Knowledge

Knowledge and technical articles from practice

We write down what we experience every day in test engineering, retrofit and machine safety: methods, standards and typical errors, clearly explained.

Test engineering

Surge testing of motor windings: finding interturn faults before the motor fails

Resonant circuit, test voltage to EASA AR100 and IEEE 522, error area ratio EAR, procedure and buying criteria: how the surge test finds interturn faults that other measurements miss.

7 November 202611 min read

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Articles by topic

Electric motor rotors with copper winding in detail

Test engineering

Surge testing

Resonant circuit, test voltage to EASA AR100 and IEEE 522, error area ratio EAR, procedure and buying criteria: how the surge test finds interturn faults that other measurements miss.

7 November 202611 min read

Control cabinet with PLC and laptop during programming

Retrofit

PLC migration to S7-1500

Failure risk, data backup, I/O reserve, cycle time, program conversion, safety technology and signal test: how a PLC migration to S7-1500 or Beckhoff becomes plannable and what determines the effort.

7 November 202616 min read

NIKLAS Pump Bench pump test bench, front view

Test engineering

Pump testing ISO 9906

Tolerances of grades 1B, 2B and 3B, head and efficiency with a worked example, measurement uncertainty, NPSH3 and test procedure: how a pump test to DIN EN ISO 9906 runs on the test bench.

7 November 202616 min read

Robot cell with safeguards during the risk assessment

Machine safety

Machinery Regulation 2027

Cut-off date, substantial modification during a retrofit, PLr and PFH, cybersecurity, digital operating instructions, notified bodies and what operators should do by 2027: the Machinery Regulation (EU) 2023/1230 in practice.

7 November 202614 min read

Planning documents and drawings on a work table

Test engineering

Test bench requirements specification

Test items, power, measurement uncertainty, cycle time, energy and acceptance with formulas and worked examples: what a requirements specification for a test bench must contain.

7 November 202614 min read

NIKLAS Vision Check visual inspection system with conveyor belt

Test engineering

AI vision inspection

Resolution, lens, exposure, sample parts, escapes and false rejects with formulas and worked examples: how to design an AI vision inspection and accept it.

7 November 202614 min read

NIKLAS Drive Bench gearbox test bench in front view

Test engineering

Gearboxes after repair

No-load or load, efficiency with a worked example, torque measurement errors, back-to-back or regenerative load, contact pattern, temperature and vibration to ISO 20816-9: how to test a repaired gearbox before installation.

7 November 202613 min read

Testing a distribution board with miniature circuit breakers

Testing services

Test report EN 60204-1

What a test report to clause 18 of EN 60204-1 contains: protective conductor, loop impedance, insulation, voltage test, residual voltage and function, with limit values, worked examples and a report template.

29 October 202613 min read

Measurement on an opened electric motor with a multimeter

Test engineering

Measuring motor windings

Winding resistance, unbalance, insulation testing to IEEE 43, PI value and DAR: measuring procedure, formulas, limit values and decision rules for motor testing.

29 October 202613 min read

NIKLAS Test Field test station with test cabin and operator panel

Test engineering

Test station to EN 50191

Checklist for a test station to DIN EN 50191: designs, emergency stop, signal lamps, safety distances, discharge time, safety test probes, staff and the question of whether you set it up yourself or buy it ready-made.

29 October 202616 min read

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Simon Niklas

Mechanical engineer, M.Sc.

+49 941 56956720 [email protected]

“Good engineering proves itself in day-to-day production. That is why we combine technical planning with a close understanding of process, operation and maintenance.”

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