Hardware Tests

Electrical, thermal, mechanical, and environmental test records.

PMSM motor

• PMSM Resistance Calibration Validation
• Power Resistor Sanity Check
• PMSM Inductance Calibration Validation

Induction motor

• Induction Motor Testbed
• Induction Motor Resistance Calibration Validation
• Inductance Calibration Validation
• Induction Motor 1-Hour No-Load Test
• Induction Motor 180 V Power Stage Bring-up
• Induction Motor 180 V 20-Minute Reversal Test

Gen7 hardware

• Gen7 Board Temperature Sensor Validation - first Gen7 test record; validates the three board NTC temperature channels against a thermal imager under a torch-applied gradient.
• Low-Power Regen 100 A Phase-Current Endurance (No Cooling) - 22-minute continuous regen at −100 A q-axis current on a dynamometer-spun induction machine with the bare power stage (no heatsink, no fan); peak board temp 80.4 °C.
• 200 A Regen to 79 °C — Gen7 Size 2 - 200 A q-axis regen staircase on Gen7 size 2, 3.14 kW average returned to the DC link, split at the first 79 °C inverter NTC reading; heatsink fitted without thermal interface material.
• Thermal OTP Trip — 200 A Regen, Gen7 Size 2 - continuation of the same recording past 79 °C through the intended thermal over-temperature protection trip and cooldown.
• Initial 400 A Regen Test — Gen7 Size 2 - first 400 A q-axis regen run with a Chroma load bank clamping the bus at 150 V (Sorensen regen sink ~50 A); 8.78 kW peak; apparent phase-current spikes later attributed to 150 A-rated Tektronix current clamps saturating (measurement artifact).
• 450 A / 13 kW Regen — Gen7 Size 2 - 450 A q-axis regen at 2,000 RPM shaft speed, 12.8 kW average returned to the DC link, sustained 78 s until the inverter overtemperature protection tripped at ~80 °C baseplate as designed.
• 200 A Regen Steady-State Thermal Test — Gen7 Size 2 - 54.7-minute continuous 200 A regen on the thermally-pasted assembly; baseplate plateaued at 44.4 / 44.0 °C against 22.5 °C ambient, validating the interface rework.
• 200 A Motoring Steady-State Thermal Test — Gen7 Size 2 - motoring-direction counterpart: 42-minute 200 A positive-torque hold drawing 2.46 kW, baseplate plateau 43.6 / 43.5 °C in cooler night ambient — same rise over ambient as regen, completing bidirectional 200 A continuous-duty validation.
• 300 A Regen Steady-State Thermal Test — Gen7 Size 2 - 22.9-minute continuous 300 A regen at ~2,600 RPM returning 11.7 kW to a 150 V-clamped bus; baseplate reached effective steady state at 63.2 / 61.7 °C (~39 K over ambient). Stopped because the Zero ZF75-10 machine hit 86 °C on the thermal imager, not due to any inverter limit or fault.

Cross-cutting

• Motor Self-Commissioning Accuracy Report - aggregates the calibration-validation measurements into a single accuracy record for the self-commissioning routine.