Custom Test Solutions

Elizabeth Zybczynski – Engineering Mgr MN Office Dave Ohmann – Applications Engineer Wyatt Meek – Software Sales/VISTA

Meeting Agenda

• VI Engineering Overview • LabVIEW and other programming languages • Engineering Process/Quality Standards • Example Applications • Discussion of Cummins Raptor application – Functional tests – Environmental stress screening – Random vibrational testing – Monitoring of temperature, voltage, power

VI Engineering - Delivering Proven Solutions for 12 Years • Industry Focus • Automotive, Life Sciences, Heavy Equipment, Aerospace • Office Locations • Detroit, Minneapolis, Indianapolis, SoCal • • Two Core Competencies • Project Management – System Integration, Hardware Partners • Software Expertise Three Business Units • Turn-Key Test Systems • Engineering Information Management • VISTA – Software Development Consulting/Tools

BUSINESS BACKGROUND Test System - Customers

Interactive Engineers Desktop

• DIAdem is a data management, visualization, analysis and reporting tool • Made for engineering data no column and row constraints • Robust analysis tools are included and custom toolboxes can be developed • Works on a variety of data file types • Tight integration with LabVIEW to allow easy communication to your instrumentation

DIAdem – Enterprise Service

• Multiple active processing jobs from each lab • Test Execution and Post Test Analysis are geographically dispersed • Algorithms need to be managed centrally • Regulated environment – FDA, FMVSS

Cummins, Inc.

• DIAdem Standard for Corporate Analysis Tools • DIAdem Based Custom Toolbox • Leverages Best Practices • 90% Productivity Gain Through Automation • VI Engineering Supports as Librarian • Corporate Taxonomy – Universal Naming Conventions – Standard Engineering Units – Standard File Types

DIAdem Toolbox GUI

Test and Measurement Software Languages

LabVIEW Visual Basic C++ Measurement Studio HP VEE/Agilent VEE LW/CVI C Softwire None 0.75% 4.75% 4.50% 4.25% 9.75% 0% 0.75% 5% 5.50% 10% 15% 17.25% 20% 25% 27.50% 30%

Software Experience

• Using LabVIEW since 1992 • 95% of all developers are Certified LabVIEW Developers or Architects • Developed highest level LabVIEW course – Advanced Application Dev • Developed 1 st quality standard – VISTA Tools – Requirements Management – Define and modify requirements; notify users – Traceability Matrix – Configuration Management – Manage development, verification and release of software – Reuse Strategy – Style Guides – Reuse libraries available to all groups – GOOP Software Architecture

Quality Assurance

Quality is a dynamic process that is cultivated through a project life-cycle.

Quality Assurance

• • • • • Requirements Design Development Validation Verification

Quality Assurance Requirements

– – – • System Constraints System voltage measurement accuracy must be +/- 1 mV.

• Non-Functional Requirements

System must provide easy access to all the system components for maintenance.

• Functional Requirements

The oven must be able to cycle and control temperature anywhere between 32 degC and 70 degC.

Quality Assurance Design

• • • Traceability Review Impact Analysis

Quality Assurance Development

• • • • • • Defined Process Prototyping Review Partial Integration – Independent Code Reviews Checklist – Report Unit Test

Quality Assurance Validation

• • • • Traceability – System Constraints Check List – Non-Functional Requirements Evaluation Criteria – Functional Requirements Discrete Testing

Quality Assurance Verification

Documenting the use of our process

Simplified Waterfall Model for Software Design

research/ definition design coding testing ship/ maintain

All Too Often…

LabVIEW makes it very easy to quickly put something together

research/ definition design coding testing ship/ maintain

Developers do not follow a process

Case Study

Source: CMU/SEI-94-TR-013

Case Study

Source: CMU/SEI-94-TR-013

VIE Applications

• Component Test Systems • Visions Systems • Consumer Products Functional Tests • Research and Development Systems • Monitoring Systems

Component Test Experience

• Oxygen Sensor • Fuel Systems • Wiper Blades • Bearings • Light Bulbs Chrysler Body Hardware – Door Locks, Windows, Doors, Decklids • Electric Motors • Sun Roofs • Capacitors & Batteries • Alternators & Batteries • Brake Pads • Seat tester • Throttle body • Axles & Axle bearings • Seals • Clutches • Brake Dampers • Seat Heaters • Radios

Component Test Cells

Horicon Division

National Instruments Confidential

Component Test System

• What the component test system does?

