Motor Design Validation and Quality Assurance Test System

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Motor Design Validation and Quality Assurance Test System

Magnetic Innovations is equipped with a special quality control system to test and monitor the thousands of electric motors, they design and manufacture each year. This system has recently been expanded to include a new test system within the production line. It is fully customized to the R&D and production needs of its proprietary range of electric motors. The test system enables Magnetic Innovations to be a full-service development partner in motor design, design validation, and compliance testing according to international safety standards.

The design of an electric motor largely determines its physical properties. In order to validate the electric motor design, against the design objectives, elaborate testing is required. For quality assurance of the production process of electric motors, many specification items are inspected in the production line.

For both of the above aspects, Magnetic Innovations is equipped with a comprehensive test system.

Quality control during the design phase and production

Magnetic Innovation uses hardware to conduct common tests on electric motors such as insulation testing and measuring coil resistance, coil inductance and back-EMF. In addition, the test system is equipped to measure motor efficiency, torque ripple (cogging), hysteresis and eddy current losses, saturation and thermal behavior.

Measurement of the efficiency of electric motors with permanent magnets

Measuring permanent magnet motor efficiency requires accurate speed and torque measurement as well as a three-phase power analyzer to measure the power that feeds the electric motor. Copper losses of an electric motor greatly depend on the actual torque level whereas hysteresis and eddy current losses largely depend on the rotational speed.

Therefore permanent magnet motor efficiency is always depending on the torque and speed levels at which the electric motor is operating in practice, this can be fully programmed and measured with the test system.

Testing motor losses of electric motors

Motor losses are identified by heat and warm up the electric motor. Usually, the insulation of the motor coils is the limiting factor of the maximum power that can be delivered by the electric motor. Thermal classes of insulation up to 180°C or even higher are common.

For certain applications, lower temperatures are desired however. For this purpose, the test system can set operating conditions as desired and record temperature readings of all known temperature sensor types. Furthermore it can determine coil temperature by measuring the coil resistance increase which is often required for compliance testing to safety standards.

New test program in the production line of Magnetic Innovations

As part of the quality assurance system, the test system is seamlessly integrated into the production line of Magnetic Innovations. The design of the test system enables this by the easy installation of motors onto the test stand and generates test reports and stores data of measurement results for the purpose of statistical process control (SPC).

The product range of Magnetic Innovations holds many motor variants which have different specifications. Their product labels contain a 2D barcode that is scanned by the test operator, additional information such as used components in the motor is also scanned. With the scanned information, the test system identifies which motor is going to be tested and automatically selects the appropriate test program. This test program determines which tests need to be conducted on the electric motor and what the pass and fail criteria are. This way of working prevents human errors and further increases the quality assurance level.

By implementing production inline and end of line quality assurance tests, the electric motors are of high quality. This makes Magnetic Innovations a reliable manufacturer of electric motors.