The Model RT6400 Rotor Test System features a Windows™ Operating system.  

The RT6400 is a fully automatic accept/reject tester specifically designed for testing wound rotors on the production floor.  No masters are required.  No operator decisions are necessary; all decisions relating to the acceptability of the rotor-under-test are made automatically.  All test steps are automatically sequenced.  

The RT6400 can be used for the prevention-of-defects approach, in addition to the more traditional detect-and-fix approach.  New and repaired rotors can be tested for integrity before time consuming installation begins.  Ultimately, it can help bring about a reduction in factory labor, manufacturing waste, and above all, an increase in product quality.

This tester is capable of detecting faults such as shorts between windings, insulation breakdowns, open windings, wrong wire size, wrong number of turns (if they fall outside of the resistance limits) and excessive leakage and breakdowns between the wire and the adjacent metal.

(Automatic Model Shown on the right)

Tests Performed:

Surge Test:

ESW utilizes both forward and reverse surge techniques to stress the part to it’s fullest potential.  We have determined that reversing the polarity of the feed pulse through the part under test will detect some unique insulation weaknesses. The tester also utilizes a Manual Set Up feature that allows you to view the waveform from a particular coil winding and to optimize the setup parameters.

The surge test applies steep pulses of energy to the coil winding under test.  The Model RT6400 Tester uses a Waveform Signature Analysis technique to gather data from the ringing pattern produced by the part under test.  This data is then compared to the waveform signature of a good part. Ringing time, amplitude, frequency and number of ringing cycles are analyzed using a 64-bit digital signal-processing technique.  ESW rotor testers optimize the waveform ringing by automatically selecting the proper discharge capacitance needed for resonance with the coil winding under test.  Pulse amplitude is digitally monitored and displayed on the user video screen.  Surge voltage is adjustable from 0 to 3000 volts. 

 The surge test will reject winding and insulation faults such as shorts between the windings and insulation breakdowns.

Resistance Test:
Resistance is obtained by applying a constant current to the part using a Kelvin connection, which allows for accurate resistance readings.  A Kelvin connection is made to ensure a highly accurate and repeatable resistance test even in the low milliohm ranges.   Two sets of two contacts are used, which omits any resistance being read from the tooling to the test source.  Ambient temperature compensation is incorporated into the test to compensate for fluctuations in the resistance of the part being measured, due to the room temperature (Infrared Temperature Compensation is available as an optional feature.).  There are 16 different resistance ranges available, from 10 milliohms to 1000 ohms (1k), having resolutions from 1 micro-ohm to 1 ohm respectively.  All resistance readings are compensated to 25 degrees Celsius. 

The resistance test will reject open windings, wrong wire size, or wrong number of turns if they fall outside of the resistance limits.

Hipot Test (AC):
Hipot testing is performed by applying a voltage, ten times greater than the motor or appliance will ever use,  to the part.  The voltage is applied between the coil windings and the rotor lamination 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 voltage limits.  If excessive leakage is detected, the hipot voltage is immediately removed to prevent further damage to the part.

 The hipot test is capable of rejecting rotors for such discrepancies as excessive leakage and breakdowns between the wire and the adjacent metal.

 The hipot voltage is manually adjustable from 0-3000 volts.  Test times are programmable from .1 to 10 seconds.

 A built in hipot fault feature prevents the rotor from going through the test without a proper hipot test being performed.  If a proper hipot test is not performed, a screen alert appears.

The hipot test is capable of rejecting stators/fields for such discrepancies as excessive leakage and breakdowns between the wire and adjacent metal.

Magnetic Field Test (Optional Test):  
Magnetic Field testing applies a low AC bias current to the coil winding under test.  The resulting magnetic field produced by this energized coil is measured with  analog Hall Effect sensors positioned at a specific radial and axial location within the rotor’s lamination core.  Use of the Hall Effect transducers eliminates the need for removing an inductor rotor probe during the surge test.  This test data is compared to the signature data saved from a good part. 

 The Model RT6400 tests single phase rotors.    Phase and field strength differences detected during this test can be caused by improper slot loading of the winding, core-losses and/or mixed lead connections.  All of these characteristics can have negative effects in final product performance. 

 The ESW magnetic field probe will operate within a broad range of lamination sizes.  The radial and/or axial probe location seldom needs to be altered as long as it remains located somewhere within the lamination core.  Each winding signature is individually saved as part of the limit record for each rotor setup.

With the use of ESW’s probes, each winding is checked individually for proper wire connection, phasing, and core-loss.

• 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 computer's main screen.  Totals are kept for good, reject, 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. 

• 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.  You will have the ability to print out all test data, good parts only, or reject parts only. 

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

• Mounted on casters for portability.

• Password Software Interface provides tighter restrictions on who is accessing the system's software.

• Data Logging.  Automatically gathers 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.

• 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 workstation 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 testing allows your 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 attached workstations.  Two test fixtures are required.

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

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

• Line printers, label printers, Bar Code Readers and Marking Systems.

• Ramped Hipot/Surge Voltage.

• Insulation Resistance.  Measures the overall integrity and value of the insulation resistance between the coil winding and the parts lamination.

• Inductance Testing.  Measurements range from 10 nH to 100 kH at selectable test frequencies of 100Hz, 1kHz, 10 kHz or 100 kHz.

• Standard and Adjustable V-Blocks prevent movement of the rotor. This fixture makes loading and unloading of a part safer and easier for your operators. 

Hipot:

Adjustable .50-3000 Volts AC
30 VA, line frequency
+/- 5% accuracy and programmable Leakage Fault of 0-10 mA 

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

Resistance:

Kelvin connection
.0001-1000 ohms, 4½ digit resolution
Ambient resistance temperature compensation 

Surge:

Adjustable from 30-3000 Volts
Forward and reverse directions

Magnetic Field Test:

0-4 amps, line frequency

Power Requirements:

120 VAC 60 Hz (50Hz available)

Test System:

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.