, and verifying the UUT quickly and efficiently on the motor dynamometer, all while maintaining the utmost quality standards. This integrated approach not only facilitates a more effective testing process but also accelerates time-to-market for new electric driveline technologies, ultimately supporting innovation in the automotive industry.

By utilizing the motor dynamometer effectively, engineers can gain valuable insights into the performance characteristics of their designs, helping them to make informed decisions throughout the development process. This capability is crucial as the demand for high-performance electric drivetrains continues to grow, necessitating reliable and efficient testing solutions like the motor test bench.

PM dynamometer

** Parameters can be changed according to customer needs

Asynchronous dynamometer

** Parameters can be changed according to customer needs

** Parameters can be changed according to customer needs

Small power high speed motor dynamometer

** Parameters can be changed according to customer needs

High-speed motor test bench for durability tests

This test stand helps customers’ e-motors and PHEV electric motors reach new heights in dependability and durability. The robust rig offers the fastest possible validation of robustness to maintain the speed to market target while ensuring the lifespan of UUTs. The four-quadrant durability test system, known as the durability test stand, is always in operation.

A wide variety of evaluations, including durability, availability, maintainability, and durability, are covered by the high-speed motor test bench for durability tests. Along with making processes for accumulated mileage, cold start, warm-up, and manufacturing batch tolerance monitoring easier, it also makes environmental testing in extremely hot and cold temperatures possible. Furthermore, it lets customers build e-motors that are both dependable and fully operational without having to rely entirely on expensive and high-maintenance road testing. The rig can gather kilometers more quickly because of the creative test techniques, which also cut down on handling expenses and test time overall.

Enabling clients to produce dependable and efficient electric motors and plug-in hybrid motors is the top priority, and this is demonstrated by the high-speed motor test bench. The durability test stands have an advantage over traditional testbeds with dynamometers in that they can test two UUTs simultaneously. While one UUT generates energy, the other one recovers it.

• Reliable mechanics with experience with UUT speeds up to 30,000 rpm
• Modifiability with torque flange, climatic chamber, power analyzer, more potent DC supply, and coolant conditioning
• Economical approach that uses automation and numerous back-to-back configurations while sharing the battery power supply

EV motor test bench for NVH tests

One important component of driver satisfaction is noise, vibration, and harshness (NVH). For better, quieter, and more enjoyable driving, specialized rigs, methods, and procedures can be provided for measuring, testing, calibrating, and eventually reducing NVH.

A rising portion of contemporary transportation uses electrified drivetrain technology. Modern NVH engineering is under growing pressure due to the shifting noise or sound environment. To improve vehicle sound quality both inside and outside, DynoEquip has procedures and solutions. Depending on the testing needs, the NVH motor test bench for e-motors ranges from high-end to precise to efficiency setup.

The typical project of a high-speed motor test bench for performance tests

The test bench for performance tests is mainly used for UUT development and performance testing. It is capable of realizing different operating conditions such as speed, torque, and power during the development process. Verification can test the steady state electric and power generation performance of the system, and electric and power generation cycle working conditions. It can meet the requirements of the industry and national standards for dynamic simulation tests, and realize the development and verification of high-speed motors. The motor test bench meets the following main test content:

• Motoring MAP test
• Generating MAP test
• Motoring and electric-generating duty cycle tests
• Motor overspeed test
• Temperature rise test
• Voltage fluctuation test
• Controller overload capability test and controller protection function test
• Ambient temperature test

Unit under test

Various asynchronous motors, permanent magnet synchronous motors, and their controllers for electric vehicles.

Reference list of configurations

1. Dynamometer and converter

   The motor dynamometer converter with an electric energy feedback function, electric mode, and power generation mode needs to be applicable.

    

2. DC-regulated power supply

   The DC-regulated power supply provides power for MCU, BMS, TCU, and other controllers.

    

3. Battery simulator

   Simulating a variety of vehicle power battery characteristics and models, including common lithium iron phosphate, nickel-metal hydride batteries, and ternary lithium batteries.

    

4. Power analyzer

   The UUT’s input and output current, voltage, power, and other parameters are measured accurately.

    

5. Cooling system

   The cooling system can take away the heat generated when the UUT and controller under test are working to ensure that the UUT and controller work at a suitable temperature.

    

6. Data acquisition system

   It can collect data on the temperature and vibration of the motor dynamometer and the measured parts, the measured parts, the inlet and outlet pressure of the inverter, and other parameters.

    

7. Low-voltage power supply and UPS power supply

    

8. Automation control system:

   • Testbed control with complete automatic control functions (startup, shutdown, operation monitoring, etc.).
   • Control of bench-related equipment (e.g. temperature control system, power analyzer, etc.).
   • Automation of the test program, which can switch working conditions based on temperature, torque, speed, running time, etc. as variable conditions.
   • Data acquisition (temperature sensor, voltage and current, CAN, etc.).
   • Real-time data display.

    

9. Mechanical system

   Matching motor dynamometer mounting base, mounting bracket, and other mechanical parts, mainly including dynamometer mounting base, coupling and L-type bracket, intermediate bearing housing, protective cover, and so on.

    

10. Climatic chamber

    Temperature range: -45℃ to +150℃

High-speed motor test bench up to 25,000 rpm

In response to recent client requests, DynoEquip has created a bench system for the development of high-speed electric motors. The rig has to be built to withstand high speeds of up to 25,000 rpm that simultaneously provide high outputs of torque and power. The base could be swiveled, or tilted, and comes with or without an adjustment table. Compatibility and flexibility are made possible by the modular architecture. This makes incorporating solutions into customers’ operations straightforward.

The enhanced design’s greater damping capabilities achieve lower vibration levels. The new mounting bracket completes the intermediate frame and high-speed drive shaft system. This results in a high degree of rigidity, which, when combined with the recently constructed climatic chamber adapter, allows for the best possible connection of the UUT with the least possible vibrations. Temperatures between -40°C and +155°C can be simulated.

During the bench development phase, the UUTs with base frame design have been optimized in the simulations. As a consequence, the high-speed motor test bench system was created that provides very high structural resonance, minimal rotor excitations, and noticeably better damping properties to prevent vibrations when operating.

Safety technologies and sensors guard the components as well as the test cell. The test cell and its occupants are protected by the shaft system’s verified burst protection. The modular design also has the advantage of using a climate chamber configuration. The mechanical solution is backed by structural dynamic analysis using a finite element model of 3D CAD with proper boundary conditions to maximize outcomes on the testbed, minimize risks, and decrease rig downtimes.

The test stand redesigns the bearing idea to make the system easier to maintain. The bearing unit is much simpler to change and does not require alignment following a bearing service because of a cartridge-based design solution.

The high-speed electric motor’s adjustment bench enables the operator to precisely modify the UUT to decrease coupling forces or lessen vibrations. There are five independent directions in which the mounting table could be adjusted.

• The high-speed motor test bench with a typical solution of 25,000 rpm
• Modular design with matched and verified components provides flexibility.
• Because of the well-designed and very effective dampening substance, there is less vibration.
• Testbeds with climate chambers offer advantages that assist
• Brake stall to ensure UUT placement accuracy
• A shaft system’s verified burst protection

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