The Model AT6000 Armature Test System is a fully automatic, pass/fail system designed to test single flyer, double flyer, odd bar, even bar and unique wound armatures. (Dual Station unit shown left)  This unit combines hipot, surge and resistance testing into one automated test instrument. Other tests are optionally available.

Resistance Test (End-to-End and Bar-to-Bar):
The resistance test reads all of the 180º resistance readings at each 180º pair of commutator bars.  Every reading is compared to the internally stored low and high resistance limits.  The ranges are .02-1000 ohms with a resolution of .0001 ohm on the 1 ohm range.  The Series 6000 tester features ambient temperature compensation, which allows for fluctuations in the room temperature.  Infrared temperature compensation is available as an option.  Resistance readings are compensated to 25° Celsius.  Click here to view the set-up screen.

Resistance testing will detect errors such as broken wires, stretched wires, open coils, wrong number of turns and wrong wire size.

Surge Test:
ESW's surge test is far superior to the competition.  We are able to stress the windings with a greater amount of energy,  enabling the most sensitive of shorts to be detected.  

A capacitor is discharged into the windings. The system monitors and analyses the surge waveform by measuring the ringing time and amplitude of the characteristics ringing waveform.  Voltage is adjustable from 0-3000 volts. Testing is performed in both forward and reverse directions.  Click here to view the set-up screen.

This surge test will reject windings and insulation faults such as shorts between windings and breakdowns between wires.  It also detects incorrect turn counts, shorted turns and improper connections.

Chips between  the commutator bars can also be detected.  If a chip is touching both bars, the weld and resistance tests will detect the fault.  However, if the chip is wedged in and not touching both bars, ESW's surge test will detect this.

Weld Test:
The Series 6000 testers perform both bar-to bar and end-to-end weld tests.  The end-to-end test is the most accurate method of detecting armature weld flaws.

• End-to-end readings are scanned and the lowest and highest readings are selected.   The readings are scanned and the deviations between opposite coil readings are compared.

• Bar-to-bar testing is useful on some hand-staked applications.  The readings show  wire size and stretch of one flyer versus the other winder flyer.   Controlling the flyer and wire size variations will result in less need for balancing corrections.

If a weld reject is detected, the test will stop and the weld resistance and position of the commutator bar will be displayed.  This insures that bad welds are detected regardless of their location.  Limits as low as .0001 can be set on the 1 ohm resistance range

Weld testing detects armatures with open bars, poorly fused commutator bar connections, out of limit welds, side-to-side electrical imbalances, winder and wire tension device differences and different sized wire on opposite sides.

Hipot Test:
A hipot voltage is applied to the armature between the commutator, stack and shaft.  The voltage is applied at the zero crossover point of the sine wave to prevent a voltage surge.  The leakage current is constantly monitored and compared to the internal low and high leakage limits.  If excessive leakage is detected, the hipot voltage is immediately removed to prevent further damage to the armature.  Voltage is adjustable from 0-3000 volts; higher voltages are available as an option.  Test time is adjustable from .1 to 10 seconds.  Our hipot testing also features our exclusive hipot fault process.  This prevents the armature from going through the test without an accurate hipot test being performed.  Click here to view the set-up screen.

Hipot testing is used to satisfy regulatory requirements by detecting armatures with excessive leakage and breakdowns between the wire and the adjacent metal.

Optional Tests:

• Commutator Offset.  (AKA: Bar Advance Testing.)  Detects armatures wound in the wrong slot or connected to the wrong bar.  No other test available can detect this type of winding fault.

• Secondary Hipot.  Two hipot voltages are applied to the armature between the commutator, stack and shaft.  Both voltages are applied at the zero crossover point of the sine wave to prevent a voltage surge.  The leakage currents are constantly monitored and compared to the internal low and high leakage limits.  This test is necessary when testing double insulated armatures.

• Low Resistance Armature Testing.  ESW has developed a testing process specifically for low resistance parts.  Due to the uniqueness of the process and properties of these parts, special methods are necessary.

• Corona Testing.  The corona test is performed during the standard surge test.  This testing method will detect the high frequency component on the surge discharge waveform.  No null adjustments or compensation are required.  Corona can be detected on turn-to-turn , phase-to-phase and coil-to-core.

