Enhanced Quality Assurance

Electric Motor Test Systems

Comprehensive Test Solutions for
all kinds of Electric Motors
Electric Motor Test Systems

Customisable for application specic End-of-Line

and In-Process Testing requirements

Crest Technology is a pioneering company in the eld of Test &

Measurement which specializes in designing and manufacturing
speciality test solutions for Motor Manufacturers, Power Sector,
Metros & Railways, Battery Industry, and Test & Certication Labs.

Crest has an experience of developing test systems for End-of-Line

and In-Process Testing for various kinds of motors. We also have an
in-house facility for custom designing precision mechanical test
xtures according to the shape and size of the motors to be tested.
Depending on the motor type, a vast suite of tests are available right
from torque-speed characteristics and current and voltage
measurements which are common for almost all types of motors, to
a specic type of tests which are applicable only to a particular
motor type. These tests help the manufacturer to determine that
the manufactured motors conform to the specied performance
parameters and are free from any manufacturing defects.
Types of Motors We Test

Ÿ AC motors Ÿ Stepper motors

Ÿ AC synchronous motors Ÿ Unipolar stepper motors
Ÿ AC induction motors Ÿ Bipolar stepper motors
Ÿ AC traction motors and gearbox Ÿ Disc magnet motors

Ÿ DC motors Ÿ Linear actuators

Ÿ Permanent magnet DC motors (or brushed
DC motors) Ÿ Universal motors
Ÿ Miniature brushed DC motors
Ÿ Brushless DC motors (BLDC)

A List of Tests & Measurements We Perform

Ÿ Currents Ÿ Power
Ÿ No load current Ÿ Input power
Ÿ Starting current Ÿ Output power
Ÿ Full load current Ÿ Power factor
Ÿ Locked rotor current Ÿ Efciency
Ÿ Phase currents Ÿ Copper loss
Ÿ Current undulation Ÿ Bearing friction and windage loss

Ÿ Voltages Ÿ Speed
Ÿ Starting voltage Ÿ Torque speed characteristics
Ÿ Capacitor voltage Ÿ Current speed characteristics
Ÿ Generated voltage Ÿ Voltage speed characteristics
Ÿ Phase voltages Ÿ RPM, RPS
Ÿ Back emf
Ÿ Frequency
Ÿ Resistances Ÿ Running frequency
Ÿ Stator winding resistance Ÿ Slip frequency
Ÿ Rotor winding resistance
Ÿ Insulation resistance Ÿ Direction of rotation
Ÿ Step angle
Ÿ Winding inductance
Ÿ Linear travel
Ÿ Torque
Ÿ Noise measurement
Ÿ Pull-in torque
Ÿ Pull-out torque Ÿ Vibrations measurement
Ÿ Pull-up torque
Ÿ Locked rotor test
Ÿ Detent torque
Ÿ Rated torque Ÿ Temperature rise test
Ÿ Peak torque
Ÿ HV test
Ÿ Breakdown torque
Ÿ Stall torque Ÿ Encoder parameters
Ÿ Holding torque Ÿ Jitter
Ÿ Switching torque Ÿ Phase error
Ÿ Friction torque Ÿ Mechanical error
Ÿ Ripple torque Ÿ Frequency
Ÿ Locked rotor torque Ÿ Duty cycle
Ÿ Torque constant
 End-of-Line (EOL) Systems

1-phase/3-phase AC Induction Motor Test System

The AC Induction Motor Test System is used for assessing the Measurements
performance and performing quality analysis on AC Induction Ÿ Torque
motors by using a regenerative load, optical encoder and reaction Ÿ Speed
torque sensor/load cell arrangement. The system makes use of a Ÿ Current
PMDC motor as a generator which acts as a load and a Ÿ Voltage
sophisticated regenerative module that feeds the generated Ÿ Input power
power back to the motor under test. This technology ensures that Ÿ Output power
the system consumes very little power from the mains supply even Ÿ Efciency
during the full load test. It makes use of a reliable and robust Ÿ Power factor
production-class hardware for accurately measuring various Ÿ Copper loss
parameters by performing a number of tests sequentially. A Ÿ Bearing friction and windage loss
precision machined mechanical xture is used for securing motors
of various frame sizes to have minimal axial misalignments with the
measuring hardware. All measurements are made by the system
according to the parameters selected by the user and the test
results are displayed on a PC for evaluation.

