LabVIEW Consultants2019-06-25T15:34:22-04:00

LabVIEW Consultants

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Testimonials

“Very impressed…kudos to Viewpoint”

I really want to thank you for all your help getting us to this stage in automating our testing. We had our customer in this week to oversee some testing and they were very impressed, which is definitely kudos to Viewpoint.

David, An Aerospace & Defense Company

“Significant value”

The Viewpoint team provides significant value to our projects, and I really enjoy working with Viewpoint.

Jerzy Wolujewicz, PhD, Nammo Pocal Inc.

“Valuable part of our global team”

I have been working with Viewpoint for 15+ years on multiple projects. They have always provided creative and quick solutions to all of the problems we have placed in front of them. I have always considered them a valuable part of our global team.

Engineering Group, A Global Manufacturer

LabVIEW Case Studies | Projects

Custom Test System Using NI PXI for Electrical Test

Custom Test System Using NI PXI for Electrical Test

Updating an obsolete tester that maintains functionality

Client – Medical Device Manufacturer

Challenge

Our client already had a test system in place, but the tester (really two test systems testing two different product variants) was becoming obsolete.  The tester was old, hardware was failing, and it was getting harder and harder to keep it reliably running.  They wanted a new tester to improve reliability, but maintain the functionality of the existing tester to keep the FDA-mandated verification and validation time to a minimum.

Solution

The updated end-of-line manufacturing test system maintains the functionality of the old test systems, but with updated hardware and software.  The same software is utilized for both the manual test system update and the automated test system update.  Our client deployed 6 manual testers and 1 automated tester.

Benefits

  • Improved maintainability and reliability with updated hardware and software
  • Maintains existing test system functionality to keep certification time down

System Overview

There were two variants of the new test system.  One was for an older product line that utilized manual test, with an operator that connected/disconnected the UUT, and initiated the test.  The other was an automated tester, integrated into a manufacturing machine.  Both testers utilized custom fixtures (provided by the client), off-the-shelf NI measurement hardware (selected by Viewpoint), and custom test software (developed by Viewpoint).  The software is configurable for both the manual test system and the automated test system.

SOFTWARE FUNCTIONS
Read UUT limits from config file
Perform tester self-test
Measure impedance
Power UUT
Pressurize UUT
Measure UUT output
Perform leak down pressure test
PLC interface (for automated tester) for start, done, pass, fail
HARDWARE USED
Custom test fixture (provided by client)
NI PXI
PXI Multifunction I/O Module
PXI Digital I/O Module
PXI Relay Module
PXI Digital Multimeter Module
PXI Switch Matrix Module

*- images are conceptual, not actual

Manufacturing Inspection System Uses Machine Vision to verify assembly and labeling

Manufacturing Inspection System Uses Machine Vision to verify assembly and labeling

Reducing human error with automated inspection

Client – Automotive Component Manufacturer

Challenge

Our client already had an end-of-line tester in place.  However, preventing incorrect product shipments drove them to add machine vision capabilities to verify that the part being packed is of the correct physical configuration and that the part was labeled correctly.  They also wanted a more automated way to track which serial numbers were being shipped.

Solution

Viewpoint enhanced the existing end-of-line tester by adding machine vision capabilities to verify correct part assembly and part labeling.  This capability also allowed for automated tracking of which parts went into which shipping container.

Benefits

  • Automated part assembly verification to reduce human error from manual visual inspection
  • Automated label verification to reduce the chance of shipping the wrong product

System Overview

The enhanced system added machine vision-based capabilities to an existing end-of-line manufacturing test system.  New hardware (cameras, lighting, fixture) was selected and integrated by the client.  Viewpoint developed the image analysis routines using the Cognex In-Sight software.  These routines were then downloaded and controlled using LabVIEW software developed by Viewpoint.  In addition, the LabVIEW GUI contained the image acquired by the camera and the results of the image analysis.  The tester can inspect four different part types.

