DC Motor & Gear Motor Dyno Testing Capabilities

While you may know ISL Products as leading DC motor and DC gear motor manufacturers, you may not know that we also have the capability to provide detailed performance testing for a variety of small DC motors and gear motors. We are able to evaluate motors and gear motors via our in-house custom brake dynamometer and bench test equipment. These evaluations are typically offered complimentary to our customers during the motor selection and design process.

A dynamometer, or “dyno” for short, is an electromechanical device that measures the overall performance characteristics of a motor. It simultaneously measures the rotational speed and torque. With the addition of other bench top equipment and electronics we can also measure power, current draw, and operating efficiency across the entire torque range. All of the data is then exported to a proprietary software where we can then extrapolate a detailed motor performance curve.

Our dyno testing allows us to evaluate dc gear motors & dc motors to ensure projected performance data is accurate. This can be useful for multiple situations like evaluating first article samples, comparing two different motors, diagnosing a field failure, or simulating a particular duty cycle.

When a motor or gear motor is designed for the first time, a lot of the calculations are based on prior designs, experience and mathematical calculations. Brake dynamometers, like ours, allows manufacturers to prove those theoretical calculations in a more realistic setting, proving the motor or gear motor is operating as it was intended.

Motor testing is complimentary to all customers once a sample order is placed. Customers looking to benchmark incumbent motors prior, may require an additional fee. Contact a member of our engineering team to ask any questions.

Testing Capability Guidelines

We are able to test a wide range of brushed and brushless dc motors and gear motors. If a customer has an incumbent motor or gear motor that needs to be tested, we can provide that testing as well. To take advantage of our testing capabilities, just ask!

Our motor testing equipment is designed for our most prominent product offering, so we do have some testing limitations. Below you will find guidelines and parameters that encompasses our current testing capabilities:

• Peak Operating Voltage: < 30VDC
• Current Draw: < 30A
• Input Power: 900W (max)
• Torque: 5 – 120 kg.cm
• Speed: < 2,200 rpm
• Physical Size: 28mm – 52mm diameter (inline types)

*NOTE: If your motor or gear motor requirements fall outside of these guidelines, please contact ISL Products. If we are unable to do a complete evaluation, partial testing may still be possible dependent upon your request. Our test equipment and capabilities are constantly expanding so its always best to just ask!

Contact Engineering to Get Started

Testing Metrics and Procedures

ISL Products’ dyno testing involves multiple stages so that we can provide our customers with a complete representation of a motor or gear motor performance specifications.

No-Load Testing

During this test, we test the no-load conditions of the motor or gear motor. The no-load condition of a motor or gear motor can be defined as the conditions at which no load is being applied to the output shaft or the motor or gear motor, also known as the “free running” condition. Since there is no-load applied to the motor during this test, the torque level is always zero.

Parameters Measured: No-load Speed (rpm) & No-Load Current (A or mA).

On-Load Testing

During this test, we install the micro motor or gear motor to our motor fixture on our brake dynamometer . The dyno then simulates a gradual load from minimal to maximum torque capacity. This data is then exported to our simulation software where we are able to use all of the data points to formulate a full performance curve. All of the motor’s performance characteristics can be determined from this test, giving you a full picture of how the motor performs over its entire torque capacity.

*NOTE: Stall conditions are typically simulated. Stall testing is considered to be a destructive test and the motor or gear motor may be damaged during testing. If you require a stall test, please make sure to provide extra samples due to the tests destructive nature.

Parameters Measured: On-Load Torque (kg.cm, Nm), Stall Torque (kg.cm, Nm), On-Load Speed (rpm), On-Load Current Draw (mA, A), Stall Current (mA, A), Output Power (W), Efficiency (%).

Load Simulation Test

We can also run a load simulation test on a motor or gear motor. In this test the dyno is programmed to simulate the speed and load conditions similar to what would be experienced within your application. This will illustrate how a certain motor will perform under your expected load conditions.

Understanding your full duty cycle is important for this type of test. To run an intermittent duty cycle simulation we need to factor in any and all dwell times for accurate readings.

Parameters Measured: On-Load Torque (kg.cm, Nm), On-Load Speed (rpm), On-Load Current Draw (mA, A), Output Power (W), Efficiency (%).

Complete Test Report

During each test, we will provide you with a Motor Analysis Report. Within the report you will find the following information:

• Types of Tests Performed
• Description of Samples
• Performance Curve (PDF) – showing speed, torque, output power, current draw and efficiency.
•  Raw Test Data (Excel) – showing duty cycle simulation (if applicable), performance curve data, no-load data.
• Photographs (JPG) – showing the test setup.

How To Read a Motor Performance Curve

Benefits

Our testing will give you a better understanding of how a particular dc motor or dc gear motor performs, proving to be highly useful during the motor selection process. This is a useful tool at any stage of your development cycle.

While most motor suppliers will provide estimated performance data of their motors, we believe that real world testing offers a more complete understanding of how a motor or gear motor will perform. It also allows us to validate any performance projections or simulations that we provide at the early stage of a development.

Instead of conducting an endless search, contact ISL Products first! Our team of dedicated engineers will work with you to ensure you have the most optimal motor or gear motor for your application. From the initial design all the way through post production, ISL Products is your motor solution partner.