Electric motors power our world. From refrigerator compressors and smartphone actuators to electric vehicle (EV) drivetrains, electric motors are helping to make modern life a reality wherever we go. In fact, we're so used to relying on electric motors that we often only come to our attention when they don't work – a problem that can be prevented with motor testing.
The importance of motor testing
Motor testing is essential to ensure the reliability, efficiency, and safety of the motors we rely on. These tests, performed at various stages of the motor lifecycle, provide essential information about the overall health of the motor and provide many benefits to designers, manufacturers, technicians, and consumers.
Motor testing can improve:
Reliability: Testing identifies potential problems and allows for predictive maintenance to prevent failures and extend the life of the motor.
Efficiency: Through testing, technicians can address electrical energy issues, resulting in less loss and lower operating costs.
Safety: To protect the people who use the motor, the test reveals potential hazards such as electric shock or fire.
Performance: By evaluating characteristics such as speed and energy consumption, testing can reveal opportunities for performance improvements.
R&D: Collect data through testing to inform the creation of more advanced motor technology.
Standards compliance: Motors can be tested to verify compliance with all applicable industry standards before they are deployed for use.
Motor test type:
While the specific tests performed will vary depending on the complexity of the motor, the application, and the parameters to be evaluated, some of the key tests used in motor testing include:
- Electrical testing, such as polarity checks and voltage level measurements.
2. Vibration testing to detect any imbalance or misalignment.
3. Thermal test, which is used to monitor the temperature of the motor to avoid overheating.
4. Dynamic testing to see how the motor behaves in transient conditions.
5. Noise tests to evaluate acoustic properties against sound standards.
6. Insulation testing to ensure that the insulation material of the motor does not deteriorate during operation. Some examples include megohmmeter testing, high-voltage (high-voltage testing) testing, and surge testing—tests that look for turn-to-turn, coil-to-coil, and phase-to-phase defects that cause electrical faults.
The industry standard for motor testing
In all motor applications, from industrial compressors to dental drills, testing helps verify that the motor meets the specifications set by the manufacturer and the quality and safety parameters (such as energy consumption and sound pressure level) determined by industry standards.
In order to meet industry standards, motor testing must meet international and local requirements. At the international level, standards such as interoperability and security are consistent across countries, while local standards may include requirements that recognize specific national priorities, such as environment and culture. Some of the agencies that have created and implemented these standards include:
American Electrical Manufacturers Association: https://www.nema.org/standards
International Electrotechnical Commission: https://www.iec.ch/government-regulators/electric-motors
Japan Industrial Standards Survey: https://www.jisc.go.jp/eng/
British Standards Institution: https://standardsdevelopment.bsigroup.com/search/Standards?Term=Motors&Source=category
National Standard of the People's Republic of China: http://mee.gov.cn/
Motor test tools
Are you testing a wind turbine or a transportation system, an industrial fan or an elevator, and there are many different types of tools available for motor testing, depending on the parameters and characteristics you are evaluating. Some of these tools include:
Power analyzer: Measure electrical parameters such as voltage and current to diagnose electrical connections.
Tachometer: Measure the speed of the motor.
Thermal imaging camera: Captures temperature changes to identify hot spots and cooling issues.
Megohmmeter: Measure the insulation resistance of a motor's windings to detect insulation deterioration (also known as a megohmmeter).
Torque sensor: Torque is measured by converting mechanical rotation into an electrical signal.
Simulation in electric motor testing
While physical testing is essential for gaining insight into motor performance, it has limitations. Simulation helps technicians extend testing by looking inside to reveal exactly what is going on inside the motor, both now and in the future, as well as showing the deepest inside the motor.
With simulation, engineers can explore various design options for different operating scenarios and make adjustments before production, during production, and even when the motor is in use. Especially in cases where physical testing is limited by a lack of visibility (due to the size or location of the test), simulation can quickly perform the calculations required for an accurate assessment. Some common motor tests that require the use of simulation include:
Electrical test: Measure the back electromotive force (EMF) in a brushless permanent magnet motor.
Thermal Testing: Evaluates overheating during continuous operation of the S1.
Dynamic testing: Predict short-circuit faults in brushless permanent magnet motors and measure stalled rotor performance in AC induction motors.
The use of simulation in electric motor testing not only increases the speed and efficiency of the test process itself, but also improves the quality, depth, and reliability or certainty of the data collected. Simulation software, such as Ansys Maxwell and Ansys Motor-CAD, performs coupled multiphysics calculations to provide technicians with comprehensive evaluations of complex systems that cannot be achieved by performing one test at a time.
By leveraging simulation to run physical tests in a virtual environment, engineering teams can save time and money. In addition, simulation reduces the number of design iterations and identifies problems before any hardware is built. This results in a better, more robust design and ensures that there are no surprises when it comes to physical testing.
The test reveals the answer
Many of the most important functions in modern society rely on the reliability, safety, and efficiency of electric motors. Through testing, we gain valuable observations, knowledge, and insights that will lead us to the next generation of technological advancements in power generation that will continue to move humanity forward.
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