Laboratory test bench for electric motors - prototypes and small series

The project

We have developed a customized laboratory test bench for a leading Tier 1 supplier to the automotive industry, which is specially designed for testing electric motors in the prototype phase and for small series production. With its comprehensive test coverage and modular expandability, this test bench enables precise quality control and meets the high standards of the automotive industry.

With this laboratory test bench for electric motors, AUTFORCE offers a high-performance, flexible solution that meets the requirements of modern electric motors and ensures reliable quality control with the help of measuring systems from our technology partner Dewetron.

Keyfacts

  • Number of variants: 3 component types
  • Type and product extensions are easy to implement
  • Flexibly configurable sequence changes (tests, speed up to 3000 rpm)
  • Loading: manually by crane
  • Data analysis: graphical evaluation of measurement data, raw data analysis possible
  • User-related individual HMI design

Description of the process

The entire test run is started and monitored by the operating personnel, with the autfactory test bench software taking over the automated process. The steps in detail:

  • Preparation and insertion of the test specimen: The motor to be tested is placed in the test stand by crane; all mechanical and electrical connections are established by the operator.
  • Start of the test process: After the cover has been closed manually and the test specimen has been secured, the test process is triggered by pressing the start button.
  • Automated testing: In combination with a PLC, the autfactory software automatically checks the safety interlocks and the test sequence according to the configured specifications. The status of the test run is indicated by a signal light.
  • Data storage and processing: Once the test has been completed, the test data is stored in the autfactory software and made available as a CSV file for further processing.
  • Unloading the motor: After a successful test, the mechanical connections are released by the operator and the motor is lifted out of the test bench by crane. To save time, a pre-equipped test specimen (set-up plate) can be inserted into the system directly afterwards.
Laboratory test bench for electric motors, suitable for testing electric motors in prototype production and small series production.

Tests and procedure

The electric motor undergoes a previously defined test sequence in which all critical parameters are systematically checked. This ensures a complete assessment of the performance and safety of the electric motor:

Step 1

Insulation test

First, the insulation resistance is measured to ensure that no leakage currents occur and that the motor is safely protected against short circuits.

Phase resistance

The insulation test is followed by a check to ensure that the phase resistances are within the tolerance range and that there are no imbalances in the windings.

Step 2

Step 3

Temperature sensor check

The motor’s temperature sensor is checked for accuracy and functionality. In addition, temperature compensation is carried out using an infrared thermometer.

HV interlock

The high-voltage fuse is tested to ensure that the motor switches off properly in the event of voltage faults.

Step 4

Step 5

Resolver check / direction of rotation

In this step, the direction of rotation of the motor and the function of the resolver, which is responsible for the precise control of the motor, are checked.

Baking EMF test

The generated reverse voltage of the motor is measured in order to evaluate the efficiency and performance of the motor.

Step 6

Step 7

Drag torque test

Finally, the drag torque is measured to determine the engine’s friction losses at idling speed.

Advantages of this test stand

Simple operation

Thanks to the flexible autfactory test bench software, the test process is easily configurable and requires no programming knowledge.

No operator required

During the automated test run, the staff can already prepare another motor on a separate set-up plate.

High process reliability and transparency

Full traceability of test specimens and data storage for detailed analysis.

Parallelization of measurements

As some of the measurements / evaluations carried out have the same basic parameters, they can be carried out at the same time.

Individual measuring devices

The measuring devices are selected individually for the respective application. Numerous existing interfaces in the autfactory software enable simple integration.

Efficient use of space

The compact design of the test bench reduces the space required and can therefore also be accommodated in small laboratory areas.

Find out more about electric motor test benches!

E-motor development test bench. Functional tests: Insulation test, phase resistance, temperature sensor check, HV interlock, resolver check, direction of rotation, back EMF test, drag torque
E-motor development test bench for testing prototypes in the development process.
Modular expandable electric motor test bench for the development of electric motors, prototype production and small series production.

Do you also need a solution in the field of electric motor test benches?

At AUTFORCE, we specialize in testing systems & industrial software . Get in touch with us. Together we will find the best solution for your needs!

Rainer Jung
E-Mobility Testing Expert
+49 (160) 922 32 797
rainer.jung@autforce.com

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