References

Test benches for electronic steering column locks

• cyclic actuation of electronic steering column locks over several hundred hours, alternately under load or without load
• configurable sequence control, either time-based or based on number of cycles, with selectable number of simultaneously controlled test specimens
• steering column simulation via Dunkermotoren brushless DC motors of the BG series with CANopen interface, position or torque controlled depending on state
• connection of the test bench peripherals via Kvaser PCIEcan HS/HS CAN controller
• control of the test specimen via Vector VN8912 network interface with VN8950 CAN/LIN plug-in module
• acquisition and output of analogue and digital signals via Goldammer MultiChoice USB basic
• cycle-based data storage and error logging in TDM format

Flat output drive test bench

• end-of-line test and endurance test (cyclic load) of angular gearboxes
• simultaneous independent testing of up to three specimens at three test stations
• central database-supported parameterisation, visualisation and evaluation of all three test stations on one PC
• acquisition and output of analogue and digital signals as well as torque control via National Instruments compactRIO 9064 PAC
• communication between PC and PAC via EtherCAT using Beckhoff EL6695 EtherCAT bridge
• torque measurement either analogue or via RS-485 using torque sensors from Lorenz Messtechnik GmbH
• cyclic data storage in TDM format
• automatic report generation in PDF format and transfer of result parameters to a central database

Generic measurement application for CAN data acquisition on vehicles

• parameterisation and configuration of measurement tasks (DIAdem DAC diagrams) and evaluation functions based on a generic exchange file in XML format
• improved clarity as well as easier change tracking and versioning by replacing numerous graphical function blocks with a single online script
• combination of sequence control, channel calculation and offset correction in the online script
• dialog-guided generation of the online script
• automated evaluation of the measurement data up to the test report (PDF report) with visual marking of passed and failed tests
• generation of an HTML report overview with links to the individual reports

Endurance test bench

• cyclic loading of hydraulic cylinders with up to 10 million load cycles
• three independent test stations with central operation, configuration and visualisation
• acquisition of 16 configurable analogue inputs per test station via HBM QuantumX MX840 universal amplifiers
• central acquisition and output of analogue and digital control signals via NI 9144 EtherCAT slave chassis with corresponding input and output modules
• configurable sampling rate for data acquisition between 500 and 2000 Hz
• connection of the system components via EtherCAT, HBM CX27 EtherCAT gateways and Beckhoff EL6692 EtherCAT bridge
• connection of external Bosch Rexroth HNC100-3X digital axis controllers and the test bench PLC via Profinet and Hilscher cifX 70-RE IO controller cards
• import of the QuantumX configuration via parameter file
• monitoring of up to 10 acquired signals per test station for static and dynamic limits
• cyclic data storage in a freely configurable cycle pattern as well as event-driven data storage
• manual, semi-automatic and automatic tests
• recording and graphical generation of tolerance bands

Pump test bench

low-cost modernisation of an existing system

• minimal hardware changes while reusing components that are in part decades old
• acquisition and output of analogue and digital signals via Beckhoff bus terminals and EtherCAT bus couplers
• hardware connection via EtherCAT
• flow and pressure controlled operation
• automatic test report generation
• test report search

Visual Basic Script programming for PAC-based test benches

• extension of the standard DIAdem functionality by around 30 application-specific commands
• acquisition and output of analogue, digital, CAN and Profibus signals via National Instruments compactRIO
• access to single values and signal waveforms
• dynamic channel configuration – assignment of hardware interfaces and associated scaling rules to signals by command
• integration of any standard DIAdem functions (commands, scripts, dialogs etc.) possible
• simple user interface – exclusively script-based
• parallel processing using DIAdem worker technology

