1 range
This standard specifies the terms and definitions, models, basic environmental parameters and circuit diagrams, requirements, test methods, inspection rules, marking, instruction manuals, packaging, transportation and storage of permanent magnet brushless DC motors.
The electric motors specified in this standard are applicable to various industrial traction motor systems, such as traction motors for oilfield pumping units and traction motors for mining equipment.
2 Normative references
The following documents are essential for the application of this document. For dated references, only the dated version applies. For undated references, the latest version (including any amendments) applies.
GB755-2008 Ratings and performance of rotating electrical machines (idtIEC60034-1:1996)
GB/T1993-1993 Cooling Methods for Rotating Electrical Machines
GB/T2423.17-2008 Environmental testing for electrical and electronic products – Part 2: Test methods – Test Ka: Salt spray (IEC60068-2-11:1981)
GB4343.1-2003 Electromagnetic compatibility requirements for household appliances, power tools and similar appliances - Part 1: Emission
GB/T4772.1-1999 Dimensions and power ratings of rotating electrical machines—Part 1: Frame sizes 56-400 and flange sizes 55-1
GB/T4942.1-2006 Classification of protection levels (IP codes) of enclosures for rotating electrical machines (IEC60034-5:2000, IDT)
GB9969.1-2008 General Rules for Instructions for Use of Industrial Products
GB10068-2000 Mechanical vibration of electric motors with a shaft center height of 56 mm and above – Vibration measurement, evaluation and limits (idtIEC60034-14:1996)
GB10069.1-2006 Noise Determination Methods and Limits for Rotating Electrical Machines – Part 1: Noise Determination Methods for Rotating Electrical Machines (ISO1680:1999, MOD)
GB/T12665-2008 Requirements for damp heat test of electric motors used under general environmental conditions
GB20113-2006-T Electrical Insulation Structure (EIS) Thermal Classification
3. Terms and Definitions
back potential coefficient
A coefficient that reflects the characteristics of the back electromotive force of a motor.
4. Model, Environment, Basic Parameters and Circuit Diagram
Model 4.1
4.2 Environment
4.2.1 Altitude
The altitude shall not exceed 1000m. When the altitude exceeds 1000m, the relevant provisions of GB755-2008 shall apply.
4.2.2 Temperature
When the ambient temperature is between -25℃ and 40℃, the motor and its controller can operate according to the specified rating.
4.2.3 Humidity
The motor and its controller can operate normally when the relative humidity does not exceed 100%, and the motor should be able to operate safely even when its surface temperature is below the dew point, i.e., when condensation occurs on the surface of the motor.
4.2.4 Voltage fluctuation
The voltage fluctuation range of the motor during operation should not exceed 8%.
4.3 Basic Parameters
4.3.1 Enclosure Protection Rating
The motor enclosure protection rating is ≥IP44.
4.3.2 Cooling Method
The motor is cooled by IC00, or customized according to customer requirements.
4.3.3 Insulation Class
The insulation class of the electric motor is ≥B.
4.4 Circuit Diagram
The electric motor consists of two parts: a driver and the motor body (including a position sensor), and its circuit diagram is shown in Figure 1.
5 requirements
5.1 Basic Requirements
The electric motor shall meet the requirements of this standard and be manufactured in accordance with the drawings and technical documents approved through the prescribed procedures.
5.2 Quotas
The motor's rating should conform to the specifications in Table 1. Unless otherwise specified, the data in Table 1 refers to the data during forward rotation. Products can be customized to meet specific customer requirements.
5.3 Mechanical Dimensions and Installation
The mechanical dimensions and installation of the electric motor conform to the provisions of GB/T4772.1-1999.
5.4 Appearance
The motor should have a clean appearance, with no rust, mechanical damage, or peeling coating. The colors and markings should be clear and accurate, the fasteners should be securely connected, and the leads or terminals should be intact and undamaged.
