Electric test system

on siteautomatic

Overview
Modular test system for flange sockets with interchangeable adapters to cover 3-, 4- and 5‑pole configurations and common current ratings (16 A, 32 A). Designed for semi-automatic testing with automatic contacting and enclosure while allowing manual operation of the DUT switch via an insulated handle.

Industry
Electrotechnical / electrical industry

Challenge
The main challenge was the high variety of flange sockets: different pole counts (3, 4, 5), different current ratings (16 A, 32 A) and varying contact rotations (clock positions). Requirements included short set-up times, reproducible contact and test procedures, and a semi-automatic workflow with manual actuation of the socket switch.

Solution
Short set-up times were achieved using a modular concept with exchangeable adapters. The system includes a removable basic support for the switch housing, exchangeable plug adapters, exchangeable terminal adapters and adapters for auxiliary switches. Plug and terminal adapters are rotatable to match the contact rotation of the DUT. Adapter type and rotation settings are detected and verified by software to ensure only configurations matching the selected test program are used, preventing incorrect tests and equipment damage. The DUT is automatically contacted and enclosed by a pneumatically closing, split test hood to prevent unintentional contact.

Hood closure is secured by a two-hand operation. A non-conductive plastic handle enables manual operation of the DUT switch during the test; the tester can monitor correct switching via a continuous open/closed contact display. Even if the tester holds the handle against the DUT during high-voltage testing or reaches into the access opening, electrically conductive parts are not accessible, ensuring operator safety.

Benefits

• Short test cycles
• Semi-automatic testing
• Short set-up times via interchangeable adapters
• Reduction of operator errors through adapter coding and software verification

Technical data

• High voltage test: 100 - 5,500 V AC / 0 - 100 mA
• Continuity test: visual continuity check

Characteristics / technical specifications

• Compatible with flange sockets 3‑pole, 4‑pole, 5‑pole
• Supports typical currents: 16 A and 32 A
• Interchangeable adapters: basic support, plug adapters, terminal adapters, auxiliary switch adapters
• Plug and terminal adapters rotatable to match DUT contact rotation (clock positions)
• Software detection/coding of adapters and rotation to prevent wrong configuration
• Pneumatically closing, split test hood for automatic contacting and enclosure
• Hood closure secured by two‑hand operation
• Manual operation of DUT switch via insulated plastic handle with continuous open/closed display
• Operator protection: no electrically conductive parts accessible via handle or access hole
• Adapter exchange time: seconds