PAC-based test benches for electro-pneumatic valves

• testing of devices with analogue, digital, bus (Profibus, Profinet, SERCOS III) and mechanical interfaces (actuation by Schunk PRH miniature servo rotary module with CANopen interface)
• fully and semi-automatic as well as manual test and adjustment functions
• parameterisation, software updates and automatic adjustment of the test specimens via RS-232, TCP/IP, HTTP POST and TFTP as well as via acyclic communication with Profinet and SERCOS III
• data acquisition, dynamic setpoint output as well as control and safety functions via National Instruments CompactRIO
• pressure measurement via WIKA P-30 pressure transmitters with CANopen interface
• flow measurement and control via Bronkhorst EL-FLOW Base mass flow meters and controllers with EtherCAT interface
• integrated measurement system analysis (repeatability of the test setup) and self-test

Automated measurement operation on stationary vehicle measurement setups

• data storage at configurable intervals, taking maintenance breaks into account
• interruption of measurement operation when free storage falls below an adjustable reserve
• retention of measurement files with adjustable storage depth
• permanent availability thanks to activity monitoring via operating system services
• error notification by e-mail
• server-based application for automatic data transfer and
  processing
• parameterisation of measurement computers and server application via a central configuration database
• autonomous operation of the measurement computers using local parameter files

Integration of test benches into OpCon MES

• transfer of test result data in any format to the Bosch OpCon MES manufacturing execution system
• host computer application – no changes to the individual test benches required
• continuous transfer of test results to OpCon MES
• conversion of different parameter structures into OpCon-compatible syntax
• transfer of XML structures via TCP/IP
• data buffering in case of errors

Universal test benches for electro-pneumatic automotive components

• framework application consisting of several instances for high test speed through parallel parameterisation, testing and evaluation
• sequential execution of predefined test steps in any order
• database-based parameter management and test bench configuration
• data acquisition, dynamic setpoint output as well as control and safety functions using National Instruments CompactRIO – analogue, digital, PWM, PROFIBUS DP (via master/slave module for NI CompactRIO PROFIBUS), CAN (via NI 9853)
• control of the test circuit via Bosch Rexroth LP04 series valve manifold system with PROFIBUS DP interface
• flow measurement and control via Vögtlin mass flow meters and controllers 'red-y smart series' with PROFIBUS DP interface
• evaluation of the test steps according to static and dynamic criteria
• automatic test report generation (tables, charts)
• reduction of test time from 15 minutes to 90 seconds

Application concept (German)

Cycling test – alternating thermal load on components

• data acquisition and control via National Instruments compact RIO real-time controller (PAC), consisting of cRIO-9112 backplane and cRIO-9012 controller
• temperature measurement via pyrometers and line scanners over RS-232 as well as via thermocouples
• emulation of control signals for an (existing) PLC
• selectable operating modes (cyclic data acquisition and storage, line scan (semi-automatic) or manual)
• limit monitoring
• visualisation and parameterisation via a tailored application on the host PC
• continuous data storage on the PAC in NI TDMS format
• automatic transfer of the measurement files from the PAC to the PC and data export
• autonomous operation of the controller application (host application not permanently active)

Production test benches for electro-pneumatic valves with SERCOS III interface

• application based on the test benches for electro-pneumatic valves described below
• data acquisition, dynamic setpoint output and parameterisation via Hilscher CIFX 50-RE/+ML, the corresponding SERCOS III master and a self-developed driver interface
• exchange of parameter files via TFTP (Trivial File Transfer Protocol)

Quiescent current measuring station

• 16-channel acquisition of currents, voltages and temperatures via Klaric Klari-Fuse 2
• CAN bus connection via Kvaser PCIcan interface card
• automatic detection of connected probes
• convenient system configuration via tailored dialogs
• limit monitoring
• automatic generation of Word test reports

Centrifugal pump test bench

low-cost modernisation of an existing system

• end-of-line testing of centrifugal pumps of different designs
• automatic, semi-automatic and manual test modes
• connection to the existing Interbus architecture via Phoenix Contact IBS PCI SC/I-T PCI interface board and Phoenix Contact IBS OPC server
• replacement of a proprietary FoxPro-based parameter database (CeView) by an ODBC-based one
• adaptation of existing DIAdem program components (DAC diagrams, scripts, report layouts) to current program versions
• operating system change from Windows NT to Windows XP
• automated (script-based) import of legacy data

