Overview

For more than 40 years Baker Instrument Company has focused on quality control testing of electrical windings. We manufacture fully programmable automated test systems and insulation test instruments.

Test systems include winding resistance, high potential, surge, and other tests for a wide variety of windings, from fractional horsepower appliance motors up to 3,000 kilowatt traction motor armatures. Our broad range of experience along with a focus on providing the most advanced and practical technology combine to create quality control workhorses for your business.

With this sytem, DC HiPot, Bar-toBar Resistance/Weld and Span Surge tests are standard. Single and double insulated armature AC HiPot testing is available as an option. Any winding can be tested thoroughly and accurately in seconds.

WinAST8800 ESATS Operation

What sets the WinAST8800 ESATS system apart from other winding test systems is its highly sensitive computer controlled testing, analysis and report generation. The WinESATS8800 computer makes testing fully automatic and masterless.

• No Master Winding: A Master winding need not be connected to the tester during routine production testing. Neither does 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 WinESATS8800 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.
• Automation: To testing a winding, a Master data file is created and assigned. In a manually operated 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. Quality control with an WinAST8800 ESATS system is quick.

WinAST8800 ESATS Testing

• AC & DC Tests: For AC HiPot (High Potential-Optional) testing, the WinAST8800 ESATS 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.
• Bar-to-Bar Resistance/Weld: The bar-to-bar resistance/weld test is used to identify faults in the winding, such as high-resistance welds, improper wire gauge, and incorrect turn count. A true differential, 4-wire resistance measurement technique is used in the WinAST8800 ESATS to eliminate errors on low resistance windings. The bar-to-bar resistance/weld test can be analyzed with one or more of several methods to locate poor welds between the windings and the commutator bars. Ambient temperature compensation is a standard feature and infrared temperature sensing is optional.
• 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.

Reports & Statistics

Reports can be displayed on the monitor, printed, stored on floppy or hard disk, or transferred over a computer communications network.

Fixtures

All WinAST8800 ESATS must have fixturing to connect to the armature commutator. A variety of single and dual station standard and custom fixtures are available. These fixtures can be incorporated into fully automated or manually operated production lines.

ARC Systems, Inc. offers motor windings to become an integral part of your assembly, saving space and reducing weight. All laminations are stacked utilizing designed stacking tools and fixtures. ARC Systems, Inc. is truly one of the few remaining, totally integrated, suppliers of specialty custom windings in the electromechanical motor and components industries. Our in-house machining capabilities enable us to grind/hone stacks to .0002" tolerances on both Outer Diameter and Inner Diameter. If the application demands, closer tolerances can be achieved. Capabilities include: Potting, Vacuum Impregnation, Grinding, Honing, and MIL-STD-2000 Soldering. Types of Magnet Wire used: Copper, Solderable, Polyester-Imide, Polyester-Amide-Imide, and Polyimide. Winding Types include: Skein Wound – Hand Inserted, Symmetrical Insertion, Wave Insertion, Lap Winding, and Concentric Winding. Our internal capabilities, such as vacuum impregnation, precision bonding of aerospace laminations, multi-helix angle skewing capabilities, and powder coating, provide low cost solutions for our customers. From concept through engineering and production, ARC is committed to producing the highest quality components at competitive prices, delivered on time. As an ISO 9001:2000 Certified manufacturer, our commitment to quality is uncompromising. We serve both the aerospace and commercial markets. Our technical support staff would be delighted to assist you in finding the optimal solution to your application. We have thousands of custom designs and modifications that can be tailored to your application.

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.

Product Details

• UL 60950/IEC 60950 Annex U Approved
• UL 1446 Electrical Insulation System:
• NE-F1 - Class F (155°C)
• Single-End, Stranded, and Litz Conductors
• Supplementary and Reinforced Insulations

Technical Information
The most common winding wire is magnet wire in either its single-end or stranded "Litz" form. The magnet wire coating is generally not sufficient for insulating between winding turns, separate windings, and between the winding and ground as the magnet wire coating can easily be damaged. It is for this reason that additional interleaved insulation is needed.

NEWind® Specialty Winding Wire solves this problem by insulating the conductors with thin layers of insulation. The insulation layers are extruded in either two layers (Supplementary) or three layers (Reinforced). This design ensures that defects in any one layer will not reduce the insulating ability. Motors and transformers can then be manufactured without additional insulation thus reducing their cost and size.

Engineering Services: Custom designs from your specs, reverse engineering from samples, build-to-print, modification of one of more than 60 current designs

Applications: RF, IF, pulse, power, microwave

Wire Gauges:

• #1 to #50
• Multifilar ®
• Many other types of specialty wire

Engineering Services: Custom designs from your specs, reverse engineering from samples, build-to-print, modification of one of more than 290 current designs

Applications: RF, IF, pulse, power, impedance matching, audio

Wire Gauges:

• #1 to #50
• Multifilar ®
• Many other types of specialty wire