Product Overview: automotive brake motors are mainly brushless motors. AIP's tester tests the stator, rotor, and motor of the automotive brake tester.
Test objects: motor permanent magnet rotor, motor stator, and motor.
Suitable for motors: This series of products is used for testing the safety and performance indicators of automotive brake motors, for testing motors before they leave the factory, and for customizing test plans based on different motor specifications.
Ⅰ. Test items
1. Permanent magnet rotor test items: back electromotive force, Hall characteristics, phase difference, magnetic distribution;
2. Motor stator test items: DC resistance, AC hi-pot, insulation resistance, surge;
3. Motor test items: motor no-load/load (voltage, current, power), back EMF, NVH test, cogging torque test, performance test, friction torque test, TN curve, etc.
Ⅱ. Features
1. Quick clamping: Design the test fixture according to the motor structure, quickly dock and improve the test efficiency;
2. Ultra-high efficiency: one-time wiring and automatic detection of all test items;
3. Modular design: plug-in structure, convenient for after-sales maintenance, modular functions, no interference between projects;
4. Power-on self-test: When the test system is powered on, it will automatically detect whether each functional module is normal. Abnormal modules will automatically report errors and prompts;
5. Fast data processing: The test system control core adopts an ARM high-speed processor, and the data processing is efficient and accurate;
6. Data sharing: The equipment is connected to the Internet to realize data interaction and resource sharing; it is connected to the MES system, and the test data can be automatically uploaded to the customer server. This function is optional;
7. Remote maintenance: With a built-in network module, the test system can be remotely maintained and upgraded after connecting to the Internet to ensure the timeliness of equipment maintenance.
8. Customized development: AIP automotive brake motor tester can be customized according to motor characteristics and enterprise process requirements to ensure that every defective product is detected.
Ⅲ. Working Principle of automotive Brake Motor
The car brake motor is usually installed near the car's brake drum or brake disc and is connected to the brake system through a mechanical transmission device. When the driver steps on the brake pedal, the car brake motor receives the signal and controls the braking force according to the strength of the signal, thereby achieving the braking effect.
The automotive brake motor is an electric device used to control the brake system. The main function of the automotive brake motor is to achieve smooth deceleration and parking of the car by controlling the size and distribution of the braking force of the brake system.
Ⅳ. Causes of automotive brake motor system failure
1. Circuit problems lead to failure of the car brake motor system;
2. The damage to the automotive brake motor leads to the failure of the automotive brake motor system;
3. The sensor of the automotive brake motor system fails;
4. The control unit of the automotive brake motor system is faulty;
5. External environmental factors are the failure of the automotive brake motor system;
6. Improper maintenance leads to failure of the automotive brake motor system;
7. Unstable power supply is one of the causes of failure in the automotive brake motor system.
1. Motor permanent magnet rotor test items:
Model | Permanent Magnet Rotor Tester |
Test items | Back EMF, Hall characteristics (high and low levels, frequency, duty cycle), phase difference (back EMF, Hall, back EMF, and Hall), magnetic distribution |
Test subjects | Brushless motor rotor |
Test station | Duplex |
Back EMF |
Voltage measurement range/accuracy | 20.0～200.0V ±(0.5%×display value+0.5V) Range can be customized |
Speed setting range | 200-3000rpm ±1rpm Recommended back EMF test speed is 1000rpm |
Phase difference | 0.0-360.0° ±1° |
Hall Effect |
VCC power supply | 3.00～18.00V ±(0.5%×set value+3 words) |
High and low-level range and accuracy | 0.00～18.00V ±(0.5%×display value+3 words) |
Frequency range | 1Hz～599Hz |
Duty cycle/accuracy | 0.0～100.0% ±(0.5%×display value+2 words) |
PG/Hall waveform | Waveform display |
Phase Difference |
Phase difference judgment | Back EMF phase difference, Hall phase difference, Back EMF, and Hall phase difference |
2. Brushless motor stator test items:
Model | AIP891X Series | AIP9863 Series |
