Claims:1. A system (100) for testing specifications of a motor (110), said system comprising:
a VARIAC (Variable Autotransformer) 102 configured to provide desired potential difference and controlled current to motor (110);
a controller 104 operatively coupled with one or more sensors 108, wherein the one or more sensors 108 are configured to evaluate any or a combination of torque, RPM, voltage, current, input power, and a specification attribute of the motor (110); and
one or more routines stored in a memory, which when executed by a processor of a computing device 106, enable the controller (104) to receive data from the one or more sensors (108) and output specification results for the motor (110).
2. The system of claim 1, wherein the system enables application of frictional torque on shaft of the motor (110), output of which helps measure at least one attribute of the motor specification.
3. The system of claim 1, wherein the system further comprises a load cell (112) and a load cell controller (114) operatively coupled thereto, wherein the load cell (112) and the load cell controller (114) are configured to measure apparent weight after motor (110) starts to rotate.
4. The system of claim 3, wherein data from the load cell (112) and the RPM sensor (108) is given to a USB device NI USB-6001 (202).
5. The system of claim 1, wherein the system further comprises one or more weights (116) for application of physical torque by friction.
6. The system of claim 1, wherein the system is operatively coupled with a modified rope brake dynamometer for torque measurement.
7. The system of claim 1, wherein the modified rope brake dynamometer comprises a load cell, and wherein the modified rope brake dynamometer allows rope slippage to enable measurement of torque at different angular speeds.
8. The system of claim 1, wherein the modified rope brake dynamometer comprises of a pulley made of aluminum to reduce self-weight, wherein the pulley is hollowed out to enable additional cooling, and wherein rope used is a nylon friction belt.
9. The system of claim 1, wherein the system is operatively coupled with Remote Optical Sensor for RPM measurement.
10. The system of claim 1, wherein the system is operatively coupled with a power analyzer for measurement of any or a combination of voltage, current, and power input.
, Description:TECHNICAL FIELD
This present disclosure pertains to validation of motor specifications, and more specifically relates to quality analysis and benchmarking of obtained motor data.

BACKGROUND
Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
During evaluation of a motor, typical input parameters include potential difference (voltage) and frequency (Hz), and output parameters include measurement of current (Ampere), input power (Watt), Torque (mNm/Nm), RPM (number of cycles/minute), which can help calculate and evaluate power factor (kW/kVA), efficiency (Pout/Pin), and output power (Watt).
Motors are typically tested for Torque-RPM characteristics before use in product from quality point of view to check for transit damage or manufacturing defect. During product design, motors selected need to be physically verified to match design requirements, wherein currently motors are tested by third party vendors, which costs more than INR 10000 per motor and even reliability of such data is an issue. Existing setups for such motor testing currently cost anywhere above 12 Lakhs INR, where for spares or new fixtures, a premium price needs to be paid as such parts are only available with the OEM that initially sold the setup.
Eddy current type absorber is a typical setup that is used for testing of motor specifications, where Eddy current (EC) dynamometers are currently among the most common absorbers used in modern chassis dynos. EC absorbers provide a quick load change rate for rapid load settling. Most are air cooled, but some are designed to require external water cooling systems. Eddy current dynamometers require an electrically conductive core, shaft, or disc moving across a magnetic field to produce resistance to movement. Iron is a common material, but copper, aluminum, and other conductive materials are also usable. In current applications, most EC brakes use cast iron discs similar to vehicle disc brake rotors, and use variable electromagnets to change the magnetic field strength to control the amount of braking. The electromagnet voltage is usually controlled by a computer, using changes in the magnetic field to match the power output being applied. Sophisticated EC systems allow steady state and controlled acceleration rate operation.
A powder dynamometer is similar to an eddy current dynamometer but a fine magnetic powder is placed in the air gap between the rotor and the coil. The resulting flux lines create "chains" of metal particulate that are constantly built and broken apart during rotation, creating great torque. Powder dynamometers are typically limited to lower RPM due to heat dissipation problems.
Hysteresis dynamometers use a steel rotor that is moved through flux lines generated between magnetic pole pieces. This design (as in the usual "disc type" eddy current absorbers) allows for full torque to be produced at zero speed, as well as at full speed. Heat dissipation is assisted by forced air. Hysteresis and "disc type" EC dynamometers are one of the most efficient technologies in small (200 hp (150 kW) and less) dynamometers. A hysteresis brake is an eddy current absorber that, unlike most "disc type" eddy current absorbers, puts the electromagnet coils inside a vented and ribbed cylinder and rotates the cylinder, instead of rotating a disc between electromagnets. The potential benefit for the hysteresis absorber is that the diameter can be decreased and operating RPM of the absorber may be increased.
Electric motor/generator dynamometers are a specialized type of adjustable-speed drive. The absorption/driver unit can be either an alternating current (AC) motor or a direct current (DC) motor. Either an AC motor or a DC motor can operate as a generator that is driven by the unit under test or a motor that drives the unit under test. When equipped with appropriate control units, electric motor/generator dynamometers can be configured as universal dynamometers. The control unit for an AC motor is a variable-frequency drive, while the control unit for a DC motor is a DC drive. In both cases, regenerative control units can transfer power from the unit under test to the electric utility. Where permitted, the operator of the dynamometer can receive payment (or credit) from the utility for the returned power via net metering.
In engine testing, universal dynamometers can not only absorb the power of the engine, but can also drive the engine for measuring friction, pumping losses, and other factors.
Electric motor/generator dynamometers are generally more costly and complex than other types of dynamometers.
As can be seen, multiple disadvantages are associated with currently available dynamometers, few of which include the high cost of investment, dependence on Original Equipment Manufacturer (OEM) every time a new designed motor needs to be tested as new fixtures need to be made, requirement of trained professionals for running existing setups, high energy requirements, need for existing systems to be placed in specific environment (Humidity, Temperature, etc.), and non-availability of spare parts, among other disadvantages.
There is therefore a need for an improved system/setup/configuration for testing/validation of motor specifications.
All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

