Standardized Tester System at Siemens IS EDM
Initial Situation and project task
Because of changing and increasingly complex demands towards functional testing with various hardware interfaces, Siemens IS EDMS decided to implement a standardized tester solution for all its facilities, in 2005.
In this context, NOFFZ had to define a flexible, modular and manufacturer-independent tester system for current and future demands towards test facilities. The system should offer a standardized configuration of measurement and stimulation devices and had to include an adapter interface for low medium numbers of items. The system should also be able to realize product-related test stations for a high number of items and for constantly high capacity utilization.
Programming language and user interface of the new tester system had to be standardized as well. Common software interfaces and platforms had to be controlled. Calibration and maintenance of the system should be able to be carried out economically and without production downtimes.
Traceability and the ability of integration into the existing QM system have been required as well. The system should also allow for external generation of testing programs.
Implementation and challenge
The tester system has been implemented within a standard 19“ switching cabinet, which includes all measurement equipment such as a universal adaptor, a universal AC power supply, a controller unit, a DMM, a relays module, an analogue DC output card, a functions generator, an RS232 interface, a digital I/O module and an 8 channel digitizer.
Due to the Pylon interface being used for connection to the testing adaptor, the system offers all flexibility needed for future projects and modules. The interface provides all signals generated within the switching cabinet. Signal, high current, coax, pneumatic and vacuum contacts have been integrated.
Standardized adaptors for angular desks, which include device-related configurations, have been implemented. These adaptors also comprise additional components, such as interface electronics, LED inspection and a USB-8451 for flashing WAGO modules.
LED inspection is performed by means of optical fibres and allows for evaluation of wavelengths and intensity.
Interface electronics include extensive device-specific configurations such as high-precision resistors, loads, protective measures for devices under test, the whole measurement system and the signal distribution unit of the Pylon interface.
Due to integrated adaptor recognition within the interface electronics, the correct combination of adaptor and testing sequence can be ensured. Additional safety is offered by an integrated system which recognizes if a device has been inserted and if the test chamber has been properly shut.
It is also possible to disconnect the circuit board from the adaptor and to replace it with a new one.
Because of changing and increasingly complex demands towards functional testing with various hardware interfaces, Siemens IS EDMS decided to implement a standardized tester solution for all its facilities, in 2005.
In this context, NOFFZ had to define a flexible, modular and manufacturer-independent tester system for current and future demands towards test facilities. The system should offer a standardized configuration of measurement and stimulation devices and had to include an adapter interface for low medium numbers of items. The system should also be able to realize product-related test stations for a high number of items and for constantly high capacity utilization.
Programming language and user interface of the new tester system had to be standardized as well. Common software interfaces and platforms had to be controlled. Calibration and maintenance of the system should be able to be carried out economically and without production downtimes.
Traceability and the ability of integration into the existing QM system have been required as well. The system should also allow for external generation of testing programs.
Implementation and challenge
The tester system has been implemented within a standard 19“ switching cabinet, which includes all measurement equipment such as a universal adaptor, a universal AC power supply, a controller unit, a DMM, a relays module, an analogue DC output card, a functions generator, an RS232 interface, a digital I/O module and an 8 channel digitizer.
Due to the Pylon interface being used for connection to the testing adaptor, the system offers all flexibility needed for future projects and modules. The interface provides all signals generated within the switching cabinet. Signal, high current, coax, pneumatic and vacuum contacts have been integrated.
Standardized adaptors for angular desks, which include device-related configurations, have been implemented. These adaptors also comprise additional components, such as interface electronics, LED inspection and a USB-8451 for flashing WAGO modules.
LED inspection is performed by means of optical fibres and allows for evaluation of wavelengths and intensity.
Interface electronics include extensive device-specific configurations such as high-precision resistors, loads, protective measures for devices under test, the whole measurement system and the signal distribution unit of the Pylon interface.
Due to integrated adaptor recognition within the interface electronics, the correct combination of adaptor and testing sequence can be ensured. Additional safety is offered by an integrated system which recognizes if a device has been inserted and if the test chamber has been properly shut.
It is also possible to disconnect the circuit board from the adaptor and to replace it with a new one.
Programming languages which haave been used in the past, all have been replaced with LabVIEW and LabWindows/CVI. Using a standardized software system, it is possible to improve working conditions for planning and testing departments. Therefore, the test management software ‘TestStand’ has been used as test sequencer. By means of a standardized user interface, periods of vocational adjustment can be reduced, the number of error sources can be minimized and user friendliness can be increased.
Devices are directly embedded via TestStand or via integrated LabVIEW, LabWindows/CVI/C++ tester functions. The operator interface provides all information required and allows for access to any parameters of the tester or the device under test.
TestStand also offers a platform for sequence control, branching, reporting and database integrations and allows for connection to any common development environment, being used at Siemens IS EDM, WAGO or NOFFZ.
Conclusion and future prospects
This new tester system will be used at all facilities of Siemens IS EDM as a standardized tester system for various different products. Due to an abstract software kit and due to flexible measurement hardware, it was possible to benefit from synergistic effects. Due to a high degree of reusability of hardware and software modules, time and money could be saved significantly.
Because of the high number of devices by National Instruments and other well-known manufacturers being used within the system, a modular and future-proof tester could be implemented.
A standardized adaptor interface has been designed for default applications. This way, a relocation of the production of a certain product within Siemens’ facilities can be carried out much easier.
Since 2007, PXI test stations are used at Siemens IS EDM. Inspection planners from all their facilities are instructed on LabVIEW, WindowsCVI and TestStand.
Devices are directly embedded via TestStand or via integrated LabVIEW, LabWindows/CVI/C++ tester functions. The operator interface provides all information required and allows for access to any parameters of the tester or the device under test.
TestStand also offers a platform for sequence control, branching, reporting and database integrations and allows for connection to any common development environment, being used at Siemens IS EDM, WAGO or NOFFZ.
Conclusion and future prospects
This new tester system will be used at all facilities of Siemens IS EDM as a standardized tester system for various different products. Due to an abstract software kit and due to flexible measurement hardware, it was possible to benefit from synergistic effects. Due to a high degree of reusability of hardware and software modules, time and money could be saved significantly.
Because of the high number of devices by National Instruments and other well-known manufacturers being used within the system, a modular and future-proof tester could be implemented.
A standardized adaptor interface has been designed for default applications. This way, a relocation of the production of a certain product within Siemens’ facilities can be carried out much easier.
Since 2007, PXI test stations are used at Siemens IS EDM. Inspection planners from all their facilities are instructed on LabVIEW, WindowsCVI and TestStand.