DMC worked with a major automotive OEM that needed to expand testing capacity for their new electric vehicle (EV) production line at their high-volume assembly plant. Their existing end-of-line tester was slow, inflexible, and deeply coupled with the overall line builder’s PLC workflow. Furthermore, the test provider had a proprietary test sequence editor that only they could support. This created a challenging dependency on a singular test provider for new features and updates to their test process. The OEM wanted to remove that dependency by using industry-standard testing tools and software platforms.

To add to the challenge, the OEM’s product development team was constantly revising their test requirements while simultaneously needing to begin building up their production test cells. We see this as a common trend among our customers: a race to get to market first, to capture market share and reduce overall product development costs. As a result, the traditional “waterfall approach” of developing a product and then creating a test solution around that prototype just takes way too long. With an agile/lean new product development approach, they are seeking to parallelize product design and software development with the design, build, and commissioning of the test systems required to validate their “still evolving” products.

DMC and our close partner, NI Emerson, were introduced to the OEM’s Test Engineering Team and recognized the customer’s challenges as an excellent opportunity to showcase DMC’s Battery Production Tester (BPT) framework, which is built on top of NI’s TestStand software platform. DMC had successfully used BPT as the foundation for numerous battery test projects over the past few years, so we knew it would provide the OEM with both the value and flexibility of NI TestStand, along with the simplicity and refined features they enjoyed in their incumbent battery test provider’s solution.

Replacing the incumbent solution turned out to be no small challenge, with many factors, including politics and familiarity with legacy approaches posed real obstacles for adoption of the DMC BPT. Ultimately, though, it was hard to argue with the results. DMC deployed our BPT platform on the first line, integrating seamlessly with the OEM’s existing hardware and controls while delivering faster cycle times, comprehensive test coverage, and complete data traceability.  The BPT platform allowed for rapid test development. Within 1 week of being onsite with the OEM’s new battery pack, the battery cycler, and the other test equipment at the customer site, DMC had a complete test up and running. The OEM told us that it usually took their previous test supplier over a month before the software framework was operational enough to run a full test on their packs, so this was clear value to them: ensuring the project stayed on track and met production timelines. It is also worth mentioning that DMC’s decades of battery test expertise played a critical role in helping the OEM overcome roadblocks with their BMS (battery management system) flashing process, which allowed us to provide the customer not only the tools but the expertise to quickly stand up a battery test line.

The result of our work together was a future-proof, software-centric solution that displaced a decade-long incumbent and positioned the OEM for scalable growth. DMC is now working with this same customer to deploy the BPT solution to over a dozen other EV and Plugin Hybrid EV (PHEV) battery pack production lines. The project has not only strengthened the customer’s battery test capabilities but also resulted in numerous updates, improvements, and hardening of DMC’s BPT platform, which we’re excited to share with other customers looking to optimize their battery test operations.

Figure 1: DMC’s Battery Production Test (BPT) Software. Shown Screen: BPT’s low-code BPT Socket Test Overview Screen

Customer Benefits

• 13% Faster Test Cycle Time – Increased throughput, without adding additional test stations. This optimization occurred over the span of 1 month, compared to the optimizations that the incumbent had been implementing for years.
• Multi-DUT testing – With parallelization capabilities and BPT’s enhanced multi-up configuration UIs, it’s easy to design your test sequence for one DUT but test on multiple sockets for improved utilization of capital-intensive equipment like high-power battery cyclers.
• Seamless Integration – The BPT solution fits into existing production line architectures with minimal hardware changes. The BPT HAL (hardware abstraction layer) allows for supporting different brands and models of PLCs, cyclers, and other devices and instruments required for a test. No new capital expenses are required to swap out the existing test system hardware!
• Centralized Configuration & Deployment – Push software, configuration, parameter, and grading updates across stations and easily reuse test sequences on new battery pack models.
• Expert Support – DMC’s engineers helped resolve BMS flashing issues and debug the customer’s product software to meet their production deadlines
• Comprehensive Test Coverage in a Modular Form Factor – Electrical, BMS, and power capability tests in one station, or split across numerous lines for improved takt time. DMC’s BPT software is modular and supports one “do-it-all” test station or deployment across numerous, tightly scoped test stations to increase throughput. Simply select your station type and BPT manages all the configured devices/instruments and available test files for you!

