Custom Test Solutions
Elizabeth Zybczynski – Engineering Mgr MN Office
Dave Ohmann – Applications Engineer
Wyatt Meek – Software Sales/VISTA
Meeting Agenda
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VI Engineering Overview
LabVIEW and other programming languages
Engineering Process/Quality Standards
Example Applications
Discussion of Cummins Raptor application
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Functional tests
Environmental stress screening
Random vibrational testing
Monitoring of temperature, voltage, power
VI Engineering - Delivering Proven Solutions for 12 Years
• Industry Focus
• Automotive, Life Sciences, Heavy Equipment, Aerospace
• Office Locations
• Detroit, Minneapolis, Indianapolis, SoCal
• Two Core Competencies
• Project Management – System Integration, Hardware Partners
• Software Expertise
• Three Business Units
• Turn-Key Test Systems
• Engineering Information Management
• VISTA – Software Development Consulting/Tools
BUSINESS BACKGROUND
Test System - Customers
Interactive Engineers Desktop
• DIAdem is a data management,
visualization, analysis and
reporting tool
• Made for engineering data no
column and row constraints
• Robust analysis tools are
included and custom toolboxes
can be developed
• Works on a variety of data file
types
• Tight integration with LabVIEW to
allow easy communication to your
instrumentation
DIAdem – Enterprise Service
• Multiple active processing jobs
from each lab
• Test Execution and Post Test
Analysis are geographically
dispersed
• Algorithms need to be managed
centrally
• Regulated environment – FDA,
FMVSS
Cummins, Inc.
• DIAdem Standard for Corporate Analysis
Tools
• DIAdem Based Custom Toolbox
• Leverages Best Practices
• 90% Productivity Gain Through Automation
• VI Engineering Supports as Librarian
• Corporate Taxonomy
– Universal Naming Conventions
– Standard Engineering Units
– Standard File Types
DIAdem Toolbox GUI
Test and Measurement Software Languages
27.50%
LabVIEW
Visual Basic
17.25%
9.75%
C++
0.75%
Measurement Studio
HP VEE/Agilent VEE
4.75%
LW/CVI
4.50%
C
4.25%
Softwire
0.75%
5.50%
None
0%
5%
10%
15%
20%
25%
30%
Software Experience
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Using LabVIEW since 1992
95% of all developers are Certified LabVIEW Developers or Architects
Developed highest level LabVIEW course – Advanced Application Dev
Developed 1st quality standard – VISTA Tools
– Requirements Management
– Define and modify requirements; notify users
– Traceability Matrix
– Configuration Management
– Manage development, verification and release of software
– Reuse Strategy
– Style Guides
– Reuse libraries available to all groups
– GOOP Software Architecture
Quality Assurance
Quality is a dynamic process that is
cultivated through a project life-cycle.
Quality Assurance
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Requirements
Design
Development
Validation
Verification
Quality Assurance
Requirements
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System Constraints
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System voltage measurement accuracy must be +/- 1 mV.
Non-Functional Requirements
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System must provide easy access to all the system
components for maintenance.
Functional Requirements
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The oven must be able to cycle and control temperature
anywhere between 32 degC and 70 degC.
Quality Assurance
Design
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Traceability
Review
Impact Analysis
Quality Assurance
Development
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Defined Process
Prototyping
Review
Partial Integration
Independent Code Reviews
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Checklist
Report
Unit Test
Quality Assurance
Validation
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Traceability
System Constraints
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Check List
Non-Functional Requirements
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Evaluation Criteria
Functional Requirements
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Discrete Testing
Quality Assurance
Verification
Documenting the use of our process
Simplified Waterfall Model for Software Design
requirements
research/
specification
definition
design
coding
testing
ship/
maintain
All Too Often…
LabVIEW makes it very easy to quickly put something together
requirements
research/
specification
definition
design
coding
Developers do not follow a process
testing
ship/
maintain
Case Study
Source: CMU/SEI-94-TR-013
Case Study
Source: CMU/SEI-94-TR-013
VIE Applications
• Component Test Systems
• Visions Systems
• Consumer Products Functional Tests
• Research and Development Systems
• Monitoring Systems
Component Test Experience
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Oxygen Sensor
Fuel Systems
Wiper Blades
Bearings
Light Bulbs Chrysler Body
Hardware
– Door Locks, Windows, Doors,
Decklids
• Electric Motors
• Sun Roofs
• Capacitors & Batteries
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Alternators & Batteries
Brake Pads
Seat tester
Throttle body
Axles & Axle bearings
Seals
Clutches
Brake Dampers
Seat Heaters
Radios
Component Test Cells
Horicon Division
National Instruments Confidential
Component Test System
• What the component test system does?
