As a key device widely used in industry, transportation, home appliances, and other fields, the performance and reliability of motors directly affect the stable operation of the system. To ensure the proper functioning of motors and improve their efficiency, motor testing programs become crucial. In this paper, a series of programs for various types of motor testing will be overviewed to help readers fully understand the scope and importance of motor testing.

I. Brushless motor test items

A brushless motor is a type of motor that does not have brushes in the motor. Brushless motors usually use electronic commutation technology to drive the motor by switching the current at the right time through a controller. When performing brushless motor testing, the following motor test items are routinely performed:

1、 AC hi-pot: also known as a high-voltage test or hi-pot test, used to detect whether the motor in high voltage can work normally, whether there is leakage and other safety hazards of the motor test program.

2、Insulation resistance test: Test the insulation resistance of the motor to ensure that the insulation performance meets the requirements.

3、Load test: Load test is a kind of test process to evaluate the performance of a motor under different loads by connecting the motor to a certain load and gradually increasing the load to simulate the actual working conditions. The main purpose of the load test is to check the operating characteristics of the motor under different working loads, such as current, voltage, power, efficiency, and so on.

4, Hall test: If the motor uses Hall sensors for position detection, you can test the Hall high and low levels, Hall duty cycle, Hall frequency, and other items to ensure that the sensor works properly.

5、Motor parameter measurement: Measure the rated current, rated voltage, rated speed, and other parameters of the motor.

6. Rotation speed test: A test method to test the speed of a motor under different steering conditions. This item verifies that the motor rotates in the expected direction and is capable of delivering a speed that meets the design requirements under various operating conditions.

7. Noise test: test the noise level generated by the motor during operation.

8. Vibration test: Check the vibration level when the motor is running to ensure the structural stability of the motor.

Ⅱ. Brush motor test items

Brushed motor test items include motor test, rotor test, and brushed motor stator test, which can be used to evaluate the performance of brushed DC motors under different operating conditions. Below are some common brush motor test programs:

1, AC hi-pot test: used to detect whether the motor can work normally under high voltage, whether there is leakage, and other safety hazards of the motor test program.

2、Resistance test: Test the resistance of each phase of the motor to ensure the balance of resistance between the phases.

3, No-load test: under a certain load (or no load), the current, voltage, power, and speed of the motor, to assess the performance of the motor in the actual load (no-load) conditions.

4. Rotation speed test: A test method to test the rotation speed of a motor under different rotation conditions. This item verifies that the motor rotates in the intended direction and is capable of delivering a speed that meets the design requirements under various operating conditions.

5、Armature test: test the motor armature rotor performance, such as bar-to-bar resistance, diagonal resistance, welding resistance, insulation resistance, ac hi-pot, and surge.

Ⅲ. AC motor test items

1, AC hi-pot: used to detect whether the motor can work normally under high voltage, whether there is leakage, and other safety hazards of the motor test program.

2, Insulation resistance: motor insulation resistance is the motor insulation system to the current impedance, usually used to assess the insulation performance of the motor.

3, Surge: to verify the insulation performance of the motor winding and the test, by applying a high voltage test, detect whether there is leakage or breakdown between the windings.

4, DC resistance: The motor DC resistance test measures the resistance of the motor winding by applying DC voltage to evaluate the conductivity and detect the break or contact problem within the winding.

5、No-load characteristics: under the condition of not being connected to the load, the no-load characteristics test can evaluate the current, voltage, power factor speed, and other parameters of the motor, to determine the performance and efficiency of the motor in no-load operation.

6. Low Voltage Starting: Simulates motor starting under low voltage conditions to assess the starting performance of motors in low voltage environments. The test detects the motor's ability to start under unfavorable conditions.

7, inductance: The motor inductance test measures the inductance of the motor windings by applying a varying voltage or current signal. This test helps to evaluate the inductive characteristics of the motor and provides important information for the control and regulation system to ensure proper motor operation.

8. Counter-embedding: Measurement of the electric potential of the motor windings by applying a DC to evaluate the performance of the motor at different speeds and loads.

9, Rotation: by controlling the input signal of the motor, verify that the motor rotates in the expected direction. The steering test ensures that the motor performs the rotation operation correctly during normal operation.

10, cast aluminum rotor test: test motor armature rotor performance, such as broken bars, thin bars, air bubble air gap, resistance, reactance, the largest value, and the smallest value.