OBJECTS OF THE INVENTION
An object of the present disclosure is to provide an improved system/setup/configuration for testing/validation of motor specifications.
Another object of the present disclosure is to provide an easy to use system/setup that does not require training of personnel.
Another object of the present disclosure is to provide a system/setup that is inexpensive and affordable.
Another object of the present disclosure is to provide a system/setup that, in case of a new motor, enables the customer to manufacture fixture for the same on his own instead of depending on an OEM/third-party.
Another object of the present disclosure is to provide a system/setup that has low energy consumption, say of less than 800W, including PC and excluding motor.
Another object of the present disclosure is to provide a system/setup that is robust and can be used form 20oC to 55oC.
Another object of the present disclosure is to provide a system/setup that is not impacted by humidity and atmospheric pressure.
Another object of the present disclosure is to provide a system/setup, spare parts of which, are easily available and can be replaced by locally available components.

SUMMARY
This present disclosure pertains to validation of motor specifications, and more specifically relates to quality analysis and benchmarking of obtained motor data.
In an aspect, the present disclosure relates to a system for testing specifications of a motor, wherein the system comprising a VARIAC (Variable Autotransformer) configured to provide desired potential difference and controlled current to motor; a controller operatively coupled with one or more sensors, wherein the one or more sensors are configured to evaluate any or a combination of torque, RPM, voltage, current, input power, and a specification attribute of the motor; and one or more routines stored in a memory, which when executed by a processor of a computing device, enable the controller to receive data from the one or more sensors and output specification results for the motor.
In an aspect, the system enables application of frictional torque on shaft of the motor (110), output of which helps measure at least one attribute of the motor specification.
The system includes a load cell and a load cell controller operatively coupled thereto, wherein the load cell and the load cell controller are configured to measure apparent weight after motor starts to rotate. In an instance, data from the load cell and the RPM sensor can be given to an Analog Voltage measurement device NI USB-6001.
In an aspect, the system can include one or more weights for application of physical torque by friction.
In another aspect, the system can be operatively coupled with a modified rope brake dynamometer for torque measurement, wherein the modified rope brake dynamometer comprises a load cell, and wherein the modified rope brake dynamometer allows rope slippage to enable measurement of torque at different angular speeds, and wherein the modified rope brake dynamometer can include a pulley made of aluminum to reduce self-weight, wherein the pulley is hollowed out to enable additional cooling, and wherein rope used is a nylon friction belt.
In an aspect, system of the present disclosure can be operatively coupled with Remote Optical Sensor for RPM measurement.
System of the present disclosure is further operatively coupled with a power analyzer for measurement of any or a combination of voltage, current, and power input for the motor under test.
Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components

BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
FIG. 1 is an exemplary architecture/construction of the proposed system.
FIG. 2 illustrates an exemplary wiring for the load cell controller and RPM sensor in accordance with an embodiment of the present disclosure.
FIG. 3 illustrates an exemplary representation of how the proposed computing device presents motor test bench.
FIGs. 4A and 4B illustrate exemplary representations of Rope brake dynamometer and its construction.
FIGs. 5A and 5B illustrate exemplary representations of optical sensors used for RPM measurement.
FIGs. 6A and 6B illustrate results obtained by testing different motors (OEM motor, damaged motor, and new motor) using construction of the present invention.

DETAILED DESCRIPTION
The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
This present disclosure pertains to validation of motor specifications, and more specifically relates to quality analysis and benchmarking of obtained motor data.
In an aspect, the present disclosure relates to a system for testing specifications of a motor, wherein the system comprising a VARIAC (Variable Autotransformer) configured to provide desired potential difference and controlled current to motor; a controller operatively coupled with one or more sensors, wherein the one or more sensors are configured to evaluate any or a combination of torque, RPM, voltage, current, input power, and a specification attribute of the motor; and one or more routines stored in a memory, which when executed by a processor of a computing device, enable the controller to receive data from the one or more sensors and output specification results for the motor.
In an aspect, the system enables application of frictional torque on shaft of the motor (110), output of which helps measure at least one attribute of the motor specification.
In another aspect, the system can further include a load cell and a load cell controller operatively coupled thereto, wherein the load cell and the load cell controller are configured to measure apparent weight after motor starts to rotate. In an instance, data from the load cell and the RPM sensor can be given to a USB device NI USB-6001.
In an aspect, the system can include one or more weights for application of physical torque by friction.
In another aspect, the system can be operatively coupled with a modified rope brake dynamometer for torque measurement, wherein the modified rope brake dynamometer comprises a load cell, and wherein the modified rope brake dynamometer allows rope slippage to enable measurement of torque at different angular speeds, and wherein the modified rope brake dynamometer can include a pulley made of aluminum to reduce self-weight, wherein the pulley is hollowed out to enable additional cooling, and wherein rope used is a nylon friction belt.
In an aspect, system of the present disclosure can be operatively coupled with Remote Optical Sensor for RPM measurement.
System of the present disclosure is further operatively coupled with a power analyzer for measurement of any or a combination of voltage, current, and power input for the motor under test.
In an exemplary aspect of the present disclosure, with reference to FIG. 1, the proposed system/apparatus 100 can include a VARIAC (Variable Autotransformer) 102, a controller 104, a combination of one or more routines stored in a memory and executed by at least one processor of a computing device 106, one or more sensors 108, and a motor 110 that is to be tested/validated. In an aspect, the present disclosure can be configured to provide characteristic curve of RPM vs Torque and current at different points, wherein the system works by applying frictional torque on the motor shaft and measuring the RPM, current, and voltage at that instance.
In an aspect, VARIAC 102 can be configured to provide desired potential difference and controlled current to motor. Controller 104, on the other hand, can be enabled to perform speed data acquisition from the one or more sensors 108 and I/Os (Input/Output devices). Routines stored in the memory of the proposed computing device 106 may not need to be stored in the device 106 per se, and can also be retrieved at runtime from a server/cloud, wherein the routines, which when executed by the processor of the device 106, can be configured to perform data analysis, calculations, and display of input parameters (voltage, weight applied, pulley, and rope radius).
In an aspect, one or more sensors 108 can be selected from sensors that are configured to give a pulse every time pulley makes one revolution, wherein, in an exemplary aspect, RPM can be calculated in software at 1Khz.
In another aspect, system of the present disclosure can further include a load cell 112 and a load cell controller 114 operatively coupled thereto, wherein the load cell 110 and the controller 114 can be configured to measure apparent weight after motor starts to rotate. System 100 can further include one or more weights 116 for application of physical torque by friction. FIG. 2 illustrates an exemplary wiring for the load cell controller 114 in accordance with an embodiment of the present disclosure. FIG. 3 illustrates an exemplary representation of how the proposed computing device 106 can show motor test bench, where, as can be seen, multiple graphs such as for RPM vs Torque, RPM, Load, etc can be presented.

