Wire quality test Instrument catalog - DSE · Wire quality test Instrument catalog . 2 Optimizing...

Wire quality test

Instrument catalog

2

Optimizing the processes

Knowing and controlling the parameters within production of enamelled wire is absolutely cru-

cial for the economy in manufacturing of enamelled wire.

The Tangent Delta Tester from DSE Test Solutions delivers all the information needed for opti-

mising and controlling the many processes. The measured data are compressed and displayed

in a full curve, showing the Tangent Delta as a function of the temperature.

This method is the ultimate way of making a fast, accurate and reliable determination of the

enamelled curing, and at the same time, showing any residual solvents or additives in the insu-

lation. Both residual solvents and curing state are factors that have high influence on tempera-

ture index, lifetime and physical behaviour of the wire.

Valuable information in few minutes means

30 years in the wire business means Experience knowledge and support

Continuous innovation and development

Reliable supplier of instruments,

with a remarkable track record

Improve the quality

Time and cost savings

Documented quality control

Optimised production parameters

Reduction of scrap

Under cured Normal cured Over cured

DSE Domicile since 1981…

Vers

ion 3

.1

1988

1994

2008

TD9000

TD300

TD5

TD3

2014

No. 1 in Tangent Delta

3

TD5 Tangent Delta Tester

TD5 is suitable for quality control of enamelled

wire. During heat-up of the wire, the TD5

automatically calculates the TgD temperature

(Tangent Delta temperature).

With a full curve, it is possible to determine

and display all valuable information about the

quality of the wire, among others:

Enamel curing

Enamel quality

Residual solvent

Absorption of moisture

Enamel type ID, and combinations

Increased profitability in manufacturing

of enamelled wire

Easy and fast test/analysis of the selected

samples from the production means:

Improved quality

Time and cost savings

Documented quality control

Optimised production parameters

Reduction of scrap

The central component in a TgD tester is the

oven. With a temperature range up to 400oC

(optionally higher) the TD5 is designed for

testing any type of enamelled wire.

For manufacturing

TD5 is designed to deliver fast consistence

measurements with high reliability. Test results

are ready after 3 minutes, depending of the

size of wire

For laboratory

The accuracy in all parameters sets new

standards for what is possible. The high-

precision heating elements with IHR

(Integrated Heating Regulation) and access to

adjustment of parameters make it the best

oven for research and development.


TD5 - built for the future!

TD5– Quality optimising technology

High temperature oven

High consistence of the measurements

Round and Flat wire in one system

High speed

High accuracy

Approve/reject function

Reference wire in display

Up to 99 pre-settings

Low maintenance needs

Multi user language

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High temperature oven

Round and Flat

0.008……..8 mm

Up to……..8x22 mm

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Easy operation and helpful features

TD5 is user-friendly, and easy to operate.

Results can be compared directly on the

screen, also comparison with a reference curve

is possible. All made to simplify the subse-

quent analysis of test results. Handling of data

The use of Microsoft SQL

database structure ensures

easy saving and retrieving

of wire data from a local PC

or from a central server.

Advance Database search function

Efficient search function makes it possible to find

and combine data stored in the database. Re-

trieving data for e.g. a specific customer com-

bined with result and time is simply done by

means of few mouse clicks.

High precision and cooling technology

TD5 sets new standards with respect to low

maintenance needs. Extended service intervals

are ensured by using innovative mechanical

design and, combined with it’s top quality met-

al hardware, the number of samples which can

be handled between each service is very high.

The combination of convinc-

ing technology and the use

of passive neutral graphite

as external conductor make

it the instrument with the highest reliability,

and the best repeatable measuring results

available.

Data input

For fast and precise data input, pro-

duction code and wire ID ext.

can be entered into the data-

base via Barcodes.

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TD5 Features

Multiple Curves Reference curves

During measurement the curve is visible and

combined with a reference wire the operator

has the best possible overview.

Software option B

This software tool evaluates the PEI base coat

on self-bond wires (XWE types). A mathemati-

cal evaluation of the PEI curve lies beneath the

self-bond signal and the Tangent Delta curve.

This function eliminates the need for stripping

self-bonding overcoat of the wire.

Documentation of production quality

It is possible to make test reports in PDF format.