Ⅳ. Motor performance test items

1, Motor load performance test: motor load performance refers to the performance of the motor under different load conditions, including torque output, efficiency, power factor, and other parameters.

(1) Motor efficiency: Motor efficiency is a measure of the efficiency of energy conversion of a motor, usually expressed as a percentage. Testing of motor efficiency involves measuring input power and output power and calculating the ratio of the efficiencies. The efficiency of a motor at part load and rated load provides insight into its overall performance.

(2) Torque/Speed Characteristics: The torque/speed characteristic curve describes the torque produced by the motor under different loads and speeds. This is important to understand the motor's ability to adapt to loads and match them. For testing, the torque output of the motor can be measured at different loads and speeds.

2、Motor Friction Torque Testing: Motor friction torque testing is designed to evaluate the frictional resistance to which a motor is subjected during operation, which is an important factor affecting motor performance and efficiency. Friction torque testing can help determine the energy loss of a motor in actual operation, and provide useful information for improving design and efficiency.

3, Motor cogging torque test: motor cogging torque refers to the torque generated by the presence of cogging during the operation of the motor. Cogging torque is a torque generated by the motor rotor during operation. The magnitude of the cogging torque varies periodically with the relative position of the stator and rotor, with an average value of zero, and no external work is done. The cogging torque test can help to understand the performance of the mechanical parts of the motor during operation.

4, Separation torque test: The motor separation torque test is to measure the torque output of the motor by isolating the motor from the load. This test helps to evaluate the torque performance of the motor under different load conditions.

5, Torque fluctuation test: The motor torque fluctuation test assesses the stability and fluctuation of motor torque by measuring the change of motor output torque within a certain period. Torque fluctuation test helps to understand the dynamic characteristics of motor torque in operation.

6, performance test: motor performance test is through a series of test items, such as no-load test, load test, efficiency test, etc., to evaluate the performance of the motor in different working conditions.

7, torque constant test: motor torque constant test is through the application of a known load, measuring the motor output torque and the corresponding current, to calculate the torque constant of the motor.

V. Dynamometer Test Items

The motor dynamometer test program covers many aspects of the motor, including power, torque, speed, temperature rise, voltage, and current parameters. These test results can provide an important reference for the design, manufacture, maintenance, and use of motors, and improve the performance and reliability of motors.

1. Efficiency testing: Dynamometers can be used to evaluate the efficiency of a system under different load and speed conditions. Efficiency is the ratio of output power to input power, usually expressed as a percentage.

2, power test: The motor dynamometer can measure the actual power of the motor, by inputting different load conditions, it can detect the power factor, efficiency, and other performance parameters of the motor. This is important for evaluating the working conditions and performance of the motor.

3， Torque test: Torque test is one of the most basic items in the motor loading test. Through the torque test, the torque performance of the motor under different loads can be detected, to evaluate the output performance of the motor. During the test, the input and output torque of the motor are usually measured to calculate the efficiency of the motor.

4, Overload test: The overload test is used to evaluate the performance of the motor over the rated load. Through the overload test, you can understand the efficiency, temperature rise, and operational stability of the motor under overload conditions. During the test, the load is usually increased gradually until the motor reaches its maximum capacity.

5, Speed test: The motor dynamometer can measure the speed of the motor, by inputting different speed conditions, it can detect the speed stability, torque, and other performance parameters of the motor. This is important for assessing the dynamic characteristics and control accuracy of the motor.

6、Temperature rise test: By measuring the temperature rise of the motor, the motor dynamometer can analyze the thermal performance of the motor under different working conditions. This is important for assessing the life and safety of the motor.

7, Voltage and current test: A motor dynamometer can measure the voltage and current of the motor, by analyzing these parameters, the electrical performance and efficiency of the motor can be assessed. This is important for assessing the design and manufacturing quality of the motor.

8, Vibration and noise test: A motor dynamometer by measuring the vibration and noise of the motor, can analyze the mechanical properties and stability of the motor. This is important for evaluating the motor's operating condition and maintenance needs.

Motor test programs cover a variety of aspects, from performance evaluation to fault diagnosis, all kinds of motor test programs are key elements to ensure the normal operation of the motor, to ensure the qualification rate of the factory motor. With the continuous innovation of motor test technology, motor test systems are also pushing forward, AIP keeps pace with the times and is committed to providing more reliable motor test solutions for various industries.

AIP specializes in global motor testing, free-of-charge motor testers, and motor test solutions to cope with the factory testing of electric motors in different industries!