Endurance test bench for DC motors

Electric motors must not only be highly efficient but also withstand adverse environmental conditions and operate reliably over the entire service life of a vehicle. Depending on the application, such motors must also be controllable in their power output or remain in sleep mode until they are "woken up" by commands from the bus system in the vehicle.

Manufacturers and suppliers serve a global market with applications in the temperature range from -40 °C to well over 70 °C and with enormous humidity. These, sometimes extreme, climatic conditions have to be simulated over several weeks or months during the validation of the engines in endurance tests.

CARMEN repeatedly runs the above-mentioned load scenarios under climatic conditions over a very long period of time and monitors thereby the parameterised limits. In a selection or random sampling test, components are tested for fatigue and wear by means of load tests, e.g. under pressure and temperature changes.

These CARMEN endurance test systems are designed in such a way that a gap-free and time-synchronous recording of all measurement data over a long period of time is guaranteed and enables subsequent analysis. For reasons of time, several test objects must usually be tested simultaneously (up to 4 channels) in endurance testing. CARMEN therefore controls several test sections in parallel and records or logs the results.

Since not all working ranges from idling to block usually have to be controlled dynamically and without gaps in the service life test, simpler hysteresis brakes, mechanically fixed brakes or even systems without a load unit can also be implemented here. If there are previous CARMEN tests and thus test sequences, these can now also - thanks to the uniform system software - be transferred very easily and quickly to the endurance test or the environmental simulation test .

In the case of several simultaneously operated measuring sections, this process then takes place n-fold in parallel. The analysis of all these measurement data then takes place after the end of the test in offline mode. It is also possible to connect a climate chamber.

electronic control via LIN bus or pulse width modulation
dynamic current measurement from 0.5 µA to 100 A without signal gaps at the measuring range limits of a voltage measurement up to 100 V
detection of smallest fault currents under climatic conditions (e.g. penetration of moisture)