Short Circuit Detection

With the initial application of power to a product there is always a possivility that the input power line to the product is short-circuited.  To protect the operator and the product, a short circuit detector can be used.  It operates faster than a circuit breaker and its level can be an adjustable test parameter.

Audit Station

When a high volume of appliances is being manufactured and tractability of each product is not required, an audit station becomes  practical solution.  Basic test stations without data acquisition are used in the manufacturing cells.  A single audit station is used to test samples from the line.  The audit station has extended test capacity and provides statistical analysis of the data for quality control.

Long Term Cycle Testing

A complete quality monitoring system calls for life cycle testing.  Cycle test stations allow continuous testing while monitoring and recording critical parameters.  Automatic controls assure functional tests are performed on schedule and out of tolerance products are turned off.  The automatic data collection system provides MTBF data as well as statistical analysis of the product’s performance.

Tracing Repair Actions

If a total product history is desired, repair action and audit results on non-conforming products can be recorded.  These can be traced to the affected product by model and serial number.

We hope you found these suggestions helpful and informative.  Feel free to leave your own in the comments section or ask us any questions you might have.

Bar Coding of Products

If bar codes are available on the products, they provide an ideal way of programming the test station for the proper series of tests.

Dielectric Testing of Powered Products

If the product contains safety circuits, or if a minimum total test cycle time is desired, simultaneous testing should be considered.  This feature allows the product to be in operation during the performance of the dielectric test.

Ground Fault Circuit Interrupters

When a product is plugged in the first time, or the operator is required to make adjustments to the electrical circuit, the use of GFCI’s should be considered.  Full time ground fault interrupter circuits protect the operator should they contact the electrical circuit.

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Mixing Domestic and Exported Products

Appliances for North America and the International market are manufactured and tested in the same cell by using quick change test receptacles.  An outlet strip containing the carious receptacles may be used.  The test station can furnish the proper voltage to each.  The correct frequency can also be supplied if necessary.

Teach the Tester

If you manufacture products such as hair dryers or fans, but the product mix changes frequently, use a special feature that teaches the tester.  A good sample product is cycled through its various speeds and heat settings.  The tester measures the results and uses them (with tolerances applied) as test parameters to test similar products.  Safety tests such as dielectric strength are not affected with this process.

Central Data Collection Point

Networking all test stations within a product group to a host computer allows all test data to be retained at a single point.  This supports your data acquisition and statistical process control efforts.

Ground Verification

For operator safety, a second test circuit verifies that the frame of the product is held at a true ground potential whenever power is applied.

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Work Cells

When the concept of just-in-time inventory is important to your operation, manufacturing cells are one of the major solutions to this need.  Cells allow immediate feedback if a problem develops and promotes a strong team spirit.  Individual test stations can be provided as standalone testers, or networked to a host computer, whichever makes the most sense for your operations.

Connect Once Only

To achieve the fastest test cycle time with lowest operator fatigue, perform all tests with a single connection.  With careful design of the test area, the operator can plug in the product once and perform any cycle, safety, or performance tests.

Run-in

If the product is a motor driven or a heating appliance, a run-in period may be desired.  If so, design the test area so the product remains connected from run-in through final test.  Automatic circuits can be used to control the timing period.  Also, keep in mind a turntable with rotating receptacles may improve efficiency.

Central Control of the Test Parameters

Networking test stations ensures that uniform test parameters are applied to all products.  This not only allows the data to drive your processes, but also gives you the added benefit of analyzing and measuring the effectiveness of your testing line, giving you real time feedback on what’s actually happening on the floor.

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1. Adherence to Standards

A good place to start is to evaluate your internal and external standards for compliance.  All equipment manufacturers have to adhere to external testing standards as specified by the UL, CSA and TUV, but where they are lacking is establishing a set of internal standards to take it one step farther and ensure product quality.

2. Testing Spectrum Evaluation

Another area to evaluate when determining if your testing is procedures are best in their field is to evaluate the types of testing you’re currently doing.  Safety tests are just one area you can look at.  You also want to make sure you’re measuring on performance, quality, reliability, acceptance and routinely auditing all of these procedures.

3. Manual vs. Automatic Operations

When looking at your testing system as a whole, what percentage of the process is automated and what portion is manual?  The more automation and customization you can incorporate into your testing process, the lower the possibility for error and the more streamlined your system as a whole will be.  Most people can’t see the forest for the trees when it comes to evaluating their testing procedures.  Take some time to critically evaluate your current system for increased efficiencies.

Long Story Short

There are a number of other areas to evaluate when determining if your testing procedures meet the grade, but by starting with these three important criteria, you’ll have a good understanding of where your current systems might be lacking and what direction you’ll need to take to improve them.

It’s All About the Benjamins

Obviously a big factor for consideration.  While most full featured hi-pot testers will put a dent in even the most considerable budgets, there’s another solution that costs less and is a better fit for your own manufacturing processes.  People are usually surprised to find that they can have a fully automatic test station with data acquisition included for less than the price of a micro-processor type hi-pot tester.  Which leads us to our next point.

Cut Once, Measure Twice

There have been considerable advances in data acquisition in the past decade when it comes to testing industrial equipment.  It’s become so affordable and efficient, you can usually get a test station designed to your specs for less than you would spend on the components to build it.  All companies recognize having full and complete records of every production test on a real time basis is invaluable.  Everything from rejection rates, liability protection, quality trends, production flow and management reports can be pulled to diagnose your testing programs in a custom solution.  However, these features are not always included in a standard hi-pot testing unit, so be sure to evaluate this when considering new equipment.

Does it Gel?

The last thing, but arguably the most important to consider, is how well does the solution you’re looking at match your current manufacturing processes and flows?  Does a plug and play tester suit your needs, or would you find value in having an automated test station with data acquisition and a wide range of test programs included?  These are all things that need to be considered when looking at implementing or upgrading your test equipment within your organization, and while there’s no easy answer, you’ll have a much better idea of what you need and if a custom solution is right for you after evaluating these criteria.