The Real World of Magnet Wire Tests

A look into the history of developing devices to detect bead and HVC faults in magnet wire.

The Fusion System

We first combined the bead test system with the HVC test system into the "fusion system" which accomplishes both tests with a single detector and sharing the same computer and software. Compared to installing both systems, half the floor space and half the inline space was required and with about 33% savings in total cost-this looked like a sure winner. And was.

Lear Fusion Systems are now in use far and wide. After 6 years, the results are excellent and most sales are to repeat customers. Have we had to go out and tweak the software and such? You bet. No surprise again but all within the scope of customers having different ideas on how the system will interface with their operation.

Functions performed by the Fusion System include classifying the beads as "small" or "large" with correlation to spool length. HVC fault currents are listed when above user (or NEMA or IEC) set-in specs and with correlation to spool footage. Beads and HVC faults per 100' or 30 m are displayed together on a split screen sharing the same length axis. The spool reset function automatically closes the spool file and restarts the next (all totals are reset to zero for the new spool) and much more.

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