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JRS AUTOMATION Specializes in manufacturing of motor testing equipments including Armatures, Stators and Solenoid Coils.
We are exposed to all types of Projects in Motor Industries for the past Five years. (We have working experience in the same field more than 13 years).
We have been known throughout the Electric Motor Industry for developing innovative testing solutions. We have not only built our reputation on technology but also on our superb and timely service. Our goal is to continue to serve the electric motor industry by developing features and products that you, our customer, are looking for. |
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JRS has received a reputation for manufacturing reliable, versatile and easy to use testing equipment. We utilize quality solid-state components throughout our entire test systems. All of our systems undergo rigorous life testing by our qualified technicians and are also subject to in-house R & R studies prior to approval by our customers. Only upon successful completion of all our in-house analysis are our units shipped to customers.
Our test systems employ a modular layout, making troubleshooting easy. The components are all clearly marked and easily accessible. Each system comes with a complete operation manual, which includes instructions, schematics and troubleshooting procedures. |
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| Automatic Stator Test System |
The system is a fully automatic, pass/fail System for testing stators, fields and coils. This unit combines hi-pot, surge and resistance testing into one automated test instrument. It is intended for use with all AC and DC stators or fields in any production environment including operator load.
No masters are required and there are no meters or scopes for the operator to interpret. All pass/fail test parameters are preprogrammed into the system. The lead wire colors are also programmed into the system and displayed on the video monitor; this shows the operators where to connect the leads into the clip block. The operator simply loads the part and engages the start test. All decisions relating to the acceptability of the part are made automatically. |
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| Tests Performed |
Surge Test:
The stator windings are surged by discharging a capacitor into the windings. The system monitors and analyses the surge waveform by measuring the ringing time and amplitude of the characteristics ringing waveform.
JRS surge test is unique due to the amount of energy we can dump into the part. This allows us to stress the windings with greater energy, enabling us to detect the most sensitive shorts.
The surge test will reject winding and insulation faults such as shorts between adjacent windings, shorts within a winding, and insulation breakdowns between wires.
Resistance Test:
The Kelvin principle is used on the coil resistance tests. Ranges are from .01 to 1000 ohms. Ambient temperature compensation compensates for any fluctuations in room temperature. All resistance readings are compensated to 25 degrees Celsius.
The resistance test is capable of rejecting defects such as open windings, bad crimp connections, wrong wire size, stretched wire or wrong number of turns.
Hi-pot Test:
Hi-pot testing is performed by applying a voltage, ten times greater than the motor or appliance will ever use, to the part. The voltage is applied between the winding and the lamination, at the zero crossover point of the sine wave to prevent a voltage surge. The leakage current is continually monitored and compared to the high voltage limits. If excessive leakage is detected, the hi-pot voltage is immediately removed to prevent further damage to the part.
- The hi-pot test is capable of rejecting stators/fields for such discrepancies as excessive leakage and breakdowns between the wire and adjacent metal.
- Insulation Resistance. Measures the overall integrity and value of the insulation resistance between the coil winding and the parts lamination.
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| Automatic Armature Test System |
Tests Performed
Resistance Test (End-to-End and Bar-to-Bar):
The resistance test reads all of the 180º resistance readings at each 180º pair of commutator bars. Every reading is compared to the internally stored low and high resistance limits. This tester features ambient temperature compensation, which allows for fluctuations in the room temperature. Resistance readings are compensated to 25° Celsius.
Resistance testing will detect errors such as broken wires, stretched wires, open coils, wrong number of turns and wrong wire size.
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Surge Test:
JRS surge test is far superior to the competition. We are able to stress the windings with a greater amount of energy, enabling the most sensitive of shorts to be detected.
A capacitor is discharged into the windings. The system monitors and analyses the surge waveform by measuring the ringing time and amplitude of the characteristics ringing waveform.
This surge test will reject windings and insulation faults such as shorts between windings and breakdowns between wires. It also detects incorrect turn counts, shorted turns and improper connections.
Chips between the commutator bars can also be detected. If a chip is touching both bars, the weld and resistance tests will detect the fault. However, if the chip is wedged in and not touching both bars, JRS surge test will detect this. |
Weld Test:
The testers perform both bar-to bar and end-to-end weld tests. The end-to-end test is the most accurate method of detecting armature weld flaws.
- End-to-end readings are scanned and the lowest and highest readings are selected. The readings are scanned and the deviations between opposite coil readings are compared.
- Bar-to-bar testing is useful on some hand-staked applications. The readings show wire size and stretch of one flyer versus the other winder flyer. Controlling the flyer and wire size variations will result in less need for balancing corrections.
If a weld reject is detected, the test will stop and the weld resistance and position of the commutator bar will be displayed. This insures that bad welds are detected regardless of their location.
