• PC controlled test system
• custom made, exchangeable adapters with pneumatic contact for 4-wire technique
• resistance measurement from disc to disc or via 180° of collectors
• programmable surge test with graphic representation and evaluation of
  oscillation curve
• testing of switch angle (neutral zone)
• high voltage test (500 VA) for operating and safety insulation

This test system designed for workshop production includes measurement plug-in with multimeter, change-over matrix, surge tester, high voltage tester together with an industrial PC with monitor and keyboard.

The single components in the system cabinet have been ergonomically arranged. The keyboard can be comfortably operated when standing. The exchange adapter is easily accessible and can be quickly exchanged. A flexible test system has been designed which allows a large variety of types to be tested. The different rotor adapters for variable rotor sizes and disc numbers are easy to mount into a base station.

The test process is started automatically by closing the enclosure or manually via a start key. A mandrel at the pneumatically driven swivel arm then slides onto the upwards arranged shaft end, the shaft is contacted electrically and the DUT is thus safely supported. The laminated core insulated by the shaft is also contacted pneumatically.

Next follows a high voltage test with 500 VA transformer capacity for the operating and the safety insulation. The surge test and the subsequent evaluation of the graphic representation of the oscillation curve on your PC allow a safe assessment of the winding quality. Only with this technique can insulation weaknesses in the winding be discovered before an inter-turn short circuit occurs. The position of the switch angle (neutral zone) is tested with a Hall sensor.

Precondition for a reliable statement on switching errors and the ohmic resistance are: the contacting of all discs of the collector in 4-wire technique and the measurement of all single resistances. To evaluate the cross resistance an additional measurement displaced by 180 ° is performed at the collector. A special measurement method which evaluates the welding contact resistance serves to test the low ohmic welded joints of the winding wires in the µW range. The resistance measurements of the windings are also performed in 4-wire technique and are scaled on 20 °C (measurement and surrounding temperature).

The high voltage must only be switched via special ceramic high voltage relays. This is why the test station has two such relays which separate low and high voltage areas. The complete design of the test system in 4-wire technique assures reliable contacting of the DUT and this provides the precondition for the correct performance of the safety tests.

The test systems are equipped with industrial PC's which have the following advantages: a user-friendly WINDOWS Software and the easy composition of a test process. Via mouse click individual tests can be configured and composed in any number and order into a complete test process.

The test programmes can be created on any PC applying WINDOWS and can be transferred via a network to the test system. All of the required operating instructions, e.g. »Please close the enclosure«, and the respective measurements and cylinder movements are displayed on the monitor.

The results are stored in a protocol file, depending on the pre-selected parameters either locally or on the network. The protocol can be easily read into a data bank (e.g. ACCESS) and can be easily managed and statistically evaluated then.