I am looking help. I want to know what type of test is happening in below pictures
I don't know exactly but looking this picture.i am guessing, there is current source machine ,wire and thermocouple



I think the test is happening to measure the temprattemp of conductor wire

I think this is part of test bench to find the capacity of conductor wire

I am just guessing not sure about that

 

Hello,

I am wondering if this could be a test to see how successful the crimps on the ends were.
Crimps are very important for heavy current wires like that.
Could be doing other tests too.

I actually did a test like this back in the 1990's but it was with very thin wire and it was to try to measure the wire gauge by running a known current through a known length of wire at a known ambient temperature and measure the voltage drop.

 

My thinking runs with that of MrAl. They look to be supplying a high current to a pre measured section of copper wire. They could be measuring voltage drops at various points as well as total length drop along with temperature rise. Beyond guessing and not seeing the collected data it is really hard to say what they are doing.

Ron

 

My thinking runs with that of MrAl. They look to be supplying a high current to a pre measured section of copper wire. They could be measuring voltage drops at various points as well as total length drop along with temperature rise. Beyond guessing and not seeing the collected data it is really hard to say what they are doing.

Ron

Hi,

Yes good idea, seeing the data they were after would clear this little mystery up quickly.

 

. Beyond guessing and not seeing the collected data it is really hard to say what they are doing.

Ron

My friend discussed with this picture. He written code for control motor used in transformer, he is from computer science. branch. He doesn't have much knowledge on electronic I am asking behalf of him
I have additional information. In this test they are using fixed transformer, variable transformer, thermocouple, data logger,

Any Gus's what type of automation is this

 

Any Gus's what type of automation is this

Automation is sort of a peculiar word to use. We do have automated MATE (Modular Automated Test Equipment) but in the picture, unless the power supply is remotely driven by a computer for example and the collected data stored with a form of data acquisition there is no automation really visible. Just as an example the power supply can be remotely run ramping up the current at a given rate. While this is happening data can be collected like voltage drops and temperature rise of the wire. Just looking at the picture and not seeing the data there is no way to tell what is being tested and exactly how.

Ron

 

Just looking at the picture and not seeing the data there is no way to tell what is being tested and exactly how.

Ron

I know I don't have full information. I am trying to figure what happening on copper wire with available information.

At the very high current and temperature, copper wire start to disjoint

I think this is type of test bench that is use to find capcity of wire at different temperature by giving known voltage and current.

Variable type of transformer used to supply different voltage

How can we test copper wire capcity

 

Hi,

The length looks too short to me to be any kind of comprehensive test of the wire itself i think. Heat is dissipated out of the ends too and so a longer length would be better for testing i think. But again we dont know anything for sure here because we dont have the data set or test procedure.

 

Can you tell me about copper cable lug temperature testing in high voltage and current. Lug also work certain temperature If we want to know the maximum and minimum working range of temperature lug can work

Finally what we need to know if we are trying to figure out temperature test on lug using software

 

When we crimp a lug on a large gauge wire we want a very firm crimp as the crimp is after all a junction. With a weak or poor crimp there will be higher resistance resulting in heat being generated. The higher the current the more heat and as the heat increases so goes the resistance of the junction. So for a good crimp as the current rises the heating effect will be minimal. We can plot temperature rise against the current through the crimp. Also a crimp can be tested using a pull test.

That is not to say that is what is being done in your image. It is just a possibility.

Ron

 

I am not creating another thread . if you both have no problem I would like to ask some more doubts.

What would be required to find out current carrying capcity of copper cramping terminal manually ?

How to know that it can carry 1000 amp, 1500 amp

 

I am not creating another thread . if you both have no problem I would like to ask some more doubts.

What would be required to find out current carrying capcity of copper cramping terminal manually ?

How to know that it can carry 1000 amp, 1500 amp

Hello,

Maximum temperature rise, which is the basis for many tests, which is used to determine suitability for a given application.

Wire capacities vary with application, so you have to have an application really. Other than that we can only state some general test principles like insulation melting temperature. If the wire or crimp gets hot enough to melt something, it's not good.
To get more detailed, we'd have to specify the ambient temperature also. Thus we might end up with 1000 amps at 20 deg C for example.
We can also specify an intermittent type of operation, which again would tie to the application in a big way. For example, 500 amps continuous, 1000 amps on for 10 seconds, off for 20 seconds.

There's also the efficiency viewpoint. If something like that gets hot, it is using up power that could have gone to the output of the system for better use. In this case we might want to limit the temperature rise to some given value like 50 deg C.
Since the resistance would rise, we might also not be able to tolerate too much voltage drop increase so we'd have to specify a max temperature rise for that too.

Carefully feeling the connections while the unit is running helps to identify problem areas, although you do have to be careful here. A temperature gun could help more, and for more comprehensive testing an IR camera (much more common these days) would be used.

 

Crimp type terminal lugs are designed for a specific crimp using a given amount of force. Larger lugs often require a crimp tool suggested by their manufacturer to apply the proper crimp. The current capacity of the lug should handle the current capacity of the wire it is used with. Generally you will not see a current rating on the lug since the lug is designed to handle the max current handling capability of the wire it is intended to be used with. Electrical testing is also not the only method of testing used, a pull test may also be used.

