Click to Enlarge
 
 
 Project Details
Back
 
 Domain  Special Purpose Machines
 Project Name  Automatic Test Line for Phase Modules
 Client  EPCOS Spain
 Consultant  
 Project Highlights A fully automatic line for testing phase modules. The type of the module identified by the barcode scanner at each test station and its test parameters are automatically loaded in PLC from the central SQL SERVER.
The GPIB communication with the C&TanD meter.
System Configuration

1

PLC/Drives

: S7 200 ( 4 Nos).

2

HMI

: Application SW in VB, SQL SERVER 2000, TP170B

3

Communication Protocol

: MPI, IEEE 488.

4

IO Count

: 700

5

Software

: VB, Step7, GPIB communication for C& TanD meter.

Project Synopsis

The fully automatic line is developed for the complete electrical and functioning testing of the phase module of all types of variations. The type of the module is identified by the barcode scanner at each test station and its test parameters are automatically loaded in PLC from the central SQL SERVER. The machine operates in five modes of operation: Auto Remote, Auto Local, Manual Remote, Manual Local and Maintenance.

The central QA station controls all the test stations in remote mode. The online status, test parameters recipe with version control management and reports are available at central QA station.

The three electrical tests are 1) BDT test 2) HV test 3) CTanD test.

After all three electrical tests the phase module is either sent to rejection table or to the assembly station. After assembly the functional test of phase module is done.

In BDT test a high voltage of 3000V or 6000V is applied across the capacitor (all 3 windings shorted) and body of the module for the test time of 10 sec. The applied voltage and the leakage current are monitored during this test time. In HV test station, it checks the capacitor current to balance the inductive load on application of high voltage 200 Amps current for 30 seconds is passed through the phase mod. In CTanD test, it checks the actual capacitance and the loss factor values of the windings to be within the tolerance limits using LCR meter. In function test, functioning of the phase module at the rated voltage is tested.

The scope of work included:

  1. Machine concept development and FDS
  2. Mechanical and electrical design of machine.
  3. Machine building
  4. Software development
  5. Commissioning and Performance trials