Endurance test stand for rotor position sensors

Rotor position sensors are central components of electric drives. They capture the angular position of the rotor with high accuracy and pass it to the motor controller in real time. Only this makes precise torque control and high efficiency possible.

If the sensor fails, the whole system can fail with it. To secure the required quality, rotor position sensors have to be tested under realistic extreme conditions: high speeds, fast acceleration and deceleration, changing temperatures and cyclic loads. Endurance tests with environmental profiles show that the sensors keep working reliably, even after many years.

Typical test requirements

• Long-term testing over several hundred days
• Parallel testing of several devices (typically six) for statistical evaluation
• Realistic temperature cycles (e.g. -40 °C to +180 °C)
• Speeds up to 24,000 rpm, ramps up to 25,000 rpm/s
• Monitoring of all sensor values, with abort logic on malfunction

TMX endurance test stands for rotor position sensors

TMX develops fully automated endurance test stands designed for rotor position sensors. The systems combine high dynamics with precise control, flexible software and continuous data acquisition, matched to your requirements in development or quality assurance.

Test stand mechanics

The mechanics are built around a standard temperature chamber with six integrated test stations:

• Temperature chamber with feedthroughs for motor and signal cables
• Six vibration-isolated high-speed motors
• Rotors (targets) mounted on the motor shafts
• Stators held in a dedicated mounting cage, in their real installation position in the vehicle
• Stone blocks damp vibration of the drive units

Drive and control

Each device under test has its own drive and control:

• Speed range up to ±24,000 rpm
• Acceleration up to 25,000 rpm/s
• One frequency inverter per drive unit
• Ramp and cycle control for realistic profiles

Measurement and control technology

The measurement and automation technology provides accurate acquisition and continuous monitoring:

• Distributed measurement system with fast sampling for each device under test
• Acquisition of all sensor signals: speed, temperature, voltage, current, output signal
• Online evaluation and trend analysis
• Fault detection with a configurable response for each device (e.g. individual shutdown)

Operating software

The test stand software is easy to use and powerful:

• TMX test sequence editor for simple configuration
• Guided user interface for setup and test execution
• Live display of the status of every device under test
• Automatic PDF reports

Summary

The TMX endurance test stand for rotor position sensors is a future-proof test solution for automotive use. In series quality assurance or development validation, the test stations deliver robust results and adapt to new test scenarios, with simple operation and high test stability.