Your local contact:SCHLEICH – Leading in test devices.
Strong in test systems.
Turnkey test systems, complete production lines, and custom single-station test systems
For decades, SCHLEICH has been developing and manufacturing high-precision test devices for almost every space in the electrical industry – from laboratories to series production. These devices form the technological basis for the second strong pillar of our company: custom test systems and complete production lines, which we custom plan and realize according to our customers' requirements.
Whether a single test station, a built-in EOL solution, or a complex large-scale system with transfer systems – SCHLEICH combines state-of-the-art hardware and software, intelligent mechanics, and a deep understanding of electrical test processes into turnkey solutions of the highest technical standard. This results in systems that are precisely tailored to your products, processes, and quality objectives.
Our customers benefit from comprehensive project support: from technical consulting, design, and system integration to Commissioning and subsequent support.
And because our test systems are always equipped with current SCHLEICH test devices, you receive solutions that are precise, reliable, and sustainably expandable.
In short:
SCHLEICH does not just supply test devices.
SCHLEICH supplies complete test technology.
Contact us – we develop the right solution for your production.
SCHLEICH is your competent partner for turnkey test systems / production systems
With decades of experience, highly qualified employees, and a detailed understanding of complex projects, SCHLEICH is a reliable partner in test equipment systems engineering. The consistent use of state-of-the-art technologies and our exceptional manufacturing depth enable us to deliver modern, turnkey test equipment for the Industry 4.0 era from a single source.
Mechanics, control, electronics, software, and test technology – we develop and manufacture precisely the solution that meets your requirements. In doing so, we rely on state-of-the-art, computer-aided development and manufacturing methods to ensure the highest quality and precision.
For our production lines, we exclusively use proven automation components. Depending on the project, either the test PC or a PLC is used as the system control – naturally with custom developed control software. The workpiece holders for the pallets are also specialized in their construction and completely manufactured in-house by us.
The result: well-engineered, reliable, and high-performance systems that perfectly fit into your production processes – from start to finish, from a single source.
Data storage
Particularly complex system solutions require a corresponding concept for data storage. In an extensive production process with multiple test stations, different test devices can autonomously run tests from one production step to the next. Provided that the product or the workpiece carriers are uniquely identifiable by a serial number, the individual test results are stored at each station with this serial number in the central memory. Our memory software reads out the individual test results and documents them under the serial number of the final product.
This is the basis for seamless traceability.
Project examples
Fully automatic Test and bonding system
The system is fully built-in into the customer's production line and was completely developed and realized by SCHLEICH. The control of mechanical processes and communication with the production line are carried out via a PLC.
- Devices under test are placed on workpiece carriers
- Loading a workpiece carrier into the test cell
- Lifting the entire workpiece carrier into the processing position
- Gripping the device under test and swiveling it into the final processing position
- Automatic contacting using four-wire technology
- Test and thermal bonding
- MTC3 Stator Tester with these functions
- Winding test
- Safety test
- thermal bonding
- Communication with the conveyor system
- Communication with the customer's MES/ERP system
Test system for pumps with transfer system
- Fully automatic conveyor circulation with built-in
loading and discharge station - Automatic ejection of non-GO parts for reliable fault separation
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Electrical safety tests: high voltage test, protective conductor resistance, insulation resistance
- Function tests with variable operating voltages for different pump types
- Testing of the floater switch including precise angle measurement
- Sense of rotation test of the pump drive
- Laser marking for clear and permanent product identification
- GLP2-MODULAR as a test device and for central system control of all processes
Rotary indexing table with six stations
- Automatic setting of insulation displacement terminals
- Precise cutting of wire ends with built-in suction
- Complete winding test
– High voltage test
– Surge test
– Resistance measurement
– Sense of rotation test - Thermal bonding of the winding components for permanent stability
- Marking of GO parts for immediate good/bad part separation
- MTC3 for precise winding test
- GLP3 for thermal bonding and overall system control
Test and bonding system as a rotary indexing table
While loading and discharge are performed manually, all process steps within the test cell run reliably, quickly, and fully automatically – ideal for medium to high production volumes.
- Semi-automatic contacting for precise and process-reliable test sequences
- MTC3 Stator tester for comprehensive winding Test (incl. HV, surge test, partial discharge, resistance, sense of rotation)
- GLP3 Functional Test device for thermal bonding with high current and for complete system control
- Extraction of thermal bonding fumes for a safe and clean working environment
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Cooling after thermal bonding
- Bidirectional communication with the MES for seamless process integration and traceability
Fully automatic Test system – custom built-in into a production line
In the simplest integration scenario, we supply our customers with a complete, ready for Connection production cell that can be seamlessly integrated into existing production lines. SCHLEICH handles the complete mechanical and electrical setup – including custom contacting solutions precisely tailored to the customer's product.
The existing system control on site manages the functional sequence such that the product carrier with the device under test automatically enters the production cell and stops precisely in position. A built-in lifting unit raises the product carrier into the Test position, where the device under test is automatically contacted and then tested.
