Test system for safety magnets

Locking solenoids must be checked for functionality and safety before deployment in industrial robots.

Industry: electrical industry


In order to achieve the shortest possible testing time, simple loading and contacting of the very small test connector was necessary. In doing so, the different positions of cylinders, as well as the performance of the test piece, had to be captured. Furthermore, it had to be verified by measuring spring tension whether the right spring was fitted during assembly. Test pieces that failed the test were intended to be removed by operator control, while checked and passed pieces were to be clearly labelled.


A reduction of testing time is achieved by means of a rotary plate with two testing stations. The DUT can thus be replaced at one station, while testing is taking place at the other. Loading is manual, the subsequent testing is fully automatic.

In order to protect the user, the rotation of the plate is secured by a light curtain. This allows for a further reduction in cycle time, because no protective doors need to be closed and reopened. Actual testing is secured by with an enclosure.

Cylinder stroke can be very precisely measured by means of a laser sensor. Measuring spring tension takes place via a force sensor. Function current can be adjusted via an adjustable power source.

Once a test piece has passed testing, marking is carried out via a center punch. A faulty test piece is signalled to the user via the software, as well as warning lights. Further testing can only take place after removal of the faulty piece. Capturing the removal of faulty pieces takes place via a sensor; this serves to avoid swapping faulty and operable test pieces.

  • Short testing time due to rotary plate
  • Fully automatic process after manual loading
  • Automatic capturing of the removal of faulty pieces
  • Low personnel expenditure for testing
  • Simple, intuitive operation for trained personnel
  • High voltage testing up to 800 V between coil and enclosure
  • Testing of spring tension up to 10 N via power sensor with a measurement accuracy of 0.2% of the final value
  • Activation for functional testing via setting current at up to 2 A
  • Capture of lifting motion via laser sensor with a repeat accuracy of 4 micrometres
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