Motor Testing and Validation

Introduction

The tag Motor Testing and Validation underscores HENTACH's non-negotiable commitment to performance and reliability before a product leaves our facility. It is a comprehensive, multi-stage process designed to verify that every motor, from a single prototype to a high-volume production batch, meets or exceeds the precise electrical, mechanical, thermal, and acoustic specifications defined by the client and internal quality standards. This process is critical, as it provides the quantifiable data necessary to guarantee operational integrity and predict service life in the final application, minimizing the costly risk of field failure.

Our validation process spans three main areas: Design Verification Testing (DVT), Process Validation Testing (PVT), and End-of-Line Production Testing (EoL). DVT is performed on new designs and prototypes. This includes highly rigorous tests such as Accelerated Life Testing (ALT), where the motor is run under extreme loads, temperatures, and duty cycles to simulate years of service in a compressed timeframe. We perform thermal analysis using thermocouples and infrared imaging to map heat dissipation, ensuring our Motor Housing Die Casting and cooling fins perform as designed. We also use specialized test benches to generate the motor’s performance curves—speed vs. torque, efficiency vs. load, and current draw—which are then compared directly against the engineering model. PVT confirms that the mass production process consistently yields products that meet DVT-approved standards. This involves rigorous statistical process control (SPC) and ensuring all manufacturing tools (including our High Precision Machined Parts) are within tolerance. EoL testing is performed on 100% of the production volume. This automated process includes essential checks like no-load current measurement, winding resistance confirmation, high-pot (dielectric strength) testing to verify insulation integrity, and vibration analysis to flag any mechanical defects before shipment.

All testing equipment and sensors (dynamometers, high-speed data loggers, encoders, etc.) are regularly calibrated to traceable international standards, as mandated by our ISO 9001 certified Quality Management System. For specialized motors like our Encoder Equipped DC Motors, validation includes checking the angular accuracy and pulse consistency of the encoder signal. Our commitment to transparent validation means we can provide comprehensive test reports, including performance curves, life test results, and acoustic measurements, to our B2B partners, providing the data necessary for their final product certification.