Manual Workstation for Functional Testing of Comfort Control Devices
Initial situation and project task
Since the beginning of the year 2007, an automotive supplier united the departments for ‘Manufacturing Engineering’ of all its divisions. In order to achieve a consistent support structure, end-of-line-testers (EOL) all over Europe should now be programmed by means of a standardized test software solution.
The B&S division (Body & Security, BCM, Sensor Modules, Key Fobs ...) already used a well-standardized software environment. Therefore, this software solution should be modified and extended for divisions such as mechatronics and the production of comfort control devices. The automotive supplier was not interested in increasing its own human resources for the development of the new test stand. For this reason, the developed has been carried out in cooperation with NOFFZ ComputerTechnik GmbH.
In the course of the project, the new Pan-European standard for EOL tester systems for mechatronic products should be extended to all divisions.
Implementation and challenge
The software solution is based on a TestStand/LabVIEW framework and its connection to the production’s databases. By means of a user rights management system, access rights of users and service technicians can be controlled. The whole user prompting is visualized on a monitor, so that all parameters and relevant information can be accessed and adjusted.
The implemented hardware is based on standard components by well-known suppliers and has been .complemented by suitable NOFFZ developments.
Hardware framework for the tester system is a Bosch desk frame, including a lamp and a document holder, which has been expanded by the required control buttons. The framework also comprises an industry PC, a LIN communications interface and measurement hardware consisting of multifunctional NI cards and NI DIO.
In order to ensure operational reliability and for the prevention of data loss due to fluctuating power supply, the system includes a 19” rack by Schroff with a power rack module, providing an ELCB and an uninterruptible power supply.
Another important part of the system is the NOFFZ signal conditioning system including a distributor print, a patch panel and suitable connection technology. The system also comprises an integrated camera system as well as an exchangeable device adaptor for adjustment to various different devices under test.
Since the beginning of the year 2007, an automotive supplier united the departments for ‘Manufacturing Engineering’ of all its divisions. In order to achieve a consistent support structure, end-of-line-testers (EOL) all over Europe should now be programmed by means of a standardized test software solution.
The B&S division (Body & Security, BCM, Sensor Modules, Key Fobs ...) already used a well-standardized software environment. Therefore, this software solution should be modified and extended for divisions such as mechatronics and the production of comfort control devices. The automotive supplier was not interested in increasing its own human resources for the development of the new test stand. For this reason, the developed has been carried out in cooperation with NOFFZ ComputerTechnik GmbH.
In the course of the project, the new Pan-European standard for EOL tester systems for mechatronic products should be extended to all divisions.
Implementation and challenge
The software solution is based on a TestStand/LabVIEW framework and its connection to the production’s databases. By means of a user rights management system, access rights of users and service technicians can be controlled. The whole user prompting is visualized on a monitor, so that all parameters and relevant information can be accessed and adjusted.
The implemented hardware is based on standard components by well-known suppliers and has been .complemented by suitable NOFFZ developments.
Hardware framework for the tester system is a Bosch desk frame, including a lamp and a document holder, which has been expanded by the required control buttons. The framework also comprises an industry PC, a LIN communications interface and measurement hardware consisting of multifunctional NI cards and NI DIO.
In order to ensure operational reliability and for the prevention of data loss due to fluctuating power supply, the system includes a 19” rack by Schroff with a power rack module, providing an ELCB and an uninterruptible power supply.
Another important part of the system is the NOFFZ signal conditioning system including a distributor print, a patch panel and suitable connection technology. The system also comprises an integrated camera system as well as an exchangeable device adaptor for adjustment to various different devices under test.
In order to sort out faulty devices reliably and promptly, a slide for faulty parts has been attached, so that faulty parts can be separated from proper devices.
In order to allow for better integration into the production process and for high traceability of all production steps, the test stand also comprises a barcode scanner and a 2D data matrix scanner. Therefore it is possible to properly register all tested parts and components with their specific test results.
Conclusion and future prospects
A modular, flexible and reliable OEL tester for comfort control devices for the automotive industry has been implemented. The tester optimally can be integrated into the production process because all devices under test are registered by means of a barcode scanner and reliably are sorted out in case of failure. In addition to that, the system is protected against accidental data loss by means of a clever power management system and an uninterruptible power supply.
Due to the integrated test adaptor concept, the tester can be individually adapted to changed or new products. The system can also be modified according to the specific demands of other production departments.
A high number of product variants and product families could be implemented into the test stand . Currently, about 100 product variants can be handled.
In order to allow for better integration into the production process and for high traceability of all production steps, the test stand also comprises a barcode scanner and a 2D data matrix scanner. Therefore it is possible to properly register all tested parts and components with their specific test results.
Conclusion and future prospects
A modular, flexible and reliable OEL tester for comfort control devices for the automotive industry has been implemented. The tester optimally can be integrated into the production process because all devices under test are registered by means of a barcode scanner and reliably are sorted out in case of failure. In addition to that, the system is protected against accidental data loss by means of a clever power management system and an uninterruptible power supply.
Due to the integrated test adaptor concept, the tester can be individually adapted to changed or new products. The system can also be modified according to the specific demands of other production departments.
A high number of product variants and product families could be implemented into the test stand . Currently, about 100 product variants can be handled.