Motor Assembly & Testing
Connect repeated motor assembly with resolver alignment, dimensional checks and measured torque-speed performance. Select compatible teaching and test stations for the required tasks.
The Training Route
Follow the motor from mechanical assembly and resolver alignment through dimensional and magnetic checks to measured operating performance.
Practise stator, rotor and end-cover assembly with the specified fixtures, fastening sequence and inspection tools.
Document the assembly checks required before the motor proceeds to a powered test.
Fit and zero the resolver, then record coaxiality and magnetic-flux measurements using a repeatable procedure.
Explain how the alignment and measurement records support the assembly inspection.
Use a compatible performance station for approved motor tests and record the load, temperature and measurement conditions.
Interpret torque-speed performance and compare results obtained under documented conditions.
The Equipment Combination
Use T036 for motor assembly, resolver alignment and mechanical checks, with a compatible T076 station for operating-performance exercises. The selected motor, controller, coupling, supply and load define the permitted test envelope.
Training Equipment
Practice motor assembly, resolver adjustment and mechanical inspection before investigating selected circuit faults.
Training Equipment
Explore motor performance through controlled load tests, speed and torque measurements, and curve analysis.
| Item | Teaching Configuration |
|---|---|
| Assembly motor, T036 | PMSM; 80 V DC; rated power ≤15 kW / peak power ≤29 kW; rated torque ≤30 N·m / peak torque ≤110 N·m; peak speed ≤7,500 r/min; class H insulation, S9 duty in the reference configuration. |
| Assembly control and measurement | CAN-H/CAN-L and USB-CAN interface; printed circuit panel with insulated 2 mm test terminals. Controller voltage range is a subsystem specification, not permission to exceed the motor rating. |
| Performance station, T076 | Test equipment rated power ≥11 kW; 380 V AC three-phase five-wire supply. Confirm selected motor, coupling and load configuration. |
| Dynamometer envelope | Rated speed ≥2,000 r/min; maximum speed ≥4,000 r/min; rated torque ≥30 N·m; measurement range ≥50 N·m. Confirm exact ordered limits. |
| Measurement specification | Speed accuracy ±0.1% full scale; torque accuracy ±0.2% full scale; speed resolution 0.1 r/min; data update interval 20 ms. |
| Teaching tasks | Stator and rotor assembly, end-cover installation, resolver fitting and zeroing, magnetic flux density and coaxiality measurement, followed by approved performance tests. |
| Mechanical preparation | Confirm assembly fixtures, press and measuring tools, fastening procedures, guarding and the inspection criteria used before energizing. |
From Equipment to Teaching
Move groups from assembly inspection and alignment records to approved powered tests, using common measurement procedures and documented conditions for comparisons.
Make resolver fitting, zeroing and verification a scored part of motor assembly. Learners complete the model-specific inspection and alignment procedure before any powered test, giving the instructor a clear record of readiness.
Use the specified fixtures and fastening procedure to support correct end-cover seating and alignment. Record coaxiality and clearance checks, and investigate an out-of-tolerance assembly before allowing it to proceed to a powered test.
Define a repeatable probe position, orientation and instrument procedure for magnetic-flux measurements. Ask each group to explain its recorded values in relation to the motor model and approved torque-speed data, making comparisons meaningful.
Use a matched load system and document setup, temperature and load conditions for each run. Review calibration, sensor ranges and the T076 measurement specification before asking learners to interpret differences between their recorded performance curves.
Pair an accessible assembly unit with the fixtures and instruments needed for resolver, coaxiality and magnetic-flux checks. Use each inspection record to prepare for the next stage of the course.
A compatible performance station connects the completed assembly with torque-speed results. Agree the motor, controller, coupling, supply and load envelope before planning powered exercises.
Project Experience & References
Use the named competition’s dated device and task files alongside applicable 1+X assessment rubrics for the selected motor configuration.
A drive motor performance test bench was delivered to the Beijing Commercial School open industry-education practice center. The company also supplies e-drive competition equipment and a motor assembly simulation title for procedure rehearsal.
The documented competition simulation package includes ≥80 operation steps per project and reference-matched fault logic. Confirm the licensed title and hardware version for the present course.
The T076 specification states torque accuracy ±0.2% full scale, speed accuracy ±0.1% full scale and 0.1 r/min speed resolution. These expressions must be interpreted against the actual selected sensor range.
Request the current specification sheet, measurement and calibration documents, a demonstration report and the compatible motor/load schedule. Record the confirmed speed and torque limits in the acceptance plan.
Application FAQs
Do not assume that. The T036 reference specification lists rated power ≤15 kW and peak power ≤29 kW, while T076 has its own speed, torque, power and coupling limits. The supplier must confirm a compatible test configuration and approved operating envelope for the intended exercises.
A cutaway is useful for component recognition. Assembly competency also requires alignment checks and evidence that the completed unit meets inspection criteria. A compatible performance station adds measured operating results where the course calls for them.
Record the assembly inspections, resolver verification, coaxiality and flux measurements, followed by permitted performance data. Use the same documented conditions for each group and keep virtual simulation scores separate from observed physical competence.
