Design and development of a windscreen wiper motor durability test system

• Proposed an integrated wiper motor durability test system covering multi-parameter measurement and condition simulation. • Achieved 1% accuracy calibration of torque sensors via attitude correction and polynomial fitting. • Established a dynamic mapping model for magnetic powder brakes to simulate real motor loads with high precision. In response to the need for high-fidelity durability evaluation of automotive wiper motors, this paper develops an integrated test system that combines synchronized acquisition of torque, voltage, current, rotational speed, and temperature with in-situ calibration and programmable load simulation. Beyond conventional bench integration, the proposed method introduces an attitude-corrected torque-sensor calibration scheme based on a measuring arm and pose sensor, a residual-based outlier screening and polynomial-model-selection workflow, and a calibrated current-torque mapping for magnetic powder brakes that enables closed-loop reproduction of real wiper loads. To reduce inter-station discrepancies, torque-sensor calibration is evaluated with weighted residual sum of squares and root mean square error, through which a quadratic model is selected as the best compromise between accuracy and robustness; for the magnetic powder brake, a cubic model captures the weakly nonlinear current-torque relationship under dynamic operation. Representative cyclic endurance-operation results over approximately seven successive wiping periods show stable and repeatable corrected-torque and brake-current waveforms across successive wiping cycles, while the selected torque-calibration model satisfies the full-scale accuracy requirement. A brief uncertainty analysis based on the static torque-reference chain and the dynamic brake-control chain indicates that the dominant error sources arise from sensor sensitivity, arm-length/angle calibration, and fitting residuals rather than from the acquisition-module resolution. The proposed system therefore provides a reliable platform for durability evaluation, control optimization, and life assessment of automotive wiper motors.