Production Engine Control Module (ECM) End of Line Tester

Automated Test System
Written By Reese Gallagher

Problem

A Tier 1 Heavy-Machinery Supplier required a comprehensive end-of-line tester for their Engine Control Module (ECM) production line to test Board & Assembly level products. Over 1,000 custom tests needed to be developed with each step requiring unique ECM control & waveform analysis. Majority of tests involved utilizing programmable power supplies, custom loads (resistors/inductors), oscilloscopes, frequency generators, CAN communication, and high-channel-count multiplexers to switch connected hardware components for each test.

Solution

Novum designed, developed, built, and tested a turn-key End of Line tester solution for the end customer utilizing National Instruments’ LabVIEW & TestStand software solutions.

  • Programmed LabVIEW Solution utilizing Delacor Queued Message Handler (DQMH) Architecture to allow for rapid development and testing of individual hardware component controls/communications

  • Utilized NI TestStand for Test Sequencer solution due to Customer’s knowledge and background

  • Created Custom Load Boxes (Resistors and inductors) to simulate Engine in order to perform comprehensive tests on ECM

  • Scoped and procured all hardware components such as Oscilloscope, Frequency Generator, High-Current DC Programmable Power Supply, Digital Multimeter, NI PXI Chassis & CAN Communication, and Keysight Multiplexer

  • Programmed custom waveform analysis for all unique driver circuits and provided extensive troubleshooting of customers’ product due to limited accurate documentation

  • Utilized several hundred Control Relays and Multiplexers to programmatically switch physical test circuits for each unique test

Reese Gallagher
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