Use of Proposed System for Torque Measurement
In an aspect, system of the present disclosure can be operatively coupled with a modified dynamometer, which in an exemplary aspect is a modified rope brake dynamometer. Rope brake dynamometer is typically a form of absorption type dynamometer which is most commonly used for measuring the brake power of the engine. It consists of one rope wound around the flywheel or rim of a pulley fixed rigidly to the shaft of an engine. The upper end of the ropes is attached to a spring balance while the lower end of the ropes is kept in position by applying a dead weight as shown in Fig. In order to prevent the slipping of the rope over the flywheel, wooden blocks are placed at intervals around the circumference of the flywheel. In the operation of the brake, the engine is made to run at a constant speed. The frictional torque, due to the rope, must be equal to the torque being transmitted by the engine. Power of the machine = T? = (F×r) ? = (Mg?s)r. Exemplary representation of the Rope brake dynamometer and its construction is shown in FIG. 4A and 4B.
In the proposed modified rope brake dynamometer, spring balance is replaced by a load cell with a least count of 0.1grams to eliminate human error while noting the readings, wherein, in an aspect, the above construction can be used only for measuring absolute braking power of engine, and therefore the rope is allowed slippage to enable to measure torque at different angular speeds. The torque is absorbed by converting it into heat, hence oil is applied to provide cooling and additional slippage. Pulley is made of aluminum to reduce self-weight and hollowed out to enable additional cooling. The rope used is a nylon Friction belt, since additional slippage is there, wear and tear of rope is reduced significantly.

Torque Calculations:
t=(w_1- w_2 )*(R+r)
t=Torque
w_1= Known Weight
w_2= weight on load cell while motor is spinning
R = Radius of pulley
r = Radius of Rope

The above modified System has no change in data if there is change in coefficient of friction between rope and pulley contact surface.
Proof:
t=(w_1- w_2 )*(R+r)
w_2= w_1- µw_1
t=(w_1-(w_1-?µw?_1))*(R+r)

?t=µw_1*(R+r)

RPM is also being measured,
For RPM=constant
t? µw_1
?µ? 1/w_1 For same RPM
Hence point on graph will shift but remain on the curve.

Use of Proposed System for RPM Measurement
In an exemplary aspect, ROS-W (Remote Optical Sensor) (one of the sensors 108) can be used for measuring RPM, wherein the sensor detects reflective tape on dark background, and wherein the data can be given as pulses in TTL logic. Every time pulley rotates, a reflective tape is detected by the sensor and a pulse is given. FIG. 5A illustrates an exemplary representation of the Monarch ROS-W Sensor.
RPM can also be measured by using a Remote Optical Sensor (one of the sensors 108), which can be used for RPM measurement by contactless optical method. An exemplary representation for the optical sensor is shown in FIG. 5B. In an aspect, threaded stainless steel remote optical sensors have a visible red LED light source and green LED ‘On Target’ indicator. Exemplary Technical Specifications for the sensor can be shown in Table 1 below.
Operating Distance from reflective tape 3 feet (1 m) and 45°
Speed Range 1-250,000 RPM
Operating Temperature -10° to 70°C
Power Required 3.3 to 15 Vdc @ 45 mA
Output Signal TTL Same as Source
Standard Cable 2.4 m
Dimensions 73 x 16mm
Table 1

Use of Proposed System for Measurement of Voltage, Current, and Power Input
In an exemplary aspect, voltage, current, and power input parameters can be measured using a Power Analyser, wherein for voltage measurement, motor wires are connected in parallel, and for current measurement, motor wires are connected in series.

Use of Proposed System for Data Acquisition
In an exemplary aspect, data from load cell 114 and RPM sensor 108 can be given to NI USB-6001 (202 of FIG. 2). In an exemplary implementation, data from energy meter is in Rs485 Modbus RTU protocol, which can be converted to RS-232 Modbus RTU protocol using ADAM – 4520 convertor. Data from all controllers can be fed into the computing device 106 to help calculate, analyze, and tabulate the data.

