Stator/Bond Test System.  Each coil is bonded independently, producing the most even bond available on the market. Contact is made to the coils either through stranded wires attached directly through the actual magnet wire insulation, or to terminals set within the stator.

The part is loaded into the tooling, the leads are connected and the safety slide cover is closed; initiating the test/bond cycle. The resistance of the coil is read and compared to the high and low limits. If the limits are within the specifications established, these resistance values will be stored and used for the initial bonding sequence. Immediately after the resistance test, surge and hipot tests can be performed. If the windings pass these test limits, the bonding process will begin.

If a reject occurs during any test, the test sequence automatically terminates. The rejected coil is highlighted on the video monitor so the operator can quickly identify which winding is at fault or which of the wires may not be properly connected. This information is locked on-screen until the safety cover is opened.

Armature Test/Bond System  Armature coils are bonded simultaneously at 180°. Contact is made to the coils through the commutator bars outside of the brush track. The armature is not rotated.

The part is loaded into the tooling and the safety slide cover is closed, which initiates the test/bond cycle. The resistance of the armature is read and compared to the high and low limits. If the limits are within the specifications established, these resistance values will be stored and used for the initial bonding sequence. Immediately after the resistance test, weld, surge and hipot tests can be performed. If the part passes all of the test limits, the bonding process will begin.

If a reject occurs during any test, the test sequence automatically terminates. The rejected bar is highlighted on the video monitor so the operator can quickly identify which winding is at fault. This information is locked on-screen until the safety cover is opened.

Stand-Alone Bonding System  These units can be used either on a manual or an automatic line. This type of system allows bonding to be performed in one area while testing is being done in another area.