Following information can be added to each indi-

vidual sample: Enamel type, supplier name, order

number, machine ID and other comments at-

tached to the measurement in the remark field.

Company logo can be imported and shown on

pages. Updating information in the fields for

remarks is possible also after the test is

completed.


Limits for approval or rejection of a measur-

ing can be set for two tangents for easy eval-

uation of the results.

1. Tangent 2. Tangent

Set up menu

Up to 99 customised pre-sets can be stored,

and easily found in the drop down box at any

time.

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5

Multi-language

The control software is at this stage available in

English, German, Chinese and Russian, contact

DSE Test Solutions for updated information.

Compare with reference wire

Up to 5 different curves can be displayed sim-

ultaneously. The possibility of comparing a

new measurement with a reference wire is

helpful in the interpretation of the result.

Flat up to ……..8x22 mm

Round 0.008mm ……..8 mm

Dimensions

Round and flat wire

TD5 is built to handle a wide range of dimen-

sions in both round and flat wire.

Multiple frequencies

For maximum flexibility during research and

development the following measuring frequen-

cies can be selected: 100 Hz, 120 Hz, 1 KHz,

10 KHz and 100 KHz.

Default according to the Norm IEC 60851-5

the measuring Frequency is 1KHz.

Calculation and presentation

TD5 starts to measure and calculate the TgD

temperature automatically when the sample

holder is loaded into the oven.

During the measurement, the development of

the curve is displayed on the monitor.

The software enables setting limits for the mini-

mum and maximum TgD temperatures.

In case TgD temperatures exceed the preset

limit values, an “Approved/Rejected” window

will appear.

Standard sample holder

Sample holder

The sample holder simplifies sample preparation,

and is designed for absolute minimum need of

maintenance. The standard sample holder can be

used for both round and flat wire.

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TD5 Features

Handle both round & flat wire

Sample holder for Ultra fine wire 0.008…..0.1mm

Fine wire sample holder

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TD5 contains

Oven with high-precision temperature control-

ling unit, power supplies, precision analyser,

interface for PC via USB.

Temperature range 45-400oC

Resolution ±0.1oC

Readout ±0.1oC

Dimensions (DxWxH): 440x530x360 mm

Ambient temperature: 10˚C - 35˚C

Net weight 33 Kg

Implementation Standard: IEC 60851-5

Precision analyser

Tangent Delta resolution:

0.0005 at C > 100 pF

Measuring frequency 100 Hz, 120 Hz,

1 KHz, 10 KHz, 100 KHz

Measuring voltage 1 Volt RMS

PC

Type, size, RAM and hard disc according

to current standards

Flat-screen monitor

Keyboard and mouse

Windows 7

Mains supply

100..230 VAC ± 10%

50/60 Hz With protective ground

Power consumption approximately 0.5 kW

Setup: TD5 connected to PC and printer.

Included accessories

Sample holder, holder for sample holder, cables,

service kit, 10ps graphite bottles, applicators, wire

sample dryer, manual in

German, English or Chinese, application notes for

evaluation of Tangent Delta Temperature curves in

English.

Technical specifications

Standard wire sample holder

Wire range:

Round 0.02...8.0 mm

Flat up to 8.0 x 22.0 mm

Fine wire sample holder:

Fine wire range 0.008..0.1 mm

Software:

Multi curve function

Comparison with reference wire


Scales, DIN or Logarithmic view

Scaling D-values up to 1.0

Programmable oven temperature range

Password management

Advanced Microsoft SQL data base

Report in printable PDF format

Test limits for automatic approval or rejection

Automatic printout of the individual curves and the

calculated data

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TD5 Specifications

Calibration tubes

Holder “ Third hand”

Optional accessories

Spare part kit

Calibration tubes including certificate

Software option B for automatic evaluation of

self bonding wire.

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TD3 is applicable for quality control of enamelled

wire. During heat-up of the wire, the TD3

automatically calculates the TgD temperature

(Tangent Delta temperature).

With a full curve, it is possible to determine and

display valuable information about the quality of

the enamel, among others:

Enamel quality

Enamel curing

Residual solvents

Absorption of moisture

Enamel type ID, and combinations

Product description

The combination of reliable technology and the

use of non toxic passive neutral graphite as

external conductor ensures high reliability in all

types of enamel.