5.5 Electric motor steering
The motor can run in both directions. When viewed from the shaft extension end, the motor should rotate counterclockwise, and this direction is defined as the positive direction; for double shaft extensions, the end without leads (or terminals) is the reference point.
5.6 overspeed
The motor should be able to withstand an overspeed test of 2 minutes of no-load operation at 1.2 times the rated voltage without affecting the motor's performance.
Harmful deformation of energy.
5.7 Temperature Rise Limit
Under the environmental conditions and duty cycle specified in this standard, the electric motor shall meet the temperature rise limit specified in 8.10 of GB755-2008.
5.8 Overcurrent
Under rated voltage and hot conditions, the motor should be able to withstand a short-term overcurrent test of 1.6 times the rated current for 1 minute without stopping or causing harmful deformation.
5.9 Insulation resistance
The insulation resistance between the conductive parts of the motor and the casing should be no less than 10 MΩ in the cold state and no less than 2 MΩ in the hot state; after the alternating damp heat test, it should be no less than 1 MΩ.
5.10 Withstand Voltage
The insulation between the conductive parts of the motor and the casing should be able to withstand a withstand voltage test for 1 minute without breakdown or flashover. The test voltage value is 2UN1000V, with a minimum of 1500V. The frequency of the test voltage is 50Hz, and the waveform is an actual sine wave.
The test voltage after the damp heat test shall be 70% of the standard voltage.
During the test, the leakage current limit of the motor coil shall be implemented in accordance with the provisions of Table 2.
When inspecting and testing motors produced in large quantities continuously, the test time may be shortened to 3 seconds, while the effective value of the test voltage is 120% of the original test voltage. For repeated withstand voltage tests, the test voltage is 80% of the standard test voltage.
During type testing, the withstand voltage test should be performed after the overcurrent test and the overspeed test.
5.11 Back potential coefficient
It should meet the motor design requirements. The difference between the actual measured and calculated values and the theoretical values should not exceed 10%, and the difference between the three back EMF coefficients should not exceed 5%.
5.12 Salt Spray
The salt spray resistance of the motor and controller should meet the relevant requirements in GB/T2423.17-2008.
5.13 Humid and hot
The motor should be able to withstand alternating damp heat test. After the test, the motor should be able to pass the withstand voltage test, which shall be conducted in accordance with the provisions of Table 3. After the test, the motor shall be inspected and there shall be no rotor jamming, and the surface of the motor casing shall be free of obvious rust and paint bubbles.
5.14 Low temperature
The motor should be able to withstand a low temperature test of -25°C, and at low temperatures, the motor should be able to start and run under no-load conditions.
5.15 vibration
The vibration limits for electric motors shall comply with the relevant provisions of GB10068-2000.
5.16 Electromagnetic Compatibility
The radio interference (electromagnetic compatibility) generated by the electric motor during normal operation should not be too great and should comply with the relevant provisions of GB4343.1-2003.
5.17 Noise
When the motor is running at rated voltage, rated speed and rated torque, the noise measured at the A-weighted power level meets the requirements of GB10069.1-2006.
6. Test Methods
6.1 Test Conditions
6.1.1 Environmental conditions
Unless otherwise specified, all tests shall be conducted under the following conditions: Ambient temperature: 15℃-35℃, Relative humidity: 45%-75%.
6.1.2 Electrical measuring instruments
Unless otherwise specified, electrical measuring instruments (excluding megohmmeters) with an accuracy class of not less than 0.5 shall be used during type testing. The accuracy class of digital tachometers shall be not less than 0.1%±1, the accuracy class of dynamometers and torque meters shall be not less than 1.0, the error of temperature measuring instruments shall be within 1℃, the accuracy class of force gauges shall be not less than 1.0, the accuracy of weights shall be not less than Class 5, and the accuracy class of resistance measuring instruments shall be not less than 0.2.
When there is a dispute over the selected instrument, the magnetoelectric DC meter shall prevail.
When selecting an instrument, the measured value should be within 20%-95% of the instrument's measurement range.
