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E-Motor Test Rig / Dynamometer
Rev 03
Spark Product Innovation was part of a consortium to
develop an innovative lightweight electric motor using
thermoplastic composites via Innovation UK funding.
The motor being developed was high torque low
speed; catalogue test rigs didn’t meet the project
needs. Spark Product Innovations role was to create a
test rig customised to the motor which had fluid
requirements due to the R&D nature of the project.
We are now using this test rig to test, develop and
qualify several custom 3 phase motor controllers for
our clients.
25Nm 6000 RPM magnetic brake capable of
delivering high torques at zero RPM. (higher
torques are possible with reduced duty
cycles.)
High accuracy 50Nm inline rotary torque
sensor capable of 4000 samples per second
for high-resolution measurements.
Input power measurements (between the
inverter and the motor). This test rig uses an
oscilloscope-based system; 2 x current
probes and 2 x voltage probes (Blondels
Theorem) with high bandwidth power
measurement software. Other methods could
also be used.
Logging software to record the speed, torque
and power.
Transparent Polycarbonate safety enclosure
mounted on a T slot table to ensure accurate
alignment of the drive train.
S co p e
Create a customised high torque
electric motor test rig for a lightweight
composite 3 phase Brushless DC
(BLDC) motor
Solu t ion
Spark Product Innovation created a
3KW 25Nm motor test rig with a
configurable magnetic brake, high
accuracy torque/speed sensor, motor
controller, input power
measurements, AC\\DC power
supply, configurable mounting
brackets and an
aluminium\polycarbonate safety
cage.
Contac t Deta i l s
Spark Product Innovation Ltd
Bristol & Bath Science Park
Dirac Crescent, Emersons Green
Bristol, BS16 7FR
T: +44(0)1172441915
www.sparkpi.co.uk
A b ou t
Spark Product Innovation is a multi-
discipline team specializing in
electronic PCB design, software,
embedded firmware, DSP, power
electronics, inverters, FPGAs. We
also offer product packaging to give
our customers a complete turnkey
solution.
Serv ices
Electronic and software design
services
Mechanical packaging
Prototyping
System, electronic and motor
testing
Low and medium volume
Manufacturing
Automatic Test Equipment
Feasibility studies
Contac t Deta i l s
Spark Product Innovation Ltd
Bristol & Bath Science Park
Dirac Crescent, Emersons Green
Bristol, BS16 7FR
T: +44(0)1172441915
www.sparkpi.co.uk
Rev 03
System Architecture
Brake Speed / Torque Curve
Speed, Torque, power and time
stamps recorded.
Up to 4000 samples per second.
Input parameters from the inverter
and/or input power meter can also be
logged.
25Nm 6000 RPM magnetic brake
capable of delivering high torques at
zero RPM.
Higher torques are possible with
reduced duty cycles.
2.5kW input power curve shown –
batteries or 3 phase AC input could
provide higher power curves.
System architecture diagram showing
the key items in the test rig.
Logging SW