Figure 2: Station Type configuration file organization

Figure 3: Test Station configuration User Interface

Technologies

Hardware:

• NI cDAQ chassis
• Industrial PC
• NI RMX power supply
• Battery cycler (any brand/model)
• PLC (Rockwell / Siemens)
• Safety interlocks, RFID scanners, thermocouples, etc.

Software:

• DMC Battery Production Test (BPT) platform
• CORTEX framework (DMC’s NI TestStand-based test executive)
• CAN, Modbus, Ethernet/IP, Automotive Ethernet, MES, MQTT, SystemLink integration modules and more!
• Custom, low-code overview screen
• Live waveform visualization and manual mode diagnostics
• DUT Variant Parameterization: Allows reuse of a single test sequence for multiple DUTs with different test limits or other test variations
• Separated engineering IDE and operator UI for distinct workflows

Solution

The Battery Production Tester (BPT) platform is a software package, built with NI LabVIEW and on top of NI TestStand. The software was designed with two primary users in mind:

• Test Operators: People working on the production line who need a simple user experience to understand what is happening on the line and make modifications if needed
• Test Engineers: Experts on battery test who want to design optimized test sequences quickly to test new products or identify potential product defects.

To accomplish this, BPT has a “BPT Application” component that is deployed on each test station, as well as a “BPT Engineering Environment” component that is used by engineers on their development laptops. From this environment, engineers can fully configure a test station remotely, push their changes using industry-standard version control tools, and track changes made to test configurations.

The BPT Application provides rich user interfaces that show live data in summary views and waveform graphs and display parametric test results in a modern UI. Operators have access to a limited subset of functionality, depending on the user role and permissions assigned to them, either locally managed or IT-linked LDAP.

The BPT Engineering Environment provides engineers with all the power and capability that NI TestStand offers, without the complexity of setting up the TestStand infrastructure. BPT has simple configuration dialogs for all the main settings and convenient parameterization that engineers often need to test a battery pack efficiently. These smart features greatly simplify the engineering workflow compared to starting over from scratch each time. Furthermore, DMC exposes a rich and expanding library of common battery test devices and instruments (including CAN, Automotive Ethernet, Power Supplies, DI/DO/AI/DO, Modbus, EthernetIP, etc.). These sequence steps provide high-level, configuration-only building blocks that engineers can drag and drop into their test sequence. Each step can have a unique Testpoint assigned to it, which allows easy traceability into which test steps are failing most often, something your quality team cares deeply about.

Figure 4: BPT Application – Test Sequence Execution View

Figure 5: BPT Engineering Environment (Built into NI TestStand via Extensions)

The BPT platform also supports centralized configuration management, allowing engineers to push updates to multiple test stations simultaneously. By single-sourcing sequences and parameterizing them across different DUTs, the customer dramatically reduced the engineering effort required to maintain and scale their test systems.

For this project, we customized DMC’s BPT to work seamlessly with the OEM’s existing test cell setup — including their chosen battery cycler and assembly line PLCs. Thanks to BPT’s modular plugin system, making those connections was straightforward. The hardware abstraction layer (HAL) also positions the OEM to easily swap out instruments and optimize their hardware expenses in the future – without major rewrites to their test sequences. This flexibility ensures long-term adaptability as the OEM continues to evolve its battery production strategy.