Brushed DC Motor Test System

The Brushed DC Motor Test System is used for assessing the

performance and performing quality analysis on Brushed DC
motors by using a regenerative load, optical encoder and reaction
torque sensor/load cell arrangement. The system makes use of a
PMDC motor as a generator which acts as a load and a
Measurements
sophisticated regenerative module that feeds the generated
Ÿ Torque
power back to the motor under test. This technology ensures that
Ÿ Speed
the system consumes very little power from the mains supply even
Ÿ Current
during the full load test. It makes use of a reliable and robust
Ÿ Voltage
production-class hardware for accurately measuring various
Ÿ Input power
parameters by performing a number of tests sequentially. A
Ÿ Output power
precision machined mechanical xture is used for securing motors
Ÿ Efciency
of various frame sizes to have minimal axial misalignments with the
Ÿ Copper loss
measuring hardware. All measurements are made by the system
Ÿ Bearing friction and windage loss
according to the parameters selected by the user and the test
results are displayed on a PC for evaluation.
Test System for Universal Motors

The Universal Motor Test System is used for assessing the

performance and performing quality analysis on Universal motors
by using an electronically controlled brake, optical encoder and
reaction torque sensor/load cell arrangement. The selection of
measurement components is done keeping in mind the high RPM
and low torque nature of universal motors. The system also has
built-in selectable AC and DC power supplies. It makes use of a
reliable and robust production-class hardware for accurately
measuring various parameters by performing a number of tests Measurements
sequentially. A precision machined mechanical xture is used for Ÿ Torque
securing the motor to have minimal axial misalignments with the Ÿ Speed
measuring hardware. All measurements are made by the system Ÿ Acceleration
according to the parameters selected by the user and the test Ÿ Current
results are displayed on a PC for evaluation. Ÿ Voltage
Ÿ Direction of rotation

Miniature PMDC (Brushed DC) Motor Test System

The Miniature PMDC Motor Test System is useful for assessing the Measurements
performance and performing quality analysis on Miniature High- Ÿ Torque
Performance Brushed PMDC motors. It makes use of a reliable and Ÿ Torque constant
robust production-class hardware for accurately measuring Ÿ Speed
various electrical and physical parameters by performing a number Ÿ Voltage
of tests sequentially. All measurements are made by the system Ÿ Current
according to the parameters selected by the user and the test Ÿ Current undulation
results are displayed on a PC for evaluation. at rated voltage
Ÿ Rotor winding resistance
Ÿ Direction of rotation
Additional parameters can be measured as per the
requirement 

Stepper Motor and AC Synchronous Motor Test System

The Stepper Motor and AC Synchronous Motor Test System is Measurements

used for assessing the performance and performing quality analysis Ÿ Torque
on Stepper and AC Synchronous motors by using an electronically Ÿ Speed
controlled brake, optical encoder and reaction torque sensor/load Ÿ Current
cell arrangement. It makes use of a reliable and robust production- Ÿ Voltage
class hardware for accurately measuring various parameters by Ÿ Direction of rotation
performing a number of tests sequentially. A precision machined
mechanical xture is used for securing the motor to have minimal
axial misalignments with the measuring hardware. All
measurements are made by the system according to the
parameters selected by the user and the test results are displayed
on a PC for evaluation.
Stepper Motor Step Angle Measurement System

The Step Angle Measurement System is used for measuring the

step angle of Unipolar and Bipolar Stepper Motors. It makes use
of a reliable and robust production-class hardware for
accurately measuring the step-angle using a high-resolution Hall-
effect sensor. A precision machined mechanical xture is used
for securing the motor to have minimal axial misalignments with
the measuring hardware. All measurements are made by the
system according to the parameters selected by the user and the
test results are displayed on a PC for evaluation. 
Measurements
Ÿ Step angle of Stepper Motor in CW and CCW
Ÿ Scatter in step angle in CW and CCW

BLDC Motor Test System

The Brushless DC (BLDC) Motor Test System is an End-of-Line Measurements

Test System which performs a number of mechanical and Ÿ Torque
electrical tests on BLDC motors. This test system is capable of Ÿ Torque constant
testing 2-wire, 3-wire, 6-wire, 8-wire and 9-wire BLDC Motors Ÿ Speed
ranging from 6 V to 48 V. Test parameters related to a large Ÿ Current
variety of BLDC Motors can be pre-programmed using a PC and Ÿ Voltage
stored in the memory and relevant parameters can be loaded Ÿ Resistance
when testing a motor of a particular type and rating. The system Ÿ Inductance
is capable of testing motors running as high as 40,000 RPM in real Ÿ Back emf
time. Ÿ Thermistor voltage
Ÿ Enable/Disable logic
Ÿ Direction of rotation
Additional parameters can be measured as per the requirement 

