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.

Category :
Automotive Industry
Date :
10th Mar, 2021
Link :
Rating :

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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