Testing and Measuring System NTS

Universal tester EOLT

The tester has been developed based on the many years of experience of ELCOM, a. s. in supplying End of Line testers (EOL) for various customers in many industries and forms. The great variety of customer requirements has led to the need to evaluate the most important aspects and elements that testers must meet. Based on this analysis and know-how, ELCOM, a. s. developed the optimal HW and SW concept for the universal platform called EOLT.

Device description:

• The device is designed as a stand-alone device with a rotating carousel that has 8 working or testing positions
• Each position is occupied by a universal loading point for interchangeable palettes (jigs) that are uniquely designed for the product under test
• The positions can be equipped with different test technologies according to customer requirements, such as camera tests, haptic tests, vibration tests, optical tests, electrical tests
• The positions can be equipped according to the customer’s requirements with various production technologies, such as simple manufacturing processes (assembly of parts, application of pastes, adhesives, paint), as well as mechanical, laser or ink jet marking
• Robots can be installed in 5 positions according to the customer’s choice. Depending on the purpose and optimal use, the robots can be of the 6-axis or scara type
• The loading of parts into the tester can be carried out:
  • Manually
  • Automatically using robotics or manipulators
  • Automatically using a collaborative robot
  • Automatically using the Bin Picking function directly from the box (bulk material loading)
• Unloading is fully automatic – robotic with sorting into OK or NOK parts. Belt conveyors are used as output devices
• The tester meets the strictest safety requirements
• The tester can be supplied according to the customer’s request:
  • In an ESD version
  • An optional colour version
  • Possibility of anchoring into the ground or vice versa without anchoring

Possibility of assembling teste and work positions according to customer’s wishes

Camera tests

The tester uses the Unitester platform for camera measurements developed by ELCOM, a. s.

Tested parameters:

• Absolute measurement of the area distribution of brightness in cd/m²
• Evaluation of uniformity
• Colour checking according to the CIE 1931 standard
• Pattern checking, presence detection
• Other parameters according to customer needs

Hardware

Several types of camera inspection with corresponding camera HW are used on the tester.
The most prominent type of HW is the representation of Technoteam’s photometric system. This is the LMK 5-6 TechnoTeam luminance camera.

Haptic and vibration tests

• Possibility of mounting on 2-4 positions of the tester
• Force measurement 0-12 N – Burster analogue force sensor, digitalisation of the Beckhoff measuring card
• SMAC servo actuator – position resolution 0.005 mm
• Optional adjustment of actuator speed
• Optional force limitation – overload protection
• Data sampling 10 kHz
• PLC data acquisition + ETP evaluation – ELCOM Test Platform
• Precise positioning with robotic arm – repeatability 0.02 mm
• Capacitive measuring finger material for interaction with capacitive foil in the product + grounding

Mitsubishi Assista collaborative loading robot

• Mitsubishi Assista collaborative loading robot
• PILZ safety assessment
• Special ELCOM gripper design

ETP SW

The software platform of these testers is ETP (ELCOM Test Platform), a universal software environment for configuration and automatic execution of tests, developed by ELCOM, a. s. for Windows operating system. This platform includes applications that apply at all stages of the tester lifecycle:

• Test sequence editor (sequence creation by the user)
• Sequencer (executes the configured sequence in production mode)
• Operator application (selection of the production mode and visualization of the executed tests)
• Production statistics (application showing detailed statistics of production timing and error rates derived from real-time tester data)
• Report viewer (viewing test results by the user, from files or from the database)

The sequencer communicates with all functional elements of the tester during the tests: PLCs, measuring instruments, cameras, power supplies, robots, labeling, databases, etc.

The sequencer can also communicate with the product under test using DIO signals or any communication interfaces, typically CAN, LIN, Ethernet, RS-232, etc.

Control SW

• The EOLT control system is HW and SW using the Beckhoff platform
• Safety system also uses Beckhoff platforms

ELCOM, a. s., is a traditional manufacturer of functional testers for testing products for customers in the Czech Republic and foreign countries. The main customers of these test systems are manufacturers of parts for automobiles, consumer electronics and electronic components.

Functional testers are made to measure according to the specification and practice of the customer. In cases where it is an unknown a priori concept device or there are doubts about its feasibility, our specialists work with you to prepare a feasibility study.

Functional testing systems typically test a variety of disparate parameters including electrical tests, the test camera and the measurement noise or vibration. The components used in the construction of our test systems come from reputable manufacturers around the world. Measuring and software core components of these devices use a development environment from National Instruments, a strategic partner ELCOM, a. s.

Why it is inique

ELCOM, a. s., there are a number of specialists in various technology measurement and testing, as well as designers and construction workers in the fields of mechanical design, power and low-voltage electrical, and software engineering. The concentration of these professions within the same company warrants that the design of our equipment will be thought of in terms of participating in technical fields and their individual components are compatible with each other and well-coordinated. The fact that the entire design and manufacture of test equipment is carried out by our company guarantees our customers complete control and the ability to manage the process of the production test system and its functionality.

Tested parameters

Dimensions and shapes of components

The dimensions and shapes of components or parts, including length, diameters and radii, angles relative to the rotational elements of the product. The measurements are carried out either by contact methods (eg. using gauges) or using contactless methods (camera or laser encoder / distance).

Colors

These are the colors of parts of articles, printing, cables, fabrics, but also as fruit or pills. It can be color illuminating objects, such as LEDs. The measurement is done using a camera system and a relative, pattern matching, respectively modeled image.

The surface texture.

