Production Engine Control Module (ECM) End of Line Tester
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