EOL Services- End-of-line Tester Services

EOL Services- An end-of-line tester is a crucial quality control process in the automotive industry. It involves testing vehicles at the end of the assembly line to ensure that they meet specific quality and safety standards before they are delivered to customers. Using National Instruments (NI)hardware and software solutions for test, measurement, and control systems TMCS offers a range of eol services & solutions that can be used for developing and implementing end-of-line testers for automotive applications. End-of-line Tester (EOL) systems can measure and check the functionality of automotive electronic control units, mechanical parts and related systems. Key factors considered are high test quantity, test completion and low system with upgrade costs. Today it’s important to have a flexible test platform with the growing intricacy of automotive electronics. TMCS has an End of Line Testing platform which is flexible and offers complete consistency. End of line system allows error free, faster, accurate and a thorough testing of any type of UUTs. At TMCS, we are specialized in providing customized and certified EOL testers as per customer’s requirements. These testers can be ruggedized or mobile if needed. TMCS serves the entire transportation portfolio business sector including Automotive OEM, MCV, HCV, off-highway vehicle manufacturers Tier 1, Tier 2, and Special purpose Machine builders. With years of experience in the testing industry, we can say that no two automotive manufacturers are the same, and neither are their EOL requirements. End-of-line tests ensure that every component of the vehicle, from electronics to mechanical systems, is functioning as intended. Automotive manufacturers rely on EOL testers to detect defects and inconsistencies that may have arisen during the manufacturing process, preventing potentially costly technical recalls and reputation damage. With National Instrument hardware, PLC, and other third-party hardware, we leverage comprehensive testing solutions to meet the highest industry standards of safety, performance, and quality. High performance, high-speed data acquisition systems, and modular instrumentation make this EOL more efficient.

Motor Test System:

EOL testers are developed to control and log data of Motor under test. Various tests like Voltage regulation, Temperature rise test, etc. can be carried out automatically. The test data is stored in real-time. Data is then gathered and stored for subsequent analysis. Pass and Fail results will be displayed based on configured data for further analysis.

Alternator Test System:

The major challenge was to develop a solution over the Alternator (End of line) Testing System that shall continuously monitor the temperature rise, during the heat-run test. With identifying and selecting the apt NI resources, we could finish the entire test 12 to 14 minutes earlier, reducing the alternator’s Test Cycle Time by 10+%

ECU Test System:

This tester is designed to evaluate the functionality of a vehicle’s Electronic Control Unit (ECU). The EOL tester conducts tests for communication protocols, sensor inputs, actuator outputs, and overall system integration. These testers have a combination of hardware and software to simulate real-world conditions and various operational scenarios, allowing them to assess the ECU’s responsiveness, accuracy, and overall reliability.

Car Door Handle Tester: The test bench is a specialized setup designed to simulate various actions performed by a user to lock or unlock a car door handle. This system recreates real-world scenarios within a controlled environment, facilitating the evaluation of the door-locking mechanisms’ performance and durability.

Spring Tester: EOL tester is used for calculating compression and tension values for different sized springs. EOL Tester to Test Signalling Group Relays:The sequence of testing the particular UUT (Group) is defined in form of a excel table.

Engineering Support

Panel lay Out, Documentation, Electrical Schematic, Point to point Diagrams, LabVIEW, NI hardware Integration team.

Mid range VFD Panel – CE marked VFD panel with MCCB, Control relays, Panel Cooling fans, Input output terminals for supply.

DAQ Control Panel – DAQ panel provides sequential operation based on input from sensors placed in process. Reduced noise interference due to professionally designed layout.

Power Panel – Panel is provided with incoming protection by MCCB. Panel cooling FAN.

HMI Panel – HMI provided operation as well as display of process parameters.

Network Panel – Set of panels controlling a process including enclosure for Power components, Multiple controllers and Indicators.

PC Panel – Compact design provides interference free operation of the process. The height and layout of the panel is designed considering the ease of operation for the operator.

Advantages

Benefits of EOL

Comprehensive testing capabilities- Functional, Electrical, Communication, and many more
Reconfigurable, scalable design
User-friendly interfaces
Traceability (Multichannel, multidevice)
Customizable reporting formats (Graphs, tables, Integration with customer’s databases)
Remote Monitoring and support (as an additional feature)

Case Studies

Explore our case studies to see how our End-of-line testers have helped automotive manufacturers achieve higher quality standards, reduce defects, and increase overall production efficiency.

Hydraulic Steering test System:

For conducting steering tests, it’s essential to define the specific requirements and performance criteria for the steering system in accordance with relevant industry standards and regulations.
Additionally, safety considerations should be incorporated into the test setup to protect operators and prevent any potential damage to the vehicle or testing equipment.

Torque Measurement:

Measure the steering wheel torque required to turn the wheels at different operating conditions, such as stationary, low-speed, and high-speed turns. This parameter helps assess the smoothness and ease of steering.

Steering Wheel Position:

Monitor the steering wheel position to ensure it aligns correctly with the wheels during straight-line driving and turns.

Steering Angle Measurement:

Measure the actual steering angle of the wheels concerning the commanded steering angle. This parameter ensures accurate wheel positioning and alignment.

Steering Wheel Returnability:

Assess the steering wheel’s ability to return to the center position after completing a turn.

Steering Noise and Vibration:

Monitor and analyze steering noise and vibrations to identify any abnormal or excessive feedback that could affect driving comfort.

Steering System Integrity:

Verify the integrity of communication interfaces, such as CAN or LIN, between the steering system components and the vehicle’s network.

Functional Tests:

Perform various functional tests to ensure the steering system operates as expected, including left and right turns, U-turns, and parking maneuvers.

Load Tests:

Apply different loads on the steering system to evaluate its performance under varying conditions.

Temperature Tests:

Assess the steering system’s behavior at different operating temperatures to ensure it remains reliable in extreme weather conditions.

Safety Tests:

Verify that safety mechanisms, such as electronic stability control (ESC), are functioning correctly during steering maneuvers.

Using National Instruments’ wide range of hardware, such as data acquisition (DAQ) devices, signal conditioning modules and communication interfaces, we acquire and process the necessary data for these tests.
The LabVIEW software platform is used to develop custom test sequences, perform data analysis, and generate comprehensive test reports.

Advanced Solutions for Every Industry

Automotive

TMCS Caters to the automotive industry requirements with various tests like Hardware in Loop (HIL) Performance, EOL, Production and Embedded software tests, and Data Logging systems. Vehicle testing and validation….Read More

Aerospace Defense

With customizable off the shelf platforms and systems TMCS serves Aero defense sector with verification and validation systems , Modular Automated Test Equipment for R&D as well as production .Electromechanical set ups, control systems… Read More

Engineering Service Provider

Engineering service providers rely on test systems to deliver comprehensive testing and validation to their clients TMCS helps these companies for test fixture design, control panel engineering ,data acquisition and monitoring… Read More

Power Electronics

Using hardware platforms such as NI PXI, Compact DAQ we perform testing and validation for Motor drive , inverter etc., Design and Simulation, Power Quality Analysis and pc based data acquisition This includes measuring parameters such as voltage…. Read More

EV

With EV revolution around the globe, TMCS serves the industry with environmental chambers, thermal management systems, Hardware in Loop simulation, Motor controllers, efficiency, monitoring, current, voltage, and power…. Read More

Looking for Help With EOL Testing?

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