The software ran a full end-of-line test that checked electrical performance, ran BMS diagnostics, and verified hi-power charge and discharge capabilities. All the results were automatically saved and sent to a central database for easy tracking, while preserving local copies of the test results for immediate viewing on the test station if needed. The automated test software ran without any human-in-the-loop, triggered by a line PLC. The BPT UI screens gave the operators a clear understanding of what was happening with the test system and  provided them with the necessary tools to step in and troubleshoot the system when needed. The engineering team could watch the test results stream in live from their SystemLink connection, making access to the test data easier than ever to retrieve and analyze.

BPT Features

Built on the CORTEX framework, DMC’s BPT platform delivers robust and scalable test architecture tailored for battery production environments. It includes many valuable features, including:

• Open, standards-based software architecture: Unlike proprietary test systems that lock users into vendor-specific tools, DMC’s BPT is built on NI TestStand — an industry-standard platform. This gives the OEM complete control over test sequences, enables easy integration with third-party hardware, and ensures long-term flexibility without vendor lock-in.
• Standardized Sequencing – Built on NI TestStand with a custom Sequence Editor and reusable step libraries, enabling engineers to develop and maintain tests efficiently using industry-standard tools.
• Hardware Abstraction Layer (HAL) – Abstracts instruments and devices through plugin classes, supporting DMMs, DAQ, serial and industrial protocols (Modbus, Ethernet/IP, Automotive Ethernet), power supplies, PLCs, and more. This allows the customer to swap out hardware as needed without rewriting test sequences.
• Configuration Over Code – Dynamic workspaces, station configurations, and device-socket mapping enable engineers to configure multi-up stations and test logic without deep programming expertise.
• Production-Grade User Experience – Includes Auto and Manual test modes, device dashboards, live channel viewer, alarms, and role-based user permissions. Operator and engineering interfaces are separated to support distinct workflows.
• Reporting & Traceability – Combines parametric test reports with engineering waveform logs (TDMS), enabling root cause analysis and complete visibility into test execution.
• Ecosystem Integration – Seamlessly connects to PLCs, MES systems, custom databases, and IT infrastructure (e.g., LDAP for user management), ensuring the test system fits into the customer’s broader manufacturing environment.

Figure 6: Live Waveform (Data Server Viewer)

Figure 7: DUT Parameters Editor for configuring variables on specific product models, enabling reuse on a shared test sequence

Figure 8: DMC BPT Results Viewer Tool that combines TestStand Report Results with Continuously Acquired Data

Let’s Start a Conversation

Looking to modernize your EV battery testing process? Have specific concerns for your battery test project? Wondering if BPT can help your team? DMC’s BPT platform delivers speed, flexibility, and deep test coverage, without disrupting your existing production line.

Contact us today to learn how we can help you scale your battery manufacturing with confidence.

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While there are drivers to control each device, most importantly, this application orchestrates smart switching and connection rules. For each API request, the application checks a series of rules to ensure the requested measurement is safe to conduct. Here is a subset of the enforced rules and features: 

• Free matrix y-lines 
• Avoid matrix hot switching 
• Power sourcing instruments are not connected to a DMM in a low impedance mode (current measurement) 
• Automatic y-line and internal switch control, so the client application only has to request the test points to measure rather than specifying every relay in the circuit 

This allows the sequencers to safely perform measurements on any instrument without worrying about additional connection logic. 

Easy Integration

The application is self-describing, so a client application knows what devices are present and lists the available APIs. The application hosts a Swagger page, so it’s easy to test and visualize the available API. 

Highly Tested

We leverage the API interface to write PyTests that test each API. The test scripts are automated, making it easy for our team to test the whole application and produce a test report. Since we test through the API interface, testing is exactly the same as the way client applications will use the application. 

Modern and Version Controlled Deployment

To provide a stable and controlled deployment environment, we build the application into a Docker image and run the image within a container on a Linux industrial PC. The entire build process is managed through a Continuous Integration/Continuous Deployment pipeline for end-to-end traceability. 

Key advantages: 

• No issues with Windows updates
• Traceable – we know exactly what code went into the build 
• Testable – we can run the exact same tests on the source and containerized version of the application 

If you’re interested in highly tested, modular test and measurement systems like this one, contact DMC to discuss your project.

