Automatic AC Motor Comprehensive Test Bench

I. Project Description

The whole system is divided into two parts, the first part: the front-end power supply part; the second part: the measurement control part. For the power range of the motor under test: 110KW; power type: AC three-phase; voltage level: AC 380V/220V, etc., the system adopts industrial computer and digital signal processing unit, which integrates resistance, insulation, withstａnd voltage, turn-to-turn, no-load and many other measuring equipment. It has the advantages of high speed, high precision, strong stability, and convenient use. It is a comprehensive testing equipment for intelligent motors.

II. System function

2.1 Quipment environmental requirements and scope of application:

Power supply voltage: 220V±10% 50Hz

Working temperature: 0～40℃ Ambient humidity: less than 85%RH

Application object: It is specially used for factory testing of medium and small three-phase asynchronous motors in laboratories or production lines.

2.2 Equipment composition and system configuration:

2.2.1 Cabinet configuration

a) Single-station complete sets of cabinets are used.

b) This project is designed for the rapid inspection of the assembly line. Put the DUT on the assembly line and test it with alligator clips or magnets.

c) The external spray color is gray-white, with dark blue corners. The system is equipped with casters and includes a braking device.

d) Modular design of each test circuit board, with clear levels, reasonable structure, overall harmony, and convenient disassembly and assembly.

e) Multiple (3-6) lead alligator clips are designed on the equipment, which is convenient for automated testing of different wire products of customers.

2.2.2 Computer software configuration

a) Operating system: WindowsXP system, all English interface.

b) According to the characteristics of this project, a set of standard factory system software is adopted.

c) It has various types of motor parameter input and storage functions, and can be easily recalled.

d) The test items can be single-item or multi-item optional, and can be automatically judged, and a buzzer alarm will be issued if the test is unqualified.

e) The test data and curves can be saved automatically and manually, so that the test results can be checked at any time.

f) It has the functions of data storage, reporting, statistics and analysis; it can generate data reports, which can intuitively, comprehensively and accurately reflect the performance of the motor under test.

g) The data report can be printed out through the self-provided printer and kept as the historical data archive of the motor performance verification.

2.2.3 Computer hardware configuration

a) P4 industrial grade computer, 17" LCD monitor, 2G memory, 500G hard disk, DVD drive, USB interface.

b) Electrical components adopt international famous brands.

c) According to the actual needs of the project, configure the communication serial port (with reservation).

2.3 Basic functions of the device:

2.3.1 Item selection: You can choose any one of the test items for testing according to the test needs (see Article 6 for the test items).

2.3.2 Model selection: 300 types of motor models can be selected and automatically judged; different types of motor standards can be stored and used at any time.

2.3.3 Parameter input: You can input the upper and lower limits of each motor's factory test standard, the standard characteristic parameters of the insulation between the main and auxiliary turns are automatically calculated, and the long-term storage can be arbitrarily loaded.

2.3.4 Statistical data: Count the test data of the motor leaving the factory, and form a data report. Report distribution: year, month, daily statistical report, motor factory quality analysis report.

2.3.5 Real-time monitoring: real-time display of each test data, unqualified items have sound and light alarm function.

2.3.6 Temperature compensation: The temperature compensation value can be set arbitrarily, the default is 20°C (the ambient temperature value is automatically detected by the temperature sensor).

III. System Features

1. Modular design, standardized design, system design implements the concept of openness.

2. The factory system can perform high-speed tests of DC resistance, power frequency withstａnd voltage, insulation resistance, turn-to-turn withstａnd voltage, and no-load.

3. The system management is authorized, and the system administrator has the power to set, edit, and delete the parameter settings and model configuration of various types of motors; the test operator can only test and operate under the currently selected "motor model". Ensure that the daily management of the system is professional and facilitate system maintenance.

4. It can not only test the whole project, but also can choose the project test (check the test), and can set the qualification criteria arbitrarily. If the test result data exceeds the standard, it will automatically sound and light alarm, and the unqualified data will be stored in the database for ready to view.

5. Meet the user's high-speed measurement needs: the measurement time can be arbitrarily selected from 0.2-999S, and the measurement rate can be arbitrarily set within the range of 100mS, 200mS, 300mS, 500mS, and 1000mS.

6. Power frequency withstａnd voltage and inter-turn voltage can be set arbitrarily and automatically generate voltage stabilization effect (using IGBT/SPWM pulse width modulation method), test data is not affected by external grid voltage fluctuations, and the voltage output of withstａnd voltage test has a slow rise , Slow down function, avoid the accident of inaccurate measurement data or damage to the tested product due to overshoot.

7. Real-time monitoring of the ambient temperature, you can choose to "on/off" the resistance when the measured resistance value is converted to the set temperature value.

8. Automatically offset and correct the inherent withstａnd voltage leakage current and insulation resistance of the test system to improve the overall accuracy of the system (system error clearing function).

9. When the three-phase motor is tested for the inter-turn item of the coil, it can provide a comparison method for simultaneous measurement of two motors (one as a reference object and one as a tested object) or a function of comparing with the stored standard waveforms for The client chooses a more accustomed comparison method.

10. The system can not only automatically calibrate the parameters of each project, but also facilitate the function self-check work, realize the rapid self-fault diagnosis of the system, and identify the fault module, which is convenient for technicians to quickly grasp the crux of the problem and propose solutions in the shortest time. .

11. Rich electromagnetic compatibility (EMC) technology applications (such as grounding, shielding, isolation, filtering, etc.) and the guarantee of good manufacturing processes ensure the reliability and anti-interference ability of the system to the greatest extent. Under the environment of high voltage and strong electric shock, the system can operate stably and reliably, so as to realize the trusteeship of the test environment and use the equipment with confidence.

IV. Test items and technical indicators

1. Winding DC low resistance measurement (U phase, V phase, W phase)

a) Range 0～2000.00Ω

b) Automatic temperature compensation, the program converts the resistance value according to the set temperature value according to the temperature rise formula (default 20℃)

c) Test method: four-terminal method

2. Withstａnd voltage test

a) Test voltage: AC 0～5000V

b) Leakage current: 0～100mA

c) Test time: 1～99S (set arbitrarily in the software)

3. Inter-turn insulation impulse withstａnd voltage test

a) Test peak voltage: AC 100～5000V (set arbitrarily in the software)

b) Detection and judgment mode: the image and data simultaneously show the difference of the waveform area and the poor waveform area

4. Insulation performance test

a) Test voltage: DC 500V/1000V

b) Test range: 0～500MΩ

c) Test time: 1～99S (set arbitrarily in the software)

5. No-load test (factory-specific items)

a) Test voltage: AC 0-500V

b) Test current: AC 0-40A

c) Test power

6. Parameter table of factory test items