The measurement device constitutes a key component in the development of high-performance electric drive motors, as it enables the assessment of prototype motor characteristics, which serve as the basis for validating customer requirements. This master’s thesis presents the design and development of a measurement station for conducting characteristic tests of an electric motor, employing an identical motor as a controlled load in a back-to-back configuration. The device represents a complex measurement system, the development of which requires expertise in both mechanical engineering and mechatronics. The theoretical part of the thesis outlines the fundamental physical principles underlying the operation of electric motors. This is followed by a classification and a detailed description of the operation and control of permanent magnet synchronous motors. The engineering section presents the development of the measurement device, beginning with the definition of the expected operating range of the motor, from which the performance requirements of the measurement system are derived. Following a review of existing market solutions and the formulation of the device concept, the mechanical components are designed, and the corresponding technical documentation for ordering parts is prepared. The device is subsequently assembled, with the correlations between components properly adjusted, and both motors mounted onto the supporting frame. The mechatronic development phase addresses the selection and integration of components required for control, monitoring, and data acquisition of motor characteristics. A wiring diagram of the control and measurement system is prepared, and the components are interconnected accordingly. To validate the functionality of the measurement system, the final part of the thesis presents characteristic measurements of the motor and the brake-generator, including efficiency curves derived from the experimental results.
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