Choose the card

Total need analog input the number four, analog output 2 roads, count 2 roads, digital input 7 roads, digital output 12 road. Choose the simulation acquisition card company NI PCI-6024 boards, it has eight road different analog input, 2 road analog output, the sampling rate for 200 KS/s, 12 bits, 2 "count, 8 road digital I/O port.
Another piece of the card for rotating joint digital acquisition card PCI-6503: It has 24 road I/O port.
The overall design

• Engineers first in C opened several plate text files, files are respectively, motor performance parameters, such as voltage, current, rotary speed of the upper index; Motor vibration parameters index upper; Vibration sensor calibration coefficient; The magnetic powder brake nonlinear adjustment coefficient and so on. Every time to rotary union run the program, the first read the above a few data in a text file, as a good indicator of discrimination motor and testing coefficient. To do the benefit is that the key parameters can be only by the engineer to have the right to modify, and operators cannot be modified, avoid man-made test error. (motor testing interface as showed in figure 1.)

Figure 1, motor performance and vibration testing interface
In order to guarantee the test voltage of the motor-the correctness of the motor end in adding two root feedback lines, by manostat automatic adjustment. Manostat also choose the type controllable, namely the simulation acquisition card output a 0 ~ 5 V variable signal, to control the output voltage stabilizer. This helps to ensure that the test voltage of the motor of the accuracy and program control.

• magnetic powder brake also chooses the controllable type manostat, different test torque chooses different working voltage. Because the magnetic powder brake is non-linear element, in order to ensure the correctness of the test torque, the engineers in the motor testing rotating disc below the installation of the torque sensor after adjustments, and design the car set-up procedures.

Calibration method for: first in motor rotate the test to install a lever. One end of the crane in leveraged 500g farmer, read the torque sensor signal as the accepts the standard. Again ordinal, hanging 1000g and 1500g and 2000g, various farmers, read the electrical signals differences.
Will leverage and Jordan farmer take go to, in the test fixture to
fiber optic rotary joint install a measured motor current and only the rotation, and then gradually heightening the magnetic powder brake input voltage, then the output of torsion sensor signal also gradually raised, when achieved more different output signal value of Jordan farmer respectively to record the magnetic powder brake input voltage, the voltage is the point of the load voltage, again according to two yuan a equation, and separately calculated between two adjacent of K and B value, you will get the magnetic powder brake arbitrary point the approximation of the work load voltage.

• speed test of the encoder chooses PEPPERL + FUCHS the product of the company, the resolution for every turn 2500 pulses. Using simulation acquisition card two of the 6024 count, measured be measured the speed of the motor and motor rotation angle, the work in LabVIEW software in the example has, as long as the copy over can use.
• current signal sampling chooses 30 A / 75 mV 0.2 magnitude of current in the shunt, and of the current transmitter, becomes 0 ~ 5 V voltage to the acquisition card analog input terminal.
• voltage signal sampling chooses 0 ~ 30 V / 0 ~ 5 V voltage signal isolating device, will 0 ~ 5 V voltage to the acquisition card analog input terminal.

Vibration measurement of the PCB-choose acceleration sensor and amplifier, every time when measuring the punching bag with sensors will be put down, sensor magnets suck in motor on cabinet measurement, the vibration signal "had nine windows" and "spectrum" after the analysis and processing of output waveform vibration. In 10 ~ 4500 Hz frequency ranges are divided into four frequencies, the vibration of each frequency band with a different quantity of the upper and lower limits of used to find the defects of different motor.
At the same time, a group of motor continuous measurement vibration signal, uses the time domain analysis to identify. CGM (case Growl Measurement chassis Noise Measurement): It is used to identify rotor motor rotates cycle of the pulse signal waveform, can be measured in each rotation of motor rotor vibration signal within a week of the maximum and minimum value. It can be found that many motor defects, such as worm gear and worm commutator defect, the bearing store have scratched etc. PRI (Pulse Ratio Index Pulse rate coefficient): it can be found that the axis of tolerance, beat two points on a bending and axial commutator surface have scars, etc.