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To address this, DMC engineered a reconfigurable switching architecture using a Pickering switch matrix and a Pickering high-voltage multiplexer. The switch matrix dynamically adapted the test system’s I/O configuration to match the specific PDU variant being tested, while the high-voltage multiplexer provided isolation for hipot testing. This configuration enabled safe, automated switching between low-voltage functional tests and high-voltage insulation tests without manual intervention. 

The test fixture supported up to 20 device-under-test (DUT) pins, 12 of which provide hipot isolation, routed through the high-voltage multiplexer before connecting to the switch matrix. Functional test instruments, including programmable power supplies and DMM channels, were integrated within the matrix, simplifying signal routing and maximizing hardware reuse across different product types. 

On the software side, DMC developed a custom test control application that empowered the client to define and manage their own test specifications and functional sequences. The system also featured MES integration, enabling automatic test selection based on the scanned serial number of each PDU. This ensured that the correct test sequence was executed for every unit and maintained complete production traceability. 

By combining modular hardware design with configurable test software, DMC delivered a flexible, future-proof EOL test solution that simplified production operations and reduced testing complexity across the client’s PDU product family. 

Learn more about DMC’s Test & Measurement expertise and contact us for your next project. 

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Figure 2 DEWETRON TRIONet3

Figure 3 DEWETRON XR Modules

Figure 4 One of the Completed Test Carts with a Blender on Top

DMC is also a long-standing NI partner, and we leveraged our deep LabVIEW programming experience on this project to deliver a high- quality solution.

The cart measures current, voltage, speed, and temperature, and displays them appropriately on the custom user interface. As a sequence is running, the UI shows the progress in addition to the live data. There’s a separate tab for viewing any alarms, such as application errors, e-stops, or out-of-range values, using DMC’s Alarm Handling toolkit.

There’s also a tab for customized settings, where the customer can specify the units, scaling, and type for each physical channel in the system, depending on what unit they’re testing.

Figure 5 A View of the Test Software with Sequence Monitoring, Data Plots, and a Live Data Table View

Conclusion

DMC’s expertise in a variety of hardware and software platforms made us a great fit for this consumer goods test system, and we’re always looking to do more. Our customer was pleased with how easy it was to switch over to the new test carts,and is excited about adding new features and expanding, already given the system’s flexibility for upgrades. Every product is different, and balancing streamlined features and maintainability with customization and expandability is a challenge DMC is always up for.

Learn more about DMC’s Test & Measurement consumer goods test system expertise and contact us for your next project!

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Specification

The vision experts at DMC assisted the client with selecting camera type, resolution, optics, and lighting for that precise application. For this project, client scientists would be constructing new tests and experimenting with a variety of settings on many different material types. They needed a custom piece of software that was as flexible as their test arrangement.

DMC listened to client staff and distilled their use cases and requests into a realistic strategy. We proposed to support any industrial camera that adhered to the GenICam XML standards. This would allow NI Vision to interface with a variety of different camera makes and models. Leveraging the client’s programming skills and LabVIEW’s approachable nature, we were able to design a Processing and Grading VI template. 

This ultra-flexible setup would allow LabVIEW-savvy client staff to create VI IMAQ content inside individual subVIs. These user-created VIs, as long as the terminals remained consistent, could be called and run by the built executable.

Outcome

The final application consisted of two primary parts: the Configuration screen and the Main Test screen. The client would attach a Camera, and LabVIEW would find and list the new device, along with all currently loaded settings. An extensive Attributes list displayed all editable settings exposed to the user. Double-clicking on any Attribute would launch a configuration window, displaying valid settings and a description to help the user properly edit values.

Once settings were established correctly, the client could save the attributes to disk. A camera could easily be reconfigured for a new test by loading a different configuration file from disk. Acquisition settings, such as frame rate and exposure time, could also be configured. SubVIs, created earlier by client staff, containing different image processing algorithms, are listed under a dropdown by name. The user can select a Processing and Grading subVI to run on each image.

