Software:

LabVIEW 2015

 

Hardware:

CompactDAQ 9178

NI 9219 – Universal Input Module

NI 9375 – Digital Input Output Module

NI 9237 – Bridge Input Module

NI 9401 – 5V TTL Digital Bi-Directional Module

 

Summary

• Position control using DC Motor with encoder feedback
• Data Acquisition from Torque and Force Bridge Type Sensors
• Control of customer specific test cycle
• Automated Report Generation

 

Requirements:

To develop a software application to provide control, data acquisition and automated report generation for an Automotive Window Regulator Test Rig.

 

Description:

Software Systems Developments was asked to develop a software application which would be integrated on a test rig to support the validation program for a new Automotive Window Regulator product for Hi-Lex Cable System Co., Ltd based in Port Talbot, South Wales. Hi-Lex design and manufacture mechanical cable and linkage systems for a range of automotive OEM’s.

 

The software package developed for Hi-Lex controls the linear travel of the window regulator using a rotary encoder for positional feedback. Using the positional feedback, the system energises a DC motor to drive the window regulator through its full travel cycle, whilst acquiring data from a rotary torque sensor to measure the motor torque and a load cell to measure the stall force at the full travel. During the cycle, live readings of torque, force, motor voltage and motor are displayed on the user interface which also includes a graph displaying the torque against the travel position and also the customer specified pass fail limits.

Once the test run is complete, the software automatically generates a standard test report from a base template in Microsoft Excel format. The test report includes the graph trace of the torque and stall force against travel position, along with some statistical values from the test. Along with the test result data, the report contains specific test information relating to the part under test:

• Part Number
• Serial Number
• Test Number
• Test Operator Name

As well as the generated test report, the software also provides the raw data file in CSV format, which enables the test operator to carry out further analysis on the test data if required.

Along with the software development aspect, Software Systems Developments provided consultancy to Hi-Lex on the selection of appropriate control and measurement hardware to be used within the system.