UTP 9085
High‑Volume Test Automation
for an European automotive technology company, Nidec Elesys Europe
An European automotive technology company, Nidec Elesys Europe, located in Novi Sad, Serbia, develops and manufactures advanced electronic control devices for electric and hybrid vehicles, including inverters, ECUs, and various electronic control systems used across the automotive industry. As an important European manufacturing site (within the global Nidec Group), the company operates a modern production facility dedicated to high‑volume automotive electronics and plays a key role in supporting the growing demand for electric vehicle components in Europe.
For this project, the NOFFZ Serbia team designed and implemented a fully automated end‑of‑line and board‑level test station tailored for a new high‑volume electronic control module. From the outset Nidec Elesys Europe faced the challenge of testing an exceptionally large number of devices per week while maintaining a continuous and interruption‑free material flow. Device PCBs were supplied in trays, and the required manual handling slowed the process, increased error risk, and caused inefficient use of operator resources. At the same time, the customer aimed to minimize operator involvement as much as possible.
To enable this level of automation, NOFFZ developed an entirely new machine module: the ATSU – Autonomous Tray Stacker Unit. The ATSU autonomously stacks, positions, and prepares trays for the robotic handling system, ensuring they are always placed in the optimal location for downstream processes. Designed for ease of use and minimal physical interaction, the ATSU significantly reduces manual workload and guarantees a stable, uninterrupted material flow toward the test station. In combination with robotic pick‑and‑place handling, it forms a completely automated and highly reliable front‑end feeding system that eliminates nearly all previously required manual steps.
In addition to material handling, the project demanded compliance with an ambitious cycle time requirement. The testing process had to handle a very high number of DUTs within a tightly limited time window while maintaining operational stability. NOFFZ achieved this through a tightly synchronized system architecture consisting of rapid tray positioning in the ATSU, robotic device transfer, and parallel testing on a rotary table. This design allows handling and testing to occur simultaneously rather than sequentially, preventing bottlenecks and ensuring a continuous and predictable flow of devices through all stages. As a result, the system achieved a cycle time of under six seconds per DUT, exceeding the customer’s original performance targets.
Beyond automation performance, the system also needed to maintain flexibility in real production environments. Nidec Elesys Europe required an additional manual mode to ensure continued operation during service activities, material shortages, or downtime of the automated feeding system. NOFFZ therefore integrated a safe manual operating mode that allows operators to place DUTs directly onto the rotary table and remove them after testing. A protective light curtain ensures operator safety and compliance with industrial safety regulations. This capability guarantees ongoing production even during exceptional situations, reducing the risk of costly interruptions.
Another critical requirement was full traceability and seamless integration with the Nidec’s SAP system. As the first station in the production line to implement automatic device tracking and box assignment, the test system needed to provide robust real‑time data exchange. Working closely with the client, NOFFZ implemented a reliable SOAP‑based communication interface that securely transmits all relevant test data and device information. This enables complete traceability throughout the process and allows the customer to identify at any moment exactly which device is located in which box, ensuring quality control, transparency, and efficient logistics.
The result of this project is a powerful and highly automated test solution that not only meets but surpasses the customer’s expectations. The station supports a largely autonomous production workflow in which the system can test the planned number of devices within one hour of operation, requiring on average only about two minutes of operator interaction per hour. Combined with the exceptional cycle time performance, robust traceability, flexible operating modes, and a fully autonomous front‑end material handling system, the project sets a new benchmark in automotive end‑of‑line test automation.
This project demonstrates how the synergy between technological innovation, process expertise, and close collaboration between NOFFZ and Nidec Elesys Europe results in a stable, scalable, and future‑ready test solution – perfectly suited to the demanding production environment of modern automotive electronics.
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