Once a camera is configured and set up to acquire, the user switches over to the Main Screen, where they can start the acquisition. Each image produced by the camera is passed through the Processing and Grading subVIs, with live results displayed on the screen for convenient viewing. The program could also be configured to automatically save all or only ‘failed’ images to disk at a given compression ratio.

As always, DMC transferred the entire LabVIEW codebase over to the client staff. The bundle included example Processing and Grading VIs along with other DMC libraries for easy extension and modification.

Learn more about DMC’s LabVIEW programming services and contact us for your next project.

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The result? A tailored, high-performance solution delivered with exceptional speed, minimal disruption, and long-term adaptability. The client was thrilled with the turnaround time, functionality, and overall value.

Learn more about DMC’s LabVIEW programming services and contact us for your next project.

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Specification

DMC engineers provided platform and device options after reviewing the tight timing considerations, IO list, and system needs. We determined that an NI FPGA was the best option after ruling out the response time of leading PLC modules and estimating the number of FPGA cycles and the timing of analog output assert based on card types.

After selecting hardware, DMC also mapped out a full software design for the three separate but interconnected applications. Messaging, data exchange, and network and state diagrams were provided for programs running on the real-time target, FPGA target, and logging HMI PC.

Development & Outcome

After specification, DMC began to develop each software piece. We wrote and tested custom LabVIEW FPGA software responsible for protecting expensive high-voltage equipment before the final assembly of the RF system. Digital inputs were queried at a rate of roughly 300ns, with response times (debounce and trigger assert) hovering around 23us.

This custom FPGA software successfully replaced the client’s old detection circuitry, providing circuit changes with a few code modifications plus compile. We leveraged this flexibility by adding redundant sense lines to the routine throughout the project along with state-based reset masks and varying debounce modes.

Alongside the discrete trigger lines and rapid response, the FPGA supplies analog values to the real-time application. The real-time application, after launching the FPGA portion at boot, collects and scales a wide range of sensor data from the FPGA.

PID control, lower-speed limit alarms, and process logic are all handled by the real-time LabVIEW application. Data is sent from the cRIO chassis by the real-time program to the disk-heavy HMI PC with ample storage. Client engineers can configure slew rates, alarm limits, and power outputs on the HMI application. The HMI LabVIEW software, along with supplying a handy manual mode for local operation, can command warmup and ramp sequences.

Adding to the complexity of this solution, the cRIO program also responds to network commands from a remote line PLC. Although DMC didn’t program the PLC software in this instance, the client appreciated that we leveraged our cross-training when debugging a National Instruments and Allen-Bradley system.

Learn more about DMC’s LabVIEW programming services and contact us for your next project.

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DMC developed a LabVIEW application that allows flexible test sequencing across different test stands. In addition, we integrated generic PC peripherals with the LabVIEW application to ensure that high-level functionality of common interfaces (Ethernet, USB, and Serial) was verified. Pairing precision instruments with everyday IO in a custom test sequence allowed for end-to-end product testing and was made possible by the NI TestStand development platform.

The test system is also fully integrated with a Microsoft SQL server database to ensure compliance with modern production requirements. Database-level traceability, especially in the automotive industry, allows manufacturers to confidently and securely store production data with ease of recall for internal reporting or external audit. SQL offers an extensive toolchain for custom data analysis and process performance analysis to ensure the system continues to run reliably throughout its lifecycle.

PCB function test systems are prevalent in modern production environments. Today, Embedded PCB devices have many sub-systems, so achieving complete test coverage with automated test solutions can be demanding. By utilizing a flexible hardware design, customizable software technologies, and partners with the expertise to integrate the system components, manufacturers can ensure a highly productive and effective path to delivering high-quality products.

Learn more about DMC’s Test and Measurement and Embedded expertise and contact us for your next project.

