Description:MOTOR TEST BENCH WITH CLIMATIC CHAMBER
TECHNICAL FIELD
[001] The present disclosure relates to electric vehicle motor, more particularly relates to a test bench for testing electric vehicle motor under various test conditions including various climatic conditions with synchronous and continuous recording of all raw data continuously or as snapshots per set point (electrical signals, torque, speed, temperature, acceleration, CAN bus and much more ) for post-processing.
[002]
BACKGROUND
[003] The existing test bench for EV motors may be broadly classified into two categories i.e., test bench with climate control and one without climate control.
[004] In accordance with a prior art the test bench with climate control may require placing the entire driveline in a climatic chamber. In set-up as disclosed all the mechanical components are set up and placed in a climatic chamber. The mechanical components may include ac dynamometer, torque flange/ torque transducer, flexible coupling, the base frame of the driveline, test motor & its mounting bracket. The drawback of such a system is the huge climate chamber configured to enable such a setup.
[005] To overcome the limitation of the above set-up an overhang-mounted test motor placed in a portable climatic chamber may be used. In this arrangement, there are two setups. The first setup comprises the driveline i.e., ac dynamometer, torque flange/ torque transducer, flexible coupling, base frame of driveline, test motor and its mounting bracket. While the second setup comprises a climatic chamber unit. In this arrangement drive line & test motor position is fixed. Further, the test motor is mounted on a bracket in an overhang position. The climatic chamber is movable having a port hole which allows easy entry & exit of the test motor thru it. At the time of testing climatic chamber is parked such that the test motor will go inside thru a port hole. The drawback of such a system is moving the entire climate chamber including the test motor. Further, the overhang generates additional vibrations which require additional dampers. Also in such setups, it is difficult to mount Foot Mounted Motors as well as Wheel Hub Motors.
[006] To overcome the above limitation there is a need for a test bench configured to allow testing of plurality types of EV motors. Further, the test bench setup should be portable, flexible and easy to handle.

OBJECTS OF THE INVENTION
[007] The principal object of this present invention is to evaluate the impact of certain environmental conditions on Motor Testing performance.
[008] Another object of this invention is to enable easy handling of a portable climatic chamber so it can be easily detachable from the base frame and allow the user to access the test motor easily.
[009] Yet another object of the invention is to observe and generate closer real test results of the test motor by using a Road Load Simulation Mode wherein the Road Load Forces such as Road Friction, Air Drag, Inertia and Gradient are simulated on the EV Motor under test. The Road Load Simulation Mode helps to observe and generate closer-to-real test results of the EV Motor (test subject) within the confines of a Laboratory.

SUMMARY
In an implementation of the present disclosure, a test bench for testing a plurality type of motors is disclosed. The test bench may comprise a base frame. Further, a stool may be mounted on the base frame. In accordance with the implementation, an asynchronous dynamometer may be mounted on the stool, further, the asynchronous dynamometer may be a type of AC servo induction motor and is connected to the test motor using a flexible disc coupling. The test bench may further comprise a high-low-temperature chamber. The high-low-temperature chamber is configured to enclose the test motor mounted in the high-low-temperature chamber. A set of rails may be further provided to enable sliding of the high-low-temperature chamber with respect to the stool, and the high-low-temperature chamber is positioned at the distal end of the stool. The test bench further includes a control system. The control system is configured to test the test motor in different test modes such as Road Load Simulation Mode, Constant Torque and Constant Speed Control Closed Loop Modes.

