This series of tester is suitable for testing the electric performance of motor, such as ac fan motor, washing machine motor, air conditioner motor and other products. After the test is completed, it gives qualified and unqualified instructions and sound and light alarm.
Integrated design: Integrated innovation design solutions simplify the operation of workstations.
Fast clamping: simple and efficient clamping solution, convenient for production line personnel to operate and meet the production line pace.
Software features： user permission setting function; large storage able to save over 1000 test programs.
MES: support connects with the production management system.
Easy-to-maintain: support intelligent self-inspection, remote failure diagnosis, and online software upgrading. Insertable card design makes it easy to disassemble and replace.
Easy-to-use: Professional test software, User-friendly interface, built-in help documents, high-performance touch screen, and numeric keyboard as standard.
Multiple interfaces: the instrument comes with USB, LAN support TCP/IP network protocol, and PLC simulation technology. Instrument control and expansion are quite easy.
Test items: AC Hipot, IR, winding resistance, surge, no load, direction of rotation.
output voltage setting range/precision
AC 500～3000V ±(2%×setting value+10V)
breakdown of current testing range/precision
0.10～20.00mA ±(2%×display value+0.05mA)
Hipot current presetting alarm range
Max: 0.10～20.00mA; Min: 0.00～20.00mA
±(2%×display value+0.05 mA)；0.01 mA
test time range/resolution
output voltage setting range/precision
DC 500V/1000V ±(2%×setting value+10V)
insulation resistance testing range/precision
≤100MΩ：±(3%×setting value+0.5MΩ) ；>100 MΩ：±(5%×setting value+5MΩ)
insulation resistance alarm setting range
Max: 0～500MΩ; Min: 1～100MΩ
test time range/resolution
output voltage setting range/precision
500～3000V ±(3%×setting value+10V)
area, area difference, corona and phase 3 waveforms displayed in the testing interface
DC winding resistance
testing range and precision
10.0mΩ～20KΩ ±(0.3%×display value+3 words) temperature compensation can be set.
test time range/resolution
temperature compensation function
test range and precision
voltage testing range and precision
AC:30～500V ±(0.5%×display value+1 word)
current testing range and precision
AC:0.02～5.0A ±(0.5%×display value+2 words)
power testing range and precision
0.6-1500W ±(0.5%×display value+5 words)
test time range/resolution
Direction of rotation
CW, CCW, still
There are various types of motors used in automation, and the selection depends on the specific application requirements. Here are some commonly used motors in automation:
·Servo Motors: Servo motors are widely used in automation due to their precise control, high torque, and fast response. They offer excellent speed and position control, making them suitable for applications that require accurate and dynamic motion, such as robotics, CNC machines, and industrial automation systems.
·Stepper Motors: Stepper motors are commonly used in automation for applications that require accurate positioning and control. They move in discrete steps and can hold their position without the need for external feedback. Stepper motors are often used in 3D printers, linear actuators, and robotics applications.
·AC Induction Motors: AC induction motors are widely used in industrial automation for various applications, including conveyor systems, pumps, fans, and compressors. They are robust, reliable, and cost-effective, making them suitable for continuous operation.
·Brushless DC Motors: Brushless DC (BLDC) motors are popular in automation applications where high efficiency, long life, and precise control are required. They offer advantages such as a high torque-to-weight ratio, high-speed capabilities, and maintenance-free operation. BLDC motors are used in robotics, drones, CNC machines, and electric vehicles.
·Linear Motors: Linear motors are used in automation systems that require linear motion instead of rotational motion. They offer direct and precise linear movement without the need for mechanical transmission elements. Linear motors are used in pick-and-place machines, high-speed sorting systems, and precision positioning systems.
·Direct Drive Motors: Direct drive motors eliminate the need for mechanical transmission components such as gears or belts. They provide direct coupling between the motor and the load, resulting in improved accuracy, reduced backlash, and increased system reliability. Direct drive motors find applications in machine tools, semiconductor manufacturing, and high-precision automation systems.
The choice of motor in automation depends on factors such as the required speed, torque, precision, control capabilities, environmental conditions, and cost considerations.