Weld testing detects armatures with open bars, poorly fused commutator bar connections, out of limit welds, side-to-side electrical imbalances, winder and wire tension device differences and different sized wire on opposite sides.
Hi-pot Test:
A hi-pot voltage is applied to the armature between the commutator, stack and shaft. The voltage is applied at the zero crossover point of the sine wave to prevent a voltage surge. The leakage current is constantly monitored and compared to the internal low and high leakage limits. If excessive leakage is detected, the hi-pot voltage is immediately removed to prevent further damage to the armature. Test time is adjustable from 1 to 60 seconds.
Hi-pot testing is used to satisfy regulatory requirements by detecting armatures with excessive leakage and breakdowns between the wire and the adjacent metal. |
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Solenoid Coil Test System:
Surge Test:
JRS utilizes surge techniques to stress the part to it’s fullest potential. We have determined that reversing the polarity of the feed pulse through the part under test will detect some unique insulation weaknesses. The tester also utilizes a Manual Set Up feature that allows you to view the waveform from a particular coil winding and to optimize the setup parameters
The surge test applies steep pulses of energy to the coil winding under test. The Tester uses a Waveform Signature Analysis technique to gather data from the ringing pattern produced by the part under test. This data is then compared to the waveform signature of a good part. JRS Solenoid coil testers optimize the waveform ringing by automatically selecting the proper discharge capacitance needed for resonance with the coil winding under test. Pulse amplitude is digitally monitored and displayed on the user video screen.
The surge test will reject winding and insulation faults such as shorts between the windings and insulation breakdowns |
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Resistance Test:
Resistance is obtained by applying a constant current to the part using a Kelvin connection, which allows for accurate resistance readings. A Kelvin connection is made to ensure a highly accurate and repeatable resistance test even in the low milliohm ranges. Two sets of two contacts are used, which omits any resistance being read from the tooling to the test source. Ambient temperature compensation is incorporated into the test to compensate for fluctuations in the resistance of the part being measured, due to the room temperature . All resistance readings are compensated to 25 degrees Celsius.
The resistance test will reject open windings, wrong wire size, or wrong number of turns if they fall outside of the resistance limits.
Specifications:
Hi-pot: Adjustable 500-3000 Volts AC, line frequency +/- 1 mA accuracy and programmable Leakage Fault of 0-200 mA
Resistance: Kelvin connection .001-1000 ohms, ambient resistance temperature compensation
Surge: Adjustable from 500-3000 Volts
Power Requirements: 220 VAC 50 Hz
Test System: Fully Integrated computer with industrial grade panel mount enclosure, 200 watt regulated DC power supply, single board computer equipped with a 2.6Ghz Pentium 4 processor, built-in hard disk drive with a minimum 80Gb capacity, 1 GB of DDR memory, filtered forced air cooling system, high-speed multi-channel data acquisition system interfaced to the test system, 3 1/2 Inch Floppy Drive, USB 2.0 compatible data port and a USB 2.0 compatible printer port, VGA color monitor, mouse and keyboard. |
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| Our customers rate our service second to none. Our staffs of dedicated service professionals are ready to react to customer demands. Our number one goal is to keep all our testing equipment running at optimum performance. We have the ability to keep even our oldest pieces of equipment functioning. Customers return to JRS for products because of our ability to respond to their needs and our proven accuracy in testing. |
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JRS testers are used in a wide variety of industries including automotive, small appliances, large appliances.
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 JRS Automatic Test System.
Surge and Coil Resistance test capabilities are standard. 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 JRS AUTOMATION.
Our test systems are manufactured exclusively for each individual customer. This ensures that we meet your specifications, provide the highest degree of flexibility and provide the most durable and reliable test system available.
Automatic Test System Operation
Automatic Test 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 Automatic Test system apart from other winding test systems it its highly sensitive computer controlled testing, analysis, and report generation in a field-proven design. The Automatic Test System 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.
- 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 Automatic Test System 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.
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- Mitsuba Sical India Limited, Gummidipoondi, Chennai, Tamil Nadu.
- Visteon Powertrain Control Systems India Pvt.Ltd.Chennai.
- Crompton Greaves Limited, Goa.
- Crompton Greaves Limited, Ahmednagar,
- Titan Industries Limited, Hosur, Tamil nadu.
- Moog Control India Limited, Banglore.
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Mr. S.Raman
Marketing Executive
Mobile : 91-9791042125
JRS AUTOMATION
#168, 1st Main road, Nehru nagar, Kottivakkam,Old Mahabalipuram Road,
Chennai – 600 041.
Tamil Nadu, India
Phone: 91-44-24540263,43593040,E-mail: jrsautomation@vsnl.net, jrsautomation_tn @airtelmail.in
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