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Electric Motor Dynamometer |
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With the help of a Motor Dyno, the Electric Vehicle hardware can be tested as a complete system before it is shipped out. In this photo, the top motor is under control of the DC controller, and the bottom BLDC motor generates power to go back to the battery pack. This allows very high power levels to be used and only energy lost in the process to be supplied by the AC line. With the Dyno on the bottom, this little 6.7" ADC motor produced ~65ft/lbs of torque at 500A of motor current...Not bad for a motor this size. ---The new Dyno is on the right!-- |
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This Dyno below had problems with the belt skipping teeth after a few runs (with 1" wide pulleys) with 350A-400A at the motor. It has now been replaced with much wider 3.5" pulleys and belt on the right, along with a massive idler to transmit torque to the load cell. No more belt skipping and 500A+ current capability! When the current is cranked up, you can hear the belt start to whine! |
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-BEFORE-
Could do the job for awhile until the belt was stretched too much! |
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-AFTER-
The new Dyno was built with torque production in mind.Teflon guides were used in the new Dyno, to help stabilize the belt under load. A much larger idler was needed to handle the 3" wide belt. The new battery pack
on the right is now 12 Hawker AGM's with 144V on tap. When the Dyno is spinning the BLDC motor, the pack gets a partial recharge from the BLDC's 3 phase rectified output voltage to a PWM buck circuit, then to the battery pack. Still some calibration and checkout to do along with needing a higher current readout of current generated back to the pack! |
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-BELOW-
LabView below helps with the data collection efforts on the new Dyno. Some results are here for this poor 6.7" ADC motor. Not only has it held up, but performed better than expected for such a small motor!
Battery Pack is 144VDC for this test |
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