LabVIEW Consultants2020-08-27T15:08:09-04:00

LabVIEW Consultants

US-based manufacturers: Need a LabVIEW Expert?

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Need some existing code updated?  Need a whole new LabVIEW-based test system?  Whether you had code dropped on your lap, or you’re just too busy with other things, our LabVIEW experts can take the LabVIEW programming off your plate so you can focus on what you need to.

We have one or more:

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Certified LabVIEW Developer

Certified TestStand Architect

Certified TestStand Developer

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We’ve helped teams at some of the world’s most innovative companies

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

Industrial Monitoring for a Harsh Environment

Industrial Monitoring for a Harsh Environment

Developing an industrial monitoring system for ultrasound-based sensing in a harsh environment

Client – Energy Research Lab

Challenge

Our client was experiencing problems making temperature measurements in a hostile, irradiated environment. Traditional temperature sensors don’t last long in this environment, so our client was developing a sensor designed for these conditions.

Special equipment is required to drive this sensor. It’s an active sensor requiring an ultrasound pulser/receiver (P/R) and high-speed digitizer to make it function.

The prior attempt the client made at using an original set of special equipment was having reliability and connectivity issues. This reduced reliability was of critical concern due to the requirement for the sensor to operate for years without downtime.

In addition, the existing application was incapable of displaying live data and lacked a user-friendly interface. On top of that, data analysis had to be done after the application was run, causing delays.
Our client needed reliable and robust hardware to drive the sensors and an application that would eliminate the challenges associated with the existing system.

Solution

Viewpoint accomplished the following:

  1. Evaluated two different ultrasonic P/R sensor driver hardware solutions to select a solution that would provide the connectivity robustness, configurability, and correct sensor driver characteristics required for the given sensors.
  2. Decoupled the digitizer embedded in the original P/R by adding a PXI digitizer with better capability.
  3. Provided backward compatibility with previous measurement hardware to aid in performance comparisons with the new hardware.
  4. Developed a LabVIEW-based application that corrected all the issues with the existing application including real-time data analysis, real-time data visibility and a modern user interface. The new application also provided sensor performance traceability using the sensor’s serial number.

Benefits

The enhanced measurement system offers the following benefits:

  • Reliable sensor subsystem to ensure uninterrupted data acquisition.
  • Measurement hardware configurability for sample rate, collection duration, and pulsing repetition rate.
  • Application configurability for automating the analysis, historical archiving, and results reporting.
  • Real-time data analysis.
  • Sensor traceability through serial number and data files.
  • Engineering mode to take control of the entire measurement system.
  • Improved data logging to include raw and analyzed data.
  • Improved application user experience via robust data collection and configurability.

System Overview

The deployed temperature monitoring system consisted of the following components:

  • COTS pulser/receiver hardware for driving the sensors.
  • COTS high-speed DAQ for retrieving ultrasound signals.
  • A LabVIEW-based software application to provide real time data monitoring, error/alarm notification, data analysis, data logging, part traceability and backward compatibility with the older sensor driver hardware.
SOFTWARE FUNCTIONS
Acquire Data from Sensor Driver Device
Data Analysis
Write Raw Data to File
Write Analyzed Data to File
Configuration Utility
HARDWARE UTILIZED
Sensor Pulser/Receiver Driver
NI PXIe Expansion Chassis
NI PXI Oscilloscope Module
NI PXI Thunderbolt 3 Module
INTERFACES / PROTOCOLS
RS-232
Thunderbolt 3

Semi-Automation of an Optical Component Manufacturing Process

Semi-Automation of an Optical Component Manufacturing Process

Automation reduces waste, manufacturing cycle time and human error

Client – Optical component manufacturer of precision structured surfaces

Challenge

Our client needed to introduce automation to a highly manual manufacturing process for injection molding of precision components. The manual process was slow, and yields were low, causing excessive waste. The low yield was traced to the inability to control the critical process variables.

Solution

Viewpoint decided to integrate a PLC, a motion controller, and LabVIEW to develop a solution for a “first phase” automation system to replace the highly manual process.