At the same speed as the motor under test, the capacity of the dynamometer should not exceed three times the capacity of the motor under test. The nominal torque of the torque measuring instrument should also not exceed three times the rated torque of the motor under test (except for locked-rotor tests); if the accuracy class of the dynamometer or torque measuring instrument is higher than 1.0, the capacity ratio can be relaxed accordingly.
6.1.3 Test Installation Status
The motor is in a horizontal position. The clamping device should not affect the motor's magnetic circuit to avoid measurement errors.
6.1.4 Test Power Supply
The voltage fluctuation range of the DC power supply shall not exceed 5% of the rated voltage.
6.1.5 Measurement Route Diagram
The measurement route diagram is shown in Figure 2.
6.2 Mechanical Dimensions and Installation Inspection
The mechanical dimensions and installation of the electric motor shall be inspected in accordance with the relevant testing methods in GB/T4772-1999, and the test results shall comply with the provisions of 5.3.
6.3 Visual Inspection
The motor should be visually inspected and should meet the requirements of 5.4.
6.4 No-load test
The motor is running under no-load at rated voltage. The motor speed is measured using a non-contact method. At the same time, check for any abnormal noises in the motor. The motor speed should meet the requirements of 5.2.
6.5 Motor rotation check
Visually inspect the direction of rotation of the motor; it should meet the requirements of 5.5.
6.6 Overspeed test
When the motor is running under no-load, the voltage is gradually increased to 1.2 times the rated voltage and then operated for 2 minutes, which should comply with the provisions of 5.6. During type testing, the overspeed test should be carried out under hot conditions.
6.7 Rated data check
The speed, current, and efficiency of the motor under rated voltage and rated torque should be checked and should meet the requirements of 5.2. During type testing, the rated data should be checked after the temperature rise test and under hot conditions; during factory inspection, it should be checked under cold conditions.
6.8 Temperature Rise Test
The temperature rise test shall be conducted using the resistance method specified in 8.5 of GB755-2008, and the test results shall meet the requirements of 5.7.
6.9 Overcurrent Test
The overcurrent test should be carried out after the temperature rise test. Under the rated voltage, the load torque of the motor is increased to make its load current reach 1.6 times the rated current value for 1 minute. The test results should meet the requirements of 5.8.
6.10 Insulation Resistance Measurement
The measurement should be performed using a 500V megohmmeter, and the results should meet the requirements of 5.9.
6.11 Withstand Voltage Test
The test shall be conducted according to the relevant test method in 9.2 of GB755-2008, and the test results shall meet the requirements of 5.10.
6.12 Back EMF Coefficient Detection
Drive the tested motor in any direction to a certain speed n (n = 1/4 to 1/2 of the rated speed nN). Use an oscilloscope to detect the back EMF waveform of the motor at a certain speed (as shown in Figure 3). Record VPP and TP. Calculate the back EMF coefficient Ke(av) according to Equation 2. The test results should meet the requirements of 5.11.
6.13 Salt spray test
The test shall be conducted in accordance with the relevant test methods in GB755-2008, and the test results shall meet the requirements of 5.12.
6.14 Damp heat test
The test shall be conducted according to the alternating damp heat test method specified in GB/T12665-2008, and the test shall consist of 12 cycles. After the test, the insulation resistance of the motor shall be measured immediately inside the enclosure, and then a withstand voltage test shall be performed according to 6.10. The results shall meet the requirements of 5.10 and 5.13.
6.15 Low Temperature Test
Place the motor in a low-temperature chamber and gradually lower the temperature inside the chamber to -25℃±2℃. Keep the motor off for 3 hours. Then, apply 0.5 times the rated voltage to the motor inside the chamber. The motor should meet the requirements of 5.14.
6.16 Vibration Test
Mount the motor on the vibration test plate (the driver does not need to undergo vibration testing), then fix it on the vibration table and vibrate for 1 hour, including 30 minutes in the horizontal direction and 30 minutes in the vertical direction. The test frequency is 10 Hz and the double amplitude is 1.5 mm. After the vibration test, the motor should meet the requirements of 5.15.