The software essentially performs the following functions:

  1. Look up the expected characteristics of the part being inspected.
  2. Populate the on-camera In-Sight “spreadsheet” with configuration information used in the image analysis/inspection.
  3. Trigger the image capture and read results from the on-camera spreadsheet.
  4. Use the on-camera image analysis to check a critical angle of the part as the part is set in the nest fixture.
  5. Check the information laser etched on the part and compare the results with what should be on the part (relative to the barcode read in for the lot and the 2D barcode on the part) using the OCR/OCV capabilities of the camera.
  6. Perform other physical part characterization image analyses to verify the part was correctly labeled & assembled.
SOFTWARE FUNCTIONS
Look up expected part characteristics
Trigger image capture
Read results of on-camera image analysis
Display image taken by camera and show if test passed or failed
Monitor contiguous part failures & initiate shutdown
Log vision test failures to database
HARDWARE USED
Existing end-of-line tester
Test Fixture
(qty 2) Cognex camera
Lighting for camera
INTERFACES / PROTOCOLS
TCP/IP
HAVE A SIMILAR CHALLENGE? GET A CONSULTATION »

Automated Manufacturing Test System for Electronic Medical Devices

Automated Manufacturing Test System for Electronic Medical Devices

Using PXI and LabVIEW for modular testing of over 1,000 different models

Client – a medical device manufacturer and repair depot

Challenge

Our client manufactures hospital patient pendants used to control bed frame, nurse calling, and TV functions. The company was also growing after adapting a business model of being a repair depot for older designs for their own and the pendants of other manufacturers. As such, their products are very high mix and medium volume.

The basic functions for all these pendant models are closely related, so the client wanted a means to build a single automated test system that could verify functionality for 1000s of models. And, since the products are medical devices, the testers needed to comply to 21 CFR Part 820 and Part 11.

Solution

The testers were designed to support the common measurements needed to test the circuitry of the devices as well as the complex signals required to drive TVs and entertainment systems. A test sequence editor was created which allowed the client to create as many test sequences as needed to test each specific pendant model by creating a list from pre-defined basic measurement steps configured for each specific measurement.

For example, each device had a power supply, the voltage of which needed to be tested. To test a specific model, a voltage measurement step was added to the model-specific sequence and configured with the upper and lower measurement limits for the power supply. The complete test sequence was created by adding and configuring other measurements test steps as needed. Each test step could also be configured with switch configurations to connect the measurement equipment, such as a DMM, to the proper pins on the device circuit board.

Using this configuration process, the client was able to support the testing of well over 1000 models without any programming. A separate application was developed to create these test sequences which were saved as XML and fed to the test system for selection and execution.

The test execution was managed by NI TestStand and the pre-defined common test steps were written in LabVIEW. The test sequences and test results were interfaced to the client SQL database which they used in their ERP system. This ERP system used the results produced by the test system to help manage the workflow of production, for example by assuring that all units had passed testing before being shipped. Part 11 compliance was handled through checksums used to check if results had been modified.

Benefits

  • Test sequence editor used to develop and maintain tests for 1000s of device models
  • Enabling our client to create test sequences without programming reduced overall development costs by about 50%.
  • Test sequences and test results were stored in the client’s ERP SQL-compliant database for integration with manufacturing workflow
  • Modular and common software developed for the test systems reduced the V&V effort during IQ & OQ by allowing testing of the test execution application separate from the individual test sequences.

System Overview

The automated test system was able to execute each test sequence in three different modes: engineering, service, and production. Each mode has been specifically designed for various departments throughout the manufacturing floor. Typically, the manufacturing engineer would verify the sequence by executing it in engineering mode. Once the test sequence parameters pass, it was then approved for production testing.

During actual product testing, an approved and digitally-signed test sequence is loaded and executed via the test sequencer, designed for automated production. During execution, test results are displayed to the operator and simultaneously pushed to a database. The automated test system produces a record for each tested device, indicating the disposition of each test step and the overall performance of the device. All result data are digitally signed and protected from tampering.

