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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• 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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Our engineers created a control architecture with a standard hardware set. We utilized a standard library of process objects for PLC software and HMI controls. To allow operators to safely de-energize any piece of equipment from any of 11 remote control stations, DMC also designed a network of safety PLCs and other SIL 3 components.

Our team designed 30+ control panels to meet the UL508A standard. To meet hazardous location requirements, we utilized a combination of explosion-proof and intrinsically safe components. Collectively, we focused on the complete software development lifecycle, from requirements gathering to detailed design and programming, as well as the development and execution of test plans.

Finally, we coordinated with the construction team for power and telecommunication infrastructure.

Learn more about DMC’s PLC Programming Expertise and contact us for your next project.

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Modular Signal Emulation Hardware 

The customer had 15+ signal types that they needed to emulate to fully validate their control software. DMC was able to develop a modular signal emulation system based upon UEI hardware which allowed each signal type to be composed into different HIL configurations based upon the client’s requirements.  

Shared Test Equipment 

To reduce capital expenditures, DMC designed a set of Shared Test Equipment that was capable of automatically testing both HIL systems, while also maintaining the option for signal count expansion.

Pickering Interfaces was crucial to planning for future signal count expansions. DMC engaged with Pickering Interfaces to select the appropriate switching solution to enable testing the thousands of test points with a single set of test instrumentation.

DMC also selected instrumentation from Keysight, Keithley, and Sigilent based on the customer’s specific requirements.

Shared Test Equipment Software

A common practice at DMC when designing test systems is to include the capability to perform self-checkout of the system. This provides a way to perform automated periodic checkout of a system throughout its lifespan. For this customer, DMC was asked to fabricate two systems, both of which needed to have the capability for automated self-checkout.

DMC developed a RESTful API for the Shared Test Equipment to enable automated control by the customer’s existing test executive software.

Conclusion 

DMC was able to design and fabricate modular Hardware-in-the-Loop systems, which were able to meet the customer’s evolving requirements and maintain flexibility for increasing signal counts in each HIL system. 

Learn more about DMC’s Aerospace and Defense expertise and contact us for your next project.

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DMC worked with the client to identify potential areas where inspection speed could be increased by modifying image processing algorithms, hardware, or test sequence. With estimated cost and benefits of each option under consideration, the client was able to make informed decisions and improve the program as budget allowed.
The following image processing steps are currently included in the program utilizing NI vision tools:

1. Dot matric calibration for image distortion correction
2. Background image subtraction
3. Combining raw images to form a single composite image from each scan
4. Stitching of composite images of different areas of the part to allow analysis of larger parts
5. Brightness and contrast adjustment
6. Histogram and line profile of selected areas
7. Point-to-point measurements in real-world units
8. Color mapping to custom color scale

DMC engineers continue to work with the client to plan and implement new features for accommodating complex image processing challenges.

Learn more about our Test & Automation Solutions for Aerospace & Defense and contact us today for your next project.

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Key requirements included:

• Longevity and Support: Utilizing PXI modules and Ethernet-based communication with an LXI mainframe, the system is designed for a lifespan of 15 to 20+ years.
• Reliability and Fault Detection: Components were selected for their reliability and ability to detect faults early in runtime operations.

Recognizing that standard COTS switches alone were insufficient, we collaborated with Pickering to extend the PXI-based switching portfolio. This collaboration resulted in the custom development of the 40-619 series switching modules to meet the precise specifications required, including direct contact state monitoring and relay fault detection.  

Additionally, Pickering enhanced the safety and reliability of our test solution with: 

• 60-103B-002 LXI Modular Switching Chassis – A modified chassis with an added safety feature to asynchronously force relays open upon system fault conditions. 

• 40-792 Series PXI 2MBit/s 75Ω Tributary Daisy-Chain Switch – A modified COTS switch product providing optimal topology for switching 75Ω impedance-matched communication signals.

To mitigate risks posed by the operating environment, Pickering conformally coated all modules. The chassis’ unique “failsafe mode” feature forces all relays to their open state upon receiving an external signal, protecting the test system by disconnecting the DUT from the test equipment during external faults. 

This solution offers high channel density, resulting in a compact footprint compared to competitors. Superior impedance matching ensures signal integrity, avoiding disruptions that could lead to poor test results. 

DMC’s longstanding relationship with Pickering, combined with our expertise in PXI and switching, sets us apart. Our engineers are committed to collaborating with customers to develop solutions tailored to their specific needs, ensuring all ATE system requirements are met. 

Learn more about our Test & Automation Solutions for Aerospace & Defense and contact us today for your next project.

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The UAVs used custom airframes, which required the control systems to be custom designed in order to accommodate the unique nature of the aircraft.

Airborne Flight Control System

DMC designed the UAV’s flight control system to consist of 2 subsystems — power management and flight control:

• The flight control subsystem, controlled by multiple high-performance microcontrollers, manages the processing of flight dynamics, ensuring accurate and responsive control as well as communication with the GCS over a wireless link.
• The power management subsystem provides safety measures, as well as manages power delivery and monitoring of the aircraft’s actuators according to commands from the flight control subsystem.

DMC’s Embedded Team developed the airborne hardware and firmware with the following benefits:

• Redundant Flight Sensors: These include RTK GPS, IMU, compass, barometric pressure, etc. to provide robust positioning and attitude data for flight control and navigation.
• Precise Trajectory: DMC developed custom real-time flight trajectory following controls, allowing users to specify an exact profile for the UAV to follow.
• Redundant Power: DMC’s power management subsystem supports power delivery from multiple sources, allowing reliable flight and providing users flexibility in battery options.
• Redundant Communication: The UAV flight control system communicates to the GCS over a redundant wireless link to ensure reliable communication in a variety of conditions.
• Enhanced Safety and Reliability: Following ISO-13849 design practices, DMC implemented comprehensive safety systems to automatically detect and address in-flight and grounded failures, ensuring operator safety and flight reliability at all times.

