Temperature test stand for rotor position sensors

Rotor position sensors control a critical function in modern electric motors. Their reliability matters most at extreme temperatures. In electrified vehicles they have to work accurately and stably in arctic cold and in blistering heat, even at continuous speeds above 20,000 rpm.

Extreme temperatures affect electronic parts, circuit boards, insulation and mechanical components. Development and quality assurance therefore have to study temperature effects together with rotational dynamics, for example how eccentricity or thermal expansion changes the sensor signal.

Typical test requirements

• Temperature testing from -40 °C to +180 °C
• Speeds up to ±30,000 rpm
• Simulation of fault patterns (e.g. tilt, eccentricity)
• Monitoring of the sensor output and evaluation of signal distortion
• Safety equipment for burst or imbalance events

The TMX temperature test stand for rotor position sensors

TMX has extensive experience with high-speed and temperature testing. The TMX temperature test stand for rotor position sensors combines mechanical stability, thermal control and precise closed-loop control in one highly dynamic test system. It runs at up to 30,000 rpm, covers -40 °C to +180 °C, reproduces real fault patterns and records every relevant signal at high resolution.

Test stand mechanics

The test stand is built on a highly stable base with a temperature chamber:

• Water-cooled high-speed motor, directly coupled through the chamber wall
• Vibration-damping base frame
• Dedicated fixture for mounting the target
• XYZ positioning system to simulate fault patterns (e.g. eccentricity, tilt)
• Burst protection for rotating parts

Drive and control

The drive follows highly dynamic speed profiles:

• Speeds up to ±30,000 rpm
• Control via frequency inverter with fine ramp control
• Adjustable acceleration to simulate real load changes

Measurement and control technology

The automation delivers accurate measurements and flexible fault handling:

• Measurement of fault pattern positions in X, Y and Z
• Measurement of temperatures and speeds of the devices under test
• Monitoring of the chamber temperature
• Real-time monitoring of the sensor signals

Operating software

The software is easy to use and supports detailed analysis:

• Configuration of all test parameters in the TMX test sequence editor
• Real-time display of the measurement signals
• Guided user interface for safe operation
• Fully automatic reports including fault pattern analysis and temperature curve

Summary

The TMX temperature test stand is designed to test rotor position sensors under extreme conditions. It combines high speeds, flexible fault pattern simulation and precise temperature control. Manufacturers and developers use it to validate these critical components and to find weak points early.