– Fatigue or durability testing of components
• What products are having their components
tested?
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Lawn and Garden Tractors
Utility Tractors
Rear and front engine mowers
Gator Vehicles
LabVIEW Test System Objectives
• Develop Two Identical Turn-Key Test Systems created to
conduct Five Major Component Tests
– Cyclic PTO Test
• Responsible for stopping the mower blade once the clutch has been
disengaged.
– Cyclic Pressure Test
• Test the fuel tank for leaking
– Mower Deck Cyclic Loading Test
• Applies two differing loads to mower to engage
and disengage the clutch
– Temperature Control Test
– General Test
• Allow a custom test to be created, with a
sequence of actions and a set of interlocks.
System Components – Software
• FieldPoint Module (Execution engine)
– LabVIEW RT Operating System
– FPT receives operating parameters from host computer
– FPT controls and monitors I/O directly, capable of continuing execution stand
alone
– Executive engine will give display and load data back to host computer
• Desktop (Host) Computer
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Microsoft Office 2000
Contains the user interface
Translates the user information to the FPT module
Data logs information onto network location
New Component Test System - Controls
• Pneumatic Actuator Control (FP-RLY-420)
– Control 6 actuators independent of each other
– Cycle counter capable of 1 million cycles (without multipliers)
• Electric Solenoid Control (FP-DO-400)
– Control 6 electric (12 volt) solenoids independent of each other
– Cycle counter capable of 1 million cycles (without multipliers)
• Pressure Control (FP-SG-140)
• Temperature Control (FP-TC-120)
New Component Test System
• Data Logging
– Cycles: number of cycles so far completed in the currently
running test
– Interlock Status: trigger indicator light turns yellow and displays
the reason for the stop
– Minimum of 3 rotational speeds
– Rotational speed vs time
– Minimum of 6 pressures
– Minimum of 6 temperatures
New Component Test System
• Portability
– The system must be portable so that it could server multiple test
cells
– The system must have a small foot print, not to exceed 6 square
feet
Vision Solutions
• Vision Expertise
• Vision Applications
– Real Time Alloy Sorting
– Laser Measurement System
– Collagen Detection
– Nuclear Fusion
– LCD Vision Inspection
– Defect Detection in Optical Thin Film
– Vision Inspection of LEDS and
Fuses
– Glass Sheet Surface Ripple
– Electronic Control Module Testing
– Laser Scoring Advanced Monitoring
System
– EMC Data Acquisition and Control
BUSINESS BACKGROUND
Engineering Services - Staff
Assembly Verification
Color Identification & Verification
Automated Product Recognition &
Sorting
Particle Inspection
Thermal Imaging
Laser profiling
Robot Guidance
Microscopy
Barcode Reading
Real-Time Alloy Sorting
• Steel Recycling Plant
– Six Year Challenge
– Real-Time Alloy Sorting System
– Challenges
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Belt Speed – 2 meters/sec
Sensing
Accuracy
Decision Making
LCD Vision Inspection
• LCD Vision Inspection SPC System – 6 Sigma Quality
• Manufacturing Line Turnkey system (5 Station Tester)
• RF Test, RF Receive, Vision, Field Strength, Integration
• LCD Displays Multiple Images
– S/W Controlled Solenoids to Push Buttons
– Monitor and Analyze LCD Image
• Yields Monitored in MN in Realtime
• NI IMAQ and VISION
– Inspected characters, numbers, and patterns on LCD panel.
– LCD Screen Displays Images
Vision Inspection of
LEDs and Fuses
• Vision Inspection of LEDs
• Automotive Circuit Board - Dashboard
• Production Test Stand
• NI IMAQ and VISION Performed Color Matching of LEDs
• Vision Inspection of Fuses
• Speedboat Application
• NI IMAQ and VISION Performed Color Matching and OCR
Electronic Control Module Testing
• Universal Test System (UTS)
architecture
• Color pattern matching
EMC Data Acquisition and Control
• Generic Test
System with OCR
Vision
Collagen Detection
• Detect the collagen area and quantify the region, calculate
ratios, etc.