Ground Control Station

Our teams built a ground control station to act as the command center for the UAV system, offering comprehensive supervisory capabilities with the heart of the station being a custom .NET C# application to interface with UAVs, operators, and ground-based sensors.

DMC’s Application Development team designed this station with a focus on user-friendliness and adaptability and included:

• Real-Time Monitoring and Control. Providing operators with live flight data, including visualization of a UAV’s path on a geo-referenced map.
• Intuitive Touchscreen Interface. A custom-built graphical touchscreen interface enabling straightforward interaction and allowing operators to select flight trajectories, issue commands, and review diagnostics with ease.
• Integrated Design. DMC developed the ground control station and onboard flight control system together, providing seamless interoperability between the two systems.

Flight Tuning and Path Planning

In addition to the system design and development, DMC’s team of FAA Part 107 Certified Remote Pilots also performed real-world tuning.

Taking this additional step, DMC minimized the costs and material risks of flight controller tuning by developing a physics-based model of the aircraft and optimizing control inside a simulation environment prior to performing real-world tuning.

Our teams also developed a suite of custom flight planning tools in Python enabling the user to simplify visualizing and designing navigation missions and trajectories.

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

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1. Design and implement control systems to control the pressure and flowrate of process fluids used to create test conditions for devices under test.  
2. Exchange process data, test configuration, and status information with an external data acquisition system.  
3. Provide intuitive and detailed test configuration UI, allowing for wide range of test conditions and profiles.
4. Standardize programming with tested and validated control strategies to minimize operational risk and enhance troubleshooting capability.  
5. Minimize commissioning time and risk.  

Phase 1: Requirement Analysis and Planning  

• DMC conducted numerous onsite and offsite meetings with the end customer and various external stakeholders to establish design objectives and requirements.  
• From these meetings, we identified the required hardware and software features needed to meet our customer’s overall design objectives.  
• We conducted several rounds of design review with the facility end users to refine the user workflow for both operating the facility and processing test results.
• The final design of the hardware and software was translated into a Functional Specification document. All sequence steps, permissives, interlocks, alarms, and HMI wireframes were captured in this document for reference by both the DMC software development team as well as the facility end users.  

Phase 2: System Design and Development  

• PlantPAx 5.0 Selection: Given the need for highly performant process control and well-tested, robust programming blocks, DMC selected the Rockwell Automation P-Processor (1756-L83P) to control the facility. The selection of a P-processor allowed us to leverage the full PlantPAx v5.0 library, which comes built into the process controller’s firmware.  
• Application Code Manager (ACM): To allow for rapid development, consistent programming, and to minimize programming errors during implementation, DMC used Application Code Manager (ACM) to generate the base code for the project. This was especially important in the early phase of the project, where DMC aimed to prove out the user workflow for the facility even though the specifics of the facility’s field equipment were still being finalized. Even large changes to the list of field devices were easily propagated to the code throughout the development process, using ACM to quickly re-configure and push changes to the project.  
• FactoryTalk View SE: DMC selected FactoryTalk View Site Edition (SE) as the HMI platform for the facility. When used in tandem with the PlantPAx library, FactoryTalk View allows for rapid development of facility overview screens, since faceplates for each PlantPAx process object come pre-configured. The ability to quickly adapt screens and showcase the deep HMI feature set within the PlantPAx ecosystem gave our customers a high level of confidence in their new system throughout the design process.  

 Phase 3: Simulation and Testing  

• FactoryTalk Logix Echo: DMC employed FactoryTalk Logix Echo for emulating field devices and for advanced simulation of process pressures and flowrates. This allowed our development team to create a virtual environment that mimicked the real-life process behavior in the facility. Using simulation code running on Logix Echo, the team conducted extensive testing of our control strategies and sequence logic. We were even able to validate cross-platform communication to external software systems by connecting the simulated Logix Echo controller to FactoryTalk Linx Gateway’s OPC-UA driver.  
• Scenario Testing: Prior to field commissioning, DMC simulated various operational scenarios and validated system responses. This included normal operation, fault conditions, and emergency shutdown procedures. A wide range of test conditions and configurations was simulated, which helped identify the upper performance limits of the process system and decreased commissioning risk.  

Phase 4: Implementation and Commissioning  

• Staged Deployment: We coordinated with the end user team and external stakeholders to create a phased testing and acceptance plan, designed to ensure the system was functional at all levels of control—from individual devices, to process subsystems, to the entire facility.  
• Training and Support: We provided comprehensive training to the plant’s engineering and operations team on the new system, ensuring they were well-versed with the new features and functionalities. This included detailed operations and maintenance manuals on the system, a three-week structured onsite training course, and ongoing coordination meetings with the end users.  

Conclusion  

The successful implementation of the Rockwell PlantPAx P-Processors, Application Code Manager, and FactoryTalk Logix Echo for our client’s flight test facility showcases DMC’s expertise in deploying advanced control systems. The project not only met the client’s immediate needs but also positioned them for future growth and technological advancements. Our approach to leveraging modern tools and methodologies ensured a smooth roadmap to a fully mission-capable test facility and delivered substantial operational improvements over the legacy facility. 

Learn more about DMC’s Rockwell Programming expertise and contact us with any inquires.

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