Whether lifting and contacting are performed by the customer's system control or directly by the SCHLEICH Test cell is flexible – we fully adapt to the desired line architecture and process logic.
This creates an efficient, robust, and perfectly integrable Test station that can be incorporated into almost any production environment with minimal effort.
Fully automatic Test system for small stators
The fully automatic sequence includes the following steps:
- Infeeding the product carrier with 20 nests into the Test cell. Each nest contains a Motor to be tested.
- Automatic removal of an untested Motor from its nest and precise positioning in the Test adapter using the 3-axis system.
- Automatic contacting of the Motor – including built-in contacting monitoring.
- Electrical and functional Test of the Motor.
- Nameplate printing and automatic application of the label on the Motor.
- Return transfer of a GO Motor to the corresponding nest of the product carrier.
- Outfeeding a NOGO Motor onto a separate reject conveyor.
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Repeat the test cycle until all Motors from all nests have been tested.
- Unload the completed workpiece carrier and load the next one.
Single-station test systems from a single source
The modules can be configured as complete, built-in units or delivered as separate system components. Even with separate units, the plug-in, tested cabling is, of course, included in the scope of delivery. This way, you receive a reliable, ready-to-use, and completely turnkey test system.
Whatever you wish to Test – SCHLEICH delivers the appropriate single-station test system: custom developed, completely manufactured, and perfectly tailored to your requirements.
Project examples
Test system for EV charging cables
Charging cables are the lifeline of every electric vehicle. They must reliably transmit high currents daily – in rain, heat, cold, and through thousands of plugging cycles. A defect means trouble – and paralyzes the entire charging process.
Our Test system ensures that every manufactured charging cable is completely electrically safe and fully functional. With precise high voltage and insulation tests, continuity and interruption tests, as well as Resistance tests, we detect even the finest weaknesses.
Your Benefits:
- Fully automatic safety and function tests
- Detection of even the smallest insulation and contact faults
- Realistic tests for maximum reliability
- Documented quality for each individual product batch
- Fully automatic tests
- Test plan and test results memory
Customer-specific setup:
- Test cover Model 10
- Very good accessibility to easily connect the charging cable
- Custom test setup according to your requirements
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Interchangeable adapters for contacting various charging cable connectors
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Process guard locking during the Test.
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Automatic opening after successfully completed Test.
Test system for Hairpins – maximum safety for the electric Motor
Hairpins form the heart of modern electric drives: They determine the performance, efficiency, and reliability of the entire electric motor. A single faulty Hairpin can later lead to serious faults, power loss – or, in the worst case, to the failure of the entire electric Motor.
To prevent this, Hairpins are tested under realistic conditions with our Test system.
During the high voltage test, the Hairpins are placed in a so-called ball bath: A bath of conductive stainless steel balls that completely encloses the Hairpin. This medium acts like a perfectly fitting, all-sided electrical Connection. This allows for the detection of insulation faults, micro-cracks, and material defects that would remain undetected in classic test setups.
The result: 100% tested hairpins, guaranteed safe windings, maximum service life of the electric motor.
Your advantages at a glance:
- Fully automatic high voltage test in a ball bath for maximum measurement safety
- Detection of even minimal insulation weaknesses and manufacturing defects
- Seamless documentation for series production and traceability
- Increased operational reliability and safety for the entire E-Motor
- Ideal for automotive series production and quality laboratories
Test system for construction site power distributors – Fast. Safe. Fully automatic.
Every minute counts on construction sites – and a reliable power supply is the key to smooth operations. Our test system for construction site power distributors ensures that your distribution boxes are always safe, compliant with standards, and immediately ready for use.
Simply connect the construction site power distributor – the test system handles the rest. Every single conductor of each socket is tested fully automatically, quickly, and precisely. Interruptions, short circuits, and wiring errors are reliably detected, as are all safety-relevant parameters such as protective conductor resistance, insulation values, high voltage tests. Including RCD/FI and fuse testing.
This ensures that your distributors function reliably even under the harshest operating conditions – and your customers' projects run without failures.
Your advantage: maximum safety, minimum test time, full transparency.
Highlights
- Test system with two test stations
- Three-sided accessible, optoelectronic safety light curtains per test station – for maximum operator safety and comfort
- automatic test method switch-over
- Safely isolating station switch-over
- Discharge and earthing of the test points of the unused test station
- up to over 250 test points
Test system for cables and luminaires in the film, broadcasting, and event industries
In film productions, radio and television teams, and live broadcasts, the technology used must function absolutely reliably – because every failure costs valuable broadcast or shooting time. Extension cables, special connectors, and mobile luminaires are often exposed to extreme mechanical stresses and must function flawlessly with every use.
Our universal test system enables fast, safe, and standard-compliant testing of all cables and luminaires used in the media and event space. This reliably ensures electrical safety and full functionality – so that film sets, studios, and live productions run smoothly.
