Multitest Suite for Performing Varied Tests and Data Acquisition on Numerous Electrical Components Used in a Vehicle From One Platform

VE Commercial Vehicles Limited (VECV) is a well-known name in the field of low and medium duty (LMD) trucks and buses. Being an OEM, we need to test the various components for performance and life validation or against any failure observed in the field. Until a few years ago, the majority of our testing was done at the Automotive Research Association of India (ARAI). With the development of a reliability lab in the premises of the VECV plant, it was essential to further cut costs without trading off the testing quality.

For testing electrical components, we used small ad hoc circuits, and a test engineer ran performance checks. Though it was an economical solution, it fell short of quality and accuracy. Thus, we realized we needed an automated test system. The multitest suite (MTS) was developed with such a vision in mind, and we aimed to keep the interface operator-friendly and scalable to accommodate any number of tests.

The MTS features a set of predefined test VIs, built using NI LabVIEW system design software, that are specific to a test component. Each VI is capable of testing two samples simultaneously, if the mechanical setup allows for it. The test sequences in each VI can be modified with or without stopping the current test.

The main application consists of the following three main user interfaces (UIs):
1.Login: Logs the user with correct credentials into the system. Once the credentials are verified, it prompts the user with the Test Selection VI.
2.Test Selection: This VI can be viewed as a switchboard for turning on all of the selected tests. With the press of each corresponding RUN button, the specific test VIs open up. The user can make any necessary changes and close the appropriate pane, and the tests still run in the background. Once all the tests have been started, the user proceeds to the Test Panel.
3.Test Panel: This is the platform where each running test updates its status, such as the cumulative test cycles/hours and start time. For any information other than this, or for making any changes to the test, the user can invoke each test VI to open by clicking the VIEW button. The test panel saves a lot of screen space by organizing all running tests on one monitoring platform.

Advantages of the New System

Development of the MTS empowered us with a tool that can be used to run any endurance and performance test on all of the commonly used electrical components in a vehicle, such as the relays, fuel-level sensors, and restriction indicators. It has considerably minimized user effort and provides a quick and convenient means to note the relevant updates about all running tests from one platform.

Additionally, easy access to the code offers a means to perform any modifications for future use, thus making it a benchmark for other in-house software development. Lastly, the degree of modularity and flexibility provided by this particular application saves time and presents the operator with a wide range of test options.

Benefits of Using NI Products

The biggest advantage of using NI products is the automated testing and logging of more than four tests with just one system. The architecture of the application is scalable; hence, a number of the tests can be easily increased. Previously, such tests were carried out using printed circuit boards with the manpower required to intermittently run performance checks. This step has now been completely eliminated.