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Software for battery test execution was programmed in LabVIEW for Real-Time to capitalize on deterministic performance and stand-alone reliability.  A PXI chassis with a Real-Time operating system provides critical control logic and data acquisition.  Each chassis is capable of running 10 asynchronous tests for 1000 hours or more.  The test chassis are on a local network, and store data to a central file server running an MS Windows Server and an SQL Server.  Any test on the system can be configured, controlled, and monitored from any PC on the network.  The custom Test Interface features the ability to define test steps, configure modular hardware, access a Battery Information database, and monitor live test conditions.  Raw data is stored in a TDMS format and is viewable through a custom data viewer and NI DIAdem.

Battery and Fuel Cell test environments can present significant safety concerns.  A lab-wide safety system consists of independent, highly available cRIO devices that monitor lab conditions and are capable of automatically shutting down tests in case of hazardous lab conditions.   This functionality is achieved with LabVIEW for Real-Time and for FPGA.

The system provides a modular, scalable, and fully configurable test platform, allowing the engineers and scientists at Argonne to accommodate and accurately test a wider variety of energy storage devices.  The high level of flexibility delivers precise test results without requiring the use of any one specific battery cycler hardware device.

Learn more about DMC’s Test & Measurement Automation expertise and contact us for your next project.

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• Design and implement a highly configurable data acquisition system that supports a wide range of sensor types, channel counts, and acquisition speeds. 
• Provide an intuitive user interface, allowing for monitoring and configuration of the distributed system from a centralized location, including: 
  • Configuration of channel properties and signal conditioner settings 
  • Automatic channel calibration and scaling routine using voltage insertion
  • Live data monitoring across all channels, both during test time and during setup/monitoring phases
  • Easy export of test data from a distributed network of digitizers to a central location
  • Diagnostic tools for pre-test I/O checks
• Synchronize data acquisition across a distributed network of real-time digitizers, aligning both recording start latency and clock spread.
• Provide a redundant system of independent signal digitizers to mitigate the risk of data loss due to hardware failure.
• Exchange test configuration, sensor data, and status information with an external process control system.

Phase 1: Requirement Analysis & Planning

DMC first conducted numerous onsite and offsite meetings with the customer and various external stakeholders to establish design objectives and requirements. From these meetings, we identified the required hardware and software needed to meet our customers’ design objectives. We conducted design review meetings with the facility end users to refine the test setup and execution workflow, and presented detailed UI mockups to aid in these discussions.   

After several rounds of design review, the finalized hardware and software design was translated into a Functional Specification document. In addition to system hardware diagrams, this document included detailed state-machine logic flow diagrams and UI mockups for reference by the DMC team during software development. The final software specification consisted of an NI LabVIEW PC application that serves as the front-end for the distributed system, as well as a lightweight NI Linux Real-Time application that is responsible for data acquisition and logging.  

Phase 2: System Design & Development

While this project consisted of two data acquisition systems for two very different facilities, DMC identified many core similarities early in the design process, which allowed for significant overlap in the initial system design.  

• NI PXI and cRIO Digitizer Platforms: Given the system’s high channel count and high-speed data acquisition requirements, DMC utilized a combination of NI’s PXI and cRIO platforms for signal digitization. The cRIO is an especially rugged, small, and low-power platform ideal for the extreme environmental conditions present in some areas of this distributed system, while both platforms provide powerful processors, high channel counts, and support for time synchronization protocols.  

• Signal Conditioners: The system utilized a variety of signal conditioning hardware to meet rigorous calibration requirements and to support a wide range of signal types. In addition, DMC implemented automatic multi-channel calibration via voltage insertion from an external Source Meter. These devices are responsible for taking in signals from a wide array of sensor types and converting them into uniform voltage signals to feed into the digitizers. The separation of signal conditioning and digitization across these different hardware platforms allowed for maximum system flexibility, supporting over 10 different sensor types while keeping the digitization system simple and lightweight.  

