Stator Tester
(A device to validate the winding pattern in a stator )
Each stage in a vehicle alternator production line (especially those which are not fully automated), need to be validated accurately. The winding pattern, and the wire resistance were important parameters to be checked after the stator winding stage. I designed this device to check such parameters in a stator, so that the stator can be checked separately without a rotor. By being situated in the stator, it can measure the magnetic flux pattern generated by each of the three coils.
The deice changes the current direction through the stator windings and to measure the equivalent magnetic flux. The phase angle and magnitude of the magnetic flux reflects the correctness of the winding pattern and number of turns in each slot in a stator. Thus, any extra turn in a coil can be detected easily.
I used five PIC18f25k80 microcontrollers and thirty-two Hall effect sensors. Each microcontroller reads eight sensors’ analog signals and sends them to the master microcontroller. All gathered data is sent via UART to a Computer.
