Motor Test Bench

I. Core Components of the Test Bench

Power System

Drive Unit: Provides hydraulic or electric drive to simulate speed and torque under actual working conditions (e.g., variable-frequency motor or hydraulic power station).

Loading Device: Applies reverse load to the motor via magnetic powder brakes, hydraulic dynamometers, etc., to test its output performance.

Testing Modules

Flow & Pressure Control: Precisely regulates the flow and pressure of drilling fluid (or hydraulic oil) to simulate working parameters at different well depths.

Speed/Torque Sensors: Real-time monitoring of motor output speed, torque, and power.

Temperature Monitoring: Tracks temperature changes in critical components (e.g., motor housing, stator/rotor).

Data Acquisition & Analysis System

Sensor Network: Synchronized multi-parameter acquisition (pressure, flow, temperature, vibration, etc.).

Software Platform: LabVIEW, MATLAB, or dedicated software for data visualization, curve generation (e.g., torque-speed characteristic curves), and report export.

Auxiliary Facilities

Drilling Fluid Circulation System: Simulates downhole conditions, including mud tanks, filtration units, etc.

Safety Protections: Overpressure alarms, emergency shutdown, explosion-proof design (for high-pressure or flammable media).

II. Test Items & Standards

Performance Testing

No-Load Test: Checks starting torque and minimum starting flow.

Load Test: Measures torque, speed, efficiency, and pressure drop under rated conditions.

Endurance Test: Evaluates wear, sealing performance, and lifespan via prolonged operation.

Dynamic Characteristic Analysis

Step response tests (e.g., sudden load changes).

Vibration and noise spectrum analysis.

Compliance Verification

Meets API standards (e.g., API 7-1) or internal corporate standards.

III. Typical Test Procedures

Pre-Test Checks: Seal integrity verification, sensor calibration.

Parameter Setup: Input flow rate, pressure, load gradient, etc.

Phased Testing: Gradual operation from low to full load with data recording.

Fault Diagnosis: Issues like sudden efficiency drops or abnormal vibrations may indicate stator rubber aging or rotor wear.

Report Generation: Summarizes performance parameters and compares them with design targets.

IV. Technical Challenges & Solutions

High-Pressure Sealing: Dual-face mechanical seals or bellows structures.

Stator Rubber Adaptability: High-temperature (>150°C) simulation tests for rubber expansion rate.

Data Synchronization: High sampling rate (≥1 kHz) ensures dynamic data accuracy.

V. Application Scenarios

R&D Phase: Motor design optimization (e.g., rotor profile, lead number).

Factory QC: Ensures each motor meets performance benchmarks.

Post-Maintenance Validation: Performance re-testing after overhauls or stator replacements.