The architecture of the test system follows a typical client – server model.

All client stations communicate with a central ERP and SQL server and each computer is secured by applying operating system security. The SQL server contains all of the test definitions, device history records and results. Information from it can be queried at any time by quality engineers throughout the organization, assuming they have proper login access. This provides real time status about products ready for shipment. Also, other than the software running on the client stations, no other user has permission to write or modify any information in this database. The client is able to keep the server in a protected area separating it from the manufacturing environment while the client test stations are placed throughout the manufacturing area.

Surprisingly, there were only twelve test steps needed to uniquely configure and be combined to create sequences to test well over 2000 unique models. Test steps are capable of measuring basic resistance, current and voltage parameters as well as perform sound quality measurements and high speed digital waveform analysis. Several tests were designed to be subjective while others are fully automated and test to a specified acceptable tolerance. During configuration, each test step requires the manufacturing engineer to enter expected values and tolerance limits to define pass – fail status. Upon testing, the devices are attached to a generic interface connection box and the test system makes the appropriate connections and measurements.

SOFTWARE FUNCTIONS
NI TestStand
Low-level measurement drivers to interface to a DMM, signal generator, switches, and data acquisition cards.
Measurement-based test steps
Test sequence execution
Test sequence management
User access management
Test report creation and management
Verification of test sequence content and ability of user to execute
Verification of the content of the test results
HARDWARE USED
NI PXI chassis and controller
NI PXI acquisition cards for analog measurements
NI PXI acquisition cards for digital input and output
NI PXI DMM for precision voltage and resistance measurements
Audio amplifier for speaker tests
INTERFACES / PROTOCOLS
Ethernet

*- images are conceptual, not actual

Yes, I’d like to chat about my test system needs »

Automated Manufacturing Test Systems for Medical Diagnostic Equipment

Automated Manufacturing Test Systems for Medical Diagnostic Equipment

Using NI PXI and LabVIEW as a common architecture for multiple test systems testing several subassemblies

Client: a manufacturer of automated blood analysis machines

Challenge

Our client was embarking on a complete redesign of their flagship automated in-vitro Class 1 blood diagnostic machine. In order to meet schedule goals, the design and build of several automated test systems needed to occur in parallel with the overall machine. In a major design paradigm shift, many components of the machine were being manufactured as modular subassemblies, every one of which was an electro-mechanical device. Thus, multiple testers were required to test each of the specific subassemblies in the machine. And, since this was a medical device, the testers needed to comply to 21 CFR Part 820 and Part 11.

Solution

With a looming deadline, the testers needed a common architecture, so that all testers could leverage the development from the others. Since each subassembly could be tested independently of the overall machine prior to final assembly, the design of the testers was based on a common measurement and reporting architecture, written in LabVIEW, that interfaced to the customers Part 11 compliant database for testing procedures and measurement results. Furthermore, procedures and validation checks for calibration of the testers were part of the overall test architecture.

Benefits

  • Modularization of the test system architecture aided development and maintenance
  • Reduced overall development costs due to standardization of test sequence steps and reporting
  • Both test sequences and test results were stored in a managed database that satisfied 21 CFR Part 11 requirements
  • Modular and common software developed for the test systems reduced the V&V effort during IQ & OQ.

System Overview

Since multiple subassemblies were being tested, with one part-specific test system per part, the automated test systems used as much common hardware as possible to simplify the development effort through common hardware drivers and test steps. Measurements were made with PXI equipment. Test steps and the test executive that executed the test sequence(s) were developed using LabVIEW.

The types of test steps required to verify the proper operation of each subassembly were categorized into basic operations, such as voltage reading, pulse counting, temperature reading, and communications with on-board microcontrollers. The specifics of each measurement could be configured for each of these measurement types so that each test step accommodated the needs of the specifics of each subassembly. For example, one subassembly might have needed to run the pulse counting for 2 seconds to accumulate enough pulses for accurate RPM calculation while another subassembly might have only needed 0.5 seconds to accomplish that calculation.

