The ETE is designed to maximize flexibility for future testing of the existing HIL racks, as well as potential iterations of HIL design. It can be used as a validation tool and a general purpose debugging tool. The mass interface connectors route all input signals through configurable switch matrices to provide a connection path from every input pin to any connector on rack measurement instrumentation. The ETE system includes a PC that acts as an interface between PLANT software and rack-mounted measurement instrumentation; the main ETE application is a Python-based REST API that runs headless and does not require an external monitor. This application integrates easily with existing customer test executive software and enables the test developer to control all ETE devices as if they were operating a single unified instrument.

Self-Test Capabilities

In addition to validating HIL racks, the ETE has the capability of validating itself. This is performed by using DMC’s automated self-test sequence which can verify all 2,000+ channels are wired properly and all instruments are functional for testing.

Software Safety Rules

The ETE has software enforced safety rules that limit the duration of power sourcing instruments, number of connections between power sourcing instruments and signal lines, and signal routing limits for overcurrent protection of switching lines.

It is important to note that these software safety rules are supplemental to the system’s hardware controlled safety circuit for E-stop integration.

Built In-House

DMC’s internal Fabrication team built the ETE test system in-house. The system consists of a 24U rack system on heavy duty caster wheels which allows the system to easily move throughout the client’s testing facility. The system PC and switching hardware occupy the bottom half of the rack and measurement and power sourcing instrumentation are installed in the front, top half of the rack. The back of the rack has mass interconnects to connect to HIL racks or loop back to itself for self-test.

Custom Configurations and Scalability for Any Test System

The ETE can be expanded further to contain additional hardware to broaden test scope and allow additional channels, higher power tests, and support for more UUT functions. The modular rack design allows flexibility to scale up (or down) DUT channel count and testing functions in order to meet evolving test requirements.

Conclusion

DMC’s Helix SwitchCore hardware platform paired with the REST API software architecture gives the External Test Equipment (ETE) rack the capability to validate high signal count hardware in the loop (HIL) systems are working properly which can significantly reduce manual operator verification and debugging. The ETE’s modular rack design allows future design iterations to adapt with signal count, signal types, and other UUT requirements for HIL systems, ground support equipment (GSE), or other automated test equipment (ATE). The diverse set of measurement and sourcing capabilities allows the ETE to be used as a general purpose debugging tool, in addition to its main function as an ATE validation tool.

If you find yourself spending significant time keeping your automated test systems operational, secure, and validated, consider consulting DMC’s Test and Measurement service area to see how a Turnkey Test System may improve your testing workflow.

Learn more about DMC’s Test & Measurement Aerospace and Defense 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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Data Collection, Standardization, and Organization 

The system uses AUTOSOL ACM to connect to thousands of distributed field devices using protocols like Modbus, ABB Totalflow, and Allen-Bradley Ethernet IP. ACM then hosts the tags for Ignition to read over OPC-UA. Ignition uses UDTs and a strict tag hierarchy to maintain standardization between different equipment of the same type. 

Ignition collects data, stores trends in the tag historian, and displays tag data on dynamic screens. Navigation and displays are driven by database tables to automatically update when new sites are added. Screens use high-performance HMI design to give operators at-a-glance equipment health and performance information. 

Automated Equipment Rollout Process 

DMC designed the system to automatically generate all required equipment configuration from a template spreadsheet file. This creates AUTOSOL import files and Ignition tags, so users do not have to manually add equipment to the system. The auto-generation process is designed to both create new equipment and update existing equipment, making it easy to roll out changes to the field.  

Data Reporting and Integrations 

DMC developed custom dashboards and reports to display critical production information. Reports contain a mix of user-submitted information, trend aggregations, and live data. Reports and data can be accessed via several different means: 

• Ignition dashboard screens 
• Export-to-CSV downloads 
• REST API data endpoints 
• Alarm text, email, and phone callouts 

Conclusion 

With their new Ignition/AUTOSOL SCADA system, the client has much greater visibility into their field-wide data. They can build on DMC’s modular architecture to quickly roll out new sites and develop new features.  

Learn more about DMC’s Ignition SCADA Programming expertise 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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The test stand is capable of integrating with external measurement equipment over USB, GPIB, serial (RS-232), and Ethernet, allowing test sets to adapt to future calibration requirements. Additionally, the calibration test stand features several extra PXI slots, allowing additional instruments to be added as test requirements change over time. The mobile calibration test stand is approximately four feet tall, two feet wide, and three feet long.

