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Robot Electrical Performance Testing and Analysis

Overview

Robots, as complex systems integrating mechanics, electronics, sensing, and artificial intelligence, fundamentally depend on the quality of their electrical performance for their overall capability and reliability. Electrical performance testing runs through the entire cycle of robot R&D, production, and acceptance. It is far more than a simple power-on check; it is an in-depth verification and efficiency evaluation of its "life system"—the power architecture, powertrain, signal integrity, and energy management.

Electrical performance testing is not only the cornerstone for ensuring the safe and stable operation of robots and preventing electrical risks, but also a key means to accurately quantify their working endurance, dynamic response, and energy efficiency levels, thereby ensuring design goals are met. In the era where robots are moving towards large-scale, industrial applications, establishing and implementing a strict electrical performance testing system is an inevitable requirement to enhance product competitiveness, win market trust, and promote the sustainable and healthy development of the industry.

Robot Electrical Performance Testing

Testing Standards

5+
Performance Test Methods

Test Items

22+
Electrical Performance Indicators

Test Types

5+
Types of Tests

Importance of Electrical Performance Testing

Safety Assurance

Electrical performance testing is a key link to ensure the safe operation of robots. By testing indicators such as current, voltage, and insulation performance, potential safety hazards such as short circuits and leakage can be effectively prevented, ensuring the safety of operators and the surrounding environment.

Robot Safety Testing

Performance Optimization

Electrical performance directly affects the operating efficiency and accuracy of robots. By testing indicators such as motor efficiency, battery capacity, and energy consumption, performance bottlenecks can be identified, providing data support for optimizing design.

Battery Performance Testing
0% 25% 50% 75% 100% No Test With Test

Chart: Comparison of failure rates between robots with and without electrical performance testing

Reliability Improvement

Standardized electrical performance testing can significantly improve the reliability of robot systems and reduce failure rates

Lifespan Extension

By optimizing electrical parameters and rationally using energy, the service life of robots can be effectively extended

Cost Savings

Early detection of electrical issues can avoid high repair costs later and improve overall return on investment

Testing Standards and Methods

Applicable Standards

Standard Number Standard Name
GB/T 43200-2023 Robot Integrated Joint Performance Test Methods
T/CAMETA 001070-2025 Humanoid Robot Performance Testing Methods
GB/T 36276-2023 Lithium-ion Batteries for Electric Energy Storage
GB/T 37414.2-2020 Industrial Robot Electrical Equipment and Systems
Part 2: Technical Conditions for AC Servo Drive Devices
GB/T 37414.3-2020 Industrial Robot Electrical Equipment and Systems
Part 3: Technical Conditions for AC Servo Motors

Test Items

Test Type Test Item Test Standard
Initial Charge/Discharge Performance Test 25°C Initial Charge/Discharge Performance Test GB/T 36276-2023
Initial Charge/Discharge Performance Test 45°C Initial Charge/Discharge Performance Test GB/T 36276-2023
Initial Charge/Discharge Performance Test 5°C Initial Charge/Discharge Performance Test GB/T 36276-2023
Power Characteristic Test Power Characteristic Test GB/T 36276-2023
Rate Charge/Discharge Performance Test Rate Charge/Discharge Performance Test GB/T 36276-2023
Energy Retention and Recovery Capability Test Energy Retention and Recovery Capability Test GB/T 36276-2023
Electrical Safety Performance Test Overcharge Performance Test GB/T 36276-2023
Electrical Safety Performance Test Overdischarge Performance Test GB/T 36276-2023
Electrical Safety Performance Test Overload Performance Test GB/T 36276-2023
Electrical Safety Performance Test Short Circuit Performance Test GB/T 36276-2023
Electrical Safety Performance Test Insulation Performance Test GB/T 36276-2023
Electrical Safety Performance Test Withstand Voltage Performance Test GB/T 36276-2023

Test System and Test Software

Test Equipment
Equipment Name Model
Electrical Performance Test System PTS Series
Electrical Performance Test Software VectWorks
Load Module Optional

Test Process

1

Test Preparation

Determine test parameters, prepare test equipment, check the status of the robot under test

Record: Test environment temperature (25±2°C), equipment status check

2

Performance Test

Motor efficiency, battery capacity, energy consumption and other performance indicator tests

Record: Voltage, current, power, time...

3

Safety Test

Overcharge/discharge, insulation, withstand voltage, no-load current, stall current and other safety indicator tests

Record: Voltage, current, time, temperature...

4

Environmental Test

Electrical performance testing under high/low temperature, humidity, vibration and other environmental conditions

Record: Environmental parameters, test duration, performance change curve

5

Data Analysis

Analyze test data, generate test reports, propose improvement suggestions

Record: Data analysis, abnormal data processing, basis for conclusions

Data Analysis

Main Performance Indicators Comparison

Motor Efficiency Battery Capacity Current Stability Voltage Fluctuation Energy Consumption 0 25 50 75 100

Chart: Comparative analysis of main robot electrical performance indicators

Testing Trend Analysis

Jan Feb Mar Apr May Jun 0 2 4 6 8

Chart: Trend of test quantity and problem discovery rate

System Comprehensive Evaluation

Safety Reliability Performance Lifespan Energy Efficiency

Chart: Comprehensive evaluation of robot electrical performance

Problem Distribution Analysis

Chart: Distribution of robot electrical problem types

Conclusion and Recommendations

Main Conclusions

  1. Clear Necessity: Electrical performance testing is a key link to ensure robot quality and safety. The failure rate of untested robots is significantly higher than that of tested robots.
  2. Wide Impact: Electrical performance not only affects the safety and reliability of robots but is also directly related to their performance, service life, and energy efficiency.
  3. Cost-Effectiveness: Although adding testing links incurs certain costs, in the long run, it can significantly reduce maintenance costs and recall risks, improving brand reputation.

Testing Method Recommendations

  • Use automated testing systems to improve testing efficiency and consistency
  • Apply artificial intelligence technology for automatic analysis of test data and anomaly detection
  • Establish a testing system combining virtual testing and physical testing
  • Develop online monitoring and remote diagnosis technology to achieve full lifecycle electrical performance management

Future Outlook

Robot electrical performance testing will transcend the traditional "pass/fail" verification model and evolve into a core enabling link throughout the entire robot lifecycle. With the maturity of technologies such as embodied intelligence and swarm intelligence collaboration, the testing objects will expand from isolated components to the entire "perception-decision-execution" chain system. Autonomous testing platforms will become mainstream, realizing automatic generation of test cases and early warning of extreme working conditions. Ultimately, electrical performance testing will no longer be just a gatekeeper of quality, but a core engine driving robots towards higher reliability, stronger environmental adaptability, and better energy efficiency.

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