QC/T 792-2022Motors and controllers for electric motorcycles and electric mopeds (English PDF)

3.1 Wheel with the outer shell of motor integrated

The motorcycle driving wheel, whose wheel hub and motor casing are made into an integral part.

3.2 Continuous torque

The specified maximum torque that can work continuously for 30 minutes.

3.3 Continuous power

The specified maximum power that can work continuously for 30 minutes.

3.4 Rated speed

The motor speed at which the specified continuous power is output.

3.5 Peak torque

The maximum torque, that can be used for short periods of time.

3.6 Peak power

The maximum power, that can be used for short periods of time.

4.1 Motor model

The model of the motor shall consist of four parts: frame number, product name code, performance parameter code, derivative code.

Marking example:

4.1.1 Frame No.

The frame number of the wheel with the outer shell of motor integrated is the nominal diameter code of the wheel hub, which is specified in GB/T 13202-2015. The frame number of the outer rotor's wheel without the outer shell of motor integrated. The frame number of the inner rotor's motor is the outer diameter of the stator core of the motor (in millimeters).

4.2 Controller model

The model of the controller consists of 4 parts: product name code, voltage level, current level code, derivative code.

Marking example:

4.2.2 Voltage level

The controller adopts DC voltage input. The voltage level is indicated by the nominal voltage value of the DC bus of the controller. If it is less than three digits, add a 0 in front.

4.2.3 Current level code

The current level of the controller is indicated by the integer value (three Arabic numerals) of the maximum DC input current of the controller. If there are less than three digits, add a 0 in front.

5.1 General requirements

The motor shall be idling flexibly, without fixed-rotor friction or abnormal noises (such as periodic abnormal noises, abnormal noises caused by damaged bearings, or abnormal noises caused by foreign objects stuck in the rotating parts, etc.).

5.2 Environmental conditions for use

The motor and controller shall be able to work normally under the following conditions.

5.4 Appearance

The surface of the motor and controller shall be free of rust, bruises, cracks, peeling of the coating. The fasteners shall be firmly connected. The lead wires shall be intact. The contents of nameplate of the motor and controller shall be correct; the words shall be clear; the background color shall not fade.

5.5 External dimensions and installation dimensions

The external dimensions and installation dimensions of the motor and controller shall comply with the provisions of the technical documents of the enterprise.

5.7 Sealing performance of cooling circuit in liquid cooling system

For liquid-cooled motors and controllers, there shall be no leakage, when subjected to a pressure not lower than 200 kPa.

5.13 Phase deviation of position sensor

The phase deviation of the motor position sensor shall be within the range, which is stipulated in the technical documents of the enterprise.

5.14 Direction of rotation of the motor rotor

The direction of rotation of the motor rotor shall comply with the provisions of the product technical documentation.

5.15 No-load current

The motor runs at the rated voltage and at the speed specified in the technical documents of the enterprise, for 5 minutes without load. The bus current shall not be greater than the limit value, which is specified in the technical documents of the enterprise.

5.17 Speed control accuracy, torque control accuracy

For the motor system, which has speed control function and torque control function, the control accuracy of speed and torque shall meet the requirements of product technical documents.

5.22 Controller efficiency

The maximum efficiency of the controller, under rated voltage and rated input current conditions, shall not be less than 95%.

5.24 Controller's adjustment function

The controller for open-loop control shall have the function of motor terminal voltage regulation. The controller, whose outer loop is speed closed-loop control, shall have the function of speed regulation. The controller, whose outer loop is torque closed-loop control, shall have the function of torque regulation.

5.30 Motor and controller mass

The mass of the motor and the controller shall be within the scope, which is stipulated in the technical documents of the enterprise.

5.31 Temperature rise

The working temperature rise of the armature winding of the motor shall comply with the temperature rise limit, which is specified in GB/T 755.

5.32 Low temperature

After placed in cold power-off state at the ambient temperature range of -25 °C ± 1 °C for 2 hours, the insulation resistance of the motor and controller shall meet the low temperature requirements, which are specified in Clause 5.9. The motor and controller shall be able to start in cold state without load. The performance of the motor and controller, after standing still to room temperature, shall meet the requirements of 5.16.2.

6.2 Appearance

visual inspection.

6.3 External dimensions and installation dimensions

It is detected by general gauge.

6.5 Sealing performance of cooling circuit of liquid cooling system

Fill the cooling circuit with cooling medium. Make the cooling medium fill the cooling circuit. Empty the air in the cooling circuit. Block one end of the cooling circuit of the sample under test. No deformation affecting the sealing performance can occur. Then gradually increase the pressure to the value specified in 5.7.

6.7 Insulation resistance

Use a megohmmeter, for measurement.