6.17 Electromagnetic Compatibility Test
The measurement method for radio interference of electric motors shall be carried out in accordance with the relevant provisions of GB/T4343.1-2003, and the measurement results shall meet the requirements of 5.16.
6.18 Noise Measurement
Noise levels shall be measured in accordance with GB10069.1-2006. During the test, the motor shall operate at its rated speed and rated load under rated voltage. The measurement results shall meet the requirements of 5.17.
7 Inspection Rules
7.1 Purpose of Inspection
Each motor must pass the factory inspection before it can leave the factory and must be accompanied by a product inspection certificate.
7.2 Inspection Items
The inspection items for electric motors are as required in Table 4.
7.2 Inspection Quantity
7.2.1 Factory Inspection
For factory inspection items, the sampling quantity for random inspection items shall not be less than 2% of each batch of products (but not less than 5 units). For non-sampling inspection items, all items shall be inspected upon leaving the factory.
If any non-compliant items are found, the sampling inspection will be doubled until all items are compliant.
7.2.2 Type Testing
At least one motor shall be used for type testing. For motors of different specifications with the same center height, one specification may be selected for testing for the randomized inspection items.
7.3 Necessary conditions for type testing
Type testing must be conducted in any of the following situations.
a) Trial production of new products;
b) For products that have already been finalized, when changes in design, process, or materials are sufficient to cause changes in certain performance and parameters, further action should be taken.
The relevant or all items of the type test;
c) When the results of the inspection test deviate unacceptably from the results of the type test conducted prior to this test.
7.4 Type Test Judgment Rules
For type testing, one unit is randomly selected from the products that have passed factory inspection. If any non-conforming items are found in the test results, the sample size is doubled to retest the non-conforming items. If the retested items are still non-conforming, the product is deemed non-conforming.
8. Marking, Instructions, Packaging, Transportation and Storage
8.1 Mark
8.1.1 Motor Nameplate
Each motor should have a nameplate, which should be securely fixed in a prominent position on the motor body; the nameplate material and the data on the nameplate should be durable and not easily worn away throughout the entire service life of the motor.
The product nameplate should include the following information:
a) Manufacturer's name;
b) Model, serial number, and name;
c) Main parameters: rated power, rated voltage, rated speed, number of phases, duty cycle, cooling method, insulation class, protection class, etc.
8.1.2 Outgoing line markings and grounding markings
The armature winding leads should have appropriate markings or color distinctions, and the markings should conform to the requirements in Table 5. The grounding markings should be clearly defined.
8.1.3 Packaging Markings
The text and markings on the outer wall of the packaging box should be clear and neat, and the content is as follows:
a) Product model, name, and serial number;
b) Net weight of the product and gross weight of the packaging box;
c) The name and address of the receiving unit;
d) The name and address of the manufacturer;
e) The position marker “↑” and the word “Upward” written above the arrow;
f) External dimensions of the packaging box;
g) Packaging date.
8.2 Product Instruction Manual
The product instruction manual should comply with the requirements of GB9969.1-2008.
8.3 Packaging
Product packaging must comply with relevant packaging and transportation regulations to ensure that the product is not subject to mechanical damage during transportation and storage, and has the ability to prevent rain and dust.
The following documents should be included inside the packaging box:
a) Product certificate;
b) Product instruction manual (at least one copy for each batch of motors of the same model for the same user);
c) Packing list.
8.4 Transportation
When transporting electric motors, handle them with care, avoid heavy pressure, and ensure that they are not damaged by impact, rain, corrosive chemicals, or harmful gases.
8.5 Storage
The electric motor should be placed in a clean, well-ventilated warehouse with an ambient air temperature of -25℃ to 55℃ and a relative humidity of no more than 90%, and the air should not contain corrosive gases.
