EOL Tester

The developed test system is used to test automotive Vehicle clusters.

Problem Statement

Automate Vehicle Cluster test system to reduce EOL testing cycle time.

Challenge

  • Automating the Vehicle Cluster test system.
  • Automated calibration of dials using vision system.
  • Enhanced fixture changeover with jig detection.
  • Easiness of accessing the cluster terminals.
  • Analysing Speed, Fuel level, RPM gauges with vision system.
  • CAN based communication with cluster system.

Solution

  • Developed electro pneumatic PLC based standalone test fixture system.
  • Integrating high resolution camera with NI Image analysis.
  • Easy change over fixture with Harting connectors for electrical and pneumatic connections.
  • Pogo pin interconnection with cluster and test system.
  • NI PXI based system with relay, resistance and DIO cards.
  • NI PXI CAN modules for CAN communication with cluster.
  • Automated shutter control to reduce ambient light interference.

Hardware Used

  • NI PXI Realtime Embedded Controller.
  • PLC for standalone pneumatic operation and safety interlocks.
  • CAN Module for CAN communication with the Unit.
  • Relay Module for triggering output to automated test specification.

Impact to Customer

  • Reduced cycle time by 65 %.
  • Automated cluster movement & clamping with sensor-based interlocks and safety measures.
  • Changeover features allows reuse of existing fixture and setup for new upcoming cluster variants.
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