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Electric Motor and Inverter TestingPower and efficiency testing of electric motor and inverter

The Dewesoft power analyzers provides integrated solutions for electric motor and inverter testing, enabling the measurement of numerous voltage and current input channels. With the ability to measure up to eight 3-phase systems, along with temperature, vibration, RPM, torque, CAN, and more, all in a single, fully synchronized device, it ensures thorough and accurate testing.

Advanced features for efficiency and loss mapping on electric motors and inverters complete this turnkey solution, offering everything you need for comprehensive analysis in one powerful tool.

5 MHz bandwidth

Voltage

High Voltage

Isolation CAT II 1000 V

Isolation CAT III 600 V

Current

DC current

AC current

PTP synchronization

IRIG and GPS timecode

Resistance

Strain and Stress

Vibrations

Counter and Encoder

SD card

openDAQ compliant

USB 2.0

USB 3.0

Ethernet

EtherCAT

PoE (Power Over Ethernet)

CAN bus

CAN FD

CAN out

XCP/CCP

Electric Motor and Inverter Testing highlights

Easy to use

Dewesoft power analyzers offer plug-and-play capabilities with the award-winning DewesoftX software. The hardware and sensors are automatically detected. Just select the input channels and power parameters you wish to calculate, and the power analyzer module will handle the rest.

Four-quadrant operation

Observe motor operation across all four quadrants to gain a complete understanding of performance during both motoring and generating modes, in forward and reverse directions. This detailed view allows users to thoroughly analyze and assess the full dynamic range of powertrain capabilities.

15 MS/s sampling rate

Dewesoft power analyzer hardware includes high-speed amplifiers that offer sampling rates of up to 15 MS/s per channel. These amplifiers use SAR analog-to-digital converters with built-in hardware filtering capabilities.

5 MHz bandwidth

SIRUS® XHS power analyzers offer 5 MHz bandwidth acquisition and analysis with up to 15 MS/s sampling rate per channel.

0,03 % accuracy

Our measurement signal amplifiers offer high accuracy for voltage and current measurement, with a basic power accuracy down to 0.03%.

Power calculations

The system calculates over 100 power parameters, including P, Q, S, PF, and cos phi. It also offers full raw data recording capabilities, as well as features like an oscilloscope, FFT, and harmonics analysis. These calculations can be performed both online and in post-processing.

Efficiency testing

Dewesoft motor and inverter efficiency analysis module optimizes electric input vs. mechanical output power using advanced techniques like Clarke and Park transformations. All motor analysis settings are consolidated in the Motor Analysis module, featuring setup options, transformations, and efficiency calculations.

GPU processing

Even at sample rates as high as 15 MS/s, the Power Analyzer software delivers real-time calculations by leveraging GPU multi-core graphics card processing.

Up to 64 channels

Our power analyzer can be configured with up to 64 channels in a single chassis solution. For applications with higher channel count requirements, multiple measurement instruments can be synchronized.

Current sensors

We offer and support all types of current sensors, such as zero-flux current transducers, AC/DC current clamps, Rogowsky coils, and shunts. These sensors are true RMS sensors available in a variety of models and are powered directly by our power analyzers.

Additional inputs

Our power analyzer can also measure different signals such as IEPE, thermocouples, digital counters, speed, angle, GPS, CAN, XCP, FlexRay, video, etc. all fully synchronized.

Raw data storage

Dewesoft power analyzers always store raw data, giving you the flexibility to recalculate all parameters during post-processing. This ensures complete data integrity and allows for detailed analysis and validation after the measurement is complete.

Free lifetime updates

We release a major new version of DewesoftX software every three months. New versions include speed optimizations, bug fixes, new features to basic functionality, and new features to signal processing and math modules. All software updates are completely free forever for all existing users.

Dewesoft quality and 7-year warranty

Enjoy our industry-leading 7-year warranty. Our data acquisition systems are made in Europe, utilizing only the highest build quality standards. We offer free and customer-focused technical support. Your investment into the Dewesoft solutions is protected for years ahead.

Electric motor and inverter testing

As electric motors face increasing energy efficiency requirements, adherence to standards like the IEC 60034 is crucial. This standard mandates that all asynchronous motors meet at least the IE2 efficiency level. Unlike before, when losses were estimated at 0.5%, precise determination of these losses is now necessary. Achieving accurate efficiency and loss measurements demands the highest precision across the entire measurement chain.

