NI LabVIEW and FieldPoint Provide Powerful, Compact Automated Test Solution

Author(s):
Tony Kateryniuk - TeleFlex Canada, Inc.

Industry:
Machines/Mechanics

Products:
LabVIEW, FieldPoint

The Challenge:
Building a device that can perform repeatable and reliable Power Tilt and Trim (PT&T) unit testing.

The Solution:
Using National Instruments LabVIEW software and FieldPoint hardware to develop a flexible system capable of controlling all aspects of testing and data acquisition.

At Teleflex Canada, we manufacture hydraulic and thermal parts for several markets, including the marine industry. We recently needed a device to provide repeatable and reliable PT&T unit testing. With NI tools, we were able to develop a system to fully control all test aspects.

Mechanical System Requirements

One of the challenges we faced with the mechanical subsystem was we needed to quickly change unit styles. We addressed this by using 3D modeling software to develop a two-in-one fixture solution that includes custom designed pneumatic fixturing, which simplifies changeover from unit styles and individual unit insertion.

Another challenge was to have precise dynamic system response when force control setpoints were commanded. We accomplished this by using a PID loop toolkit and timed loops for precise control of the electro-hydraulic force control system.

A third challenge was that we wanted the test device to have a small footprint, so we structured components in a bottom-to-top design where components stack, but we could independently remove each component for inspection, repair, and maintenance.

Electrical System Requirements

For the electrical design, we required five types of power, though we implemented only minimal large power runs to the machine to save on plant wiring and shutdown safety. We required the electrical design to be easily maintainable and flexible to allow component upgrades.

We completed the electrical design in accordance with CSA guidelines for control cabinet design. With proper power conversion, we needed only two lines to run to the main control cabinet. These two main lines are interrupted by one main disconnect to allow power-down situations to occur quickly and safely.

There were numerous control boxes – all electrically interconnected – that linked the various subsystems together. We use multiple pin quick connect electrical plugs to conduct everything from large power to millivolt signals. This was very advantageous because all electrical subsystems are easily removable with no need for costly unwire/rewire situations, making maintenance time minutes instead of days.

Control System Requirements

We designed the control system to run all test aspects and the device. We required a specification database linked to each model number that would alter the test and specifications for the specific model number chosen. This gave us a test result database that would archive results on each unit tested. Connected to the company’s main servers to provide data sharing and data file backup, the database also had to be searchable and provide statistical reports by search criteria. In addition, we needed the database to have automatic e-mail capabilities to contact appropriate individuals when maintenance or production issues arose.

For our control and data acquisition hardware, we selected National Instruments FieldPoint. We chose an NI FP-2000 real-time controller interface along with dual-channel FP-TB-10 terminal base and full-rack FP-TB-1 terminal base I/O hardware to meet the large and diverse needs of the eight analog and 50 digital I/O systems.

We selected National Instruments LabVIEW software as our control platform. Both the hardware and software are known for flexibility, reliability, and ease of use.

Quality assurance staff also use the software for calibration purposes, while maintenance personnel use it for system troubleshooting.

Flexible Solution That Saves Time, Labor

NI hardware and software helped us create a very flexible, cost-effective system for which the operator simply loads the unit and the device takes over. The software reads the test specifications for the model chosen, ensuring that the chosen model works with the fixture orientation. Then it runs the unit through 11 sequential tests in 120 seconds, whereas the manual tests took about 15 minutes. It then stores all results in the test database. Larger runs of similar failures trigger alarms for manufacturing engineers while system failures send e-mails to maintenance. This has resulted in huge cycle time and labor savings.

Tony Kateryniuk

TeleFlex Canada Inc.

3831 No. 6 Road

Richmond, BC

CanadaV6V 1P6

Tel: (604) 270-6899

E-mail: tkateryniuk@teleflex.bc.ca

 

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