Beyond "Pass / Fail"
For an industrial ventilation manufacturer, motor reliability is everything. Our client was facing a bottleneck in their final assembly line. The old manual verification system presented three serious problems:
- Slowness: Switching references between different fan models required too much setup time.
- Workplace Risks: Handling high-voltage connections relied too heavily on the operator’s skill.
- Lack of Data: Results were recorded manually, losing the traceability necessary for Industry 4.0.
The goal was clear: to guarantee 100% quality in record time without compromising safety.
The Simplex Plus System
To solve the client’s challenges, we designed a centralized workstation that eliminates human variability and maximizes safety. The solution is based on two SensaMAG technological pillars working in total symbiosis:
Simplex Plus
The unit allows for multiple tests (dielectric strength, insulation, and operation) in a single cycle. Its advanced software ensures that every fan meets the exact parameters before leaving the factory.
GM10 Cage
It is not just an enclosure; it is an ergonomic system with active safety. Thanks to its intrusion sensors, we protect the operator during high-voltage testing, creating a "Zero Risk" work environment.
Looking for Simplex Plus specifications?
Access the full technical data sheet by clicking on the SensaMAG logo.
Impact and Results (KPIs)
After the implementation and the parameter tuning phase, the results speak for themselves. We have transformed a critical area of the factory into a model of efficiency.
Verification time reduced from 120s to only 45s per motor.
Automation eliminates human variability, ensuring near-perfect filtering.
Thanks to SensaMAG software, switching between references is instantaneous.
Every test is automatically recorded for total control of the history.
"What really makes the difference is not just that the machine is fast, but the ability to detect micro-defects in the motor winding that previously went unnoticed. With the Simplex Plus, our client does not ship a single defective fan to the market."
A line prepared for tomorrow's challenges
The implementation of this project has demonstrated that automation is not just a matter of speed, but of total control. With the combination of the SensaMAG Simplex Plus and the GM10 Cage, we have managed to transform a critical process into a safe, scalable, and completely digitalized environment.
- Efficient Multitesting: Performing electrical strength and functional tests in a single cycle, reducing downtime.
- Certified Safety: The closed structure and GM10 sensors eliminate any electrical risk for the human team.
- Native Digitalization: Control via HMI interface and direct data export for absolute traceability.
- Modularity: Design prepared to adapt to new motor references without the need for large future investments.