Linear Actuator Test System

The Linear Actuator Test System is an End-of-Line Test System

for measuring the stroke length of Linear Actuators under a
specied load using precision length gauges. It makes use of a
built-in power supply and driving circuit for driving the Linear
Actuator. A pneumatic arrangement for raising and lowering the
brass weights (load) onto the motor shaft is provided. Reliable
and robust production-class hardware is used for accurately
measuring the output of the length gauges. All measurements
are made by the system according to the parameters selected by
the user and the test results are displayed on a PC for evaluation.
Measurements
Ÿ Linear travel
Ÿ Displacement vs angular rotation characteristics
Ÿ Backlash
Ÿ Hysteresis
 Features of EOL Test Systems

Hardware Software
Ÿ PC-based fully automatic test systems Ÿ Windows-based software running on a touch-screen PC to
Ÿ Fully modular with option of NI DAQ or any other third-party program test parameters, carry out measurements, collect results,
hardware platforms view graphs for detailed analysis, and generate reports which can
be stored in excel format
Ÿ Built-in power supplies with drivers to drive motors of specied
ratings with stable and reproducible testing conditions Ÿ All test parameters and conditions for a motor type are stored in a
pre-programmed database
Ÿ A precision-machined mechanical xture for securing the motor to
have minimal axial misalignments with the measuring hardware Ÿ The software has facility to check and validate individual
parameters of a test item at any instance of time
Ÿ Provision for connecting external capacitor, resistor, and external
power supplies, if required Ÿ Test certicate can be stored and printed as per the manufacturer’s
format
Ÿ LED Indications for showing test in progress, test pass, test fail, and
system status Ÿ Special Engineering Mode, which is useful for debugging and new
motor development
Ÿ Barcode scanning facility can be provided

Motor Generated Voltage (GV) Tester Encoder Test System

The Motor GV Tester helps to measure the winding resistance and The Encoder Test System is useful for measuring the performance
generated voltage of fully assembled Brushed DC, Unipolar and performing quality analysis for standalone and motor mounted
Steppers, Bipolar Steppers, and AC Synchronous motors. The Encoders. It uses a reliable and robust, production-class,
motors can be tested in a clockwise and anti-clockwise direction at embedded hardware for accurately measuring various electrical
specied RPMs. The system has a very simple and easy to operate and physical parameters of encoder performance by performing a
user interface with an LCD screen for displaying test results. number of tests. A powerful multi-processor logic ensures high-
Bellow couplings of various sizes are provided so that the full range speed measurements which are essential to check Motor and
of motors can be tested. Additionally, there are BNC connectors Encoder parameters in real time. If a tachometer is tted on the
provided on the front panel of the system for connecting an motor, the system can also the GV parameters. All measurements
oscilloscope and viewing the graphs of various windings. made by the system are according to the test conditions selected
Measurements by the user.
Ÿ Generated voltage (GV) Measurements
Ÿ Winding resistance Ÿ Encoder PPR (up to 99,999 PPR)
Ÿ Duty cycle of A & B pulses
Ÿ Phase error on A & B pulses
Ÿ Mechanical error
Ÿ Jitter
Ÿ Duration of Z pulse
Ÿ Encoder current
Ÿ Frequency
Ÿ RPM
Ÿ Direction of rotation
Features Features
Ÿ Can measure Motor GV as well as Winding Resistance Ÿ Built-in power supply of suitable
Ÿ Motor is driven at a servo-controlled RPM rating
Ÿ Setting for varying the RPM Ÿ 4-line LCD to
Ÿ Variable resistance setting show all the
Ÿ Compact bench top construction results in one
Ÿ Simple analog user interface with LCD display for displaying view
Motor GV and Winding Resistance Ÿ Report generation
Ÿ The system is constructed in a modular design and all the Ÿ Built-in EEPROM programming hardware to load the error
assemblies are provided with plug-in connectors for easy compensation table for MR-type (Magneto Restrictive)
maintenance. encoders can be provided
Ÿ Can be provided with Windows-based software for test
control and waveforms storage and analysis facility
Ÿ Dual mode operation: tester & simulator
 In-process Testing (IPT) Equipment

