This introduction to low-cycle fatigue testing for electric motors covers why the test is important and key advantages.
Regarding material and machine components, the term “fatigue” refers to cracking or fracturing in an object caused by stresses that are within its operational envelop, and often within its elastic range. These cracks and fractures grow, and they can eventually lead to a failure of the component and damage or destruction to the greater assembly if left untreated.
Fatigue testing is a testing procedure used to determine the fatigue strength and life of a component. It is commonly utilized to identify potential areas of concern in a design. Test operations can be classified into two categories: low-cycle and high-cycle (LCF and HCF). The former involves subjecting the component to the fluctuating loads, typically from the machine’s operational cycles, while the latter involves subjecting the component to higher frequency, typically from a vibratory load related to structural resonance.
High-speed rotating components (e.g., centrifuges, engine rotors, fans, impellers, etc.) regularly experience stresses that can lead to fatigue damage and, eventually, a failure. Since failure can damage equipment and endanger operators, it is vital to take measures to prevent it and, if that is impossible, mitigate the consequences.
Low-cycle fatigue testing (LCF) simulates the operational cycle of a machine. The LCF test is used to verify that a component is durable enough to withstand the use in the intended application over the intended duration of its operational life, so users can trust them and reliably operate the machine. Additionally, it could help manufacturers identify and resolve potential premature failure before the part or product goes into full production.
Nascent high-speed/high-performance electric motors, ones used in EVs, undergo low-cycle fatigue testing. These tests are necessary for a number of reasons, including:
In addition to electric motors, many other rotating components also undergo fatigue testing, such as:
Fatigue test data enables electric motor manufacturers to understand the durability limit of the motor rotors, develop a dependable product life model to define appropriate product servicing life as well as establish a maintenance service schedule – the goal is to prevent any unexpected failure in the service life of the machine. Additionally, the data allows engineers to proactively plan for design improvements and modifications.
Test Devices offers low-cycle fatigue spin testing services to customers working with high-speed rotating components in demanding applications. By choosing to work with us, you benefit from:
To learn more about low-cycle fatigue testing or our testing capabilities, contact us today.