The system’s condensed size allows it to easily traverse through doors and move from building to building to access a diverse set of equipment and sensors it is responsible for calibrating. In addition to designing and fabricating the hardware, DMC also created a custom LabVIEW application to view and monitor live data, record data, and generate a calibration report.

3D model of the mobile calibration test stand

DMC’s Fabrication Studio team assembled the mobile calibration test stand in-house

Custom Hardware

DMC designed the custom front panels that secure the programmable power supply in place and provide a mounting surface for DUT and auxiliary connectors to plug into the system.

DMC designed a custom PCB mounted on the inside face of the bottom panel. The purpose of the PCB is to route signals and simplify the system’s internal wiring. This PCB was designed in-house by DMC’s Embedded Development team.

Plan for the Future

The system was designed with the future in front of mind. It was important to the client to be able to adapt to new products and changing test requirements. To help achieve this an 18-slot PXI chassis was used in the system allowing several slots to be reserved for future use. The system interface was designed to allow for maximum adaptability. Banana connectors allow the client to connect to DUTs or external test equipment with non-standard interfaces and the bulkhead USB, GPIB, serial, and ethernet (RJ45) connectors allow the client to connect new models of measurement equipment across most commonly used communication protocols.

In addition to the hardware, the LabVIEW software was designed in a way the client could expand beyond the original project scope and add support for new calibration measurement devices by using a hardware abstraction layer (HAL) and measurement abstraction layer (MAL). The HAL and MAL help simplify future code additions, allowing the client to maintain complete ownership of the codebase after its initial deployment.

Built In-House

Our Control Panel Design and Fabrication team from the DMC Fabrication Studio built the test system in-house. The enclosure encompasses a rugged 14U rack system, which allows the PXI chassis, power supply, custom signal routing PCB, and DUT interface connectors to be easily mounted. A lockable shelf at the top of the rack provides storage space for the system laptop and any testing accessories while not in use. Large rubber casters allow the system to roll indoors and outdoors to service different buildings throughout the client’s campus. The external DUT and auxiliary device connectors are secured to the front face plates, while the measurement and switching equipment are slotted into the PXI chassis near the bottom of the rack.

Conclusion

DMC leveraged the expertise of many of our service areas to design, build, and deliver a new and improved calibration system for the end client. The Test and Measurement Automation team led the overall design, the Embedded Development team designed the custom PCB, and the Control Panel Design and Fabrication team was responsible for the final assembly of the system.

The upgraded test system allowed the client to increase calibration efficiency, accuracy, and allow for room to expand the system’s capabilities in the future. DMC developed a LabVIEW application that can be expanded upon by the client and they are able to maintain complete ownership of the system after final delivery and acceptance testing.

Our extensive experience with LabVIEW programming, developing Test and Measurement Automation systems, and building turnkey solutions qualified us to deliver this modernized system and successfully upgrade the test equipment to meet the client’s present needs while making provisions to enable future enhancements.

Learn more about DMC’s LabVIEW Programming expertise and contact us for your next project.

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DMC stepped in and enabled its priority pipeline to funnel engineers from across the company and country to quickly analyze, document, and diagnose existing temperature control code. The first step the engineering team took was to create a list of opportunities for codebase improvement for the client to review. These improvements were focused on time to deployment, with an emphasis on system architecture preservation and minimum disturbance to ongoing production tests.

DMC delivered a solution that addressed fundamental issues in thermocouple reading and furnace PID control calculations as well as parallelization and independence of test fixture control. PID control was redeveloped for faster cycle times and smoother temperature trajectories. By solving these issues, temperature control accuracy was improved by 2000%, from an average swing of 60 degrees to 3 degrees over a 24-hour period. By implementing a custom PID gain scheduling algorithm developed by our certified LabVIEW developers in tandem with NI PID control VIs, DMC was able to decrease the unit test time by 1500% without negative consequences to test subjects. We were also able to supply the client with critical operating system updates for their legacy hardware.

Engineers traveled to the client site to aid in tuning, testing, validation, and deployment of the upgraded codebase. After validating the improved control, DMC empowered the client to perform system upgrades independently with rapid deployment tools and detailed documentation. This allowed the client’s engineering team to regain familiarity and confidence in the production system while spending less of their budget on external engineering hours. Within two weeks of upgrade validation, the client had recommissioned all 100 test frames at their site successfully.

Learn more about DMC’s LabVIEW FPGA & Real Time expertise and contact us for your next project.

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