Testing systems for development, laboratories and production
SYSTEC offers a broad range of testing system solutions for development, laboratories and above all for production. In addition to standalone test stands, rotary transfer units and systems based on workpiece carriers are available.
Universal testing station
The corporate specification sheets of the major automobile manufacturers for 1st-tier suppliers of in-car user interface systems (including specification sheets for haptics, lighting and acoustics) have been made much tougher in recent years. The immediate consequence is that these requirements are passed on to the producers of laboratory and end-of-line testing systems. SYSTEC has responded accordingly and has developed new solutions that are already used worldwide.
ProFLEX is a product-flexible testing system that is ideally suited for testing operating and display equipment in laboratories or at the end-of-line. In addition to electrical tests, it is also possible to conducts tests in the fields of haptics, image processing, light technology, acoustics, force feedback/sense, vibration (3D), multitouch, CAN, LIN, automotive Ethernet, MOST and FlexRAY. The systems consist of a stable steel frame with an integrated 6-kg, 4-axis SCARA robot, which in combination with an integrated rotary/swivel unit allows a virtual 6-axis robot system with high stiffness and a small footprint. This means that all the relevant light technology and haptic tests can be carried out in an angle-dependent manner. The systems are self-calibrating, self-aligning and “compatible” with Industry 4.0.
Robot-based test stand with rotary/swivel unit
The system consists of a stable steel frame with an integrated 4-axis Scara robot and a test specimen receiver featuring a rotary/swivel unit that simulates a virtual 6-axis robot with extreme stiffness and maximum flexibility. Dynamically exchangeable robot heads allow scalable functionality and a variety of options in respect of handling, sensors and actuators.
The main computer and measuring technology components are a 19” PC with a server mainboard and the latest XEON architecture, a PXI chassis with various plug-in cards (CAN, DMM, etc.) and a SYSTEC measuring rack based on innovative National Instruments sbRIO architecture. The software platform is based on NI LabVIEW (Windows/realtime/FPGA).
The following pictures provide an overall view of the system and two detailed views:
measurement uncertainty, high stiffness and, due to their design and the bearing-less torque sensor, outstanding misalignment compensation. Many three-and four-jaw grippers are available for optimally gripping rotary actuators and knobs.
Thanks to the hardware and software architecture striven for, ProFLEX is a platform that provides a guaranteed basis for cost-efficient, product-flexible production with a high level of process reliability. Key areas of focus in this regard include the adaptive and self-learning optimization of workflows, self-calibration and self-alignment, intelligent handling and semi-automatic elimination of problems, as well as conservation of resources by means of optimized sequencing and cutting-edge semiconductor and drive technologies. The systems exceed all the requirements of the current Machinery Directive, international legislation, standards and regulations.
Multilingualism and automatic adaptation to different power supply networks, and to ambient conditions (temperature and humidity) are obligatory. Uninterruptible power supplies and remote maintenance options are standard.
Sensor-adaptive robot movements allow quality checking to be carried out in a flexible manner. The robot can adapt flexibly to the test process for the respective workpiece and take the strain off the adaptive probe, as well as allowing greater flexibility in the use of each probe. However, simple reconfigurability of these robot assignments is also important for acceptance among operators, for fast retooling, and for straightforward elimination of errors and process deficiencies. It is also possible to gather information about changes in the process or in workpieces, over several cycles, from the execution data of the flexible robot motion. Processing these data in learning components which not only anticipate problems from continuous changes and can warn against future errors (predictive analysis), but which also optimize robot assignments continuously from experience (experiential learning), results in a more robust, self-optimizing system which needs little set-up or tuning.
When using the components and designing the workflows, special value is increasingly attached to the following aspects, with reference to existing low-cost intelligent automation requirements in the Industry 4.0 age:
- optimized CPTS implementation (Cyber Physical Test Systems)
- “Plug and Produce ready” (automatic detection of adapters, test specimens)
- self-calibration, self-alignment, self-learning capability, dynamic adaptation of test process, autorepair systems with dynamic replacement of redundant subsystems), test cycle optimization using advanced boundary scan technologies
- simplified generation of test sequences based on an advanced framework that covers the requirements of development and production
- fulfilment of technical specifications of OEMs (depth of testing, test conclusion, cycle times)
- light technology (light density, dominant wavelength, colour coordinates, flicker)
- image processing (pattern matching, shape matching, symbol position)
- CAN/LIN/gigabit Ethernet/Most/Fexray communication
- force feedback, force sense, acoustics
- gesture recognition
- button haptics, rocker switch haptics, rotary haptics
- 10-gigabit Ethernet switching
- high availability (long-term availability of components)
- short procurement time for components, procurability of most components
- high level of system robustness
- high performance and stiffness of drives
- little tendency to vibrate
- maximum performance and excellent future-proofness due to use of cutting-edge technologies
- Windows 10 64-bit, LabVIEW 2014 64-bit
- CUDA C, C#, .net 5.0
- CUDA accelerator cards
- parallel realtime systems
- field programmable gate arrays
- economic and ecological aspects
- outstanding value for money
- very small footprint
- subsequent costs minimal
- power consumption minimal
- sound pressure very low
- excellent ergonomics
- superb maintainability
- efficient planning and continuous optimization of all processes (parallization of processes with maximum possible freedom to overlap for individual tasks)
- availability of redundancies for almost all resources
- PMFU with standards (excellent cgk values)
- high-end drive technology with advanced encoder technology
- drives can be simulated and are teachable in Mitsubishi robot modeThe following actuator and sensor options are possible in the fully-equipped version:
- voltage supply (different voltage curves possible)
- switch on test specimen (e.g. via CAN bus/FlexRay/LIN/K‐Line/Most)measure current drawn
- provide test connection (e.g. using matrix switches; analysis of CAN messages from test specimen)
detection and analysis of electrical parameters
- haptic tests (rotary, button, rocker switch haptics with synchronized analysis of the CAN communications stream)
- image processing, dependent on angle of view via robot adjustment (shape matching, pattern matching, surface analysis, 3D measurements, homogeneity tests, and much more besides)
- light technology analyses, dependent on angle of view via robot adjustment (shape matching, pattern matching, surface analysis, 3D measurements, and much more besides)
- vibration measurement, dependent on position via robot adjustment (analysis of structure-born noise, analysis of airborne noise, with synchronized analysis of the CAN communications stream
analysis of behaviour under voltage fluctuations (spikes, glitches, curve shape generated using NI FlexRIO components and 4‐quadrant amplifiers)
- communication stress tests and analysis of responses
- logging of all data
- changes in parameters (voltage amplitude, temperature, etc.)
- repetition of measurement (parameterizable)
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