BRIEF DESCRIPTION OF DRAWINGS
[0010] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer to features and components.
[0011] Figure 1 illustrates a test bench, in accordance with an embodiment of the present subject matter.
[0012] Figure 2 illustrates an embodiment of the test bench, in accordance with an embodiment of the present subject matter.
[0013] Figure 3 illustrates another embodiment of the test bench, in accordance with an embodiment of the present subject matter.
[0014] Figure 4 illustrates yet another embodiment of the test bench, in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION
[0015] Some embodiments of the present disclosure, illustrating all its features, will now be discussed in detail. It must also be noted that as used herein and in the appended claims, the singular forms "a", "an" and "the" include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, system discloses a test bench for testing a plurality type of motors, is now described.
[0016] A motor test bench with a climatic chamber is disclosed for performance as well as endurance testing of synchronous as well as asynchronous ac servo induction motors variants. Motors are tested for different torque & speed test points (rated torque, peak torque, stall torque). The control system along with ac drive helps to control the ac dynamometer in constant torque, constant speed mode and road load simulation mode. This setup facilitates the evaluation of the test motors in all 4 quadrants of operation. The climatic chamber allows testing of the motors under variable temperatures with uniform humidity conditions having the following features:
- Temperature range: air cooled refrigeration system & heater arrangement allow to set temperature from -10°c to 70°c. Heat input will be controlled by solid-state relays through a microprocessor programme. Heaters are located in the conditioning space which avoids direct radiation of heat on the test subject.
- Low-pressure moisture generator is provided to generate moisture & add humidity in the chamber for uniform humidity conditions.
- Single-stage air-cooled refrigeration system is provided with a semi-hermetic compressor. Environment-friendly refrigerant R404A is used.
- Work space: 600 x 600 x 600 mm (work space is customisable & depends on frame size of test motors).
- Unique feature of the chamber is; it is portable & mounted on rails. So it gets easily detached from the base frame & allows the user to access the test motor easily.
- For certain tests, if a user prefers to perform without the chamber and in open test cell ambient conditions within an external blower fan, in such case without disturbing the EV Motor (fixture), without disturbing the connected driveline, the Chamber can be undocked/disengaged from the test bench and slide back using V Rails and parked at a convenient location. The process of unlocking the Chamber from the Test Bench is a quick process and can be completed in a short time.
- Similarly, when the Chamber is required to be put back in operation for any cyclic thermal tests, the Chamber can be slid in perfect alignment using the ground V Rails and docked /engaged with the test bench within a very short time.
- Interior of the climatic chamber is of 18 SWG Stainless Steel 304 argon arc welded.
- Exterior of the climatic chamber is 18 SWG CRCA MS sheet Powder coated.
- Insulation: 100mm thick rock wool/glass wool insulation.
[0017] In accordance with another exemplary embodiment, a test bench may comprise an asynchronous dynamometer. The asynchronous dynamometer may be mounted on a stool, and further, the stool may be mounted on a base frame. Further, the asynchronous dynamometer may be a type of AC servo induction motor. The asynchronous dynamometer may further be connected or coupled to the test motor.
[0018] A flexible disc coupling may be configured to enable the coupling of the asynchronous dynamometer with the test motor. Further, a flange may be provided to couple the asynchronous dynamometer to a driveline, and further may be mounted on an output shaft of the asynchronous dynamometer. The disclosure further discloses a torque measurement verification kit. The torque measurement verification kit may be configured to perform periodic torque measurement verification for the flange. In accordance with the exemplary embodiment a dyno coupling locking arrangement may be mounted on a drive end of the output shaft of the asynchronous dynamometer. The dyno coupling locking arrangement may enable the mounting of a torque measurement verification kit.
[0019] In accordance with the exemplary embodiment, the test bench may further comprise a test motor driveline adaptor. The test motor driveline adaptor may be coupled with a flexible disc coupling of the output shaft of the test motor. The flexible disc coupling may further enable coupling between the asynchronous dynamometer and an intermediate bearing pedestal. The intermediate bearing pedestal may be a self-aligning type, life lubricated, and may be further provided in close proximity to a high-low-temperature chamber.
[0020] Further, the test motor may be enclosed in a high-low-temperature chamber. The high-low-temperature chamber may be mounted on a set of rails. The set of rails may be provided to enable sliding of the high-low temperature chamber with respect to the stool or the base frame. The high-low-temperature chamber may be moved towards and away from the test motor such that the high-low-temperature chamber encloses or enables access to the test motor.
[0021] Referring to Figure 1 illustrates an exemplary embodiment of a test bench in accordance with the present disclosure. The test bench 100 as disclosed comprises an asynchronous dynamometer (1). The asynchronous dynamometer may be an AC servo Induction Motor. Further, the asynchronous dynamometer (1) may have a compact dimension with a high dynamic response. The asynchronous dynamometer (1) may be connected to the test motor. The test motor may be selected from a plurality type of elective vehicle (EV) motor using a flexible disc coupling. A flange may be further provided, to couple the asynchronous dynamometer (1) to a driveline and is mounted on an output shaft of the asynchronous dynamometer (1). Further, the flange may be suitable for a rated torque range of 200 Nm with a 0.05 accuracy class.
[0022] The asynchronous dynamometer (1) may further comprise a torque measurement verification kit (4). The torque measurement verification kit (4) may be configured to perform periodic torque measurement verification for the flange. The torque measurement verification kit (4) may further comprise a calibration arm, a counterbalance arm with Rider Weight, a weight pan assembly, and one set of calibration weights to verify the full torque rating of the Dynamometer (S1 Duty).
[0023] The test bench may further comprise a dyno coupling locking arrangement (5). The dyno coupling locking arrangement (5) may be mounted on a drive end of the output shaft of the asynchronous dynamometer (1). Further, the dyno coupling locking arrangement (5) may be used for locking the flange during calibration using the torque measurement verification kit.
[0024] The asynchronous dynamometer (1) may be mounted on a stool (2). The stool (2) may be configured to maintain a workable centre height of about 850 mm from ground level. Further, the stool (2) may be stress relieved and designed to withstand dynamic shocks and ensure the asynchronous dynamometer (1) rests on four points. The asynchronous dynamometer (1) may be coupled to an intermediate bearing pedestal (7) by a flexible disc coupling (6). The flexible disc coupling (6) may be capable to transmit nominal & peak torque of 190 Nm & 250 Nm respectively with an inertia of 0.003 kg.m². Further, the flexible disc coupling (6) may support a maximum axial misalignment of +/-2.4 mm and a maximum angular misalignment of 2 x 0.75 degrees.
[0025] The flexible disc coupling (6) along with the intermediate bearing pedestal (7) is also configured to enable coupling between the test motor. The flexible disc coupling (6) may operate between temperature ranges - 10° to 70° C. Further, the intermediate bearing pedestal (7) may be a self-aligning type, life lubricated, bearings & keyed shaft and is in close proximity to a high low-temperature chamber (13). The high-low-temperature chamber (13) enables testing of the test/EV motor under variable temperature conditions. The temperature range of the chamber may be -10° C to 70°C ± 1°C in a steady state. The test chamber may comprise of an air-cooled refrigeration system and a heater for temperature conditioning. Further, a fan may be provided in a blower for continuous air circulation.
[0026] The high-low temperature chamber (13) may be further mounted on a set of rails (14). The set of rails (14) may be provided to enable sliding of the high-low-temperature chamber (13) with respect to the stool (2). Further, the high-low-temperature chamber (13) is positioned at the distal end of the stool (2).
[0027] The test bench may further comprise two distinct types of fixtures to enable the mounting of the test motor on the stool (2) and the base frame (9). The first fixture may be a fixture for a foot or flange-type EV motor, and the second fixture may be a fixture for a wheel hub-type EV motor. The foot or flange-type EV motor may be mounted on a T-slotted common base frame (9). The fixture would cater for the mounting of one such variant only. Further, the wheel hub type EV motor (also referred to as Outer Rotor type) may be mounted on the T slot.
[0028] The base frame (9) may ensure easy & quick alignment of an asynchronous dynamometer (1) w.r.t the test motor. Further, the base frame (9) may be stress relieved and designed to withstand the Dynamic shocks. The base frame (9) may be mounted on levelling cum anti-vibration mounts that enable it to level off the frame as well as dampen low amplitude vibrations which may arise during testing.
[0029] The test bench may further comprise a trolley (10) for mounting the current transducer. The current transducers/sensor may be mounted on a wooden base as insulation media. Further, the trolley (10) can be parked in close proximity to the EV Motor under test. Further, a control system (11) having a combination of PC, PLC & HMI screen is disclosed in accordance with embodiment. The control panel (11) may be configured to execute end-of-line test logic, log the test results, and print vehicle pass or not pass labels after completion of the test.
[0030] The test bench may further comprise a spot cooling blower. The spot cooling blower may be a centrifugal blower enabling airflow on the test motor body and taking away some of this heat by convection. The airflow of the blower may be 1800 m³/hr with a noise level of the blower is 75 dBA @ 1 metre.
[0031] The test bench may further comprise a sheet steel guard with suitable thickness to secure and provide safety against rotating assemblies during testing. Further pivotal cover and quick-release mechanical lock may be provided.
[0032] Further, a test motor driveline adaptor (16), wherein test motor driveline adaptor (16) is provided to couple the flexible coupling (6) with the output shaft of the test motor.
[0033] Figure 2 illustrates an embodiment of the test bench, in accordance with an embodiment of the present subject matter. The test bench may comprise a test motor (12). Further, the test motor maybe a foot or flange type EV motor, or wheel hub type EV motor. Further based on the type of motor there may be two distinct types of fixtures (8) to enable the mounting of the test motor on the stool (2) and the base frame (9). The first fixture may be a fixture for a foot or flange-type EV motor, and the second fixture may be a fixture for a wheel hub-type EV motor. The foot or flange type EV motor, or wheel hub type EV motor (also referred to as Outer Rotor type) may be mounted on a T slotted common on the base frame (9).
[0034] Figure 3 illustrates another embodiment of the test bench, in accordance with an embodiment of the present subject matter. The test bench may further comprise a trolley (10) for mounting the current transducer. The current transducers/sensor may be mounted on a wooden base as insulation media. Further, the trolley (10) can be parked in close proximity to the EV Motor under test.
[0035] Figure 4 illustrates yet another embodiment of the test bench, in accordance with an embodiment of the present subject matter. The test bench may further comprise a control system (11) having a combination of a Digital Embedded PC Based Dynamometer Control System, a GUI comprising of the latest configuration commercial PC with LabVIEW-based data acquisition, test sequencing and report generation unit in accordance with the present invention. The control system (11) is configured to execute EV motor performance tests, durability tests, efficiency tests and short-duration power tests in different modes of Asynchronous dynamometer (1) and EV under different ambient conditions.
[0036] In an exemplary embodiment of the present invention, the Control system allows Real-time/offline calculations with traceability formulas on all channels simultaneously with a full sample rate of 2 MS
- Instantaneous Power, Apparent Power, Active Power, Reactive Power etc.
- Mechanical torque, speed, and angle; mechanical power
- Efficiency, lambda, Fundamental power, cos Phi
- Space Vector and DQ0 Transformation
- Torque Ripples and Cogging Torque Measurements
- Back EMF Calculation
- Flux Calculation & Flux Maps
- Noise and Vibration Measurements
- Winding Temperature Measurements
- Ability to Analyse 3 to n-phase systems, n-phase motors or motor generators.

