benlong 
AC contactor comprehensive test machine
AC contactor comprehensive test machine performs contact gap/over‑travel, synchronization, Hi‑Pot (2.5kV), pick‑up/release, over/undervoltage tests in one automated station. Quick‑change tooling (<5 min), multi‑model compatible, data logging. Reduces test time by up to 60%, eliminates multiple testers. Ideal for contactor QC and production lines.
Universal AC Contactor Automatic Comprehensive Test System
The AC Contactor Comprehensive Test System is an automated solution for ensuring the quality of AC contactors through a high volumetric throughput test. It automates all significant functional testing requirements of an AC contactor at one location including (1) the verification of both the contact gap and the contact over-travel (2) the testing of the AC Contactor contact synchronization (3) the Dielectric (Hi-Pot) withstand voltage testing (4) the pick-up and drop-out (pull-in) voltage test (5) the Over-Voltage/Under-Voltage testing of the AC Contactor. This comprehensive testing solution has interchangeable tooling and custom designed software; it is a single consistent testing solution across multiple models of AC contactors having different specifications. This solution greatly enhances the production quality control of the entire production facility by ensuring that your facility’s production is compliant with the entire production facility’s production requirements while providing the highest possible efficiencies.
Standard delivery: 45-60 days | Quick‑change tooling | Multi‑model compatible
What Problems Does This Test Machine Solve?
Testing of AC contactors in traditional ways tends to have a separate station for several types of testing requires separate accommodation for mechanical dimensions testing (mechanical, over-travel and synchronization), separate station for electrical testing (Hi-Pot) and separate station for electrical coil performance (pickup/release vs. over/under voltage) and this method can be very costly because it will require several pieces of equipment and operators as well as there will be differences between the operators’ methods therefore can create further variability. Using our single automated Comprehensive Testing Machine to combine all combined testing types into one single machine will save considerable industrial floor space, eliminate any additional handling of products between tests, reduce the amount of time it takes to changeover CM’s between models because there will be no tooling replaced and we will give only one pass or fail result for each contactor. The testing system will log all test results for easy traceability and to help manufacturers comply with the continuous quality management principles defined in ISO 9001 and IEC 60947-4-1. All tests and fixtures can additionally be custom built and setup according to our customers’ requirements for their specific contactor series model due to the reason that they have a non-standard product.
Utilizes accurate linear sensors to verify mechanical stopping and contact over-travel against design specifications.
Time in between main contacts being closed/opened have been measured to ensure that the switching process was balanced and arcing was minimized.
In order to validate the insulation integrity according to IEC 60947-4-1, high voltage is applied between the coil/contacts and ground.
Measures maximum drop‑out voltage and minimum pull‑in voltage – highest must not exceed 110% of lowest.
Test Capabilities & Customer Benefits
Thông số kỹ thuật
| Test functions | Contact gap & over‑travel, contact synchronization, Hi‑Pot (dielectric strength), pick‑up voltage, drop‑out voltage, overvoltage, undervoltage– |
|---|---|
| Contact gap measurement accuracy | ±0.01mm– |
| Synchronization timing accuracy | ±0.1ms– |
| Điện áp thử nghiệm Hi-Pot | Programmable up to 2,500V AC, adjustable duration– |
| Pick‑up/release voltage accuracy | ±1% of reading– |
| Test cycle time | 15‑30 seconds per contactor (depends on number of tests)– |
| Compatible contactor types | AC contactors, various frame sizes (9A‑95A, up to 400A optional)– |
| Thời gian chuyển đổi | <5 minutes (quick‑change tooling + recipe selection)– |
| Hệ thống điều khiển | PLC (Siemens) with HMI, recipe storage for 50+ models– |
| Nguồn điện | 380V ±10% 50Hz | Hi‑Pot circuit 220V– |
Core Customer Benefits – Why Manufacturers Choose This System
Benefit 1: 4‑in‑1 test consolidation
By using one automated tester that performs several different test functions (i.e., contact gap, sync, Hi-Pot, and coil performance) instead of having multiple machines to do the same thing, you can save up to 50% in capital cost, and 60% in floor space compared with having separate stations for each test function.
