Electric Motor Test Bench

It can accurately simulate various actual operating conditions of the UUT, conduct comprehensive tests including steady-state/dynamic performance, durability, and accurately measure key parameters such as torque, speed, efficiency and temperature rise. The motor test bench can identify potential design flaws and performance defects in advance, avoiding safety risks and economic losses, shortening R&D cycles and improving test accuracy.

The JKT electric motor test bench is equipped with precise and reliable mechanical system,  highly dynamic and dependable control system, and powerful software packages. A suitable motor test bench can be found for the parameters of any UUT from JKT.

1Model Selection of High-Speed Dynamometer

Motor test benches vary greatly depending on different application fields and test objects.

We classify motor test benches into high-speed high-power motor test benches and high-speed low-power motor test benches.

We provide not only direct-drive dynamometers but also dynamometers equipped with gearboxes.

Customized gearboxes can be supplied and mounted on the output side of the dynamometer to meet testing requirements for multi-axis operation or higher speed.

High-speed high-power dynamometer：

JKT can provide customized products according to customer requirements.

High-speed low-power dynamometer

JKT can provide customized products according to customer requirements.

MAIN TEST ITEMS

• Power and torque characteristic test

• Temperature rise test

• Steady-state test

• Design and verification test of the control strategy

• Maximum speed test

• Regenerative braking energy test

• Motor external characteristic test

• Development and matching optimization test of the powertrain for the motor and controller

• Calibration test

• Efficiency map test

• Accelerated response test

• Torque response test

• Durability test under steady-state cyclic loading

• Lock-rotor test

MAIN TECHNICAL PARAMETERS

• Torque measurement control accuracy：±0.05%FS

• Speed sensor pulse resolution：1024/600pprppr

• Torque control accuracy：±(0.5~1)%FS

• Speed control accuracy：±(0.01~0.05)%FS

• The max vibration value of dynamometer（RSM）：≤2mm/s（no load）

• The bearing support temperature rise：≤35℃

• The max vibration value of the bearing support（RSM）：≤2mm/s（no load）

• DAQ sampling rate：1kHz

• Current measurement channel:4/6

• Voltage measurement channel:4/6

• Measurement accuracy of power analyzer: ±0.05%

• Temperature sensor measuring range: -50℃~200℃

• Measurement accuracy of temperature sensor: A class

• Vibration sensor measuring range: 0~20mm/s

Typical Application Project for electric motor test

Test benches test electric motor of the electric vehicles (EVs), for example drive motors, electric suspension drive motors, oil pump motors, etc.

Main test contents:

• Efficiency MAP test

• External characteristic test

• Torque test

• Speed test

• Temperature rise test

• Over-load test

• Steady-state test

• Maximum speed test

• Durability with temperature climate test

• CLTC/WLTC cycle condition test

• User-defined cycle condition test

• Regenerative braking energy test

• Controller calibration test

• Road load simulation test

• Accelerated response test

• Torque response test

• l Lock-rotor test 

 

Basic configurations:

Dynamometer & Mechanical System: A high-dynamic asynchronous or synchronous motor is selected as the dynamometer, equipped with a high-speed drive shaft system and precision, reliable mechanical components.

 

Frequency Converter: A four-quadrant frequency converter is adopted for dynamic or steady-state control of the dynamometer. It enables control of rotational speed, torque, allowing the dynamometer to operate in either motoring or generating mode.

 

Battery Simulator or Bidirectional DC Power Supply: Simulates an on-board battery pack to supply power to the MCU and the motor.

 

Power Analyzer & Mobile Cart: A high-precision power analyzer is used to measure parameters such as current, voltage, efficiency and harmonics of the motor and controller. It can also receive torque and speed signals synchronously for calculating the motor’s mechanical efficiency.

 

MCU Power Supply: Provides an adjustable low-voltage power supply for the motor controller.

 

Test Object Cooling System: Supplies cooling medium for the tested E-axle and E-drive. An oil or water-cooling system is available for certain oil-cooled or water-cooled test pieces. Parameters including temperature, pressure and flow rate of the cooling system are fully adjustable. The water-cooling system can also use ethylene glycol as the cooling medium.

 

Climate Chamber: Provides a simulated operating environment with controllable high/low temperature and humidity for the test objects.

 

Automated Measurement & Control System: Conducts overall control and condition monitoring of the entire motor test bench.

300kW 16000rpm 500N.m Test bench with climate chamber for EV motor 

400kW 10000rpm 2000N.m Test bench for EV motor

20kW 20000rpm 30N.m Test bench for EV suspension drive motor

Typical Application Project for High Speed EV motor test

To improve the performance of electric vehicles, the maximum speed of drive motors is becoming increasingly higher.

In response to the characteristics of test pieces with rotational speeds exceeding 25,000 rpm, JKT has designed a series of high-speed motor test benches. The test benches adopt the following innovative designs:

• Higher machining and assembly precision of the rotating shaft system

• Higher dynamic balance grade of the rotating shaft system

• Application of damping design technology for bearings

• Vibration excitation analysis performed on the bench base and rotating shaft system, with optimized base and shaft structure to achieve low no-load vibration characteristics

• Broken shaft protection design for tested motor, which effectively prevents damage to the test bench in the event of a shaft breakage of the motor under test

• Special vibration isolation and lubrication design, enabling the test bench to withstand severe vibration from the tested motor without any damage.

400kW 25000rpm 500N.m Test bench for EV motor