TD3 sets new quality standards with respect to

low maintenance needs. Extended service

intervals are ensured by using innovative

mechanical design and, combined with its top

quality metal hardware, the number of samples

which can be handled between each service is

very high.

Easy operation

TD3 offers user-friendly operation, thus

minimising the need for operational training.

Because the calculated results are displayed as

curves on the monitor, the subsequent analysis

of test results is easily made.

Suitable for laboratory and production

TD3 is designed for fast delivery of reliable test

results from production lines as well as laboratory

applications.

Oven and Controller built in one compact

unit

The oven, controller , precision analyser, and

power supplies are all built together in one stable

metal cabinet. The compactness and low weight

of the complete system makes it portable and

easy to move around inside a production plant.

For obtaining flexibility the system operates with

a standard configured Windows PC or Laptop and

different sizes of the PC Monitor

Communication between External PC and TD3

system is handled via USB standard interface.

High repeatability-Low maintenance

TD3– Cost efficient TgD tester

High repeatability of the measurements

Compare results with multiple curves

Round and Flat wire in one system

Multi language user interface

Reference wire in display



Compact and low weight

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Multiple Curves

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TD3 Features

Fast measurements

It is designed for quick heat-up, and a full Tan-

gent Delta curve is produced in few minutes,

depending on enamel type and wire dimen-

sions.

The basis software for TD3 controls


Automatic calculation of TgD temperature

Printout of each curve and calculated data

(manual or automatic)

Rapport in PDF format

User-interface in multiple language

D-value axis scalable up to 1.0

Multiple tangent calculation

Approve/Reject function for 1. first Tan-

gent

MS-SQL database function

Software option A with additional features:

Compare result with multiple curves

Use of reference curves

Approve/reject function also for the

2. Tangent


Sample holders

The design of the sample holders for TD3 ensures easy applying of graphite combined with low need for

maintenance.

Heavy wire

2.0……..6 mm

Up to……..6x12 mm

Standard wire

0.05……..2.0 mm

Up to……..2.0 mm

Easy access for applying graphite

The zone for applying graphite is shown directly on the sample holder. Innovative design of the contact

blocks makes the inserting of the wire very easy and ensures a reliable contact to the wire.

Compare results with multiple curves

Results can be compared directly on the screen.

In multiple view up to 5 curves can be evaluated

simultaneously.

Software description

Optional features

Beside of the standard software package two op-

tions are available

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TD3 Features

TD3 contains

Oven with high-precision temperature

controlling unit, power supplies, measuring

bridge, USB interface for Windows 7 PC.


Resolution ±0.1oC

Readout ±0.1oC

Dimensions (DxWxH):500x360x280 mm


Net weight 15 Kg

Mains supply 100..230Vac±10% with pro-

tective ground

Power consumption max 500W

Implementation Standard: IEC 60851-5

Precision analyser

Tangent Delta resolution:

0.0005 at C > 100 pF

Measuring frequency: 1 KHz

Measuring voltage: 1 Volt RMS


One standard sample holder

Cables, plugs and sockets, wire sample

dryer.

10 pcs. graphite bottles and applicators

Application notes for evaluation of Tan-

gent Delta Temperature Curves in English

Optional accessories

Heavy wire sample holder

Spare part package

Calibration blocks including certificate.

Software option A

Software option B


Limits for approval or rejection of a measure-

ment can be set in order to avoid mistakes.

Optional also for 2. tangent.

1. Tangent 2. Tangent

Software option B

This software tool evaluates the PEI base coat

on self-bond wires (XWE types).

A mathematical evaluation of the PEI curve

lies beneath the self-bond signal and the Tan-

gent Delta curve. This function eliminates the

need for stripping the self-bonding overcoat of

the wire

Sample holder

TD3 Basic includes one sample holder.

Wire range: Round 0.05-2.0mm

Sample holder for Heavy wire (optional)

Wire range: Round from 2.0-6.0mm

Flat up to 6.0x12.0mm

Reference Curves

Reference curve can be selected and up to 3

reference curves can be attached to each set up

to simplify the subsequent analysis of test re-

sults.

Set up menu

Up to 99 customised pre-sets can be stored, and

easily found in the drop down box at any time.

Set up menu

Drop-down box

10

Description

TD9000 Tangent Delta Tester is the most

advanced and accurate tool for any type of enamel

or enamelled wire.

