11kVA End-of-Line Motor Drive Test System with Regenerative Load
The scope of supply encompasses the design, assembly and commissioning of a complete motor drive test system integrated within a 19-inch cabinet, including a regenerative AC load designed to significantly reduce the customer’s utility costs and carbon footprint.
Key Features:
- 19-Inch Industrial Enclosure: Unified rack-mounted automated test system.
- Programmable AC Power Source: Controlled electrical input for automated test profiles.
- Custom Load-Side Magnetics: Sine-wave filtering and voltage step-down for safe load interfacing.
- 11kVA Regenerative AC Load: Dynamically sinks drive output while returning energy to the grid.
- Power Distribution & Protection: Integrated power management and system protection.
- PXI Control & Instrumentation: Automated measurement, control, power supplies, and communications.
- Comprehensive Documentation & Support: Production-ready turnkey delivery.
- Bespoke Metal Fabrication: Custom mechanical integration for the system and test hardware.
Custom Load-Side Magnetics:
An industrial sine-wave filter and a large step-down transformer are placed after the unit under test (UUT) to smooth the output and reduce the voltage to safely match the requirements of the load.
Programmable Power Source:
Providing the foundational electrical input required for the test profiles.
Regenerative Load System:
A high-efficiency regenerative electronic load capable of dynamically sinking the full 11kVA output of the drive under test while recycling energy cleanly back into the grid to minimise thermal footprint and operational costs.
Motor Drive Test System Block Diagram
Control & Instrumentation:
A dedicated control tray driven by a PXI system chassis.
It integrates a programmable Digital Multimeter (DMM), low-voltage power supplies (5V, 12V, 24V), and multi-protocol communication networks including CAN bus, RS485, and RS232 to interface with different motor drives.
The subsystem also incorporates a bespoke sheet-metal tray enclosure design and custom machined nylon parts.
Modular Interface & Pneumatics:
A versatile, top-mounted mechanical docking system engineered for rapid production changeovers. The system features interchangeable top fixtures to accommodate different drive variants, utilising pneumatic actuation to securely deploy test probes onto the unit under test for highly repeatable electrical connections.