[0037] The test bench as disclosed in the exemplary embodiment may provide the following advantages:
- High accuracy in the measurement of torque, power, and efficiency;
- Test specimens adjustable from -10 °C to 70 °C with cooling medium.
- Adaptations are also possible for motor-gearbox combinations;
- Comprehensive programming and data acquisition;
- Pressure humidification with fast response times
- Easy for handling as it is a portable climatic chamber so it can be easily detachable from the base frame & allow the user to access the test motor easily.
- The test bench (100) for testing a plurality type of motors (12) may comprise:
an asynchronous dynamometer (1),
a stool (2),
a flange (3),
a torque measurement verification kit (4),
a dyno coupling locking arrangement (5),
a flexible disc coupling (6),
an intermediate bearing pedestal (7),
two distinct types of fixtures (8)
a base frame (9),
a test motor (12),
a high low temperature chamber (13),
a set of rails (14),
a control system (11) to simulate Road Load Simulation mode.
[0038] The foregoing objects of the invention are accomplished and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiment. Detailed descriptions of the preferred embodiment are provided herein; however, it is to be understood that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure, or matter. The embodiments of the invention as described above and the methods disclosed herein will suggest further modification and alterations to those skilled in the art. Such further modifications and alterations may be made without departing from the scope of the invention.
, Claims:I/We claim:

1. A test bench (100) for testing a plurality type of motors (12), the test bench (100) comprising:
a base frame (9);
a stool (2) mounted on the base frame (9);
an asynchronous dynamometer (1) mounted on the stool (2), wherein the asynchronous dynamometer (1) is a type of AC servo induction motor and is connected to the test motor (12) using a flexible disc coupling (6);
a high low-temperature chamber (13), wherein the high low-temperature chamber (13) is configured to enclose the test motor (12) mounted therein; and
a set of rails (14), wherein the set of rails (14) are provided to enable sliding of the high low-temperature chamber (13) with respect to the stool (2), and the high low-temperature chamber (13) is positioned at a distal end from the stool (2).

2. The test bench (100) as claimed in claim 1, further comprises an encoder based on feedback to provide closed-loop speed control.

3. The test bench (100) as claimed in claim 1, further comprises a flange (3), wherein the flange (3) is provided to couple the asynchronous dynamometer (1) to a driveline and is mounted on an output shaft of the asynchronous dynamometer (1).

4. The test bench (100) as claimed in claim 1, further comprises a torque measurement verification kit (4), wherein the torque measurement verification kit (4) is configured to perform periodic torque measurement verification for the flange (3).

5. The test bench (100) as claimed in claim 1, further comprises a dyno coupling locking arrangement (5) mounted on a drive end of the output shaft of the asynchronous dynamometer (1).
6. The test bench (100) as claimed in claim 1, further comprises a flexible disc coupling (6), wherein the flexible disc coupling (6) enables coupling between the asynchronous dynamometer (1) and an intermediate bearing pedestal (7).

7. The test bench (100) as claimed in claim 1, wherein the intermediate bearing pedestal (7) is a self-aligning type, life lubricated, and is further provided in close proximity to the high-low-temperature chamber (13).

8. The test bench (100) as claimed in claim 1, wherein the base frame (9) is mounted on levelling and anti-vibration mount.

9. The test bench (100) as claimed in claim 1, further comprises a test motor driveline adaptor (16), wherein the test motor driveline adaptor (16) is provided to couple the flexible coupling (6) with the output shaft of the test motor.

10. The test bench (100) as claimed in claim 1, wherein the asynchronous dynamometer (1) and the test motor (12) are mounted on the base frame (9), and further the high low-temperature chamber (13) is moved towards and away from the test motor (12) such that the high low-temperature chamber (13) encloses or enables access to the test motor (12).

11. The test bench (100) as claimed in claim 1, further comprises a control system (11), wherein the control system (11) is configured to test the test motor in different test mode such as Road Load Simulation Mode, Constant Torque and Constant Speed Control Closed Loop Modes.