Electric Motor Testing - Test Stands

Electric Motor Testing for Performance Evaluation

Testing of motors such as brushless DC (BLDC) motors is commonly undertaken in order to evaluate and characterize performance under real-world conditions, such as when combined with a propeller in the propulsion system of a manned or unmanned aircraft.

By finding the most optimal combination of motor and propeller, system designers can ensure that the aircraft’s flight time, range, fuel efficiency and payload capacity are maximized. For applications such as rotary aircraft, different motor configurations can be trialed, including single-axis, coaxial and offset.

Test Stands for Electric Motors

Electric motor testing stand by Tyto Robotics

Electric motors are often tested using a specialized test stand, which can be used to measure a wide range of characteristics including thrust, torque, voltage, current, RPM and efficiency. Thrust stands may be rated for their ability to measure up to a specific value of thrust or torque.

Electric motor test stands can often be programmed to automatically carry out a range of test programs. These include step tests that change parameters such as throttle percentage at set intervals, and sweep tests that smoothly ramp up through a range of values.

Test stand software can log test results and use the data to plot graphs such as motor efficiency versus RPM or propeller efficiency versus thrust, allowing developers to make optimal design decisions.

Motor Testing for Endurance & Quality Control

Electric motor testing may also be carried out to determine the longevity of the motor and its response to certain environmental conditions. Motors may be put through long-duration tests to find out when components will fail and to determine their useful lifespan, as well as loading tests to determine fatigue conditions.

Other environmental tests that electric motors may undergo include vibration, acoustic noise, dust and water ingress, icing, and temperature. These tests may take place in specialized test chambers or wind tunnel facilities. Environmental motor testing may be critical for ensuring that systems can pass safety tests and obtain vital certification.