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E-Mobility & Automotive
Electric Drive Unit (EDU)

High-Voltage Stator Test Bench

Compact design with index-table system for stator testing

The constant innovations in the field of electromobility are moving stator production more and more into the focus of the value-added chain of automotive manufacturers. The rapid progress in electronic and control systems of electric motors also has considerable impact in this area: Ever faster switch-on and switch-off times of the power semiconductors lead to ever steeper voltage peaks. This poses completely new challenges to the robustness of the stators.

Our stator testing system is tailored to these increased quality demands. The compact test stand operates in three positions in parallel and with optimized cycle times for different stator power classes. Thanks to full automation, there is no need for the intervention of a worker and no changeover effort. The stator contacting is optimized for the individual product and offers the possibility of a four-wire measurement to compensate for the test leads.

According to the latest state of the art, the fully automated turntable test stand developed with our external measurement technology system partner offers the test criteria shown below.

1

Overview

Test methods and contents

Weight measurement and determining the difference (pre-impregnation to post-impregnation) for the evaluation of the correct amount of impregnation resin

- Surge voltage measurement

- Partial discharge measurement by means of surge voltage and microwave antenna

- Insulation resistance measurement

- High-voltage AC measurement

- Winding resistance measurement including temperature compensation by means of non-contact temperature measurement

- Inductance and capacitance measurement

2

Description

High-Voltage test stations for stator (hairpin-type or bobbins) production line

Test stations: 2 test stations for testing stators before impregnation

2 test stations for testing stators after impregnation and all stations are identical.

Location:

‍The test benches  are designed as interlinked test benches within a test facility integrated into stator production.

3

Operational concept as testing station

Automatic in-line test station as rotary indexing table with 5 different positions.

Loading and unloading by interlinking robots and Adaptation to the test object with automatic units directly in of the station, without set-up before or after the station. 

- Measurement of ambient temperature and relative humidity

- Contact check of the ground contact (continuity check)

- Dielectric strength AC between the 3 phases and ground + NTC sensors; Ramp freely adjustable; including I-peak detection

- Insulation measurement DC NTC sensor

- Dielectric strength AC between NTC sensors and 3 phases + ground; Ramp freely adjustable; including I-Peak acquisition

- Resistance measurement NTC sensor incl. adjustment to 25°C with the air temperature

- Equip potential bonding measurement between end shield and intermediate housing

- Resistance measurement of the 3phases U, V, W incl. compensation to 20°C

- Automated logging of results and transmission to the OpenCAQ system

4

Specifications

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