• Calibration routine for dyes
Defect Detection in Optical Thin Film
• Optical components for high
powered lasers i.e., lenses,
mirrors, optical crystals
• Used both power sensors
and analysis of diffraction
patterns
Glass Sheet Surface Ripple
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Pristine glass used for LCD displays
Inspection of glass sheets 1.5 x 2 M
Extremely small defects <10nm
Scanning rates >800mm/s
Excellent long term calibration stability
Systems deployed in four countries
Savings >$1M/Yr solving 15 yr old problem
Patent Pending
Laser Scoring Advanced Monitoring System
• VIE Patent
• High Accuracy
– 10-3 mm measurement resolution
– 10-2 mm scoring tolerance
• Robustness
– Directly measure height and thickness
– Independent of material’s optical
property
– Measure any MRT and hole depth
– No blockage of probe beam by small
hole opening
Vision Experience
• Vision Laboratory with Compact Vision, PCI IMAQ,
Lenses, Lighting, Fixturing
• Experienced with Existing Infrastructure Components
• Vision Experts with Photonics Backgrounds
• Database Integration Experts
Consumer Electronics
• X-Box Controller Test System
• Test time reduced 20 fold
• Compact and rugged chassis
ideal for Far East production
• User interface
– Engineering
– Production
“I am extremely impressed with VIE’s
problem solving abilities, their
understanding of our needs and their
dedication to a quality solution. This has
made them partners I will continue to work
with well into the future. V I Engineering is a
world class system integrator.”
- Jeff Alexander
Lead Hardware Test Engineer
Microsoft Corporation
Consumer Electronics
• Honeywell - Mexico
– LCD Vision Inspection SPC System – 6 Sigma Quality
• Manufacturing Line Turnkey system (5 Station Tester)
• RF Test, RF Receive, Vision, Field Strength, Integration
• LCD Displays Multiple Images
– S/W Controlled Solenoids to Push Buttons
– Monitor and Analyze LCD Image
• Yields Monitored in MN in Realtime
• Vision System
– Inspected characters, numbers, and patterns on LCD panel.
– LCD Screen Displays Images
Nuclear Fusion
• DOE – $1.2 B LLNL National Ignition Facility
– Focus and Target 192 Laser Beams Evenly
– Target – Hydrogen Isotope
– Ignite Nuclear Fusion
Nuclear Fusion
Vision system to align
target with 192 lasers
• 25 micrometer at 7 meters
• 3 Motion Axes
• Specially Designed Target
Pattern
• Low Power Illumination
HVAC Production Testing
• Quality control tests of Compressor and Chiller Products (Air or
refrigerant) for calibration data.
• Replacement of antiquated testing equipment
– Replacement of Scientific Atlanta 2521 for vibration measurements
– Replacement of Bentley Nevada/DVF2 from balancing
• Design and Integrate a state-of-the-art production test system for
detecting and quantifying baseline vibration characteristics
– Improve reliability of test system
– Increase efficiency in diagnosing a solution to a problem
– Develop deeper analysis for product improvements
System Overview
• Number of Test Systems: 8
• Type of Tests:
– Balancing Test/Steady State Vibration Test
– Sound Test
– Hit Test
• Type of Products:
– Direct Drive Compressors
– Gear Drive Compressors
– Chillers
Hydro Forming Monitoring
• Form and Fill pressures are monitored
– Pressure is represented by current
– Live trending
• Fill and Form Pressures of the previous parts represented by Current-1 and
Current-2
– Seamless integration with assembly line PLCs
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Extract Fill Time (Front/Rear) From PLC
Extract Form Time (Front/Rear) From PLC
Extract Cycle Time (Front/Rear) From PLC
Graph Fill Time (Front/Rear)
Graph Form Time (Front/Rear)
Graph Cycle Time (Front/Rear)
OUR CUSTOMERS
What They Say About VIE…
• “VI’s staff is unbelievable. You guys are just great. I mean
you know hardware, software…and you know how to help us
on the floor. Your people are really professionals.” Honeywell
• “Everyone here loves you guys, I’ve been in this business for
a long time and I’ve never seen a group as professional as
you guys…” - Bosch
OUR CUSTOMERS
What They Say About Us…
• Would it be OK if I hugged you?” – Intel
• Ya know…you guys could teach us..” and “You guys
need to slow down, we can’t keep up…”
- Microsoft