Designing an Electrical Motor Dynamometer Test Stand

[steverhnm]

Could someone point me in a better direction that I am presently going? I have a need to test several AC & DC electrical motors ranging from ~8 to ~77 in-Lbs (full load torque) and free-running RPMs from 5,000 to 12,000, and 1-6 HP (not respectively, these are just ranges). I don't have a lot of information on the motors. I have looked at Magtrol and a few other places that build electrical motor testers but I have had limited success. I would like to do full range speed torque curves as well as load points, locked rotor torque, and torque from the motor's brake.

I have been trying to learn as much as possible but I have come across the concept of using a VFD as a dynamometer and it has me interested in learning more. I an an instrumenation & controls tech, not a motor engineer. I would like to do the software and systems integration (LabVIEW) , whatever data acquisition is required, but would be interested in buying the mechanical portion of an integrated system (speed, torque, motor control, voltage & current sensors, etc).

I have had limited success searching the internet.

Can you point me to any locations that might have:

1. whitepapers or articles on the subject of building electrical motor test stands for motors in this range?

2. A good book on the subject?

3. A systems house that may do partial engneering or consulting? Most manufacturers are hesitant to let out partial systems, they want to integrate the entire thing.

 

[MikeHalloran]

I think you could use a VFD _and_another_motor_ as a dynamometer. That would simplify your DUT brake testing a bit. You'd still need torque and RPM measurement, mechanical guards, couplings, structure, cooling, data collection and user interface hardware, etc.,

... and probably most of a year of your time to tie it all together, write and debug the software, write and re-write the documentation and training materials and such.

If the cost of your time is not hidden somehow, e.g. coming out of overhead or some other project's budget, then whatever Magtrol might propose is going to look cheap, in hindsight,

... to your replacement.



Mike Halloran
Pembroke Pines, FL, USA

 

[DickDV]

Actually, using a regen VFD just might be the simplest solution. You will need a special motor at those rpm. Electric Appratus Company in Brighton MI is a good source. ABB makes regen ACS800 drives that are perfect for these speeds and loads and will do a good job without an encoder.

I have done at least a dozen of these test cells for military hydraulic pump manufacturers with speeds up to 22500rpm and hp's up to 500.

If you are in the USA and need application help, I'm available.