6.8 Withstanding voltage

Use a withstanding voltage tester, to perform withstanding voltage test.

6.9 Stator resistance

Use a DC bridge or other instruments, that meet the accuracy requirements, to measure the resistance of the stator windings of each phase of the motor.

6.10 Stator inductance

Use an inductance bridge, to measure inductance of the stator windings of each phase of the motor, at a frequency of 1000 Hz.

6.11 Phase deviation of position sensor

Use an oscilloscope to simultaneously measure the phase deviation of the back EMF of the motor and the signal of the corresponding position sensor. The phase deviation shall be within the range, which is specified in the technical documents of the enterprise.

6.12 Direction of rotation

Correctly connect the motor and controller. Visually observe the rotation direction of the motor, after power on.

6.13 Motor no-load current

After the motor runs at rated voltage for 5 minutes without load, measure the bus current of the controller, which is the no-load current of the motor.

6.17 Motor overspeed

Fix the motor on the test bench. Use the motor method (motor no-load method) or external power equipment dragging method, to make the motor run at 1.2 times the maximum operating speed for 2 minutes without load; there shall be no abnormal sound during the test. After the test, carefully inspect the rotating parts of the drive motor for damage or unwanted deformation, or loose fasteners.

6.19 Rated input current of controller

Fix the motor on the torque tester. Connect the controller and the motor correctly. Apply the rated voltage to the controller. Adjust the adjustment command, to make the motor run at the rated speed without load. After the operation is stable, the steering torque tester gradually increases the motor torque, until the input current of the DC bus of the controller reaches the rated input current of the controller, which is specified in the technical documents of the enterprise, for a duration of 2 hours. Visually inspect the controller for normal operation.

6.20 Controller efficiency

Fix the motor on the torque tester. Connect the controller and the motor correctly. Apply the rated voltage to the controller. Adjust the adjustment command, to make the motor run at the rated speed without load. After the operation is stable, the steering torque tester gradually increases the motor torque, until the input current of the DC bus of the controller reaches the rated input current of the controller, which is specified in the technical documents of the enterprise.

6.21 Short-term overload of controller

Fix the motor on the torque tester. Connect the controller and the motor correctly. Apply the rated voltage to the controller. Adjust the adjustment command, to make the motor run without load in the speed range, which is corresponding to the peak torque. After the operation is stable, the steering torque tester gradually increases the motor torque, until it reaches the peak torque, which is specified in the technical documents of the enterprise. The overload duration of the controller of the electric motorcycle's drive motor is 60 s.

6.24 Temperature rise

Install the motor on the bracket. Place it at room temperature. After temperature balance, measure the DC resistance of the armature winding. Record the room temperature at that time. Then make the motor run stably, at rated speed and continuous power, for a certain period of time, under rated voltage.

6.25 Low temperature

Install the motor and controller on the test stand. Without power, place them in the test box. Gradually lower the box temperature to -25 °C ± 1 °C. Keep it for 2 h. Then measure the insulation resistance of the motor and controller in the box. Check whether the motor and controller can be started without load. Test the rated performance of the motor and controller, after standing at room temperature.

6.26 High temperature

Install the motor and controller on the test stand. Put them into the test box. Make the motor run under rated voltage without load. Gradually raise the temperature of the box to 60 °C ± 2 °C. Keep it for 2 hours. Monitor the operation of the motor and controller.

After that, measure the insulation resistance of the motor and controller in the box. Test the rated performance of the motor and controller, after they are allowed to stand at room temperature.

6.27 Temperature cycle test

Install the motor and controller on the test stand. Without power, place them in the test box. Control the temperature in the test box, according to the conditions in 5.34.

6.28 Constant damp heat

After the installation mating surfaces of the controller and the motor are coated with anti-rust grease, put them in a test box (chamber) at 40 °C ± 2 °C and a relative humidity of 90% ~ 95%. After 48 hours, measure the no-load current and insulation resistance. Visually inspect the appearance of the motor and controller.

7.1 Inspection classification

Inspection is divided into exit-factory inspection and type inspection. See Table 4 for motor inspection items.

7.2 Exit-factory inspection

The motors and controllers shall be inspected by the mass inspection department of the manufacturer one by one.

7.3 Type inspection

7.3.1 Type inspection requirements

Type inspection shall be carried out, under one of the following conditions.

7.3.2 Sampling rules

For type inspection, samples shall be selected from the products, that have passed the exit-factory inspection. A total of 4 units are selected, 2 of which were used for type inspection and 2 were reserved for re-inspection.

7.3.3 Judgment rules

In the type inspection, if one product fails one item, it is allowed to re-inspect the item by double number of reserved samples.