The Dewesoft electrical power analysis solutions, combined with additional current sensor calibration options, ensure the highest accuracy for all power measurements. Our modular hardware design allows for the measurement of up to 12-phase motors, as well as mechanical parameters like speed, torque, and deformation.

Our power analyzers can also measure parameters such as vibration, sound level, and temperature, all fully synchronized with the power parameters. The inclusion of power quality analysis (fundamental power, harmonics, THD, etc.) further enhances its comprehensive analysis capabilities.

Comprehensive and accurate inverter analysis

The Dewesoft power analyzers provide detailed and highly accurate analysis of various inverters. Its modular and precise data acquisition systems support the measurement of all input/output configurations, including up to 7-phase AC systems.

It can analyze fundamental frequencies from 0.5 Hz to 3 kHz and switching frequencies up to several hundred kHz, enabling everything from efficiency determination to detailed analysis of each switching pulse. Raw data storage allows for the analysis and presentation of each individual switching pulse, such as transient behavior, in the scope. The power quality module automatically calculates THD, harmonics, and other metrics. Transient recording captures voltage and current peaks, which is particularly useful for long cable lengths.

The high edge steepness of the inverter output (up to 10 kV/μs) can cause capacitive leakage or high motor bearing currents, potentially damaging the motor. Dewesoft easily measures all these parameters, and all analysis options are available during measurement. The voltage steepness (dU/dt) for each individual impulse can be determined and statistically classified, simplifying the design and testing of inverters and filters.

Inverter testing with Dewesoft at Rimac Automobili

Combined electric motor and inverter testing

Combined motor and inverter testing demands a high number of input channels for voltage and current measurements along with fully synchronized data acquisition. The Dewesoft solution enables the measurement of 8x 3-phase systems using a single device, allowing for synchronous measurement of an entire power system (e.g., electric vehicle, aircraft, ship). This feature integrates all functionalities of motor and inverter testing and supports additional parameters such as speed, torque, temperature, video, GPS & IMU, and CAN/CAN FD.

Traditionally, testbed applications required multiple devices, including a power analyzer, oscilloscope, data logger, and CAN logger. The Dewesoft solution consolidates all these capabilities into a single device, storing raw data at the full sampling rate and enabling real-time analysis.

The DewesoftX DAQ software offers unique post-processing functionalities, allowing for analysis (mathematics, power analysis) after measurement completion. You can even change settings or correct measurement mistakes, such as adjusting phase voltages if they were connected incorrectly, without repeating the measurement. This innovative workflow provides exceptional freedom and flexibility.

See the four-quadrant operation

The dewesoft motor analysis system allows you to observe motor operation across all four quadrants. This enables users to understand and analyze motor performance during both motoring and generating modes, in both forward and reverse directions.

This comprehensive view helps in assessing the full dynamic range of the powertrain’s capabilities.

See the four-quadrant operation of electric motors

Optimize your motor performance

Maximize Performance and Longevity: By understanding the motor’s efficiency map, operators can run the motor in its optimal range, ensuring peak performance and extending its lifespan.
Improve Energy Consumption for All Machines: Identifying areas of maximum efficiency helps run the motor under conditions that minimize energy consumption, benefiting both large and small machines.
Predict Potential Failures: Analyzing parameters like torque ripple can indicate potential mechanical issues or wear, enabling timely maintenance to prevent breakdowns.
Ensure Safety and Prevent Hazards: Early detection of anomalies, such as unusual torque ripple, can avert hazardous operating conditions.
Enhance Control Algorithms: Understanding the motor’s characteristics allows for the fine-tuning of control algorithms, resulting in smoother operation and better responsiveness.
Benchmarking: Companies can compare performance across different motor brands or designs to choose the best fit for their applications.