Benefit 2: Eliminates handling‑induced variation
Relocating contactors across various testing stations creates variations in their positioning and introduces temperature changes. Testing all the design parameters with a single integrated design allows for the performance of the entire machine to be measured without having to move the product, providing accurate, reproducible results.
Benefit 3: Fast changeover for mixed production
Quick-change tooling, such as contact fixtures and coil connectors, and recipe-based HMI allow the user to change from one model of contactor to another in less than five (5) minutes. This is especially useful for the manufacturer that produces many different product families.
Benefit 4: Automated data logging for quality audits
Contactors’ serial numbers are assigned to all test results (gap values, sync time, Hi-Pot test leakage, and pick-up voltages) to ensure that all tests are completed automatically, retaining an actual link to each individual contactor. The reported results are exportable and meet ISO 9001 and IEC compliance.
Customer Success – How a Contactor Manufacturer Cut Test Time by 60%
A manufacturer of contactors in Europe had a total of four testing stations (mechanical, synchronization, Hi-Pot, and coil voltage) for their contactors. Each contactor took 2 minutes to test multiple test stations and required 3 operators to operate them. By implementing this complete test machine, they were able to:
The machine paid for itself in 10 months and freed up 12 m² of factory floor space.
Applications – Where This Machine Adds Most Value
Custom Engineering & Delivery
Request a Custom AC Contactor Test System Quote
We request that you send us your contractor samples as well as your requirements for testing and we will provide a design for a complete test machine with quick change tooling and capability for multiple models from brochures to a full return on investment analysis.
WhatsApp: +86 150 5837 0007 | Email: xsb@benlongkj.cn | Hỗ trợ tiếng Anh và tiếng Trung
Why Choose Benlong for Contactor Test Automation?
- Hơn 15 năm kinh nghiệm thiết kế comprehensive test systems for low‑voltage electrical components
- Proven integration of mechanical, electrical, and dielectric tests in one station
- Quick‑change tooling – changeover between models in under 5 minutes
- Full data logging and MES connectivity (OPC UA / Modbus)
- Dịch vụ toàn cầu và hỗ trợ phụ tùng thay thế
Máy tiêu chuẩn bao gồm
Contact Gap/Over Travel Sensor (Linear Encoder) ≤ Synchronization Measurement Module ≤ Hi-Pot Tester (2.5kv) ≤ Programmable AC Power Supply for Coil Testing ≤ Quick Change Fixture Set ≤ PLC with HMI: Siemens ≤ Data Logging Software ≤ Safety enclosure ≤ Operation Manual ≤ 1 Year Warranty
Câu hỏi thường gặp
The default testing machine includes these generally accepted tests: testing of the contact gap, testing of the limit switch; testing of the time delay between contacts; testing for dielectric strength; testing the pull-in voltage, testing the release voltage; and testing the voltage at both the pick-up and drop-out. Other tests may be performed if desired (e.g., resistance of contacts, resistance of coils).
The Standard model of the System is used in conjunction with all AC Contactors (AC coil powered); however, modifications to the power supply and control logic can be made to allow for other types of contactors such as DC as part of your consultation process.
Changeover of assembly using quick-change tooling (mechanical fixtures and coil connectors) and recipe selection via the HMI, require less than 5 minutes for most model families.
Test results (gap values, synchronization time, Hi-Pot leakage, pick-up/drop-out voltages) are all saved in memory with a time/date stamp and can be transferred via USB or to the MES via OPC UA / Modbus TCP. All test results are stored with a timestamp and can be exported to USB or exported directly to the MES via OPC UA/ Modbus TCP.
The cycle time on an item, based upon the number of tests, will range between 15 and 30 seconds per item for mechanical measurements, Hi-Pot and coil voltage tests.
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