The configuration of a test step algorithm was accomplished via an XML description. The accumulation of these XML descriptions of each test step defined the test sequence run on that specific subassembly.

Test results were associated with these test sequences by completing the entries initially left blank in the test sequence, so that all results were explicitly bound to the test sequence.

The operator user interface distinguished between released and unreleased test sequences. With unreleased test sequences, engineers could try the most recent subassembly designs without needing to wait for final validation. The released sequences were only available to test operators. This login-driven branching was managed using the Windows login, so that the client employees could use their company badge-driven login process. Once logged in, the user would be able to execute the test sequence in automated mode, where all steps happen automatically, or manual mode, where one step could be operated at a time.

Furthermore, the Windows environment was locked down using built-in user account group policies to designate the level at which a user could access Windows or be locked into accessing only the test application.

V&V Effort

During the V&V effort, each test sequence was verified for expected operation, against both known good and bad parts. Once verified, the sequence was validated against the requirements and, when assured to be as expected, a checksum was applied to the resulting XML test sequence file and all was saved in a Part 11 compliant database. Upon retrieval, when ready to run a test, the sequence was checked against this checksum to assure that a sequence had not been tampered.

Test results, saved as XML in the same file format as the test sequence, were also surrounded by a checksum to verify that no tampering had occurred.

The IQ/OQ efforts were handled in a traditional manner with the client developing the IQ/OQ documentation, with our assistance, and then executing these procedures, again with our assistance.

SOFTWARE FUNCTIONS
Low-level measurement drivers
Measurement-based test steps
Test sequence execution
Test sequence management
User access management
Test report creation and management
Verification of test sequence content and ability of user to execute
Verification of the content of the test results
HARDWARE USED
PXI chassis and controller
PXI acquisition cards for analog measurements
PXI acquisition cards for digital input and output
CAN card
INTERFACES / PROTOCOLS
Ethernet
CAN

*- images are conceptual, not actual

Yes, I’d like to chat about my test system needs »

Endurance and Environmental automated test system for electro-mechanical sub-system

(image is representative, not actual)

Endurance and Environmental automated test system for electro-mechanical sub-system

Automating tests that run for weeks at a time

Client – Automotive component supplier

Challenge

Our client was already doing validation, but it was manual, and the client’s customer started requesting faster turnaround of results. Their customer was also requesting data to be sent with the results. Our client chose to automate the validation process to enhance their productivity.

Solution

Viewpoint utilized the (mostly) existing hardware from the manual tester and developed software to automate the testing. The LabVIEW-based automated test system allows for endurance & environmental validation testing of an electro-mechanical sub-system.

Benefits

  • Automates tests that run for weeks at a time
  • Logs errors during the test (e.g., for continuous monitoring tests, logging the number of instances of when a UUT’s LIN (Local Interconnect Network) response deviates from a static, current draw outside of limits)
  • Capable of testing a large variety of product lines
  • Logs pertinent data to a database for post-test analysis/inclusion into reports

System Overview

The UUT is an electro-mechanical part that falls under a variety of different product lines.  As such, the client had a couple variants of the tester, based on the communication needs of the UUT. A total of more than a dozen testers were deployed.  The functionality of the tester evolved over time, specifically modifying software to make the tests faster / decrease cycle time.

SOFTWARE FUNCTIONS
Extensive diagnostic/manual operation of system for debug of software and electrical connections between the UUT and the test stand/tooling.
Product-specific software components to operate unique products.
Execute mechanical endurance tests.
Execute environmental endurance tests.
Database output containing results from every test cycle (either mechanical cycles or time depending on test being run).
HARDWARE USED
USB-LIN module
USB and PCI CAN Interfaces
Analog input card
Digital Input card
Digital Output card
Power Supplies
DMMs
Switch Matrix
INTERFACES / PROTOCOLS
CAN
LIN
USB
GPIB

Product Validation of Mechanical Subsystem with NI cDAQ

Product Validation of Mechanical Subsystem with NI cDAQ

The updated product validation tester automates long tests, allowing the client to prove more obviously that their part met the specification.

