Overview

Manufacturers of stators, coils, alternators, rotors, and other kinds of motor windings need the most advanced, dependable and proven test systems. If you're looking for the ability to conduct common in-process electrical tests in one automated test instrument, built to your specifications, look to Baker WINAST 8800 Automatic Winding Test System.

HiPot, Surge, and Temperature Compensation Resistance test capabilities are standard. A Rotation Direction test is available for testing stators and field coils. Because each tester is a semi-custom instrument, assembled to your specifications, its capabilities are not limited to those described here; other features are available. Please feel free to discuss options based on your needs with a Baker Instrument Company representative.

WinAST8800 Operation

WinAST8800 systems not only test your product, they also test your process. In other words, trends within the manufacturing process can be monitored allowing you to anticipate problems. What sets the WinAST8800 system apart from other winding test systems it its highly sensitive computer controlled testing, analysis, and report generation in a field-proven design. The WinAST8800 computer makes testing fully automatic.

• Automation: To test a winding, a Master data file is created. In a manually loaded system, the operator need only start each test from the test fixture. When each test is complete, a pass/fail indication is clearly displayed conveniently on the screen and on the operator's control console. The WinAST8800 can be integrated into fully automated lines with automatic fixturing and a PLC or host computer communications interface.
• No Master Winding: A Master winding need not be connected to the tester during routine production testing. The operator need not set the test voltages or pass/fail limits during model changeover saving time. Test parameters are programmed into a Master data file. Programming each winding model takes just a few minutes. The WinAST8800 program is a simple, pull-down menu driven interface. The user is prompted for all necessary information. Once the Master has been defined, it is permanently stored. Testing is then automatically sequenced according to the Master file. Your tests are accurate. Repeatability is automatic.

WinAST8800 Testing

• AC & DC Tests: For AC HiPot (High Potential) testing, the WinAST8800 uses arc detection to sense breakdowns to ground or between windings which would otherwise go undetected using average current measurement techniques. It also has capacitive compensation capability. This measures the resistive portion of the leakage current, rather than the total current. DC HiPot testing checks the integrity of the insulation system with high DC voltage. Leakage current is then measured in micro amps rather than milliamps.
• Surge Test: The high voltage surge or impulse test checks for insulation problems between turns, coils, and phases of the winding. Surge tests can also detect other faults which change the inductance of a winding such as improperly annealed lamination steel and reversed coils. The surge test also has the ability to detect corona caused by weak insulation in addition to actual insulation breakdown.
• Resistance Test: The resistance test checks for wrong turn count, poor connections, mislabeled leads, and incorrect wire size. With the use of the Kelvin connections, low resistance winding tests are accurate and repeatable. Resistance measurements are corrected for temperature to the equivalent resistance value of 25°C or to a custom specified temperature between 20k and 2 mill i-ohm.
• Rotation Direction: The rotation direction test is an option for stator testing. Both induction and Hall-effect type sensors are available. This test is also capable of detecting misconnections in some cases.

Reports & Statistics

Reports can be displayed on the monitor, printed, stored on floppy or hard disk, or transferred over a computer communications network. Report and plot information includes, but is not limited to average, standard deviation, and failure tallies.

Fixtures

All WinAST8800 testers have a standard control console, safety interlock switch, and alligator clip terminations (unless optional fixturing is requested). A wide variety of single and dual station fixtures are available. In addition, test fixtures can be custom built to specifications for any size of winding. For more information concerning fixtures click here.

High Voltage WinAST8800 Option

A high voltage version of the WinAST8800 is available for testing low inductance form coils and motor stators of greater than 500 kilowatts or greater than 575VAC. See specifications for particulars of this instrument.

Specifications