An automated line application motor tester is a specialized testing system or equipment used in automated production lines to test and evaluate the performance of motors. It is designed to efficiently and accurately assess the electrical and mechanical characteristics of motors during the manufacturing or assembly process. The tester is typically integrated into the production line to enable quick and automated testing, ensuring consistent quality and reliability of the motors being produced.
The specific features and capabilities of an automated line application motor tester can vary depending on the requirements of the motor being tested and the production line. However, here are some common functionalities and tests that such a tester may perform:
Electrical Performance Testing: The tester can measure various electrical parameters of the motor, including voltage, current, resistance, inductance, capacitance, and insulation resistance. These tests help ensure proper electrical functioning and identify any faults or deviations from the desired specifications.
Load Testing: The tester can apply controlled loads to the motor and measure its performance under different load conditions. This helps evaluate the motor's torque, speed, power output, and efficiency. Load testing ensures that the motor can operate effectively and deliver the required performance in real-world applications.
Commutation Testing: For motors that use commutation, such as brushed DC motors or brushless motors, the tester can verify the proper switching of the commutation signals and check for any abnormalities or malfunctions in the commutation process.
Mechanical Characteristic Testing: The tester may assess mechanical characteristics such as motor vibration, noise level, rotational smoothness, and physical dimensions. These tests help ensure the motor's mechanical integrity and performance, as well as compliance with specified tolerances.
Data Logging and Analysis: The tester can record and analyze the test results, generate reports, and provide statistical data on motor performance. This information can be used for quality control, process optimization, and troubleshooting purposes.
Automation Integration: The tester is designed to seamlessly integrate into the automated production line, allowing for efficient and synchronized motor testing. It may have interfaces to communicate with other equipment or control systems, enabling automated handling, testing, and sorting of motors based on the test results.
Automated line application motor testers contribute to the overall quality assurance and productivity of motor manufacturing processes. By automating the testing procedures, they reduce manual labor, minimize human error, and ensure consistent and reliable motor performance.
The use of an automated line application motor tester offers several benefits in the manufacturing and testing processes. Some key advantages include:
Improved Testing Efficiency: Automated testers significantly improve testing efficiency by performing tests quickly and accurately. They can handle a high volume of motors in a shorter time compared to manual testing methods. This leads to increased production throughput and reduced testing time, allowing for faster turnaround and improved overall productivity.
Consistent and Reliable Testing: Automated testers ensure consistent and standardized testing procedures. They follow predefined test protocols precisely, eliminating variations caused by human error. This leads to consistent and reliable test results, ensuring that all motors undergo the same evaluation process to meet quality standards.
Enhanced Testing Accuracy: Automated testers provide precise measurement and evaluation of motor parameters. They use advanced measurement techniques and sensors to achieve accurate and repeatable results, minimizing measurement errors and improving the accuracy of the testing process. This helps in identifying even minor deviations from desired specifications.
Fault Detection and Quality Assurance: Automated testers are equipped with comprehensive testing capabilities to detect various faults and issues in motors. They can identify electrical faults, mechanical problems, insulation issues, and performance deviations. By detecting and rejecting defective motors early in the production process, automated testers contribute to overall quality assurance and prevent faulty products from reaching the market.
Data Logging and Analysis: Automated testers record and store test data for each motor, which can be analyzed for quality control purposes. The collected data allows for trend analysis, statistical process control, and identification of potential process improvements. It enables manufacturers to track performance trends, identify patterns, and make data-driven decisions to optimize production processes.
Traceability and Documentation: Automated testers provide traceability by associating test results with specific motors or production batches. This allows manufacturers to track the history of each motor and maintain proper documentation for quality control and compliance purposes. Traceability helps in identifying and addressing any issues or recalls that may arise in the future.
Integration with Automated Production Lines: Automated line application motor testers are designed to seamlessly integrate with the overall production line. They can communicate with other equipment, such as robotics, conveyors, and data management systems, enabling automated handling, testing, sorting, and data exchange. This integration streamlines the production process, reduces manual intervention, and enhances overall automation efficiency.
Overall, the benefits of an automated line application motor tester include improved testing efficiency, consistent and reliable testing, enhanced accuracy, early fault detection, data-driven decision-making, traceability, and integration with automated production lines. These advantages contribute to higher productivity, better quality control, and increased customer satisfaction in motor manufacturing processes.
