High voltage coolant heater inspection
Problem
An automotive manufacturer required a quality inspection end-of-line tester for their high-voltage coolant heater production assembly line. Inspection protocol required over 50 industrial-grade tests to be performed in a matter of minutes to meet throughput demands.
Solution
Within a 4 month timeline and an ever-changing scope of work, Novum designed, developed, installed, and commissioned a fully functioning end-of-line quality inspection tester capable of performing 50 tests in 4.5 minutes, offering an 80% improvement from the previous 25 minute cycle time.
Utilized Delacor Queued Message Handler (DQMH) framework to efficiently develop and test software modules for controlling and acquiring data from multiple rack-mounted units
Built custom t-slot aluminum extrusion safety enclosure for performing high-voltage testing
Integrated newly released Banner Engineering multi-color LED work light for providing visual feedback of test status and part status (e.g. red light = failed part)
Built electrical panel with Phoenix Contact terminal blocks for safe & secure wiring connections that are vibration-proof and finger-safe
Quality inspection system was developed using multiple industrial-grade rack-mounted units for optimal performance:
Keithly DMM6500 digital multi-meters for capture of PWM curves at 300,000 Hz and feeding data into LabVIEW for analysis
Bender resistance monitoring for insuring safe operation throughout testing duration at high-voltage
National Instruments CompactDAQ hardware platform for providing basis of digital I/O control and analog feedback
Rohde & Schwarz low voltage DC programmable power supply
Elektro-Automatik High-Voltage (500 VDC) DC programmable power supply
On-Logic industrial pc for operating LabVIEW based custom software
Associated Research Hi-Pot & Isolation Resistance tester for testing up to 2,000 VDC
Associated Research Ground Bond tester
