New energy electric drive motor rotor test

As one of the core components of new energy vehicles, the electric drive motor not only bears the heavy responsibility of converting electrical energy into mechanical energy, but its performance is also directly related to the vehicle's power, economy and reliability.

Among them, the rotor is one of the important components of new energy drive motors, and its performance verification is particularly critical. This article will deeply explore the necessary content of new energy electric drive motor rotor testing, especially the verification experiments for high-speed capability, torque transmission capability and durability, in order to provide reference and inspiration for industry colleagues.

1 Core content of new energy rotor testing

New energy electric drive motor rotor testing aims to comprehensively evaluate the performance of the rotor under extreme working conditions to ensure that the motor can operate stably and efficiently for a long time.

Specifically, the test needs to focus on the following three aspects:

a Durability

Simulate the long-term operating conditions of the motor to verify the durability of the rotor under repeated high-speed rotation and temperature changes to ensure that the motor life meets the design requirements.

b High-speed capability

Verify the stability and efficiency of the rotor under high-speed rotation to ensure that the motor can continuously output strong power in the high-speed range without failure.

c Torque transmission capability

Evaluate the torque transmission capability of the rotor under static and dynamic conditions. Now the shaft and rotor are mostly matched by the interference fit itself, not by keys. This experiment is to confirm that the designed rotor will not have relative sliding between the shaft and the rotor core during the operation of the motor.

2 Experiment to verify high-speed capability: rotor overspeed test

The rotor overspeed test is an important means to verify the high-speed capability of the motor rotor. This experiment gradually increases the speed of the motor until it exceeds a certain proportion of its rated speed (usually 10%-40%) to observe and record the operating status of the rotor. After the experiment, it is necessary to pay close attention to the changes in the rotor core magnetic isolation bridge, the rotor outer diameter, and the dynamic balance of the rotor.

a Experimental purpose

Evaluate the structural strength and dynamic stability of the rotor at extreme high speeds to ensure that it can still maintain good working performance under extreme working conditions.

b Experimental steps

First, pre-rotate the rotor to eliminate initial imbalance and stress; then, gradually increase the motor speed to the preset overspeed point, record and analyze the changes in key parameters; finally, safely decelerate and stop, conduct a comprehensive inspection of the rotor, and evaluate its damage.

c Precautions

Overspeed tests are highly risky, and safety protection measures for test equipment must be complete. Special attention should be paid to the fact that the overspeed bearings must be able to withstand high speeds, otherwise the bearings may fail first in the test.

3 Experiments to verify rotor durability: high-speed speed cycles

High-speed speed cycle tests are a key step in evaluating rotor durability. This experiment simulates the long-term, high-frequency high-speed rotation of the motor to examine the fatigue life and performance stability of the rotor under repeated stress.

a Experimental design

A series of speed cycles are set, each of which includes acceleration, constant speed, deceleration and other stages to simulate the actual operating conditions of the motor. During the experiment, the rotor temperature, vibration, noise and other parameters need to be continuously monitored, and the wear and deformation of the rotor need to be checked regularly.

b Experimental significance

High-speed speed cycle tests can effectively expose problems that may occur in the long-term use of the rotor, such as material fatigue and dynamic balance imbalance, and provide an important basis for motor design optimization and quality control.

4 Experiments to verify the rotor's torque transmission capability: static torque test

a Static torque test

Static torque is applied to the rotor through special equipment to measure whether it will slip under the specified torque. This test helps to understand the rotor's load-bearing capacity and material strength under static load, and provides data support for motor design.

b Experimental method

The rotor is fixed on the test bench, and the torque is slowly increased using a torque loading device until the preset maximum value is reached or the rotor slips. The torque-deformation curve and key data points are recorded throughout the process.

Summary

It is particularly important to conduct comprehensive and in-depth testing and verification of the rotor. Through comprehensive testing of endurance, high-speed capability and torque transmission capability, the mechanical performance of the rotor can be fully evaluated, providing strong support for motor design, manufacturing and quality control.

Ningbo Nide Mechanical Equipment Co., Ltd, adhering to the customer-centric concept, focuses on the stator, rotor and complete assembly of various motors, and provides customers with one-stop solutions for highly automated, intelligent and flexible production.

We provide customers with a comprehensive solution for new energy motor manufacturing, customized automated motor manufacturing and assembly lines, including motor rotor testing machine line, new energy motor stator production lines, new energy motor rotor production lines, stator and rotor assembly lines, etc.

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