– Fatigue or durability testing of components • What products are having their components tested? – Lawn and Garden Tractors – Utility Tractors – Rear and front engine mowers – Gator Vehicles

LabVIEW Test System Objectives

• Develop Two Identical Turn-Key Test Systems created to conduct Five Major Component Tests – Cyclic PTO Test • Responsible for stopping the mower blade once the clutch has been disengaged.

– Cyclic Pressure Test • Test the fuel tank for leaking – Mower Deck Cyclic Loading Test • Applies two differing loads to mower to engage and disengage the clutch – Temperature Control Test – General Test • Allow a custom test to be created, with a sequence of actions and a set of interlocks.

System Components – Software

• FieldPoint Module (Execution engine) – LabVIEW RT Operating System – FPT receives operating parameters from host computer – FPT controls and monitors I/O directly, capable of continuing execution stand alone – Executive engine will give display and load data back to host computer • Desktop (Host) Computer – Microsoft Office 2000 – Contains the user interface – Translates the user information to the FPT module – Data logs information onto network location

New Component Test System - Controls

• Pneumatic Actuator Control (FP-RLY-420) – Control 6 actuators independent of each other – Cycle counter capable of 1 million cycles (without multipliers) • Electric Solenoid Control (FP-DO-400) – Control 6 electric (12 volt) solenoids independent of each other – Cycle counter capable of 1 million cycles (without multipliers) • Pressure Control (FP-SG-140) • Temperature Control (FP-TC-120)

New Component Test System

• Data Logging – Cycles: number of cycles so far completed in the currently running test – Interlock Status: trigger indicator light turns yellow and displays the reason for the stop – Minimum of 3 rotational speeds – Rotational speed vs time – Minimum of 6 pressures – Minimum of 6 temperatures

New Component Test System

• Portability – The system must be portable so that it could server multiple test cells – The system must have a small foot print, not to exceed 6 square feet

Vision Solutions

• Vision Expertise • Vision Applications – Real Time Alloy Sorting – Laser Measurement System – LCD Vision Inspection – Vision Inspection of LEDS and Fuses – Electronic Control Module Testing – EMC Data Acquisition and Control – Collagen Detection – Nuclear Fusion – Defect Detection in Optical Thin Film – Glass Sheet Surface Ripple – Laser Scoring Advanced Monitoring System

BUSINESS BACKGROUND

Engineering Services - Staff

Assembly Verification Color Identification & Verification Automated Product Recognition & Sorting Particle Inspection Thermal Imaging Laser profiling Robot Guidance Microscopy Barcode Reading

Real-Time Alloy Sorting

• Steel Recycling Plant – Six Year Challenge – Real-Time Alloy Sorting System – Challenges • Belt Speed – 2 meters/sec • Sensing • Accuracy • Decision Making

LCD Vision Inspection

• LCD Vision Inspection SPC System – 6 Sigma Quality • Manufacturing Line Turnkey system (5 Station Tester) • RF Test, RF Receive, Vision, Field Strength, Integration • LCD Displays Multiple Images – S/W Controlled Solenoids to Push Buttons – Monitor and Analyze LCD Image • Yields Monitored in MN in Realtime • NI IMAQ and VISION – Inspected characters, numbers, and patterns on LCD panel.

– LCD Screen Displays Images

Vision Inspection of LEDs and Fuses

• Vision Inspection of LEDs • Automotive Circuit Board - Dashboard • Production Test Stand • NI IMAQ and VISION Performed Color Matching of LEDs • Vision Inspection of Fuses • Speedboat Application • NI IMAQ and VISION Performed Color Matching and OCR

Electronic Control Module Testing

• Universal Test System (UTS) architecture • Color pattern matching

EMC Data Acquisition and Control

• Generic Test System with OCR Vision

Collagen Detection

• Detect the collagen area and quantify the region, calculate ratios, etc.

