Commutator Testing for Custom Commutators
At XDC, every commutator that leaves our factory in China has passed a tightly controlled Commutator Testing program. We design and manufacture custom commutators, but our real strength is in how rigorously we verify them. From micro-level bar geometry to high-voltage insulation and surge performance, our internal test platforms are engineered to catch defects before they ever reach your production line.
Precision Commutator Testing for Custom Commutators | XDC China
Our in-house commutator testing systems combine automatic electrical analyzers, high-accuracy geometric inspection, classic growler methods and advanced laser measurement. This combination gives you hard data on every critical dimension and electrical parameter, not just a visual OK.
Key Commutator Testing Capabilities
Our Commutator Testing capabilities are built to validate both electrical reliability and mechanical precision for a wide range of custom designs.
1. High-Voltage Insulation & Dielectric Strength
0–1500 V testing with 1 mA leakage detection to identify insulation weaknesses.
2. Bar-to-Bar & Weld Quality
Precise resistance checks (0.5 mΩ to 500 Ω) ensuring uniform current distribution.
3. Insulation & Hipot Surge
Hipot up to 5000 V and Surge testing to detect shorted turns and winding damage.
4. Geometry & Surface Finish
Controlling bar rise (<5 µm), TIR (<10 µm), and surface roughness for stable brush contact.
Laser Triangulation Measurement Station
For advanced investigation and special projects, XDC uses laser triangulation measurement:
- Laser heads with approximately 50 mm standoff and 20 mm measuring range.
- Armatures rotated around 180 rpm while data is collected.
- Data acquisition at around 2000 samples per second with low-pass filtering near 500 Hz.
- Typical measurement examples include bar gaps near 0.63 mm and commutator runout around 0.05 mm peak-to-peak.
This station supports high-resolution commutator testing where very small geometry changes must be quantified and correlated with performance.
Single-Station HV & Dielectric Test Benches
Our single-station HV rigs are compact systems designed for flexible lab and pilot production work:
- Sequential two-step HV programs (for example, commutator to shaft followed by commutator to core) run automatically with a programmable timer.
- Voltage ranges from 0–550 V or 0–1500 V, with built-in leakage monitoring around 1 mA.
- Integrated motor drives rotate the commutator at controlled speeds to ensure complete coverage.
These benches are ideal for rapid prototyping and low-to-medium volume commutator testing runs where quick changeover is important.
Dual-Station Automatic Electrical Test Platforms
For high-volume projects, we use dual-station automatic testers:
- Two independent test stations allow loading/unloading on one side while the other runs the full program.
- Functions typically include bar-to-bar resistance, weld resistance, insulation resistance, hipot and surge.
- Bar-to-bar resolution down to 0.5 mΩ, weld resistance detection in the 1 µΩ–10 mΩ range, and insulation measurements up to roughly 500 MΩ.
- Hipot capabilities up to 3000–5000 V and surge voltages up to around 3000 V.
These systems form the backbone of our mass-production commutator testing, ensuring that each unit passes through a consistent, fully documented sequence.
Commutator Testing Process Control & Standards
Beyond equipment, XDC’s strength lies in how we organize and control the commutator testing process.
EASA-Style Electrical Test Workflow
Our EASA-style workflow verifies each commutator through a layered approach including visual inspection, megohmmeter, low-resistance, growler, surge, and hipot testing, alongside mechanical checks for bar tightness, ensuring comprehensive multi-angle verification.
Traceability, Data Logging and Recipes
To ensure batch consistency, we utilize specific test "recipes" for defined limits and log all electrical and geometric results for traceability and statistical analysis, allowing customers to seamlessly align their incoming inspections with our factory data.
Calibration and Maintenance of Test Equipment
XDC maintains high process capability and low measurement uncertainty through strict periodic calibration of all electrical channels and mechanical standards, combined with preventive maintenance of clamping fixtures and sensors to ensure long-term repeatability.
Get in Touch with XDC
As a leading custom commutator manufacturer in China, XDC uses this comprehensive commutator testing framework to convert your drawings into reliable, production-ready components. If you need commutators backed by measurable electrical and geometric quality, our factory is ready to support your next project.
WhatApps
+86 17820674273
Address
Taixing Science and Technology Park, No. 3 Taixing Road, Dongguan City, Guangdong Province
XDC Precision Customer Feedback
What we appreciate most about XDC is how fast they reply. If there’s ever a delay or any issue, they tell us directly instead of hiding it. That makes planning on our side much easier. Their attitude is very straightforward and cooperative.
We tried a few suppliers before, but either the price was too high or the quality was unstable. XDC gave us a very reasonable price, and the commutators are performing well in our tools. Our failure rate in testing has clearly gone down since we switched to them.
During a new motor project, XDC helped us adjust the design of the commutator several times. They gave practical suggestions instead of just doing exactly what we asked. That saved us time and a lot of trial and error. We’re very satisfied with the technical support from their team.
We’ve placed some urgent orders with XDC, especially before peak season. They managed to deliver on time and kept us updated on the production schedule. This helped us avoid shortages and kept our production line running smoothly.
We’re based in Europe and were a bit worried about the time difference at first. But the XDC sales team arranges calls at times that work for us, and emails are answered quickly. The communication has been very smooth, so the distance hasn’t been a problem.
Commutator Testing FAQ
Here you will find answers to the most common questions regarding our manufacturing processes, ordering details, and quality standards. If you have a question that isn’t listed here, please contact our sales team directly.
Because commutators combine complex geometry with demanding electrical insulation, small deviations in bar resistance, bar rise, insulation resistance or runout can lead to serious issues. Dedicated commutator testing allows XDC to validate every critical parameter under controlled conditions, so the finished commutator is ready for integration into your motor design.
Our commutator testing platforms cover bar-to-bar resistance (around 0.5 mΩ–500 Ω), weld resistance (about 1 µΩ–10 mΩ), insulation resistance (roughly 0.1–500 MΩ at 500–1000 V DC), hipot voltages up to around 3000–5000 V and surge tests up to approximately 3000 V. These parameters are adjusted to your drawing and specification.
We routinely monitor bar-gap, bar rise, TIR, diameter and roundness. Our typical target tolerances are around 3 µm for bar gap, 5 µm for bar rise, 10 µm for TIR, about 200 µm for diameter and 5 µm for roundness. These tolerances can be tightened or relaxed according to your application requirements.
Yes. Dual-station automatic testers and semi-automatic metrology benches enable high-throughput commutator testing. With test recipes, automatic bar indexing and digital data logging, we support continuous production while maintaining stable quality levels.
On request, XDC can provide summarized commutator testing data for incoming inspection and quality documentation. This may include electrical pass/fail statistics, bar-to-bar resistance ranges and key geometric parameters, aligned with your quality plan.
For new designs, we combine our standard commutator testing sequence with additional laser-based geometry checks and extended electrical tests. This helps us establish baseline characteristics, refine machining and winding parameters, and then lock in test recipes for serial production.
Related Resource
At XDC, we share our deep insights into commutators, manufacturing processes, and industry experience on our blog. We invite you to explore these articles to learn more about our expertise.
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