With the TD9000 it is possible to analyse

parameters such as curing of the enamel, residual

solvent, additives, etc. These parameters are all

essential for obtaining the right quality and

economy.

The TD9000 offers

High-standard laboratory tester for achieving

precise measurements

Flexible measuring setup, e.g. eight samples

with different dimensions can be measured

simultaneously

Comparison with reference wire

Multiple curves can be displayed simultaneously,

which simplifies the interpretation of the result

Selectable test frequencies for optimising the

measurement of different types of wires

All significant data stored in Microsoft SQL

database.


TD9000 is the pioneer among Tangent Delta test systems.

Eight samples of various dimensions can be measured

simultaneously.

The ultimate way

With this Tangent Delta method, determination

of the enamel curing and residual solvents in an

isolated wire is done very effectively. Preparing a

sample is simple too. The wire is de-isolated and

being prepared with graphite and in a special

setup it is possible to measure the capacitance

and the D-value.

Advanced calculating software makes it possible

to combine all significant information into one

very easyly readable and informative curve, and

make a print for documentation of the produc-

tion.

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Eight precise individual measurements

TD9000 Tangent Delta Tester is able to perform

precise individual measurements of up to eight

samples at a time, and in less than one hour.

Maximum flexibility

TD9000 offers maximum flexibility, as it is possible

to simultaneously measure various diameters and

types of enamelled wire.

Multiple curves

More curves can be displayed simultaneously,

which simplifies the interpretation of the results.

Compare with reference wire

Up to 6 different curves can be displayed

simultaneously. The possibility of comparing a new

measurement with a reference wire is helpful in

the interpretation of the results.

Documentation of production quality

It is possible to add the following information to

each individual sample to secure measurement

documentation: enamel type, supplier name, and

machine no. Furthermore, all information can be

stored on the PC hard disk.

High temperature range

TD9000 is capable of making a precise

determination of the Tangent Delta Value up to

350°C. This means that almost any type of

enamelled wire can be tested, thus ensuring, the

quality of the production.

Ease of operation and information access

To facilitate operational ease no operator

attendance is required during the measuring

process. The display will show the development of

the individual curves as well as the oven

temperature. The process can be stopped and

stored at any time. After completion, all

measurements and curves of each sample are

printed automatically, and data are calculated.

Multiple measuring frequencies available

For obtaining the best test conditions, a wide

range of test frequencies is available:

50 Hz - 300 Hz, 1 KHz - 3 KHz, 10 KHz - 30 KHz,

100 KHz - 300 KHz.

Non-stop measuring

The TD9000 system is available with two ovens.

The two ovens enable non-stop measuring, which

minimises the time needed to perform quality

checks of enamelled wire.

Working principle of TD9000

TD9000 working principles are based on

determining the quality of the enamel by

measuring the relation between the Tangent Delta

(D-value) and the wire temperature.

This method was originally developed for Quality

control in enamelled wire production by DSE Test

Solutions. Today we have become are worldwide

supplier of quality test equipment for the

enamelled wire industry.

Handling of data

The use of Microsoft SQL database ensures easy

saving and retrieving of wire data from a local PC

or from a central server.

TD9000 Features

12

Software

Features

This software tool offers complete control of the entire

measuring process with a user-friendly menu in English

or German, including the following main features:

Individual temperature measuring ranges between

45 and 350°C for all 8 positions in the oven

D-value between 0 and 3.0

Up to 5 tangents

Visibility of all curves during measurement

Automatic pop-up warnings to prevent loss of data

Microsoft SQL database for storing data on a server

Automatic printout of the individual curves and the

calculated data

Automatic calculation of auxiliary lines and Tangent

Delta temperature

Multiple curve function with up to 10 curves in the

same graph

Comparison with a reference wire

Automatic calibration programme

Extended database with search features, enabling

the user to search using any stored data

Logarithmic or linear graphs

Multiple measuring frequencies

Implementation Standard : IEC 60851-5

Option B

This software tool evaluates the PEI base coat on self-

bonding wires (XWE types).

A mathematical evaluation of the PEI curve lies be-

neath the self-bond signal and the Tangent Delta

curve. This function eliminates the need for stripping

the self-bonding over coat of the wire.

