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Meeting Agenda

Custom Test Solutions Elizabeth Zybczynski – Engineering Mgr MN Office Dave Ohmann – Applications Engineer Wyatt Meek – Software Sales/VISTA. Meeting Agenda. VI Engineering Overview LabVIEW and other programming languages Engineering Process/Quality Standards Example Applications

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Meeting Agenda

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  1. Custom Test SolutionsElizabeth Zybczynski – Engineering Mgr MN OfficeDave Ohmann – Applications EngineerWyatt Meek – Software Sales/VISTA

  2. Meeting Agenda • VI Engineering Overview • LabVIEW and other programming languages • Engineering Process/Quality Standards • Example Applications • Discussion of Cummins Raptor application • Functional tests • Environmental stress screening • Random vibrational testing • Monitoring of temperature, voltage, power

  3. 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

  4. BUSINESS BACKGROUNDTest System - Customers

  5. 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

  6. 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

  7. 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

  8. DIAdem Toolbox GUI

  9. Test and Measurement Software Languages

  10. Software Experience • Using LabVIEW since 1992 • 95% of all developers are Certified LabVIEW Developers or Architects • Developed highest level LabVIEW course – Advanced Application Dev • Developed 1stquality 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

  11. Quality Assurance Quality is a dynamic process that is cultivated through a project life-cycle.

  12. Quality Assurance • Requirements • Design • Development • Validation • Verification

  13. Quality AssuranceRequirements • System Constraints • System voltage measurement accuracy must be +/- 1 mV. • Non-Functional Requirements • System must provide easy access to all the system components for maintenance. • Functional Requirements • The oven must be able to cycle and control temperature anywhere between 32 degC and 70 degC.

  14. Quality AssuranceDesign • Traceability • Review • Impact Analysis

  15. Quality Assurance Development • Defined Process • Prototyping • Review • Partial Integration • Independent Code Reviews • Checklist • Report • Unit Test

  16. Quality Assurance Validation • Traceability • System Constraints • Check List • Non-Functional Requirements • Evaluation Criteria • Functional Requirements • Discrete Testing

  17. Quality Assurance Verification Documenting the use of our process

  18. research/definition Simplified Waterfall Model for Software Design requirements specification ship/maintain design coding testing

  19. All Too Often… LabVIEW makes it very easy to quickly put something together research/definition requirements specification ship/maintain design coding testing Developers do not follow a process

  20. Case Study Source: CMU/SEI-94-TR-013

  21. Case Study Source: CMU/SEI-94-TR-013

  22. VIE Applications • Component Test Systems • Visions Systems • Consumer Products Functional Tests • Research and Development Systems • Monitoring Systems

  23. Oxygen Sensor Fuel Systems Wiper Blades Bearings Light Bulbs Chrysler Body Hardware Door Locks, Windows, Doors, Decklids Electric Motors Sun Roofs Capacitors & Batteries Alternators & Batteries Brake Pads Seat tester Throttle body Axles & Axle bearings Seals Clutches Brake Dampers Seat Heaters Radios Component Test Experience

  24. Component Test CellsHoricon Division National Instruments Confidential

  25. Component Test System • What the component test system does? • Fatigue or durability testing of components • What products are having their components tested? • Lawn and Garden Tractors • Utility Tractors • Rear and front engine mowers • Gator Vehicles

  26. 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.

  27. 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 • Microsoft Office 2000 • Contains the user interface • Translates the user information to the FPT module • Data logs information onto network location

  28. 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)

  29. 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

  30. 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

  31. Vision Expertise Vision Applications Real Time Alloy Sorting Laser Measurement System LCD Vision Inspection Vision Inspection of LEDS and Fuses Electronic Control Module Testing EMC Data Acquisition and Control Collagen Detection Nuclear Fusion Defect Detection in Optical Thin Film Glass Sheet Surface Ripple Laser Scoring Advanced Monitoring System Vision Solutions

  32. BUSINESS BACKGROUNDEngineering Services - Staff • Assembly Verification • Color Identification & Verification • Automated Product Recognition & Sorting • Particle Inspection • Thermal Imaging • Laser profiling • Robot Guidance • Microscopy • Barcode Reading

  33. Real-Time Alloy Sorting • Steel Recycling Plant • Six Year Challenge • Real-Time Alloy Sorting System • Challenges • Belt Speed – 2 meters/sec • Sensing • Accuracy • Decision Making

  34. 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

  35. 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

  36. Electronic Control Module Testing • Universal Test System (UTS) architecture • Color pattern matching

  37. EMC Data Acquisition and Control • Generic Test System with OCR Vision

  38. Collagen Detection • Detect the collagen area and quantify the region, calculate ratios, etc. • Calibration routine for dyes

  39. 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

  40. Glass Sheet Surface Ripple • 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

  41. 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

  42. 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

  43. 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

  44. 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

  45. Nuclear Fusion • DOE – $1.2 B LLNL National Ignition Facility • Focus and Target 192 Laser Beams Evenly • Target – Hydrogen Isotope • Ignite Nuclear Fusion

  46. 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

  47. 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

  48. 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

  49. 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 • 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)

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