Manufacture end-to-end automated production equipment for electrical connectors, optical connectors, and liquid-cooled connectors, and provide dedicated automated control and electronic systems.
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AboutWith the spirit of "pioneering and innovation," Unisign Automation leverages its extensive experience in design and application to provide customers with excellent and flexible comprehensive solutions. We continuously explore and innovate along the path of development.
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Technical ServiceWe provide users with advanced and professional customization of specialized automation equipment and technical services. We also offer a variety of standard products tailored for specific industries and hold a number of national patents.
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Fully Automatic Connector Voltage Withstand and Insulation Test Equipment
- Commodity name： Fully Automatic Connector Voltage Withstand and Insulation Test Equipment
- Product Description
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Equipment Introduction
- Model: UNMAC-ACVWTIT-2-1.7
- Weight: Approx. 690 kg (including basic test module)
- Dimensions (L×W×H): ≈1400mm×1200mm×1800mm
- Power Supply: AC220v±10%，50/60Hz，8A (requires good grounding)
- Air Supply: 0.5-0.8mpa (dry, oil‑free compressed air, flow ≥ 50 L/min)
- Throughput: Dual test stations, 600–700 pieces per hour (varies depending on number of test items; based on 5‑second cycle time per piece, including feeding, clamping, testing, and unloading).
- Changeover Capability: Supports quick changeover, adaptable to various connector types (e.g., different pin counts, sizes, and interface types).
- Testable Items: Can be equipped with different test instruments to measure insulation resistance, dielectric strength (AC/DC), and contact resistance of connectors.
Application Scenarios
This equipment is a fully automatic testing system specifically designed for the production quality inspection of electrical connectors used in automotive, aerospace, industrial equipment, communications, and other fields. It can be equipped with various test instruments of different precision and functionality to perform insulation resistance, dielectric strength (power‑frequency/DC), contact resistance, and other tests. By replacing manual operations with an automated process, it realizes a fully unmanned workflow from feeding, testing, judgment, sorting, to unloading, significantly improving inspection efficiency and consistency.
Equipment Features
- Automated Testing Process: Fully automatic from feeding, clamping, testing, result judgment, unloading, and sorting of OK/NG products into separate areas. Supports prompt and alarm functions.
- Flexible Test Instrument Configuration: Allows independent selection and combination of different test instruments to achieve various test functions and precision levels.
- Intelligent Parameter Recall (Optional): Automatically matches the connector model and test parameters (e.g., voltage, time, pass/fail thresholds) via barcode scanning or MES system integration, reducing manual setup errors.
- One‑Button Operation (Optional): Automatically generates and stores test reports, integrating the entire “Start → Test → Judgment → Report Generation” process. Test results are displayed (Pass/Fail) and stored automatically.
- Hierarchical Access Control (Operator/Engineer/Administrator): Prevents unauthorized operation and ensures system security.
System Composition & Core Modules
The equipment consists of five core modules: an automatic feeding system, a precision clamping workstation, a multi‑function test unit, an intelligent control system, and a sorting and unloading system. These modules work in coordination to achieve efficient and stable testing.
Module
Function Description
Automatic Feeding System
Combines a material tray with a linear conveyor belt.
Precision Clamping Workstation
Equipped with servo‑driven pneumatic fixtures. Supports clamping of various connector sizes (compatible with outer diameters from φ5 mm to φ50 mm) via quick‑change tooling. Clamping force is adjustable, and the non‑metallic fixture design prevents product damage.
Multi‑Function Test Unit
Allows flexible configuration of various test instruments to achieve different test functions and precision levels. Supports both independent and combined test modes.
Intelligent Control System
Based on PLC + industrial touch screen or PC‑based software. Supports barcode scanning and MES system integration (optional), enabling automatic parameter retrieval, process monitoring, and alarm notification.
Sorting & Unloading System
Uses servo mechanisms or robotic arms to sort OK and NG products. OK parts are transferred to the qualified buffer area, while NG parts are automatically routed to the rework area. Supports synchronization with production line takt time.
Core Functions & Technical Advantages
1. Fully Automated Testing Process
The entire process, from feeding to unloading, requires no manual intervention. The workflow is as follows:
- Automatic Feeding: Connectors are loaded from material trays onto a conveyor belt and transported to the clamping manipulator.
- Precision Clamping: A servo-driven fixture automatically positions the product at the test station.
- Multi‑Item Testing: Tests are executed in a preset sequence, including: Insulation Resistance: DC 50 V – 1000 V, accuracy ±2%; Dielectric Strength (AC/DC): 0 – 5 kV, adjustable, accuracy ±1%; Contact Resistance: 0 – 100 mΩ, accuracy ±0.5%.
- Result Judgment: Test data is compared with preset thresholds in real time. OK products are directed to the qualified product outlet, while NG products are routed to the rework area.
- Data Storage (Optional): Test results (parameters, time, operator, product barcode) are automatically saved for full traceability.
2. Flexible Adaptability
- Freely Configurable Test Items: The system supports combination of insulation resistance, dielectric strength, and contact resistance test modules. An optional insertion/withdrawal force test module can also be added.
- Multi‑Model Changeover Capability: Quick‑change fixtures combined with preset parameters enable rapid switching between different connector types.
3. Intelligent Control & Data Management
- Automatic Parameter Recall (Optional): Supports barcode scanning (product ID) or MES system integration to automatically match test parameters for the corresponding model, eliminating manual setup errors.
- One‑Button Operation (Optional): Integrates the entire workflow – Start → Test → Judgment → Report Generation. Test results (Pass/Fail) are displayed in real time, and reports can be automatically generated in PDF or Excel format.
- Hierarchical Access Control: Three‑level permission management prevents misoperation: Operator: Execute tests only; Engineer: Parameter setting and calibration; Administrator: Data export and system configuration
- Data Traceability & Analysis (Optional): Test data can be stored locally or exported via USB/network. Barcode‑linked product information enables SPC statistics (e.g., yield analysis, trend warnings).
4. Multi‑Level Safety Protection
- Mechanical Safety: Equipped with protective doors (with safety light curtains) and an emergency stop button. If foreign objects are detected or the fixture is not properly engaged during clamping, the equipment automatically shuts down.
- Pneumatic Safety: An alarm is triggered when air pressure drops below 0.5 MPa or when air flow is insufficient, preventing clamping failures due to unstable pressure.
- Environmental Monitoring (Optional): Temperature and humidity sensors (operating range: 15–35°C, 30%–80% RH) can be integrated, with alerts and test pauses triggered when limits are exceeded.
Summary
The UNMAC-ACVWTIT-2-1.7 Fully Automatic Connector Withstand Voltage & Insulation Testing Equipment combines automation, intelligence, and high precision to overcome the limitations of traditional manual testing – such as low efficiency, poor consistency, and difficult data traceability. As a key asset in the production quality inspection process for electrical connectors, it helps manufacturers improve product yield and reduce labor costs.
Keywords:
Fully Automatic Connector Voltage Withstand and Insulation Test Equipment
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