Client – Automotive Component Supplier / Manufacturer

Challenge

The client already had a test system in place, but it was old and was becoming unmaintainable.  Increasing demands from the test engineers and the old software architecture not lending itself to clean implementation of these new features (new sequencer capabilities and ECU CAN communication) drove the need for a rewrite of the software application.

Solution

The updated product validation tester supports product validation of the UUT by automating long tests (sometimes a week or more) providing the desired set point control, allowing the client to prove more obviously that their part met the stated specification.  Viewpoint developed the software and the client selected the hardware.

Benefits

  • Automate long duration tests
  • Improved operator UX by making controls and indicators more intuitive to the user as well as providing additional capability within one application.
  • Acquire ECU data along with measured UUT data to allow for engineering performance characterization analysis
  • Playback utility enables the Test Engineer to quickly view collected data to chart out a path forward for further testing.
  • Automate a Design of Experiments matrix of conditions, through new sequencer capabilities, to more quickly arrive at product characterization parameters.
  • All collected signals are now housed in one TDMS file instead of multiple files from different applications.

System Overview

The UUT is a complete engine with a focus on one of the mechanical subsystems.  Data is collected on over 100 channels, measuring temperature, vibration, strain, RPM, position and pressure.  Engine management data (e.g., component location, pressures, engine speed, and status flags) is collected via CAN. The engine speed is set via an analog output, and subsystem setpoints are sent to the ECU via CAN.  SCXI still used on some of the old test stands, but is being phased out in favor of cDAQ.  The test system software was developed in LabVIEW.

SOFTWARE FUNCTIONS
Test Sequencing
Data Visualization
Data Collection
Setpoint Control
HARDWARE USED
NI cDAQ
NI C Series Digital input module
NI C Series Digital output module
NI C Series Digital input/output module
NI C Series analog output module
NI C Series temperature input module
NI C Series analog input module
NI C Series strain/bridge module
INTERFACES / PROTOCOLS
Ethernet (TCP)
CAN

LabVIEW-based Data Logger for Product Validation of Commercial Equipment

LabVIEW-based Data Logger for Product Validation of Commercial Equipment

Synchronizing data from multiple data logging instruments

Client – Manufacturer of commercial equipment

Challenge

The client already had a method in place to log data needed for validation testing.  However, this data was acquired from multiple independent data logging applications.  They needed something to aggregate the data and align/synchronize the data across multiple instruments.

Solution

Viewpoint developed a LabVIEW-based product validation solution that continued to utilize the existing data logging hardware, but uses software to aggregate & synchronize the data from multiple sources.  This simplifies post-processing.

Benefits

  • Synchronized & aggregated data from multiple instruments
  • Ability to add capability for new instruments later on
  • Real time graphing of all channels
  • Channel averaging across multiple instruments
  • Ability to save data acquisition configurations for future use
  • Faster channel configuration than current data logging applications

System Overview

The data logging software unifies the collection of data for a particular validation test.  The software configures each instrument, kicks them off, logs the data to a TDMS file, and also graphs data and displays real-time values.

SOFTWARE FUNCTIONS
Instrument configuration
GUI
Data Acquisition
Data Synchronization
Data Logging
Multi-channel averaging
HARDWARE USED
Keysight Data Logger
Fluke Data Acquisition DMM
INTERFACES / PROTOCOLS
RS-232
USB
Ethernet
HAVE A SIMILAR CHALLENGE? GET A CONSULTATION »

Online Monitoring of Industrial Equipment using NI CompactRIO

monitoring and control for electrical power generation

Online Monitoring of Industrial Equipment using NI CompactRIO

Improving Maintenance of expensive industrial equipment

Client – Large Industrial Equipment Manufacturer

Challenge

The maintenance of the equipment was not always done at the prescribed intervals because the cost of shutting down the plant is significant. This sometimes resulted in an equipment failure. This particular application is for equipment/machinery in the energy/power industry (a generator).