Basic system

Oven

Capacity: 1-8 samples simultaneously

Temperature range: 45°C- 350°C

Resolution: ±0.1°C

Readout: ±1°C

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TD9000 Specification

Measuring bridge

High-precision component analyzer

IEEE-488 interface

Tangent Delta res. 0.0002 at C > 60 pF

Measuring frequencies:

50 Hz - 300 Hz - 1 KHz - 3 KHz - 10 KHz -

30 KHz - 100 KHz - 300 KHz

Measuring Voltage: 1Volt RMS

PC

Type, size, RAM and hard disk

according to current standards

Flat-screen monitor

Keyboard and mouse

Windows 7

Electronic module

For powering and controlling of the oven.

Accessories

TD9000 oven cooler

All cables, plugs, and sockets

Sample preparation kit

User manual in English

Application notes for evaluation of Tangent

Delta Temperature Curves

Specifications

Mains supply

Mains supply 230/115 VAC ± 10%,

50/60 Hz with protective ground

Power consumption approximately 1 KW


Mechanical specifications

Dimensions oven (DxWxH): 450x440x250mm

Net weight: 19 kg

Dim. I/O rack(DxWxH):370x425x130mm

Net weight: 15 kg

Gross weight total single system: 140kg

Gross weight total dual system: 169kg

Oven with standard or customised dimension

range

The oven is delivered as standard with 8 slots which

can handle wire dimensions:

Round wire from 0.010 to 2.0 mm

Flat wire up to 2.0 x 4.0 mm

Each system can also be customized at order to handle

following dimensions:

Round wire up to 8.0 mm

Flat wire up to 8.0 mm x 22.0 mm

Flat max 2.0 m x 4.0 mm standard version

Flat up to 8.0 x 22.0mm to be specified when ordering

Round 0.01mm ……..2.0 mm standard version

Round up to 8 mm to be specified when ordering

Dimensions

13

When the wire passes through the head the current being measured will reflect the insulation

properties of the enamel. The high voltage control circuit is designed with an advanced current control system to avoid

sparks damage of the wire insulation or electrode system. Based on the most advanced soft-

ware platform on the market, the HVC test system is applicable for testing all types of wire in-

sulation with a test voltage up to 6kV DC.

Basic operation principle

Most reliable quality control tool

Valuable documentation for each meter of a spool

Reduction of scrap Improved efficiency

Measurement with two level detection Storing of data on local or central server

HIGH VOLTAGE

CONTINUITY TESTER

In the HVC Systems there are two individually adjustable levels of detector threshold. The two

levels make it possible to devide the faults into groups for pin holes and weak spots.

The test results are collected and compressed by a processing module, a label printout allows the

manufacturer to mark or label each spool of produced wire. Connection to central server enables

calculation of thorough production statistics.

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In-line Quality monitoring

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HVC 360 Flexible Features

The low tension in soft brushes brings

new opportunities for superior quality

control of a wide range of dimensions -

and with a full 360-degree coverage.

The HVC Flexible features

Full 360 degree coverage

Wide range of dimensions

Low tension means no damage of the

enamel because of the very soft

conductive brushes

Easy to maintain

No damage from sparks

Wide output test Voltage range 350V

to 6 KV

Measuring according to standard:

NEMA MW 1000-2003 and

IEC 60851-5

OK Warning Alarm

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Data base with visible features

Complete overview in one picture

Zoom function provides precise infor-

mation meter for meter

Find defect meters on the spool

Database browser Single spool view

Select a Pre-set

To simplify the operation it is possible use up to

99 pre defined settings.

The predefined pre-sets can be password pro-

tected by the administrator of the system.

Settings in short form

Software Protection

It is possible to protect by means of password a

range of features in the software. The protection

level is divided into 3 different levels. Administra-

tor, Supervisor and Operator.

HVC Flexible High Voltage

Two Level detection TH1-TH2

By operating with two different thresholds/

sensitivities TH1 & TH2 it is possible to get a pre-

warnings in time before the wire turns into scrap.

The most sensitive threshold TH2 will start count-

ing failures caused by e.g. weak spots before

more serious problems are detected by TH1 as

shown below.