Software-controlled function generator for hydraulic pulse tests

• separately configurable two-channel setpoint output for hydraulic control valves
• output of trapezoidal signals (parameters: frequency, minimum, maximum, slopes), sine, square and triangle signals (parameters: waveform, frequency, amplitude, offset, phase and duty cycle),
  frequency range 0.001 – 100 Hz
• parameterisation of signal generation via dedicated function blocks in DIAdem
• simultaneous acquisition of temperature signals
• signal generation and data acquisition via real-time controller with analogue output and input modules
• PC connection either via Ethernet or RS-232

Condition monitor

identification, isolation and display of states in CAN measurement files

• CAN data evaluation at the push of a button according to predefined configurations
• data import using the DIAdem CAN converter
• state identification based on up to 10 freely definable events
• state isolation by saving individual files
• determination of consumer currents
• graphical display of results

Data compression and analysis on decentralised supply systems

• server-based application for automatic collection and evaluation of data
• local application for manual data analysis
• data transfer from PLCs via VPN and FTP as well as from distributed PCs via Ethernet
• database-supported configuration
• generation of daily, weekly, monthly and annual balances as Excel files
• counting of errors, operating times and events

Hydraulic accumulator test bench

• automatic testing of hydraulic piston and pistonless accumulators
• database-supported test parameterisation
• data acquisition and output as well as protection and safety functions via National Instruments compact FieldPoint distributed automation system
• PC-based automatic evaluation and test report generation (charts)

Test data evaluation

• database-supported evaluation of production test data
• continuous transfer of test results to the database
• predefined and variable queries
• automatic PDF report generation and Excel export functions

Data evaluation on a climatic wind tunnel

• test data evaluation at the push of a button according to predefined configurations
• definition of report layouts of up to 10 pages with up to 10 charts and 100 curves each
• DataPlugin import filters for various application-specific data formats
• numerous predefined (mean values, sums, differences, ranges) and user-defined calculation functions as well as generation of complex setpoint functions

Test station for ship command transmitters with CAN interface

• automatic and manual testing
• bus connection via USB interface module
• simultaneous acquisition of analogue signals via digital multimeter connected over RS-232
• database-supported management of test programs

Axle module test bench

determination of wheel spring rates of vehicle axle modules

• automatic mode for cyclic loading and unloading of the wheel suspensions (force or displacement controlled, one-sided or two-sided, in phase or in antiphase) with simultaneous recording of forces and displacements
• manual (jog) mode for free movement of the drives and for approaching manually entered target positions or forces
• test bench control via drives with Profibus interface
• parameterisation according to the PROFIBUS profile for variable speed drives PROFIDRIVE
• data acquisition via multifunction card and external instrument
• mathematical and graphical evaluation (e.g. calculation of characteristic values of the axle module, display of the measured force versus the position of the calculated wheel centre)
• database-supported management of configuration parameters (scaling, cut-off criteria, geometry data)

Motor and transformer test bench

• determination of characteristic curves and endurance testing of DC motors, transformers and power supplies
• loading of motors via hysteresis and eddy current brakes, driven by a controller with GPIB interface
• test bench control and data acquisition via Beckhoff bus terminals and EtherCAT bus couplers
• power supply via programmable power supply unit with analogue interface
• loading of transformers and power supplies via DC load with analogue interface
• speed-controlled recording of characteristic curves on DC motors
• endurance testing of DC motors under freely definable time profiles of motor voltage and load torque
• current-controlled recording of characteristic curves on power supplies and transformers
• manual test modes with free setpoint entry
• automatic evaluation and test report generation (charts)

