Electric motor test system

for statorson siteautomatic

Product description
Two nearly identical test stations were implemented to inspect stators before and after impregnation. Both stations can be used interchangeably for the two test types to cover peak production demand. The overall design addresses a wide variety of DUTs and short cycle-time requirements.

Industry
Electric motors

Task
The test systems had to be integrated into a production line. Despite large dimensional diversity among DUTs, the solution had to deliver high flexibility while keeping test times low.

Required tests

• Polarity identification (North/South pole)
• Partial discharge test in production environment
• Pressure/leak test of the stator cooling device

Solution
To achieve required flexibility, the system includes a universal DUT interface allowing contact to all DUT variants without station conversion. A pneumatic clamping system was chosen to minimize cycle time.
Dedicated high-voltage test adapters were developed for polarity testing; they are inserted into the DUT and remain in place during the test due to their HV withstand capability.
Customer-specific software enables creation and storage of test sequences on the company network. The correct sequence is automatically loaded by scanning a 2D barcode on the DUT; test parameters are populated from a networked database. Personnel safety is ensured by a test cover with pinch protection.
A dedicated test dummy performs an automatic station self-check at start-up; if the dummy test fails, no further tests are permitted.

Benefits

• Turnkey delivery including workplace design, adaptation and software
• Automatic testing after a single DUT connection
• Test sequences can be created on the station and populated from the network database
• Smooth integration into the production line
• Service-friendly design
• Short cycle times
• High flexibility via universal DUT interface

Technical features / specifications

• Universal DUT interface for wide DUT diversity
• Pneumatic clamping system for short cycle times
• Polarity test with dedicated high-voltage adapters (no removal required)
• Partial discharge testing integrated for production environment
• Pressure / leak testing of stator cooling device
• Protective earth / ground bond test capability
• Insulation resistance measurement (windings, housing, sensors)
• High-voltage AC/DC testing (windings, housing, sensors)
• 3-phase resistance measurement
• Resistance measurement of individual sensors
• Surge voltage testing
• Partial discharge measurement during surge and HV tests
• Automatic loading of test sequences via 2D barcode and networked database
• Built-in test dummy for automatic station verification
• Safety test cover with pinch protection
• Turnkey delivery including workplace design, adaptation and software