- Continuity test / Interruption and short-circuit detection
- protective conductor resistance
- insulation resistance
- high voltage test
- Leakage current measurement
- Testing of the residual current device (RCD/FI)
- Safety and current consumption test of luminaires
- Control and Test of Luminaires via DMX
Test Systems for all Types of Luminaires
Luminaires must function reliably, operate energy-efficiently, and simultaneously meet high safety requirements.
Since luminaires combine electrical, thermal, mechanical, and optical components, a careful and standard-compliant Test is indispensable. It ensures that the product, in later use, endangers neither persons nor equipment, consistently delivers the specified light quality, and fulfills all legal requirements.
A professional luminaire Test significantly contributes to,
- minimizing safety risks,
- increasing product quality and lifespan,
- avoiding complaints and failures,
- complying with legal norms and international standards,
- and ultimately strengthening the operator's confidence in the product.
- Test in compliance with EN 60598 – the most important safety standard for luminaires.
Test system for Motor end-of-line testing | EOL
This Test system comprehensively tests electric motors for rolling gates and blinds for their electrical and mechanical functionality. Despite their compact design, these particularly slim drives deliver high torque and must reliably block when de-energized to prevent roller shutters from unintentionally lowering.
To ensure the operational safety of the final products, all safety-relevant, dynamic, and functional properties are tested fully automatically.
Functional Scope
- protective conductor resistance
- insulation resistance
- High voltage test AC or DC
- Current Consumption and Power Test
- Speed Measurement in both Senses of Rotation
- Torque Measurement in both Senses of Rotation
- Holding Torque Measurement in both Senses of Rotation
- Vibration and Noise Test
- Automatic Docking of the Device Under Test to the Dynamic Load Unit
- Safety Light Curtain for Operator Protection
Test system for luminaires
Functional Scope
- Safety and Function Tests
- Control of Luminaires via DALI, DSI, DMX, and other Digital Lighting Controls
- Luminaire Brightness and LED Color Measurement for Precise Light Quality Control
- Operator guidance via PC for step-by-step operator instructions
- Pick-by-Light support for fast and error-free part retrieval
- Label printing for unique device under test identification and for packaging
- Central SQL network memory for all test and process data
- Pneumatic control of automatic adapters
- Freely programmable mechatronic functions
- Light curtain for operator protection
Standards & Norms
- Test in compliance with EN 60598 – the most important safety standard for luminaires
Test system for gate drives | Motor/gear combinations
This test system enables comprehensive evaluation of electric motors and gear units. In addition to electrical safety, both mechanical load capacity and function parameters are precisely recorded. Thanks to flexible adapter solutions and built-in protection mechanisms, the system is suitable for various sizes and diverse test tasks.
Functional Scope
- Electrical safety test
- Fully automatic function test with precise power measurement under load
- Automatic position and attitude adjustment of the DUT
- Gear loading with slow-running torque Motor
- Load test up to 1000 Nm torque
- Exchangeable adapters for various sizes
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Safety light curtain for operator protection
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Adjustment of the Motor position limit switch
- Verification of the built-in Motor electronics incl. end position shutdown
- Adjustment of the end position switches
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End position test with classic switch or incremental encoder
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Printing of the Motor type plates
Test system for refrigerators and freezers
The test system enables comprehensive safety and function test of refrigeration and freezer devices across the entire supply voltage space from 12 V DC to 230 V AC.
The Connection of loose Connection strands is reliably and quickly established via pneumatic terminal blocks, ensuring a safe test sequence.
Test functions at a glance
- Safety and function test
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AC and DC function test with built-in battery simulation
- Measurement of standby power consumption
- Contacting via pneumatic terminals
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Test station safeguarding via a light curtain
Standards & Norms
- EN 60335 – Safety of electrical devices for household and similar purposes
Test system for multiple sockets, multimedia power strips, etc.
Our automated test system performs comprehensive safety and polarity tests on all sockets. Simultaneously, the current consumption of all built-in components is efficiently measured. Built-in fuses and residual current devices (RCD/FI) are also tested fully automatically.
Since numerous test stations operate in parallel in this customer project, all test data is centrally stored on an SQL server. This ensures that the test plans of all connected test devices remain consistently up-to-date, and production management is informed about the latest test results at all times.
Test functions at a glance
- Electrical safety test
- Wiring test: Continuity, open circuit, miswirings
- Current consumption measurement of built-in components
- Function test for USB, HDMI, and DVI Connections
- USB Power Supply Test
- Automatic contacting of the sockets
- Central data storage on SQL server
Standards & Norms
- VDE 0620 – Plugs and socket-outlets for household and similar applications
- IEC 60884-1
- EN 60664-1 – Clearances and insulation requirements in low-voltage devices.
Do you require personal product consultation?
We gladly provide you with comprehensive support and advice on all our products and services.
Call us or send us an email!