Testing systems for motors 3 x 400 V / 63 A / 50 Hz

Complete testing of electric motors at the end of line. A safety and function test is necessary at the end of line for the 3-phase motors following production.

Industry: electric motors


The requirement was a turnkey solution including workplace design and programmable power source. For the stalling test, the DUT must be mechanically held in place by applying large forces on the shaft. Moreover, high power must be supplied to the DUT, which should be programmable over the entire range from the PC. In addition, the system should easily be integrated into the existing production lines worldwide.


The high power required by the DUT required appropriate structures for the mechanical set-up. Therefore, a workplace design with 3 automatic doors, which moved upwards was chosen. This allowed saving of a lot of space, which was of great importance for integration into existing production lines. The test equipment was set up, separated from the workplace. Due to the high performance the power supplies were big and heavy. The heavy DUT come with workpiece carriers in the testing area and are then electrically connected by hand. For stalling measurement, the motor shaft is automatically fixed. The PC controls the freely programmable test processes with the standard software DAT. The following tests are available:

  • Ground bond test
  • Hipot (phase, body, sensors etc.)
  • Insulation resistance
  • Winding resistance
  • Withstanding voltage test
  • 1/3 phase no-load test
  • Stall current test with mechanical stalling of the shaft
  • Brake test

The "OK" result is put out together with the motor data to a label printer. This label is also the seal of quality. An arbitrary number of test programs can be stored in the testing system PC. This allows the customer to independently write new test programs while developing new products. However, for products with identical data, it is also possible to use the same test program, which is then allocated to the respective DUT over the product list. The test results are stored automatically in XML or Access format on an arbitrary place on the network.

A separate test dummy is used to check the functionality of the testing system fully automatically. During the daily start of the testing system, the testing personnel is asked to connect this dummy and start the corresponding program. The testing system does not allow further testing without a passed dummy test.


  • Turnkey solution including DUT support, adaptation and workplace design
  • Simple, intuitive operation for semiskilled personnel
  • The DUT needs to be connected only once, then the whole test process occurs automatically
  • In network operation, all test data is automatically saved at the specified location / database
  • Long service life and service-friendly design
  • All values and settings can be made using software
  • Automatic dummy test
  • Workplace safety standard
  • Automatic test program selection
  • Short cycle time due to optimum workplace design with 3 automatic doors that move up
  • Less space required due to the 3 automatic doors
  • Programmable source for 3-phase DUT of high power
  • Simple retooling for different types of motors
  • 3-phase sources 0 – 690 V at 32 A / 0 – 100 V at 50 A
  • 12-pin terminal panel for different motors and connections
  • Resistance measurement: Motor winding and sensors
  • Hipot test up to 5,500 V AC
  • Insulation test up to 2 GΩ
  • Power measurement by power analyser [P, U, I, cos φ, rpm]
  • Withstanding voltage test for all motor windings
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