Impedance test system

for the electronics industryfor statorson site

Overview
After production of medium-power electric motors, stators are inspected for safety and function. Production is characterised by a wide product mix, low volumes and high-quality requirements. Product liability rules require permanent storage of all test data.

Industry
Electric motors

Task
Customers require automation of existing test stations, reduced cycle times, deeper diagnostic coverage and assured quality. Operation must be simple to allow use by semiskilled operators. Personnel safety must meet high standards.

Solution
Computer-controlled testing system with a relay matrix for 3-phase motors (up to 4 speed levels). The high-voltage relay matrix enables combined safety (hipot) and low-ohm functional measurements. Control is provided by the extended standard software DAT. Personnel safety is ensured by an approved light curtain on three sides with a deflection mirror. An unlimited number of test programs can be stored on the system PC; programs can be created or reused by the customer. Test results are automatically saved in XML or Access format to any network location. A separate automatic dummy test verifies system functionality; a successful dummy test is required before normal testing proceeds.

Benefits

• Turnkey solution including DUT support, adaptation and ergonomic workplace design
• Simple, intuitive operation for semiskilled personnel
• Single connection of DUT; entire test sequence runs automatically
• Network operation: automatic storage of test data at the specified location / database
• Long service life and service-friendly design
• Short cycle times through efficient workplace design with light curtain
• All values and settings configurable via software
• Automatic dummy test prior to production testing
• Workplace safety according to EN 50191

Characteristics / technical specifications

• Hipot test: 5,500 V for windings, housings and sensors
• Withstanding/overvoltage test capability up to 6,000 V
• Low-ohm resistance measurement for windings and sensors
• Rotating magnetic field monitoring via sensors
• Relay matrix for 3-phase motors with up to 4 speed levels
• High-voltage relay matrix enabling combined safety and function tests
• Controlled by DAT extended standard software; arbitrary number of test programs storable on PC
• Automatic storage of test results in XML or Access format to network location
• Approved light curtain (three sides) with deflection mirror for personnel safety
• Automatic daily dummy test mandatory before testing proceeds
• Designed for automation, short cycle times and operation by semiskilled personnel