Test items | AC hi-pot, insulation resistance, surge, DC resistance, rotation | AC hi-pot, insulation resistance, surge, DC resistance, coil inductance, rotation, back electromotive force, phase sequence, Hall characteristics |
Test subjects | BLDC motor stator (inner rotor, outer rotor) |
Test station | Duplex |
AC Hi-pot |
Output voltage setting range/accuracy | AC 200～3000V ±(2%×setting value+10V) |
Breakdown of current measurement range/accuracy | 0.10～20.00mA ±(2%×display value+5 words) |
Test time range/resolution | 0.5～999.9s 0.1s/step |
Arc Detection | 1 to 9 levels (9 is the highest sensitivity) |
Insulation resistance |
Output voltage setting range/accuracy | DC 500V/1000V ±(2%×setting value+10V) |
Insulation resistance measurement range/accuracy | 1～500MΩ ≤100MΩ: ±(3%×display value+0.5MΩ); >100MΩ: ±(5%×display value+5MΩ) |
Test time range/resolution | 0.5～999.9s 0.1s/step |
Surge testing |
Output voltage setting range/accuracy | 500～3000V ±(3%×display value+8V) |
Sampling frequency | 100MHz |
Waveform comparison items | Area, area difference, corona, phase |
DC resistance test |
Measuring range and accuracy | 10.0mΩ～20KΩ ±(0.3%×display value+3 words) |
Test time range/resolution | 0～999s 0.1s/step |
Temperature compensation function | Configurable |
Inductance test |
Test frequency | 100Hz\120Hz\1kHz\10kHz |
Test level | 0.3V\0.6V\1V |
Test range/basic accuracy | 1µH～2H 0.5% |
Rotation |
Rotation judgment | CW, CCW, Still |
Back EMF |
Voltage measurement range/accuracy | 20～200V ±(0.5%×display value+0.5V) Range can be customized |
Speed setting range | 200-3000rpm Recommended back EMF test speed is 1000rpm |
Phase sequence test |
Phase sequence judgment | ABC \ ACB |
Hall Effect |
VCC Power Supply | 3.00～18.00V ±(0.5%×set value+3 words) |
High and low-level range/accuracy | 0.00～18.00V ±(0.5%×display value+3 words) |
Frequency range | 1Hz～599Hz |
Duty Cycle | 0.0～100.0% ±(0.5%×display value+2 words) |
PG/Hall waveform | Waveform display |
3. automotive brake motor test items:
Test Products | automotive Shift Motor Tester |
Test items | AIP8921-036: AC hi-pot, insulation, surge, resistance, no-load, low start, stall, rotation, PG characteristics; AIP8922-036: AC hi-pot, insulation, surge, resistance, no-load, low start, stalled rotor, rotation (rocker roller); AIP8923-036: AC hi-pot, insulation, surge, resistance, no-load, low start, stalled rotor, rotation (magnetic field induction); AIP8924-036: AC hi-pot, insulation, surge, resistance, no-load |
Test subjects | Single-phase motor (single-speed, multi-speed) |
Test station | Duplex |
AC hi-pot |
Output voltage setting range/accuracy | AC 200～3000V ±(2%×setting value+10V) |
Breakdown of current measurement range/accuracy | 0.10～20.00mA ±(2%×display value+0.05mA) |
Test time range/resolution | 0.5～999.9s 0.1s/step |
Arc Detection | 1 to 9 levels (9 is the highest sensitivity) |
Insulation resistance |
Output voltage setting range/accuracy | DC 500V/1000V ±(2%×setting value+10V) |
Insulation resistance measurement range/accuracy | 1～500MΩ ≤100MΩ: ±(3%×display value+0.5MΩ); >100MΩ: ±(5%×display value+5MΩ) |
Test time range/resolution | 0.5～999.9s 0.1s/step |
Surge testing |
Output voltage setting range/accuracy | 500～3000V ±(3%×display value+8V) |
Sampling frequency | 100MHz |
Waveform comparison items | Area, area differential, corona, phase; the test interface displays three surge waveforms |
DC resistance test |
Measuring range and accuracy | 10.0mΩ～20KΩ ±(0.3%×display value+3 words) Temperature compensation can be set |
Test time range/resolution | 0～999s 0.1s/step |
Measuring range/measuring accuracy | -10.0℃～+50.0℃ ±0.5℃ |
No-load characteristics |
Voltage test range/accuracy | AC: 30～500V ±(0.5%×display value+1V) |
Current test range/accuracy | AC: 0.02～5.0A ±(0.5%×display value+2 words) |
Power test range/accuracy | 0.6-1500W ±(0.5%×display value+5 words) |
Low voltage start |
Voltage test range and accuracy | AC: 30～500V ±(0.5%×display value+1V) |
Current test range and accuracy | AC: 0.02～5.0A ±(0.5%×display value+2 words) |
Power test range and accuracy | 0.6-1500W ±(0.5%×display value+5 words) |
Stall test |
Voltage test range and accuracy | AC: 30～500V ±(0.5%×display value+1V) |
Current test range and accuracy | AC: 0.02～5.0A ±(0.5%×display value+2 words) |
Power test range and accuracy | 0.6-1500W ±(0.5%×display value+5 words) |
Rotation |
Rotation judgment | CW, CCW, Still |
Hall Effect |
VCC Power Supply | 3.00-18.00V ±(0.5%×set value+3 words) |
High and low-level range/accuracy | 0.00-18.00V ±(0.5%×display value+3 words) |
Frequency range | 1～599Hz |
Duty Cycle | 0.0-100.0% ±(0.5%×set value+2 words) |