Determination of surface quality based on an image of the surface of the camera. The image is then processed by mathematical algorithms that use a range of criteria assigned to the character of the surface: roughness / grain, matte / gloss, defects in the texture…

Brightness luminous elements

For light bulbs, LED displays, fiber optics, also the projection of light on the screen at the correct distance. These measurements are made by photo detector (phototransistor), or camera.

The presence of elements.

Detectors are used in contact, inductive or optical sensors, or cameras. The detectors determine the presence of mechanical parts, screws, rods, springs, keys, clipping bolts, connectors…

The presence of undesirable defects.

These are usually detected by the camera and the subsequent image analysis. Typical defects are burrs, blemishes, bubbles in the glass, knots in the fabric, dust and dead pixels in LCD displays, deformed threads, etc.

Descriptions

Images which are taken by camera are used for OCR algorithms to convert the text and the subsequent testing of different content.

Electrical Specifications

Their measurement is generally carried out using measuring instruments or DAQ cards. Measured quantities are the voltage levels of current, power, electrical properties of devices.

Physical parameters

Among the measured physical parameters include temperature, pressure / vacuum leaks, flow media, weight, strength, force required to manipulate the controls, noise, vibration, thickness of thin layers (paint).

Communication with the product

Communication with the product may include setting the operating conditions in products, reading or writing of the data contents of the internal memory products. Identifying the communication protocol correctness product interface can be Ethernet, CAN, RS – 232, K-Line, I2C, MODBUS, LIN, EtherCAT…

Duty cycle

The operating cycle of the tester may consist of:
Test preparation

• Snap-oriented product
• Physical contact with the product
• Creation of test conditions (supply voltage to switch on the product, the time needed to “wake up” the product after switching on)

Self-test, which may consist of sub-steps

• Put the product in the test mode
• Initiative to create an action, such as pressing a button on the product
• Measured response to the stimulus action
• Evaluation of the measured response

Finishing operations

• End test mode of the product
• Removal of the test conditions (cooling product discharge capacitors…)
• Writing test information in the product or in the database
• Style description, label …
• Postponement of the product

Test systems for measuring the dimensions and the presence of parts is based on scanning products by camera and the image evaluation is an important part of the solution offered by ELCOM, a. s. These test systems are made to measure according to the specification and practice of the customer. In cases where it is an unknown a priori concept device or there are doubts about its feasibility, our specialists work with you to prepare a feasibility study.

The components used in the construction of our test systems come from reputable manufacturers around the world. The core measuring and software components of these devices use a development environment from National Instruments, a strategic partner ELCOM, a. s.

ELCOM, a. s., is a leading supplier of automotive lighting testers and components for manufacturing plants. Testers are usually part of the production lines in various stages of production, from light bulbs to complete assembled multifunction lamps. Our customers include most of the major manufacturers of automotive lights in the Czech Republic.

Car light testers are made to measure according to the specification and practice of the customer. In cases where it is an unknown a priori concept device or there are doubts about its feasibility, our specialists work with you to prepare a feasibility study.

Functional testing systems typically test a variety of disparate parameters include electrical tests, camera tests, and communication tests. The components used in the construction of our test systems come from reputable manufacturers in the world. Measuring and software core components of these devices use a development environment from National Instruments, a strategic partner ELCOM, a. s.

Performed Tests

Lamps

Current Measurement:

• A constant source of light
• Detection of correct ignition curve during Xenon start-up
• Measurement of current to the coil aperture shuttering the main beam

Positioning and measuring positions of LED sources:

• The placement of LEDs on the base of the robot-guided camera
• Measuring position of LED sources with a precision positioning accuracy of 0.01 mm and an angle of 0.1 degree
• Measuring the luminance of LEDs (comparative)

Corner and fog lights

Measuring the intensity of light

Scanning the projected beam of the camera and comparing the reference sample. Finding the homogeneity and intensity of the light at selected points or areas.

Measuring and adjusting the volume in a vertical positio

Scanning the projected beam of the camera and comparing the reference sample. Finding the angle of the central bundle and its settings using positioning mechanisms in the headlight.

Headlight

High beam:

• Sharpness of the border as the intensity gradient between lit and unlit parts of the screen on which the beam is projected.
• Measuring of the intensity of the center portion of the beam by camera and comparing the reference sample.
• Position of the center of the projected beam as the focus area to which the intensity is higher than the set value, eg 85% of the maximum intensity.

Low beam:

• Location of the kink point between the light and dark parts of the projected beam, including the ability to automatically a just the beam position along the horizontal and vertical axes.
• Measuring the angle of the lines between the light and dark parts of the projected beam.
• Measurement of beam intensity at selected points and areas compared to the reference sample.
• Measuring and adjusting sharpness and color between the light and dark parts of the projected beam.

Daily, parking, designer light fixtures

The camera test looks directly at the camera light source. Detection of the presence of light sources, waveguides and the homogeneity of the light emitted.

Protective layer

Detection of the protective layer of varnish and its features on the glass covered complete automobile headlight.

Stepper Motors

Lights VAC system (Vertical Aim Control)

Checking of the vertical position of the beam controlled by a stepper motor tracking the projected beam on a screen.

Lights of AFS (Adaptive Front-light System)

Checking of the dipped beam break point angle in the horizontal and vertical axis at several points. Control of the stepper motor light using LIN, CAN, RS-232 port.

Test the quality of other parts of lights

Assembly errors using cameras

The presence of parts, screws, stickers, seals.

Communication

Verifying communication with the light via LIN, CAN, RS-232 port.