Power analysis features

Analyze 1-12 phase motors.
Analyze up to eight 3-phase systems in a single power analyzer in parallel.
Raw data storing and analysis fully enables online and offline calculations.
Transient and fault recording.
Scope, Vector Scope, Harmonics, FFT analyzer in a single device.
Additional measurements like speed, RPM, torque, temperature, vibration, deformations, etc.
Efficiency and loss analysis and mapping.
Measurement of mechanical parameters.
Different frequencies (DC, 16,7Hz, 25 Hz, 50Hz, 60Hz, 400Hz, 800Hz, variable frequency).
Voltage rise time analysis (dU/dt).
Current sensor calibration - phase and amplitude correction.
Filter analysis.

Typical power analyzer configuration

For a typical configuration, we recommend using our high-channel SIRIUS® R4 and SIRIUS® R8 data acquisition systems or a completely modular and distributed SIRIUS® XHS solution with network and PTP synchronization:

4 - 12x high voltage inputs
4 -12x current inputs
1x torque input
1x speed input
Additional inputs - analog (IEPE, thermocouple), digital, CAN/CAN FD, GPS & IMU, video, etc.

If you would like more information, you can visit our Power Analyzers product page to see all available power analyzers and choose the most appropriate one for your testing scenario.

Various wiring configurations with simple and intuitive setup

The DewesoftX data acquisition software offers a visual selection of different wiring schematics and provides power calculations for all possible connections.

Predefined Power Schematics:

Direct Current
Single-Phase
Two-Phase
Star Connection
Delta Connection
V Connection
Aron Connection
Combined Star/Delta Connection

These connections can be measured with or without currents. Thanks to the modular construction of our measurement devices and the multiple synchronized power modules in our software, Dewesoft can also analyze 6, 7, 9, or 12-phase motors.

To learn more about each connection, please look at the Dewesoft Power Analysis free online training or the Dewesoft Power Manual.

DewesoftX power analysis 3-phase start configuration

Frequency source selection

The Dewesoft Power Analyzer allows users to choose the frequency source for their measurements. The available options are:

Voltage
Current
External frequency source

This feature is especially beneficial when measuring inverters. Inverter measurements can be tricky due to the PWM-modulated voltage signal, which makes it difficult to determine the correct period of time. On the other hand, the current signal is generally less distorted because of the high inductance in the motor coil.

Therefore, using the current signal as the frequency source is often a better choice for inverter measurements. This approach ensures accurate frequency determination for every application.

Dewesoft power analyzer frequency source selection

Electrical power calculations

DewesoftX data acquisition software automatically records raw voltage and current data while simultaneously calculating and storing all power parameters, including:

Active Power (P), Reactive Power (Q), Apparent Power (S), Distortion Power (D)
Cos φ, Power Factor
P, Q, Cos φ for each harmonic

Multiple power system calculations

Dewesoft power analyzers can measure multiple power systems simultaneously. For example, the Dewesoft R8D power analyzer can synchronously measure up to eight 3-phase systems. Dewesoft supports power analysis across various frequencies, including DC, 50 Hz, and variable frequencies, while accommodating all wiring configurations, such as single-phase, 2-phase, 3-phase star, 3-phase delta, 3-phase Aron, and 3-phase V, ensuring versatile and precise measurements for any application.

Mechanical parameters measurement

Dewesoft power analyzers can also measure mechanical values like torque, speed, noise, temperature, and vibration in complete synchronization. This allows you to perform also thermal, NVH and efficiency calculations in parallel to electrical power.

Accurate frequency calculation

A single Dewesoft power analyzer and data acquisition system can measure multiple power modules simultaneously, each with an independent frequency. Supported line frequencies include:

16.7 Hz: Railway Sector
25 Hz: Public Grid
50 Hz: Public Grid
60 Hz: Public Grid
400 and 800 Hz: Aerospace
Variable Frequency: E.g., power inverters

Period values calculation

Our power analyzers also calculate period values of voltage and current, power components, power factor, and symmetrical components. Users can define cycle calculations and the overlap percentage.

Star-delta connection calculation

The system can calculate all values and waveforms for star connections from a delta connection and vice versa, displaying waveforms for U1, U2, U3 ↔ U12, U23, U31.

Real-time power output measurement

Mechanical power

Measure the real-time power output of the motor using mechanical sensors at the shaft. This enables users to assess the motor’s performance under various conditions, ensuring it operates at optimal levels.

By providing precise data on the motor’s mechanical power, users can make informed decisions to enhance efficiency, detect potential issues early, and maintain peak performance. This comprehensive understanding of the motor’s output helps in fine-tuning operations and maximizing the motor’s lifespan.

