STATOR TESTING SYSTEM
The Model ST6400 is a fully automatic, pass/fail System for
testing stators, fields and coils. This unit
combines hipot, surge and resistance testing into one
automated test instrument. It is intended for use with all AC and DC stators or
fields in any production environment including lean
cell, automatic line or operator load.
No masters are required and there are no meters or scopes for the operator to interpret. All pass/fail test parameters are preprogrammed into the system. The lead wire colors are also programmed into the system and displayed on the video monitor; this shows the operators where to connect the leads into the clip block. The operator simply loads the part and engages the start test. All decisions relating to the acceptability of the part are made automatically.
The Model ST6400 testers continually outperform the competition. Our test systems are manufactured exclusively for each individual customer. This ensures that we meet your specifications, provide the highest degree of flexibility and provide the most durable and reliable test system available.
To view a video of the ST6400 testing system click here.
Set-up & Operation
The stator windings are surged by discharging a capacitor into the windings. The system monitors and analyses the surge waveform by measuring the ringing time and amplitude of the characteristics ringing waveform.
ESW's surge test is unique due to the amount of energy we can dump into the part. This allows us to stress the windings with greater energy, enabling us to detect the most sensitive shorts.
Surge voltage is adjustable from 0-3000. Testing is performed in both forward and reverse directions.
The surge test will reject winding and insulation faults such as shorts between adjacent windings, shorts within a winding, and insulation breakdowns between wires.
The Kelvin principle is used on the resistance and weld tests. Two sets of contacts are used, which omits any resistance being read from the tooling to the test source.
Ranges are from .01 to 1000 ohms full scale with a resolution of 4½ digits. Ambient temperature compensation compensates for any fluctuations in room temperature. All resistance readings are compensated to 25 degrees Celsius. Infrared temperature compensation is available as an optional feature.
The resistance test is capable of rejecting defects such as open windings, bad crimp connections, wrong wire size, stretched wire or wrong number of turns.
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
winding and the lamination, at the zero crossover point of the
sine wave to prevent a voltage surge. The leakage current is continually
monitored and compared to the low and high voltage
limits. If excessive leakage is detected, the
hipot voltage is immediately removed to prevent further
damage to the part.
Hipot voltage is adjustable from 0-3000 volts. The test cycle is programmable from .1 to
ESW's hipot test also features our exclusive hipot fault
process. This feature prevents the stator/field from going through the test sequence
without a proper hipot test being performed.
The hipot test is capable of rejecting stators/fields for such
discrepancies as excessive leakage and breakdowns between the wire
and adjacent metal.
Rotation Test (Magnetic Field Test):
Rotation can be done on single and three phase stators. This test applies a low AC bias current to the coil winding under test. The resultant magnetic field produced by this energized coil is measured with three analog Hall Effect Sensors positioned at a specific radial and axial location within the stator lamination core. The measured field signature is characterized and evaluated by the digital signal processing system of the computer. This test data is compared to the signature data saved from a good part.
The ESW rotation 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 bore. Each winding signature is individually saved as part of the limit record for each stator setup.
With the ESW rotation probe, each winding is checked individually
for proper wire connection, phasing, and core-loss. In the older “spinner rotation” methods, only the Auxiliary (start) and Main windings were checked without any quantification of their magnetic fields, only the ability to turn the spinner probe.
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 and can determine the final direction of rotation.
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. Each testers screen is customized for the individual application.
Drawer mounted keyboard.
Visual test results
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.
Shielded monitor ensuring longevity.
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
Modem installed with our diagnostic software, which allows us to dial directly into the tester to perform remote diagnostics, changes and software upgrades.
2-6 Stator Leads 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 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.
Armature 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.
Stator Leads. Capabilities to test with more than six leads.
Automation Testing Capabilities. Output closures
permit the tester to be integrated into your production line.
- Our exclusive Clip Block design can accommodate most parts. This Kelvin clip block continues to receive excellent reviews from our customers, particularly the operators.
and Adjustable V-Blocks prevent tipping and movement of the parts. This fixture makes loading and unloading of a part safer and easier for your operators.
||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.
.0001-1000 ohms, 4½ digit resolution
Ambient resistance temperature compensation
||Adjustable from 30-3000 Volts
Forward and reverse directions
|Magnetic Field Test:
||0-4 amps, line frequency
||120 VAC 60 Hz (50Hz 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.
To request a quotation, click here and fill in the requested information
or you can call us at 262-554-1211