Solution

The online monitoring system monitors a particular parameter of interest to send warnings and alarms to the control room so that the operators know when maintenance needs to be performed on the particular part of interest.  This system has been installed in multiple plants.

Benefits

  • Enables condition-influenced maintenance intervals vs periodic intervals
  • Reduces probability of catastrophic failure by providing warning indicator

System Overview

The system monitors the generator collector health. NI-based data acquisition hardware acquires the signal of interest, logs the raw data, processes the parameter of interest, and triggers/sends warnings and alarms to the control room.  LabVIEW FPGA was used for analog and digital IO and a sensor check. LabVIEW Real Time was used for the calculation, data logging, serving data to the HMI and alarm/warning checking.

SOFTWARE FUNCTIONS
Touchscreen GUI for data/alarm display and system configuration
Data logging
Signal processing and alarming
HARDWARE USED (selected by customer)
NI cRIO
NI Touch Panel Computer
Multiple NI C Series Modules
INTERFACES / PROTOCOLS
TCP/IP

*- images are representative, not actual

I want an online monitoring solution »

Endurance Testing using NI PXI

Endurance Testing using NI PXI

An automated system permits faster validation, unattended test, an increase in throughput, and can free up resources for other tasks during the weeks long endurance test.

Client – A manufacturer of aircraft components in the mil-aero industry

Challenge

New product development drove the need for a new endurance test system for product validation. The old systems were not designed to test the newly designed part (aircraft actuators), and the company didn’t have the time or resources to reconfigure existing systems to perform the testing required.

Solution

The new PXI-based endurance test system provides automated electromechanical testing, full data recording, report generation and a diagnostic panel for intelligent debug. Viewpoint selected the NI equipment, while the test consoles, and other components were selected and fabricated by the customer.

Benefits

  • An automated system permits faster validation, unattended test, an increase in throughput, and can free up resources for other tasks during the weeks long endurance test.
  • Full data recording with a data viewer enables post analysis, which provides the ability to review and analyze raw signals captured during execution. Channel examples are actuator LVDT position, load, current, and encoder actuator position.
  • Summary report capability allows the customer to document the amount of testing completed against the full endurance test schedules.
  • A manual diagnostic operational panel provides the ability to verify particular DUT functionality or components without running an entire schedule.
  • Systems can be paused and restarted to allow for “scheduled maintenance” of the DUT such as inspections, lubrication, etc.

System Overview

The PXI-based endurance test system enables data collection, deterministic PID Loop Control, emergency shutdown and a diagnostic panel for manual test and debug operation. The system runs endurance test schedules, that are defined as a recipe for test execution. These schedules, which are customer-defined and DUT-specific, are designed to simulate the actual conditions the DUT would see in real world application as closely as possible. LabVIEW-RT was used for the deterministic looping for Closed Loop Control of Actuator Position and Load Control. LVDT demodulation was performed on a PXI FPGA card programmed with LabVIEW FPGA.

SOFTWARE FUNCTIONS
GUI
Summary Reports
Full Data Collection for Real-Time and Post Analysis
Deterministic PID Loop Control
E-Stop Management
Diagnostics Panel for Manual Test and Debug
Endurance Test Schedule Execution
Hydraulic Control Panel for Source & Load PSI Control
HARDWARE USED
PXI
Various PXI-based Data Acquisition Cards
PXI RT Controller
PXI FPGA Card
INTERFACES / PROTOCOLS
TCP/IP
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Broad range of off-the-shelf expansion cards & processing horsepower make PXI a formidable choice for many automated test applications.