Motor Winding Resistance Tester

The Motor Winding Resistance Tester is used for measuring the values
of individual windings of rotors of permanent magnet DC motors. The
system automatically measures the resistance of each winding in a
sequence and compares the results with pre-set limits to decide
Pass/Fail criteria of the motor. It can carry out tests in Loop Mode or
Cross Mode. It is a universal test system, capable of testing any motor
having up to 13 windings. The system is supplied with a custom test
xture which helps to perform tests and maintain test integrity.

Miniature Gearbox Tester

The Miniature Gearbox Tester is used to nd errors in mechanical

assembly of miniature gearboxes used in PMDC motors. Ten different
types of gearboxes can be tested using this instrument. The errors in
mechanical assembly of driving motor coupled to the gearbox result in
small changes in motor current, which are measured by using a highly
sensitive Hall-effect sensor.

Motor Magnet Polarity Detector

The Motor Magnet Polarity Detector is a simple productivity aid which

ensures that the polarity marked on the motor matches with the
direction of rotation of the motor. It is based on a highly sensitive Hall-
effect sensor that is capable of reading the weak magnetic eld which is
leaked to the outer surface of the motor body. This detection is useful
for aligning the brush end-cap with respect to the magnetic pole pieces
residing inside the body of the motor. An LED is used to indicate that
the alignment is correct.
RMB Core Open-Short Tester

The RMB Core Open-Short Tester is a simple productivity aid for

identifying short circuits in the commutator segments that may
have occurred during moulding and turning processes. The system
is supplied with a custom test xture with special spring-loaded
test probes which help to make contact with the commutator
segments at multiple locations. A test voltage of 100V DC is applied
across adjacent segments. The system detects a short circuit
condition when the current owing through voltage source
exceeds a predetermined value. The system is also capable of
detecting short circuits between the shaft and the segments

Rotor GV Tester

The Rotor GV Tester is used for testing the uniformity of magnetization of rotors used in Stepper and AC Synchronous motors. The
shaft of the rotor is coupled to a driving motor through a collet arrangement. A precision machined test xture with pneumatic
control is used for loading the rotor and running the test. The rotor is driven at a typical, servo-controlled RPM of 1500 or 1800. The
operator manually selects the direction of rotation and RPM. A set of push-wheel switches is provided for setting the GV Limit.
There is a quick connect arrangement for making electrical connections with the stator coil that is used for testing the rotors. The
stator coils which are secured on a moving slide are inserted into the rotating rotor. Digital voltmeters are used for displaying the GV
values.

Direction Check Unit

The Direction Check Unit is, essentially, a useful productivity aid

which can verify whether the shaft of the motor is rotating in the
correct direction or not. The unit consists of a disc which is rotated
by means of the shaft of the motor being tested. Depending on the
direction of rotation of the disc, the unit detects whether the shaft
of the motor is rotating in the correct direction or not. In case the
shaft is rotating in the opposite direction, the Fail LED glows and a
buzzer is sounded. There is a provision in the unit to set the passing
criterion of the motor as clockwise or counter-clockwise.
 Motor Drivers and Power Sources

AC Synchronous Motor Driver with Power Source

The AC Synchronous Motor Driver has a variable AC power source

and a control circuit to drive AC Synchronous motors of all
specications. The AC Synchronous Motor Driver is available in
benchtop conguration but can also be provided in a 3U chassis-mount
construction. The operator can set the values for operating voltage,
operating frequency, internal capacitor, and direction of rotation,
depending on the specications of the motor. There is also a provision
for connecting external capacitors, resistors, and power supply.

Stepper Motor Driver with Power Source

The Stepper Motor Driver has a variable DC power supply and a

control circuit to drive Unipolar and Bipolar motors of all
specications. The Stepper Motor Driver is available in benchtop
conguration but can also be provided in a 6U chassis-mount
construction. The operator can set the values for operating voltage and
PPS rate, and select the direction of rotation, motor type
(unipolar/bipolar), and drive (half step/full step/ wave drive), depending
on the specications of the motor. There is also a provision for
connecting an external power supply. Additionally, chopper drive,
indexer, and microstepping can be offered if required as add-ons to the
standard conguration.

