High speed test bench

几十年来，由于缺乏电力电子设备，用于驱动旋转机械的三相电机被限制在3000 rpm或更低的速度，这导致了点式优化单元。直到20世纪90年代，随着可靠、低成本电力电子设备的出现，才有可能以其他速度驱动电机，而不必使用变速箱(这在许多方面都是不利的)，也不必使用容易磨损的直流电机。有了变频器，三相电机现在可以达到每分钟3000转以上的速度。根据应用的不同，工具主轴的速度可能会达到10,000 1/分钟，电动牙钻或电动涡轮增压器的速度甚至会超过100,000 1/分钟。这种高速度具有各种优势，例如显著提高资源利用率(通过相同功率的更高速度缩小尺寸)或通过取消变速箱提高效率、动力性、使用寿命和成本。然而，由于工艺的原因，高速也可能是必要或有利的，例如在涡轮压缩机(燃料电池充电器或废气涡轮增压器)、涡轮分子真空泵、高速车削和铣削应用、飞轮蓄电池的电机发电机、微型燃气轮机或离心机驱动器的发电机中。申请人的工作组已经在研究由特殊材料制成的电机，与传统实现的电机相比，这种电机的损耗更低，特别是在高速和高频下。共同申请者正在研究：(I)非常适合驱动高速电机的高速变频器；(Ii)在高速应用中吸收转子离心力的碳纤维增强塑料(CFRP)绷带；(Iii)碳纤维增强塑料部件(如轴)，这些部件将接受高速测试，然后进行机械测试的超声波检测。申请者和共同申请者的工作组在研究重点《高效技术系统》方面密切合作。目前，高速应用的研究工作受到缺乏高速试验台的限制，无法测试和优化在现实条件下开发的解决方案，并获得新的项目。因此，需要采购一种合适的大型设备。它由主要部件机架、四象限运行主动负载机、高性能变速箱和高精度测量装置(如扭矩传感器、振动计、电流互感器等)组成。该大型装置极大地扩展了研究重点《高效技术系统》的性能范围，可供所有附属工作组和研究所使用。

For decades, three-phase electric motors for driving rotating machines were limited to speeds of 3,000 rpm and below due to the lack of power electronics, which resulted in point-optimized units. It was only with the availability of reliable, low-cost power electronics in the 1990s that it became possible to drive the electric machine at other speeds without having to use a gearbox, which is disadvantageous in many respects, or wear-prone DC motors. With frequency converters, three-phase motors can now reach speeds beyond 3,000 rpm. Depending on the application, this can be several 10,000 1/min for tool spindles, and even more than 100,000 1/min for electric dental drills or electric turbochargers. Such high speeds have various advantages, such as the significant improvement in the use of resources (size reduction through higher speeds with the same power) or the improvement in efficiency, dynamics, service life and costs through the elimination of the gearbox. However, a high speed can also be necessary or advantageous due to the process, for example in turbo compressors (fuel cell chargers or exhaust gas turbochargers), turbomolecular vacuum pumps, high-speed turning and milling applications, motor-generators for flywheel accumulators, generators for micro gas turbines or centrifuge drives. The applicant's working group is already researching electric motors made of special materials that have lower losses compared to conventionally realized electric motors, especially at high speeds and frequencies. The co-applicants are researching: (i) high-speed frequency converters, which are excellent for driving high-speed electric motors; (ii) CFRP (Carbon Fibre Reinforced Plastic) bandages for absorbing centrifugal forces on rotors in high-speed applications; (iii) CFRP components such as shafts, which are to be subjected to a high-speed test followed by ultrasonic detection for mechanical testing. The working groups of the applicant and co-applicants cooperate closely in the research focus "Highly efficient technical systems". The research work on high-speed applications is currently limited by the lack of a high-speed test bench to test and optimise the solutions developed under realistic conditions and to acquire new projects. A suitable large-scale device is therefore to be procured. It consists of the main components machine frame, active load machine in 4-quadrant operation, high-performance gearbox and high-precision measuring devices (such as torque sensor, vibration meter, current transformer). The large-scale device significantly expands the performance spectrum of the research focus "Highly Efficient Technical Systems" and can be used by all affiliated working groups and in-institutes.