• IEEE 1588 Precision Time Protocol: Due to the customer’s rigorous data acquisition synchronization requirements, DMC leveraged a timing source with IEEE 1588 Precision Time Protocol to synchronize the digitizers across this distributed system. The NI controllers’ support for IEEE 1588 PTP v2.1 protocol allows for easy integration with this timing source.  

• NI LabVIEW Linux Real-Time: DMC utilized LabVIEW Linux RT as the software platform for the PXI and cRIO digitization and data logging applications due to its seamless compatibility with these NI controllers. Leveraging object-oriented programming, DMC developed a single application to encompass both controller types, which allowed for ease of maintainability and a uniform external interface from all digitization devices. This application is responsible for continuously acquiring data at a configurable sample rate, applying channel scaling, streaming data over TCP and UDP protocols to external applications, and, during test time, recording data to disk in the TDMS file format.  

• NI LabVIEW Windows: For the front-end of this large distributed system, DMC utilized a Windows PC running an NI LabVIEW application. DMC leveraged the DMC LabVIEW UI Suite to minimize user-interface development time while providing a modern and easy-to-navigate operator interface. This LabVIEW front-end application is responsible for orchestrating calibration, data acquisition, data export, data monitoring, and diagnostic activities across the large, distributed network of digitizers, signal conditioners, and additional test hardware. DMC leveraged object-oriented software design to maintain a single LabVIEW PC application for both facilities while implementing the unique features required by each end user team.  

• LabVIEW Actor Framework Architecture: DMC leveraged the Actor Framework LabVIEW architecture across the Windows PC and Linux Real-Time applications. The modularity of the actor framework allowed for a rapid initial development phase, with many engineers working simultaneously on separate actors for various portions of the system. On the Real-Time side, DMC developed actors responsible for each of the critical portions of the application, including data acquisition and data logging. The lightweight and asynchronous nature of these actors allowed us to meet the system’s extremely rapid data acquisition speed requirements reliably. Aligning this architectural decision across the PC and Real-Time applications enabled seamless communication and integration throughout the system.  

Phase 3: Testing & Prototyping

• Device Driver Testing: Leveraging DMC’s large team of LabVIEW engineers, the initial phase of the project was carried out by a nationwide team. Driver-level device modules were thoroughly tested by DMC software developers at various DMC offices before integration into the larger applications. This greatly simplified the testing process of the full LabVIEW applications.  

• System Prototype: After developing the initial PC and Real-Time LabVIEW applications, the team assembled a full system prototype at DMC’s Chicago headquarters. By setting up one of each key system hardware element in a prototype setting, DMC was able to test the full system functionality early on, identifying and resolving any issues long before full system commissioning. DMC was able to demonstrate this system to the customer and end users, which provided an opportunity for valuable hands-on operator training and user feedback early in the development process. DMC was able to quickly implement feedback and feature requests from these initial demonstrations to ensure the final system would meet all user needs.  

Phase 4: Implementation & Commissioning

• Staged Deployment: DMC coordinated with the end user team and external stakeholders to create a phased testing and acceptance plan, designed to ensure the system met all requirements laid out in the initial functional specification document.

• Training and Support: We provided comprehensive training to the facility’s engineering and operations team on the new system, ensuring they were well-versed in the new features and functionalities. This included detailed operations and maintenance manuals for the system, onsite operator training, and ongoing coordination meetings with the end users.    

Conclusion

The successful deployment of two advanced distributed high-speed data acquisition systems demonstrates DMC’s deep expertise in LabVIEW development and National Instruments Real-Time platforms, while highlighting our knowledge in designing high-speed data acquisition systems for the unique requirements of the Aerospace and Defense industry. By leveraging our extensive experience in these areas, DMC delivered a robust, scalable solution that meets the demanding requirements of aerospace testing environments. Our proven methodology in handling large-scale test and measurement projects positions our aerospace and defense clients for continued success in their most challenging test applications.  

Learn more about DMC’s automated testing expertise and contact us for your next project. 

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