Heater Element Electrical Test Machine

Scope:

The customers process required a stand alone machine to semi-automatically test a heater element tray. The machine had be designed to accommodate various size heater elements on the tray. The machine was semi-automatic in the fact that an operator had to connect the electrical connections and start the test. Continuity had to checked on each individual heater sensor to ensure the connections have been made at the station before. A 1500V hi-pot test is performed to ensure all wiring is correct with no faults. The resistance of each element has to tested to ensure the part is correct and not faulted. The part number has to printed on the bottom of the tray, in the event a part fails the error must be printed.

Description:

A stand-alone machine was designed to mount within the customers production line. The machine has a power feed conveyor to load and unload parts. There is a door that must be closed during the test to ensure the operator safety. A mechanism was designed to mount above the tray with air cylinder to extend pins to the heater sensors to short it out to test connections. This mechanism was design to be quickly changed to accommodate various sizes of heater elements.

The control system consisted of an Allen-Bradley Micrologix PLC to control the machine. A Visual Basic HMI was designed to interface to the operator and allow communication to various electrical test components. The computer and electrical test equipment was mounted above the machine at operator eye level.

A VideoJet printer was used to print on the bottom of the tray. This would print the part number and test status of each part. The VideoJet was controlled by the Visual Basic computer.