EOL Services- End-of-line Tester 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.

Motor Test System

The control panels have the following functions:

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. Pass and Fail result will be displayed based on configured data.

Alternator Test System
With identifying and selecting the apt NI resources, we were able to finish the entire test 12 to 14 minutes earlier, reducing alternator’s Test Cycle Time by 10+%” The Challenge: Customer wanted us to develop a solution over the Alternator (End of line) Testing System that shall CONTINUOUSLY MONITOR the temperature rise, during the heat-run test.

ECU Test Bench

EOL tester are usually used to test vehicle ECU. Operator needs to manually connect all electrical cables, select model and start testing. Test sequence of different models of ECU can be set by manager. Outer Door Handle EOL

Outer Door Handle EOL

Testing
Test bench is used to simulated different door handle actions done by a driver to lock or unlock the car.

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

Case Studies

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 Angle Measurement:

Evaluate the response time and accuracy of the steering system when applying force to the steering wheel. This test helps assess the steering system’s responsiveness.

Steering Angle Measurement:

Test the power assist system (if applicable) to ensure it provides the correct level of assistance based on vehicle speed and steering wheel input.

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.