TH2 TH1

From details to complete overview

Weak spots Pin-holes

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Technical specifications

Dimensions for Heavy wire model

Height: From 0.5 mm to 8.0 mm

Width: From 2.0 mm to 26.0 mm

Round: From 2.0 mm to 8.0 mm

Dimensions for round wire model:

From 0.005 mm to 2.0 mm

PM-Processor Module

The Processor Module controls the electrode

systems. It collects, evaluates, and compresses

data and sends them to a network or a “stand

alone ” PC.

PM module features

LED indicators for the following functions

Insulation error High tension Reel change Meter count Remote control (PC connected)

I/O interface, including power supply to the

electrode systems (measuring head) Opto-isolated outputs for warning and alarm Test Voltage 350V to 6000V Serial RS485 interface Ambient temperature: 15˚C - 50˚C Humidity: 0-80% no condensation. Weight: 2 kg Line voltage: 115/230V± 10% 60/50 Hz

with protective ground

PC

The system operates from a standard PC with

Windows 7.

Database Access or Microsoft SQL Database


Cables for measuring head to processor

module 10m included per line.

Longer cables can be supplied on request Standard Holder for Measuring head

1 holder included per line Earth strap for each line

1 cable PM-PC RS485 per PC

Optional Accessories

DSE2100 Multiple position holder for

Measuring-Head RS232/RS485 converter per PC including

10m connection cable Latching relay for Alarm output

Test kit probe for test of setting

Set of spare brushes

Holder for measuring head

Each line includes a high-quality metal holder

which secures a stable mounting of the

measuring head. This means it is easy to

dismantle the unit for cleaning, etc.

0.5...8 mm

175 mm

72 mm Heavy wire

48 mm Round wire

48 mm 80 mm

2...26 mm

2 to 8 mm

0.005 to 2 mm

Implementation Standard:

NEMA 1000-2003, IEC 0851-5

Standard Holder Optional: Multi position holder

Continuity Tester

16

DSE Test Solutions A/S Sverigesvej 19 DK-8700 Horsens Denmark

Information in this document

is subject to change without

prior notice. © DSE Test Solutions A/S

Brazil

Aries Ltda.

Mr. Stefano Malpezzi Phone: +55 11 5051 2763

Mail:[email protected]

China

Peng Consulting Ltd.

Mr. Peng Qingxuan Phone: +86 756 8129 166


Greece

ModusPlan

Mr. Gregory Savidis Phone: +30 210 96 27 935

Mail: [email protected]

India

Vertical Technologies

Mr. Nara Phone: +91 44 4555 4141

Mobile: +91 98 4002 2588


Singapore

PT BUSINESS NETWORK Pte.Ltd

Mr. Garrie Giam Phone: +65 64 691 692


Syria

Techno Trade el Fouad Ltd.

Mr. Khalil Phone: +20 2 748 2484


Korea

Hada International

Mr. Pyung-Ho-Yang Phone: +82 31 469 5671

Fax: +82 31 466 1963


Japan

Fukase & Co., Ltd.

Mr. N. Fukase Phone: +81 43 276 0630


Egypt




Jordan




Malaysia

PT BUSINESS NETWORK Pte Ltd.


Fax: +65 64 666 936


Saudi Arabia



Fax: +20 2 748 2484


Thailand

PT BUSINESS NETWORK Pte. Ltd.



Turkey

Emre Kutukoglu

Phone: +90 (532) 241 4911


Vietnam

PT BUSINESS NETWORK Pte.Ltd.

Mr. Garrie Giam Phone: 0065 64 691 692


Find your local contact for product availability and support

Tel : +45 7561 8811 Fax : +45 7561 5895 Web: www.dse.dk Mail : [email protected]

Taiwan

Analytik Jena Taiwan Co., Ltd.

Mr. Roger Chung TEL: +886-2-85227886

FAX: +886-2-85227514


Ukraine

LBU-Tech

Mr. Valeriy Yakovlev Phone: 0038 050 385 2199


Indonesia

PT BUSINESS NETWORK Pte Ltd.


Fax: +65 64 666 936


Mexico

JAN INGENIERÍA DE MÉXICO

Mr. Ing Javier Amaya Nava Phone: +52(55) 5549 6433

Fax: +52(55) 5549 6433


mailto:[email protected]



Wire quality test Instrument catalog - DSE · Wire quality test Instrument catalog . 2 Optimizing...

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