The PLC:

  1. controls eight axes of motion,
  2. controls the UV light for curing,
  3. and interfaces to other process equipment such as valves and sensors .

The LabVIEW application:

  1. guides the operator through the manufacturing process step by step,
  2. interacts with the PLC,
  3. and displays real-time process data and log data to a file for further review post manufacturing.

Benefits

Besides the automation benefits of consistency and speed, the client wanted the ability to adjust configuration settings and limits for almost every aspect of the operation, such as setpoints and motion stage positions. Configuration screens were developed that let an operator run through the manufacturing steps manually while making adjustments on-the-fly; perfect for “dry-run” production simulations. These screens require special permissions to operate in engineering mode rather than production mode.

The other benefits are:

  • Reduction of set-up cycle time increasing component throughput.
  • Reduction of variability of the manufacturing process.
  • Increased product yield resulting in reduced waste.
  • Reduced probability of product contamination due to automation and cycle time reduction.
  • Data files enable review of past manufacturing data and potential process improvements.
  • Part traceability enables better process understanding and control.
  • Prompts and machine status checks help guide novice operators.
  • System is configurable for different product lines.

System Overview

The entire system consists of the following components:

  • A PLC controlling the motors responsible for positioning the tooling and other process equipment.
  • A standalone controller responsible for controlling the process temperature.
  • A LabVIEW application to serve as the operator’s interface to the manufacturing process. The application is responsible for tasks including:
    • Guide the operator through the process.
    • Provide important information about the process to the operator.
    • Display any warnings/alarms detected by the PLC.
    • Write process data to a file.
SOFTWARE FUNCTIONS
Read Data from Stand Alone Controllers
Read from, Write to PLC
Write Data to File
Comprehensive User Interface
Process Sequencer
HARDWARE UTILIZED
Stand Alone Temperature Controllers
PLC
Motion Equipment
Vision Equipment
INTERFACES / PROTOCOLS
RS-485
OPC UA

High-Speed Digital Subsystem Emulator

High-Speed Digital Subsystem Emulator

Client: A large company involved in C4ISR

At maximum throughput, the Aedis systems needed to consume and produce more than about 800 MB/s/slot.

Background

A large company involved in C4ISR was developing a system for a new high-speed digital sensor device. Viewpoint was contracted to build a test system used in design validation and ultimately endurance testing of the sensor. Since the sensor was a component of a larger system which was being developed at the same time, another test system was created to simulate the sensor by feeding signals into the system.

Challenge

Both the amount of data and the frequencies of the various digital signals were nearly at the limit of hardware capabilities. At maximum throughput, the systems needed to consume during record and produce during playback about 800 MB/s/slot. The FPGA clock on the FlexRIO had to run up to 300 MHz. The skew between triggers for data transmission needed to be less than 5 ns even between multiple FlexRIO cards even when the parallel data paths has inherent skews associated with the sensor. Finally, the systems needed to handle clocks that might be out-of-phase.

Achieving these requirements required significant engineering design in the face of multiple possible roadblocks, any one of which could have eliminated a successful outcome.

Furthermore, as usual, the development timeline was tight. In this case, it was a very tight 3 months.

Viewpoint’s Solution

To meet the timeline, we had to work in parallel across several fronts:

  • LabVIEW-based application development for both record and playback
  • LabVIEW FPGA development for marshalling data between the controller and DRAM
  • Custom FAM circuit board design and build
  • FlexRIO FPGA CLIP nodes and code for low-level data handling

Technical Highlights

This sensor had several parallel data paths of clock and data lines with clock speeds up to 300 MHz on each path requiring exacting design and build of a custom FlexRIO Adapter Module (FAM) and unique custom CLIP nodes for extending the FlexRIO FPGA capabilities. The FAM also had a special connector for interfacing to the customer’s hardware.

Additional NI hardware and software completed the system components.

Results

The choice to base the Aedis emulators on NI hardware and software was critical to completing this project. The open architecture in both hardware (custom FAM) and software (CLIP Nodes) enabled us to include some very creative extensions to the base toolset without which the project would not have succeeded in the allotted pressured schedule and on a predetermined budget. We were able to stretch the capabilities of the hardware and software very close to their maximum specifications by combining COTS and custom much more cost effectively than a purely custom design.