• Calibration routine for dyes

Defect Detection in Optical Thin Film

• Optical components for high powered lasers i.e., lenses, mirrors, optical crystals • Used both power sensors and analysis of diffraction patterns

Glass Sheet Surface Ripple

• Pristine glass used for LCD displays • Inspection of glass sheets 1.5 x 2 M • Extremely small defects <10nm • Scanning rates >800mm/s • Excellent long term calibration stability • Systems deployed in four countries • Savings >$1M/Yr solving 15 yr old problem • Patent Pending

Laser Scoring Advanced Monitoring System

• VIE Patent • High Accuracy – 10-3 mm measurement resolution – 10-2 mm scoring tolerance • Robustness – Directly measure height and thickness – Independent of material’s optical property – Measure any MRT and hole depth – No blockage of probe beam by small hole opening

Vision Experience

• Vision Laboratory with Compact Vision, PCI IMAQ, Lenses, Lighting, Fixturing • Experienced with Existing Infrastructure Components • Vision Experts with Photonics Backgrounds • Database Integration Experts

Consumer Electronics

• X-Box Controller Test System • Test time reduced 20 fold • Compact and rugged chassis ideal for Far East production • User interface – Engineering – Production

“I am extremely impressed with VIE’s problem solving abilities, their understanding of our needs and their dedication to a quality solution. This has made them partners I will continue to work with well into the future. V I Engineering is a world class system integrator.”

- Jeff Alexander

Lead Hardware Test Engineer Microsoft Corporation

Consumer Electronics

• Honeywell - Mexico – LCD Vision Inspection SPC System – 6 Sigma Quality • Manufacturing Line Turnkey system (5 Station Tester) • RF Test, RF Receive, Vision, Field Strength, Integration • LCD Displays Multiple Images – S/W Controlled Solenoids to Push Buttons – Monitor and Analyze LCD Image • Yields Monitored in MN in Realtime • Vision System – Inspected characters, numbers, and patterns on LCD panel.

– LCD Screen Displays Images

Nuclear Fusion

• DOE – $1.2 B LLNL National Ignition Facility – Focus and Target 192 Laser Beams Evenly – Target – Hydrogen Isotope – Ignite Nuclear Fusion

Nuclear Fusion

Vision system to align target with 192 lasers • 25 micrometer at 7 meters • 3 Motion Axes • Specially Designed Target Pattern • Low Power Illumination

HVAC Production Testing

• Quality control tests of Compressor and Chiller Products (Air or refrigerant) for calibration data. • Replacement of antiquated testing equipment – Replacement of Scientific Atlanta 2521 for vibration measurements – Replacement of Bentley Nevada/DVF2 from balancing • Design and Integrate a state-of-the-art production test system for detecting and quantifying baseline vibration characteristics – Improve reliability of test system – Increase efficiency in diagnosing a solution to a problem – Develop deeper analysis for product improvements

System Overview

• Number of Test Systems: 8 • Type of Tests: – Balancing Test/Steady State Vibration Test – Sound Test – Hit Test • Type of Products: – Direct Drive Compressors – Gear Drive Compressors – Chillers

Hydro Forming Monitoring

• Form and Fill pressures are monitored – Pressure is represented by current – Live trending • Fill and Form Pressures of the previous parts represented by Current-1 and Current-2 – Seamless integration with assembly line PLCs • Extract Fill Time (Front/Rear) From PLC • Extract Form Time (Front/Rear) From PLC • Extract Cycle Time (Front/Rear) From PLC • Graph Fill Time (Front/Rear) • Graph Form Time (Front/Rear) • Graph Cycle Time (Front/Rear)

OUR CUSTOMERS What They Say About VIE…

• “VI’s staff is unbelievable. You guys are just great. I mean you know hardware, software…and you know how to help us on the floor. Your people are really professionals.” -

Honeywell

• “Everyone here loves you guys, I’ve been in this business for a long time and I’ve never seen a group as professional as you guys…” -

Bosch

OUR CUSTOMERS What They Say About Us…

• Would it be OK if I hugged you?” –

Intel

• Ya know…you guys could teach us..” and “You guys need to slow down, we can’t keep up…” -

Microsoft