Exemplary Hardware Specifications
In an aspect, Table 2 below shows technical specifications for Monarch ROS-W Sensor that is used for RPM Measurement by contactless optical method. Threaded stainless steel remote optical sensors have a visible red LED light source and green LED ‘On Target’ indicator.
Operating Distance from reflective tape 3 feet (1 m) and 45°
Speed Range 1-250,000 RPM
Operating Temperature -10° to 70°C
Power Required 3.3 to 15 Vdc @ 45 mA
Output Signal TTL Same as Source
Standard Cable 2.4 m
Dimensions 73 x 16mm
Table-2

In an exemplary aspect, Load Cell 112 used can be Adiartech 20210, which is S Shaped Bending Beam strain gage based Load Cell which is temperature compensated over 0 - 60°C. It is constructed from electrolysis nickel plated high alloy tool steel for harsh industrial shock loads and corrosions. It is universal type load cell for tension and compression load/force/tension measurements.

Table-3 below shows exemplary specification for the controller

Specification Description
Power Supply 24VDC
A/D Converter
Type 24-bit Delta Sigma
Analogue Input Range 0.2mV to 25mV
Linearity <0.02% FS
Conversion Rate 12.5 SPS
Display Accuracy 1/30000
Display & Keypads
LED Display 5 digits 7 segment LED Display
Keypads 4 keys, Menu/Esc key, Enter Key, UP Key and Left Key
Calibration & Weighing
Calibration By test weights
Weighing Functions Auto Zero, Tare En/Dis
Load cells
Excitation 5 VDC
Mechanical Data
Cabinet Size 110mm(L) * 48mm(H) * 96mm (W)
Net Weight 200gm
Environmental
Relative Humidity 90% R.H without dew
IP level Front panel IP55
Table-3
In an exemplary aspect, NI USB-6001 202 is a full-speed USB device that provides eight single-ended analog input (AI) channels, which may also be configured as four differential channels. It also includes two analog output (AO) channels, 13 digital input/output (DIO) channels, and a 32-bit counter. Table-4 shows exemplary specification for the device.

General
Product Family Multifunction DAQ
Measurement Type Digital Voltage
Form factor USB
Operating System Windows
ROHS Compliant Yes
Isolation Type None
Analog Inputs
Single Ended channels 8
Differential Channels 4
Analog Input Resolution 14-bit
Number of ranges 1
Simultaneous Sampling none
Maximum Bandwidth 300kHz
Input Impedence 1GOhm
Analog Output
Number of Channels 2
Resolution 14-bits
Update range 5kS/s
Timing Hardware
Output Impedence 0.2 Ohm
Digital I/O
Bi-directional Channels 13
Timing Software
Logic level TTL/LVTTL
Input Type Sinking/ Sourcing
Counters/Timers
Watchdog Timer NO
Counters 1
Buffered Operations NO
Debouncing/ Glitch Removal NO
Pulse Generation NO
Size 32-bits
USB Power Bus Powered
Table-4

FIGs. 6A and 6B illustrate results obtained by testing different motors (OEM motor, damaged motor, and new motor) using construction of the present invention. In an exemplary aspect, NI USB-6001 202 is a full-speed USB device that provides eight single-ended analog input (AI) channels, which may also be configured as four differential channels. It also includes two analog output (AO) channels, 13 digital input/output (DIO) channels, and a 32-bit counter. Table-4 shows exemplary specification for the device.
While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
The present disclosure provides an improved system/setup/configuration for testing/validation of motor specifications.
The present disclosure provides an easy to use system/setup that dos not require training of personnel.
The present disclosure provides a system/setup that is inexpensive and affordable.
The present disclosure provides a system/setup that, in case of a new motor, enables the customer to manufacture fixture for the same on his own instead of depending on an OEM/third-party.
The present disclosure provides a system/setup that has low energy consumption, say of less than 800W, including PC and excluding motor.
The present disclosure provides a system/setup that is robust and can be used form 20oC to 55oC.
The present disclosure provides a system/setup that is not impacted by humidity and atmospheric pressure.
The present disclosure provides a system/setup, spare parts of which, are easily available and can be replaced by locally available components.