LabVIEW Layers

The host application, written in LabVIEW, managed the configuration of the data acquisition and the control of the LabVIEW RT-based FlexRIO systems. The configuration primarily dealt with the number of sensor channels in use, skew settings between digital lines, and other parameters that dealt with the organization of the data passed between the sensor and the FlexRIO.

Two FlexRIO applications were written, one for record and one for playback. Each FlexRIO application was written in LabVIEW, and managed the configuration of the FlexRIO cards and the movement of data between the FlexRIO cards and the RAID drives. Note that Windows supported for the RAID driver. Between 10 and 32 DMA channels were used for streaming, depending on the number of sensor channels being used.

And, each FlexRIO application had an FPGA layer, written in LabVIEW FPGA enhanced with custom CLIP nodes. For the record application, we developed a custom DRAM FIFO on the FPGA to assist with the latencies on the PXIe bus. For the playback application, we were able to stream directly from DRAM.

FlexRIO Considerations

The FlexRIO and stock FAMs from NI were initially considered as candidates for this project. Clearly, working with commercial-off-the-shelf (COTS) components would be most effective. Three options were available at the project start which could accommodate the required clock frequencies, but none offered both the required channel counts and skew/routing limitations. Hence, we had to design a custom FAM. This decision, made before the start of the project, turned out to be wise in hindsight because the parallel development path resulted in some shifts of sensor requirements which could be accommodated with the custom FAM but might have led to a dead-end with a COTS FAM.

FlexRIO CLIP

In LabVIEW FPGA, a CLIP Node is a method to import custom FPGA IP (i.e., code) into a LabVIEW FPGA application. CLIP stands for Component-Level Intellectual Property. We needed to use special Socketed CLIP Nodes (i.e., VHDL that can access FPGA pins) for this project because we could expose additional features of the Xilinx Virtex-5 not exposed in LabVIEW FPGA by accessing Xilinx primitives. Some specific features were:

  • Faster FPGA clocking
  • Additional clocking options
  • Individual clock and skew control
  • Custom PLL de-jitter nodes

Essentially, the FPGA design had a majority of FPGA code developed in LabVIEW FPGA and we used CLIP Nodes for interfacing the signals between the FlexRIO and the FAM.

DRAP-case-study-image

FlexRIO Adapter Module

As mentioned earlier, we had to create a custom FAM because of the need to route high speed signals from customer-specific high density connectors while synchronizing signals across multiple data channels and FPGA modules to within one (300 MHz) clock cycle.

At these high-speeds, the FAM needed careful buffering and impedance matching both on the signals as well internal components on the FAM PCB. At the start of the design, we utilized Mentor Graphics HyperLynx High Speed DDR signaling Simulation software to minimize signal reflections prior to building actual hardware. This step saved countless hours in spinning physical hardware designs.

We designed the FAM to allow channel routing and access to additional clock and trigger pins on the Xilinx chip and PXIe backplane.

I need an emulator »

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
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Learn how to choose a LabVIEW consultant

Maybe you’re LabVIEW programmer quit or retired, or maybe you’ve got some internal capabilities but need some additional support because everyone’s too busy.  From hourly rates to a range of skills, there are several factors to consider. We’ll help you weigh each one. See How to Select a LabView Consultant. 

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3,000+

LabVIEW solutions delivered

Great for automated measurement & control: manufacturing test, product validation, machine control and condition monitoring.

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Great for applications requiring seriously deterministic timing, reliable code execution, and multi-channel synchronized processing.

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LabVIEW RT systems delivered

The combination of LabVIEW RT and the RTOS on which it runs allows for the creation of applications with bounded jitter and latency.

500+

cRIO-based systems delivered

Combining a cRIO controller with the multitude of C Series modules creates a functional real-time controller in a small footprint.

1,500+

PXI-based solutions delivered

Broad range of off-the-shelf expansion cards & processing horsepower make PXI a formidable choice for many automated test applications.

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