Sensing solutions for test benches and development environments of electric drives
The development of electric motors demands high-precision measurement and sensor technologies in the test bench environment. Sensor solutions are primarily used that deliver robust and accurate signals even under high thermal and dynamic loads.
Whether at high rotational speeds, rapid load changes, or demanding test cycles: the sensing system must consistently provide clear, stable, and highly dynamic signals. Maximum accuracy is required for valid test bench results. This enables precisely calibrated motors, more efficient control strategies, and a development process that reaches its goals faster and more reliably.
Our sensor solutions create an innovative test environment that enables vehicle manufacturers to achieve maximum development quality, greater efficiency potential, and shorter time-to-market cycles.
Dynamic E-Flow (DEF) manufactures electric motors for the highest performance requirements and needed a sensor for highly accurate measurement of absolute rotor position and speed – within very limited installation space. "The rotor speed must be detected without bearings, as we use a continuous shaft. In addition, the sensor must be immune to stray magnetic fields, as it is mounted directly on the stator," explains DEF.
Especially for large shaft diameters, suitable solutions for rotor and speed detection are difficult to find. "Lenord+Bauer delivered an extremely robust system, enabling our customers to operate the test bench motors reliably up to the maximum speed and temperature range."
Condition monitoring systems can continuously capture speed, temperature, and vibration data. During an endurance test, the system detects a slight increase in vibration amplitude at the motor shaft – a typical early indicator of incipient bearing fatigue.
The controller then issues a maintenance alert, allowing the affected bearing to be replaced at an early stage before consequential damage occurs. This keeps the test bench highly available for further development and validation cycles.