Mechanical rotation

An integrated counter math module monitors the motor’s performance across various operating conditions. This helps identify regions of maximum efficiency and enables operators to run motors at optimal points, ensuring peak performance and energy savings. The counter module can work with any counter and encoder sensor, ensuring seamless compatibility and flexibility regardless of the specific counter equipment used.

Efficiency and loss mapping of AC motors and inverters

Electric motor and inverter efficiency analysis aims to enhance motor performance by optimizing the efficiency of the electric input power relative to the mechanical output power. This process can involve using Clarke and Park transformations, which provide a better understanding of the relationship between the input line phase, the induced magnetic field, and the mechanical rotation angle.

All relevant settings for this type of analysis are now consolidated under the new Motor Analysis tab within the Power module. This tab includes:

Motor analysis setup options
Transformations and efficiency calculations
Integration with multiple new stand-alone math modules

The Motor Analysis module utilizes various math modules and widgets, such as:

Resolver sensor
2D/3D mapping
Contour plot widget

For more detailed information, refer to the following resources:

Torque ripple analysis: ensuring smooth motor operation

Torque ripple is a crucial metric that captures variations in the motor’s torque during rotation. By analyzing torque ripple, Dewesoft power analyzers provide valuable insights into potential mechanical issues, imbalances, or inefficiencies that could impact the motor’s smooth operation and longevity.

This detailed analysis helps identify problems early, allowing for timely maintenance and ensuring optimal performance and extended life of the motor. With Dewesoft power analyzers, you can ensure your electric motor and inverter systems are running efficiently and reliably.

Torque ripple analysis in DewesoftX software

Simplified analysis and control of AC motors

Park and Clarke transforms are mathematical techniques used to convert three-phase motor currents and voltages into a two-dimensional coordinate system. This transformation simplifies the analysis and control of AC motors by providing a clearer and more manageable view of the motor’s magnetic conditions.

By reducing the complexity of the three-phase system, these transforms make it easier to understand and optimize motor performance, enhancing the efficiency and precision of motor control strategies.

Energy calculation

The Dewesoft Power module also automatically calculates the energy of the measured system. This feature enables the calculation of both positive and negative energy, providing a comprehensive understanding of the system's performance.

Additionally, the Math module allows users to calculate efficiency, essential for evaluating and optimizing system operations. This capability is particularly beneficial in various applications, such as:

Recuperation Brake Systems: Analyze the energy recovered during braking to improve system efficiency and performance.
Battery Testing: Measure energy input and output to assess battery efficiency, capacity, and overall health.

These features make Dewesoft Power Analyzers a versatile and powerful tool for energy calculation and efficiency analysis across different applications.

Rich visualization

After setting up the power module, you can configure and customize the measurement screen. The most relevant display widgets for electrical power analysis and power quality include the following display widgets:

Digital Meters: Display various instantaneous values calculated by the power module with unit support. Learn more.
Recorder and X/Y Recorder: The Dewesoft power analyzer provides visual recorder displays for time-domain data, showing all parameters in individual intervals. The X/Y recorder can generate orbital plots online. Learn more about Recorder and X/Y recorder.
Scope: Shows waveforms of voltages and currents, including line-to-line (U12, U23, U31) and line-to-earth (U1, U2, U3) voltages. Learn more.
Vector-Scope: Visualizes the relationships between voltages and currents for up to 3-phase systems. Multiple vectorscopes and individual harmonics can be displayed simultaneously. The "transparent" function allows for direct comparisons of phasors. Learn more.
Harmonic FFT: Offers a simple and comprehensive analysis of harmonics for voltage, current, power, and reactive power, all synchronized to the fundamental frequency of the signal. Learn more.
Contour plot: A 2D graphical representation that uses contours or color-coded regions to display 3D data. This visualization technique helps to reveal patterns and relationships in complex datasets, such as efficiency maps for motors, making it easier to understand and analyze the information. Learn more.

DewesoftX power analyzer screen with scope, vector scope, recorder, and harmonics widgets

Additional Resources

Additional information and resources on how to measure voltage and current, and perform electrical power analysis can be found in the following links:

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