As automotive motor manufacturing moves towards automation, digitalization, and intelligence, traditional testing methods that rely on manual clamping, repetitive wiring, and step-by-step inspection are no longer sufficient to meet the demands of modern production lines for testing efficiency, data consistency, and quality traceability.

Recently, AIP Instrument successfully delivered a six-station automated motor testing workstation to an automotive motor manufacturer, enabling automated testing of multiple items in automotive brake-by-wire motors and providing customers with a testing solution integrating automatic testing, intelligent scheduling, and data management.

Ⅰ. Six workstations working together to achieve fully automated testing.

This workstation is specifically designed for testing automotive brake-by-wire motors. It consists of six independent testing systems and achieves automated testing of multiple items through unified scheduling.

The six testing systems include:

■ Safety and back EMF testing system: Completes hi-pot, insulation, resistance, inductance, and back EMF tests, and automatically analyzes RMS value, peak-to-peak value, phase difference, Ke, and multiple harmonics.

■ Load performance testing system: Automatically completes TN test (1500 rpm, CW/CCW) and generates speed-torque curve and electrical parameter curve.

■ Torque fluctuation test system: Collects torque fluctuation values, maximum value, minimum value, and average torque, and performs order analysis.

■ Gear Cogging and Friction Torque Testing System: Through high-precision tooling, adaptive calculation, and filtering decoupling, it extracts weak gear cogging torque signals and generates waveforms.

■ Torque constant testing system: Automatically completes three-phase tests of UV, VW, and WU, and calculates the torque constant Kt for each phase.

■ No-load vibration testing system: measures triaxial vibration acceleration and performs spectrum analysis to help identify vibration problems such as rotor imbalance, uneven air gap, bearing defects, and electromagnetic forces.

From feeding, pressing, clamping, and inserting the shaft to testing, removing the shaft, and unloading, the entire process is completed automatically by the workstation.

Multiple tests can be completed with a single wiring connection, integrating the originally scattered testing processes into a continuous automated testing process, reducing manual operation and repetitive clamping.

II. Intelligent and modular design to adapt to multi-model production needs

To meet the diverse testing needs of automotive motor manufacturers, this workstation adopts a modular and intelligent design.

1. Modular configuration

The six test modules are independent of each other and can be selected to perform full-item testing or disable specific test items according to actual needs, supporting configurations for no less than 1,000 motor models.

2. MES System Integration

By connecting to the factory's MES system via a network interface, test data can be automatically uploaded and interacted with, reducing manual recording and data entry and improving the efficiency of production data management.

3. Abundant communication interfaces

Equipped with USB, LAN, RS232, and other interfaces, it supports TCP/IP network protocol, making it easy to integrate the device with the factory's existing systems and expand it in the future.

4. Remote diagnostics and maintenance

It supports device status diagnosis, software updates and upgrades, and fault maintenance via the Internet, improving the convenience of device operation and maintenance.

III. AIP: Committed to becoming a leading global supplier of motor testing solutions

The successful delivery of this six-station automated testing workstation demonstrates AIP's technical and project implementation capabilities in the fields of multi-project comprehensive testing of motors, automated system integration, and intelligent testing.

For automotive motor manufacturers, automated testing not only helps reduce manual operations and improve the consistency of testing processes, but also provides support for production data management and quality traceability.

In the future, AIP will continue to focus on the field of motor testing and promote the development of testing technology from single-machine automation to production line-level and factory-level collaborative development.

AIP is committed to becoming a leading global supplier of motor testing solutions, providing one-stop motor testing solutions.