Product Validation using LabVIEW RT & LabVIEW FPGA – Electromechanical Actuator Test Stand

Product Validation using LabVIEW RT & LabVIEW FPGA – An electromechanical actuator test stand

Automated testing reduces operator man hours and increases production throughput.

Client – A manufacturer of actuators in the mil-aero industry.

Challenge

New Product Introduction (in this case a new controller and new actuators) drove the need for a new automated electromechanical test stand.

Solution

New NI PXI-based electromechanical test equipment provided automated testing, report generation, and SPC data generation.  The sequencing of the test procedure, reporting, and verifiable results were managed with the StepWise test executive platform.

Benefits

  • Automated testing reduces operator man hours and increases production throughput.
  • Meets strict customer requirements regarding testing and data recording in a verifiable manner.
  • Automated Test Report Generation.
  • Collects data to support SPC (Statistical Process Control).
  • Ability to obtain the internal state of the controller FPGA via the LVDS communication link.

System Overview

Viewpoint developed the software and selected NI data acquisition and control hardware for the test stand.  There are several layers of software functionality.

HOST LABVIEW SOFTWARE LAYER
Test sequencer
Test steps (e.g. Frequency Response, Step Response, Dynamic Stiffness, Fault Response, Power Consumption)
Test Report Generator
GUI
REAL-TIME (RT) LABVIEW SOFTWARE LAYER
Data acquisition
1553 comms
Function generator
Error detection
ESTOP
LABVIEW FPGA SOFTWARE LAYER
Synch data from 3 sources (tester, UUT, external DAQ device)
Stream high-speed data to disk
Stream high-speed data to analog outputs for engineering use
Custom communication protocol used by UUT over LVDS lines
HARDWARE RECOMMENDED
NI PXIe
NI FlexRIO card with LVDS adapter module
Multiple NI R Series cards
High speed, high voltage, isolated analog input cards
INTERFACES / PROTOCOLS
MIL-STD 1553 bus
LVDS
Ethernet
Custom TCP/IP

*- images are conceptual only, not actual

Yes, I need an automated test system »
2019-10-22T13:09:43-05:00