Broken rotor bars are a form of motor failure that occurs in squirrel-cage motors. The rotor of the squirrel cage motor is composed of a plurality of copper or aluminum bars welded between two cast copper or cast aluminum rings. The conventional squirrel cage rotor is generally made of aluminum, also called cast aluminum rotor.

Broken rotor bar refers to the breakage of the rotor bar due to technological, human or other reasons during the production process or use of the rotor. Although the broken rotor bar will not affect the operation of the motor for a short time, due to the uneven force on the rotor bar, the rotor will vibrate during the operation of the motor. Because the force on the rotor bar is not uniform, the rotor will sway to a certain extent. Heat, heat for too long is bad for the motor.

Generally speaking, in the process of use, it is quite obvious that the guide bar on the cast aluminum rotor is broken, and the broken rotor bar can be observed with the naked eye. However, in the process of rotor production, the problem of broken rotor bars due to process or personnel errors requires a special cast aluminum rotor test system.

Cast aluminum rotor test system classification

1. There are two types of placement methods according to the cast aluminum rotor test: one is the vertical cast aluminum rotor test system, and the other is the horizontal cast aluminum rotor test system, both of which are classified according to the volume and weight of the tested cast aluminum rotor.

The vertical cast aluminum rotor test system is used to test the cast aluminum rotors of household electrical appliances. Because of its small size and lightweight, it is easy to rotate the rotor during the test, and the test is convenient;

The horizontal cast aluminum rotor test system mainly tests the cast aluminum rotor of automobile motors. Because of its large size and heavy weight, the test shaft selected by the test system is thicker than that of the vertical test system. At the same time, the horizontal cast aluminum rotor test system is surrounded by Generally, it is surrounded by acrylic plate or barbed wire, which has a higher safety factor.

2. According to the cast aluminum rotor test items, it is divided into a conventional cast aluminum rotor test system and a full-function cast aluminum rotor test system. Compared with the conventional test system, the full-function cast aluminum rotor test system increases the test items of the end ring.

Cast aluminum rotor test system test process

The test process of the above four rotor test systems is generally the same, divided into three steps: placing the rotor, starting the test, and obtaining the results.

For example, according to the characteristics of the small size and light weight of the cast aluminum rotor to be tested, and the manufacturer does not require the test end ring data, the conventional vertical cast aluminum rotor test system is selected for testing.

1. Place the rotor

Place the cast aluminum rotor on the tooling table. The sensor has been adjusted to the proper position before the test, and the test can be started directly.

2. Start testing

Press the start button, the rotor test system automatically starts the test.

3. Got the answer

After 4s, the test results of the cast aluminum rotor with 34 bars can be obtained. The result shows that there are 34 bars in total, no broken bars, and no thin bars. The test results show the minimum amplitude, maximum amplitude, and comprehensive value. Of course, the general test process only Just looks at the final "qualified" result.

Advantages of Cast Aluminum Rotor Test System

1. The test items are complete and fast. Rotor broken bar tester adopts a special sensor, in addition to the conventional broken bar test, it can simultaneously test the existence of rotor thin bars and air bubbles, and display the test results in 3-5s, and the test efficiency is very high.

2. Data quantization waveform display. The rotor broken bar tester can set the upper and lower limits to realize simple testing. The numerical display of the rotor test data is accompanied by a waveform diagram, which is intuitive and clear. The unqualified interface directly displays the unqualified items, which is convenient for screening.

3. Test operation with multiple options. It can test various types of cast aluminum rotors, with strong adaptability, reducing the equipment procurement cost of manufacturers.

This article introduces the classification, testing process, and advantages of cast aluminum rotor test systems. AIP focuses on global motor testing. More die-cast rotor testers are available. If you have any motor-related questions, please contact us!

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