Testing with an automated line motor tester involves the following general steps:
1. Test Setup: Prepare the motor to be tested by connecting it to the tester according to the manufacturer's guidelines. Ensure that all electrical and mechanical connections are secure and appropriate safety measures are taken.
2. Test Configuration: Configure the automated tester with the desired test parameters and settings. This includes specifying the type of tests to be performed, the test criteria or limits, and any additional test conditions required.
3. Motor Placement: Place the motor in the designated position or fixture within the automated testing system. Ensure proper alignment and secure positioning to facilitate accurate testing.
4. Test Initialization: Start the automated tester and initialize the testing sequence. This may involve initiating the motor energization, applying test signals, or triggering the automated testing process.
5. Test Execution: The tester performs the predefined tests on the motor as per the configured parameters. This may include measuring electrical parameters, applying loads, monitoring performance, and recording test data.
6. Data Collection and Analysis: The tester collects and records the test results and data for each motor. This includes measurements, performance characteristics, and any detected faults or deviations. The data is typically stored for further analysis and quality control purposes.
7. Result Evaluation: The automated tester evaluates the test results against the specified criteria or limits. It determines whether the motor passes or fails the test based on the predefined criteria.
8. Sorting and Disposition: Based on the test results, the automated tester may sort the motors into different categories or dispositions. This could involve segregating motors into acceptable and rejected categories or further categorizing them based on specific criteria.
9. Reporting and Documentation: The automated tester generates test reports and documentation for each motor, capturing the test results, timestamps, and any relevant information. This documentation serves as a record of the testing process, enabling traceability and quality control.
10. Process Integration: The automated tester communicates with other components of the automated production line, such as conveyors, robotics, or data management systems, to facilitate seamless integration and workflow coordination.
When using an automated line motor tester, it's important to take precautions to ensure safety, proper operation, and accurate testing. Here are some common precautions to consider:
1. Safety Measures: Follow all safety protocols and guidelines provided by the manufacturer. This includes wearing appropriate personal protective equipment (PPE), such as safety glasses or gloves, when necessary. Ensure proper grounding and electrical safety procedures are in place to prevent electrical hazards.
2. Training and Familiarization: Ensure that operators and personnel who work with the automated line motor tester are properly trained and familiar with its operation. They should understand the testing procedures, safety precautions, and how to handle any emergency situations that may arise.
3. Equipment Calibration: Regularly calibrate and maintain the automated tester to ensure accurate and reliable testing results. Follow the manufacturer's recommendations for calibration intervals and procedures. This helps maintain the accuracy of measurements and ensures the tester is functioning optimally.
4. Proper Motor Handling: Handle the motors being tested with care to prevent damage or accidents. Follow proper lifting techniques and use appropriate fixtures or supports to secure the motors during testing. Avoid any unnecessary stress or strain on the motors that could affect the test results or lead to equipment malfunction.
5. Test Environment: Ensure that the test environment is suitable for accurate testing. Minimize electromagnetic interference (EMI) and other sources of electrical noise that could affect the measurements. Provide adequate ventilation and temperature control to prevent overheating or adverse effects on the motors during testing.
6. Test Parameters and Limits: Set appropriate test parameters and limits based on the motor specifications and testing requirements. Ensure that the configured parameters are within the safe operating range of the motor to prevent any damage or excessive stress during testing.
7. Data Integrity and Security: Implement measures to ensure the integrity and security of test data. This includes proper data backup procedures, data encryption if necessary, and access controls to protect sensitive information. Regularly review and validate the accuracy of data collection and storage processes.
8. Maintenance and Upkeep: Regularly inspect and maintain the automated tester to keep it in optimal working condition. Follow the manufacturer's maintenance guidelines for cleaning, lubrication, and replacement of worn-out components. Promptly address any equipment malfunctions or abnormalities to prevent inaccurate testing or equipment failure.
9. Documentation and Traceability: Maintain proper documentation of the testing procedures, test results, and any relevant information for each motor. This documentation enables traceability, and quality control, and serves as a reference for future analysis or audits.
10. Continuous Improvement: Regularly review and evaluate the testing processes and results to identify areas for improvement. Seek feedback from operators and personnel involved in the testing process to address any challenges or potential enhancements.