• Built in Resistance Standard Calibration Box for automatic calibration of the test system.

• Automatic set-up of all test limits.  Individual limits will be stored in a separate part file for each part number.

• Storage up to 1000 parts.

• Automatic system voltage monitor for surge and hipot.

• Production counts are tallied and displayed on the right hand side of the computers main screen.  Totals are kept for good, rejects, and tested.

• Statistical failure analysis reporting in number and percentages.

• Full color graphics display.  All instructions and test results are displayed on this monitor.  The entire software program has a clear and precise fault messaging system.  Each testers screen can be customized for the individual application.

• Drawer mounted keyboard.

• Visual test results on screen.

• Printer output.  A printer may be connected to the tester to print out test set-up information and test results from each part.  

• Operator Interface.  All messages and text displayed on the video monitor will be in English.  Other languages are available as an option.

• Flat Panel Color Video Monitor.

• Mounted on casters for portability.

• Password Software Interface provides tighter restrictions on who is accessing the systems software.

• Data Logging.  Automatically gather and stores test data, by date and time stamp,  for all parameters on all parts tested.

• Data Viewer.  This utility gives the user the opportunity to view the test data in a spreadsheet style layout (Comma delimited files).  

• Manual mode of operation is provided for set-up or evaluation.  Test time in the manual mode is indefinite and many of the test steps can be individually selected.

• Modem installed with our diagnostic software, which allows us to dial directly into the tester to perform remote diagnostics, changes and software upgrades

• 3 - 96 bar testing capabilities. 

• Odd and even bar testing capabilities.

• Remote Workstations.   A remote workstation allows for the testing of parts at a remote line or cell. The workstation can be built as a single or dual station unit and can be located up to 60 feet away from the tester.

• Attached Workstations.  The on-board or attached workstations allows for the testing of parts at the testers location. The workstation is permanently attached to the tester. The workstation can be built as a single or dual station unit

• Dual Station Testing.  Dual Station permits the operator to load a part into one station while the other station is testing.  This option will significantly increase the output of the tester.  Dual station can be utilized with either remote or on-board workstations.  Two test fixtures are required.

• Stator Testing Capabilities.  Both armature testing and stator testing can be performed using the same tester.  Additional tooling is also required.

• Resistance Bonding.    Wire bonding can be integrated into the test system for complete test, bond, test capabilities.

• Automation Testing Capabilities.   Output closures and software permit the tester to be integrated into your production line.

• Our exclusive Quick Change Test Fixtures configure the presentation of the armature winding to the tester in a consistent normal fashion.  Thus eliminating such variables as wave vs. lap windings, number of poles, polarity and multiplicity.  

• In most cases tooling is required to operate your AT6000 Armature Test System.  In some cases, existing tooling (ESW or other manufactures) can be converted for operation on these systems.

• Other types of test fixtures include Automatic Test Heads and Pneumatic Test Sockets.

Hipot:

Programmable from 0-3000 volts
50/60 Hz, 60VAC or 3000 VA
+/- 5% accuracy and programmable Leakage Fault of 0-10 mA 

Features exclusive Hipot Fault Feature to prevent the armature from going  through the test without an accurate hipot test being performed.

End-to-end and bar-to-bar resistance testing
Kelvin connection
.0001-1000 ohms, 4½ digit resolution
Ambient resistance temperature compensation 

Programmable from 0-3000 volts
Forward and reverse directions

.0001 can be set on the 1 ohm resistance range.

English, Spanish.  Other languages available upon request.

Wired for 120VAC 50/60Hz. (higher voltages are available)

Fully Integrated computer with industrial grade panel mount enclosure, 200 watt regulated DC power supply, six Slot Passive back plane, single board computer equipped with a 2.6Ghz Pentium 4 processor, built-in hard disk drive with a minimum 40Gb capacity, 256 Mb of DDR 333 memory, integrated 10/100 Base T network card, filtered forced air cooling system, high-speed multi-channel data acquisition system interfaced to the test system, 3 1/2 Inch Floppy Drive, USB 2.0 compatible data port and a USB 2.0 compatible printer port, VGA color monitor, mouse and keyboard. 

Set-up & Operation

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or you can call us at 262-554-1211