I see MrAl has already addressed your question as I typed, fed the dogs and took a phone call.

Ron

 

Hello,

To get more detailed, we'd have to specify the ambient temperature also. Thus we might end up with 1000 amps at 20 deg C

For example, 500 amps continuous, 1000 amps on for 10 seconds, off for 20 seconds.

I didn't understand your both examples

I have spent some time on reading. I have some doubts.

For example. Lets assume We have variable transformer and crimp type terminal and wire. We have connected crimp type terminal wire at the output of variable transformer for testing. So we can supply different type of voltage and can measure reading on terminal lug. We can know melting temperature and suitable range

I am aware working with 240v is very dangerous. This question is asking regarding theory. I am not doing this at home now

 

I didn't understand your both examples

I have spent some time on reading. I have some doubts.

For example. Lets assume We have variable transformer and crimp type terminal and wire. We have connected crimp type terminal wire at the output of variable transformer for testing. So we can supply different type of voltage and can measure reading on terminal lug. We can know melting temperature and suitable range

I am aware working with 240v is very dangerous. This question is asking regarding theory. I am not doing this at home now

Hello again,

I was just talking about how detailed you can get when melding this to an actual application.
For more general purpose use we often rate the wire based on charts that tell us what the wire is good for, and we assume the crimp will be good too. But as we look into this deeper, we find that the reason for those charts is because a certain voltage drop is acceptable in most cases. Not in all cases however. For example, if we have a 20 foot run of #12 AWG wire working in a 120vac system,we probably can go to a chart that will tell us that #12 wire is good for 20 amps. In a 12v system however (like in an automobile) the voltage drop will be the same at 20 amps, yet the ratio of the voltage drop to 12v is bigger than the ratio of the voltage drop to 120v, in fact 10 times higher. This may mean we have to go to #10 in the automobile even though #12 works in the house.

With this test setup they may be testing for general problems or it could be a specific problem related to a given application. For example, a drop of 0.1v may not be acceptable at 100 amps because it either gets too hot or just wastes too much power.

It could be a go/no go test. 0.1v may indicated that the crimp was not done right.
When i worked in the power industry though the wire and crimps would be tested over hours of time. If the connections got hot to the touch then that meant that the connection was not right. That is because the bulk of the wire is sufficient to draw the heat away from the joint unless the crimp is bad and then it creates extra local heating.

I suggested that they may have the test set up to test the crimps because it looks like they have probe wires connected to the lug and to the wire, which would allow the test equipment to measure the voltage drop.

 

Hello again,

I suggested that they may have the test set up to test the crimps because it looks like they have probe wires connected to the lug and to the wire, which would allow the test equipment to measure the voltage drop.

Thanks again its improvement. I am sharing some information. They are using three transformer with wire and tarminal lug

1. Motorized Transformer specifications
1000 amp current injecting source
Input voltage 240 ac
Output voltage 270 ac

2. Transformer CT
Kva = 5
Output voltage = 5
Input voltage 240 ac
Output voltage =5
Output current =1000amp
Type of colling oil cooler

3. Current transformer to measure current throw wire .

My Guess motorized Transformer to increase or decrease voltage level

First transformer is connected with main supply and output of first transformer is going to input of second transformer. Terminal Crip lug and ct connected at Output of second transformer.

These all are the connection for manually test.

Can you guess what can be done with all connection for testing crimp lug

 

Thanks again its improvement. I am sharing some information. They are using three transformer with wire and tarminal lug

1. Motorized Transformer specifications
1000 amp current injecting source
Input voltage 240 ac
Output voltage 270 ac

2. Transformer CT
Kva = 5
Output voltage = 5
Input voltage 240 ac
Output voltage =5
Output current =1000amp
Type of colling oil cooler

3. Current transformer to measure current throw wire .

My Guess motorized Transformer to increase or decrease voltage level

First transformer is connected with main supply and output of first transformer is going to input of second transformer. Terminal Crip lug and ct connected at Output of second transformer.

These all are the connection for manually test.

Can you guess what can be done with all connection for testing crimp lug

Hi,

Maybe they are turning up the current little by little until the voltage drop exceeds a certain level and then they either compare that to a threshold or bin the type of connectors in categories according to how well they passed the test.

This is still all guesswork because we dont know for sure what they are doing.

 

This is still all guesswork because we dont know for sure what they are doing.

That is where we are always going to get back to.

Looking at the picture all day we can draw all sorts of guesses but less seeing the test procedure or the collected data it's all a guess.

Ron

 

That is where we are always going to get back to.

Looking at the picture all day we can draw all sorts of guesses but less seeing the test procedure or the collected data it's all a guess.

Ron

But I got the so many information from both of you. I didn't know anything about it before

 

I didn't want to show more pictures but I couldn't stop myself. this is my old thread here are the picture of transformer that being used in test https://forum.allaboutcircuits.com/threads/transformer-test-bench.148116/#post-1263487

Sorry the pictures is not clear. I had only two images