Process control

safeguarding the technological sequence in manufacturing processes

• database-supported server application with distributed data acquisition and output
• acquisition and output of text information via barcode scanners and LCD displays, connected via Ethernet-to-serial converters
• acquisition and output of analogue and digital signals via Ethernet bus couplers

Directional valve test benches

• static and dynamic (leakage measurement) tests with more than 50 parameters per test step
• configuration of the test sequence and parameterisation via database
• database storage of test results
• automatic generation of reject labels

AS-i test stations

test stations for pneumatic components with AS-i (actuator sensor interface) bus

• manual and automatic actuation
• connection via AS-i bus master
• control as well as signal acquisition and output via AS-i input/output modules and external leak tester

Gearshift test bench

• automatic endurance testing (up to 2 million cycles) of gearshift actuations
• test bench control and data acquisition via robotics modules and external instrument
• extensive functions for setting up and configuring the system
• implemented test modes:
  – displacement-controlled gearshift actuation with controlled counterforce
  – parallel displacement-controlled dual actuation with uncontrolled counterforce
  – gearshift actuation with force-dependent reversal

Propeller shaft test bench

• data acquisition via external instrument
• static and dynamic angle, displacement, force and torque measurement
• automatic generation of data sheets and charts

Seat foam test bench

(dynamic fatigue test according to DIN 53574 / ISO 3385)

• defined cyclic loading of foam parts over any period of time under adjustable climatic conditions
• automated hardness test (indentation test according to DIN 53579)
• test bench control and data acquisition via robotics modules
• control of a climatic chamber via RS-232
• automatic weighing (determination of residual moisture) using a weighing platform
• automatic test report generation (charts)

Process support on a paper and film coating machine

• technical and organisational support of a continuous production process
• statistical process analysis and process optimisation
• troubleshooting and programming of PLCs and instrumentation and control components

Project management for the installation of an air conditioning system for a factory hall

• ensuring project progress during installation and commissioning
• technical acceptance and contract negotiations
• operational monitoring and troubleshooting

Data acquisition and visualisation on a hall air conditioning system

• multi-channel long-term data acquisition via OPC
• extensive alarm and logging system

Brake test bench

• fast real-time control
• execution of entered and measured setpoint profiles
• wide range of setpoint variations through a cascaded parameter structure consisting of circuit sequence, circuit stage (n-fold repetition of a braking cycle), braking cycle (any number of braking cycle stages) and braking cycle stages (sequence of brake applications with identical parameters)
• connection to the existing Interbus architecture via OPC

Hot gas generator for testing catalytic converters

• real-time control of the highly dynamic combustion process (temperatures up to 1300 °C, transients of more than 1000 K/s)
• control of the entire test sequence including extensive peripherals (valves, ventilation systems)
• fast data storage over any length of time
• extensive safety functions (alarms and logging)
• dynamic visualisation of the system

Production test benches for electro-pneumatic valves

• sequential execution of predefined test steps in any order
  configuration of the test depending on previously entered device and test step parameters
• dynamic setpoint output (analogue or PWM) and simultaneous control of the test fixture (solenoid valves, digital)
• evaluation of the test steps according to static and dynamic criteria
• test report generation (tables, charts)
• integrated measurement system analysis (repeatability of the test setup)
• reduction of test time from 15 to 2 minutes

Vehicle electrical system simulator for testing car batteries

• multi-channel real-time control
• automatic switching between different load cycles depending on freely definable criteria
• configuration management
• automatic test report generation

Waste water data acquisition

• continuous (running for years) acquisition of pollutant values in waste water (via OPC from Siemens S5 / S7) and storage in daily files or in an ACCESS database, several measuring points
• remote access to the measurement computer (via network, distance between measuring and evaluation location several kilometres)
• entry of laboratory analysis data and synchronisation of these data with the continuously acquired values
• calculation of characteristic values over freely selectable time intervals
• display of results over any period (1 h – 1 year) as tables and charts

Production test bench for airbag modules

Gearbox synchronisation test bench

Affect induction experiment

psychological measurement application