Sine-Cosine Driver
The Sine-Cosine Driver is used to drive Bipolar Stepper motors and
Disc Magnet motors for evaluating the noise and vibration
performance of the motors used in critical applications. The signal
generation and amplication stages of the Sine-Cosine Driver are
based on pure analog circuitry which results in a very low harmonic
distortion output. The driver uses two independent high-compliance
adjustable current sources for driving the Bipolar Stepper and Disc
Magnet motor windings. The driver output frequency is also
adjustable for precise noise and resonance evaluation at speeds of 10
to 4000 RPM. The RMS current for each phase and the frequency are
displayed on independent digital displays. Necessary indications and
protections are provided to prevent the driver ampliers from
getting damaged due to an overload condition.
Features of Motor Drivers
Ÿ Easy to operate with simple manual controls applicable
Ÿ Built-in power supplies for stable and reproducible testing Ÿ Provision for connecting an external power supply
conditions Ÿ Provision for connecting an oscilloscope
Ÿ Electrical connections are made using quick connect Ÿ Individual displays for showing various setting values
arrangement Ÿ Easy to maintain compact bench top construction
Ÿ Provision for connecting external capacitor and resistor, if
Motor Burn-in Station

The Motor Burn-in Station is a fully-computerized turnkey solution for performing burn-in on various types of motors. The burn-in
process ensures smoother commutation and improves the motor life. It is also useful for detecting the motors with bad centering,
cracked magnets, defective bearing assemblies, etc.
The Motor Burn-in Station is developed on an embedded platform with a
Windows-based PC software for programming the burn-in parameters,
controlling the burn-in process, and monitoring the status of each channel.
The system consists of an acoustic enclosure with air inlet and exhaust ports
for providing uniform air circulation. Built-in power supplies with drives
suitable for testing motors of the specied type and rating ensure unmatched
performance. The system has all the necessary protections and safety
interlocks for safe operation.
Features
Ÿ Fully-computerized system with Window-based software for
programming burn-in parameters, setting limits, and monitoring status of
each channel
Ÿ Display of individual motor current and temperature in the software
during the burn-in process
Ÿ Facility for generating test reports through the software
Ÿ Specially designed acoustic enclosure having fresh air circulation
Ÿ Built-in power supplies and drivers suitable for the specied motor type
and ratings.
Ÿ Status LEDs and alarms for indicating burn-in status and fault conditions

Ÿ Embedded-based Ÿ Table-top
Hardware Ÿ PLC-based Ÿ In-line
Ÿ NI-based Construction
Options Ÿ Workstation
Ÿ Third-party hardware integration Ÿ 19” rack

RPM sensor type Coupling type Source type

Ÿ Optical encoder Ÿ Collet Ÿ 1-phase
Ÿ Tacho generator Ÿ Bellows Ÿ 3-phase
Ÿ Slot wheel Ÿ Beam Ÿ DC
Ÿ Proximity Ÿ K-type Ÿ VFD
Ÿ Angle encoder Ÿ Jaw Ÿ Unipolar stepper
Ÿ Bipolar stepper
Ÿ Sine/cosine
Ÿ Synchronous
Ÿ BLDC

Motor Motor Mains

Torque RPM
Load Under Power Input
Sensor Sensor
Test Source

Regenerative
Source

Motor type
Ÿ AC induction
Ÿ AC synchronous
Ÿ Universal
Torque Load type Ÿ Brushed DC
sensor type Ÿ Magnetic particle Ÿ Miniature brushed DC Power type
Ÿ Inline Ÿ Hysteresis Ÿ BLDC Ÿ 110 V AC
Ÿ Reaction Ÿ Eddy current Ÿ Stepper Ÿ 230 V AC
Ÿ Load cell Ÿ DC generator Ÿ Disc magnet Ÿ 415 V AC
Our other areas of application:

Ÿ LV, MV, HV and EHV Switchgear

Ÿ Automotive EOL Applications

Ÿ Miniature Motors

Ÿ Electromechanical Relays

Ÿ Electronics of Metro Trains and Railways

Ÿ Batteries of all types

Ÿ Machine vision

Crest Test Systems Pvt. Ltd.

25/5A/1/2, Nanded Phata, Sinhagad Road, Pune 411 041
+91 20 32419696 | www.crestech.co.in | [email protected]