SMART TEST SYSTEMS for automotive components - as individual as your products

Our flexible automated test systems, combined with powerful software solutions, allow you to perform sound and repeatable functional tests on your product.

No matter if you work in advance development, series development, production or quality assurance – your product quality is important to us.

Category

Solution

430-channel fuel cell monitoring at cryogenic temperatures

The application of measurement technology within climate chambers makes high demands on the inserted components. The measurement modules (MCM IntelliProbe) and the process module (MCM-MasterModule) are housed in a heated aluminum body. This allows the reliable use of monitoring equipment at temperatures down to -40 °C. The internal heating thereby avoids the formation of condensation within the housing. To prevent the ingress of moisture from the outside, the whole system including all connectors is designed following the requirements of the tightness class IP65.
The system concept is modular to allow applications with up to 430 channels. The application of the MCM-MasterModule enables a monitoring of the individual cell voltages with sample rates up to 1000 sps full parallel. Applications with more than 400 channels can be scanned up to 500 sps. For the disclosure of the data, free configurable Ethernet, CAN and GPIO interfaces are included.

Cell Monitoring

  • Low temperature application down to -40 °C
  • Communication via LAN, CAN and GPIO
  • Fast sampling with 1000 sps maximum
  • Internal data pre-processing within the MCM-MasterModule
  • Scalable
  • Tightness class IP65 (plugs in connected state)
  • Switchable measurement range -1 V up to +5 V or -3 V up to +3 V
  • Resolution 16 bit
  • Channel isolation 1.400 VDC
  • Configurable channel suppression

6-channel tester for endurance testing of brake control units

The functional testers for durability testing of parking brake control devices typically consists of 6 slots (subracks). Each is an independent functional unit and has an internal ARM9-based process control computer, via an individual test sequences can be defined and carried out using the Lua scripting language.

An essential key component is the SMART own high-precision wheel speed simulation for mapping complex types of sensors. To operate ECU-specific I / O channels individually developed MCM-plug-in module is used. To reduce costs, a high-quality high-current constant is used and the power Power distributed over a server to the six samples. Due to its modular and autonomous structure of each Subracks these stand-alone can be used.

Endurance Tester

Controll Unit for Elekctronic Park Brake

  • 6-channel modular fully parallel function tester
  • PC independent, long-term stability and real-time compliant test environment
  • Key component: high-precision Raddrehzahlsimualtion
  • Script-based test processes in the language Lua
  • A high-power constant for all six samples
  • Using an int. or ext. Load
  • Built IPC for Test Management
  • For touchmonitor streamlined interface for configuration and monitoring
  • Piece related ECU- and load wiring harnesses

Each channel has the following data:

  • 6x current measurement with different measuring ranges
  • 5x voltage measurement (-50 V to +50 V, resolution 10 mV)
  • 5x communication interfaces (2x CAN, 2x FlexRax, 1x LIN)
  • 4x wheel speed simulation (Programmable sensors eg. DF11, OH223)
  • 26x custom channels that can be configured dindividuell

Convertible top test

By Befundungstester the mechanics of a convertible top is checked. For this, the hood is mounted on an apprenticeship. The soft top is closed and then measured electronically. The test program is just in front of where the gauges must be placed.

Diagnostic Tester

Mechanical Convertible Top

  • E / E equipment the entire top test bench
  • Integration of various gauges and laser measurement
  • Integration Communication Interface
  • Current measurement of the rear window defogger
  • Reading the gauges

Endurance testing of control units for object recognition

The functional testers for durability testing of ECUs in the area object detection - Driver Assistance consists of 4 slots (Subracks). With each insertion two specimens can be served. Each is an independent functional unit and has an internal ARM9-based process control computer, via an individual test sequences can be defined and carried out using the Lua scripting language.

To configure and to monitor the test rig also includes namely an industrial PC, however the subracks operate autonomously. An individual touch-screen user interface is used for configuring before test start and the monitoring of the measured data during the test cycles. Another key component is a custom-developed plug-in module for use MCM-ECU-specific I / O channels and a per candidate controllable low-power constant for starting individual test points. Due to its modular and autonomous structure of each Subracks these stand-alone can be used.

Endurance Tester

Control Unit for Autonomous Driving

  • 8-channel fully modular parallel function tester
  • PC independent, long-term stability and real-time compliant test environment
  • Key Component: customized load / measuring assembly
  • Script-based test processes in the language Lua
  • Integrated power supply of control units
  • Built IPC for Test Management and Monitoring
  • For touchmonitor streamlined interface for configuration and monitoring
  • Piece related ECU wiring harnesses

Each channel has the following data:

  • 3x current measurement with different measuring ranges
  • 3x voltage measurement (-50 V to +50 V, resolution 10 mV)
  • 2x communication interfaces (Ethernet, GMLAN)
  • 17x custom channels that can be configured dindividuell
  • 1x ECU power supply (0 V to 30 V / 0 A to 30 A)

Function tester for ECU for anti-lock brakes

By functional testers for ABS ECUs individual function modules of control unit hardware can be tested. To this end, various simulation and measurement technology components from the MCM family of products are installed in the test system. Special loads can be connected via an additional load connector. If the built-in measurement and stimulation channels are not sufficient, additional modules can be upgraded.

A standalone ARM9-based process computer allows complete control of the test sequences using the scripting language LUA. These scripts are provided with basic knowledge of scripting easy to create MCM PROCESS Studio under the development environment. Made available prepared script modules that can be used in the endurance testing later.

Functional Tester

Control Unit for Anti-Lock Brake System

  • 50-channel function tester
  • Expandability
  • Signal tapping on honeycomb field
  • PC independent, own, long-term stability and real-time compliant test environment
  • Key component: Signal and fault simulation module
  • Signals can be switched to 2 FailRail
  • script-based test sequences (LUA)
  • Built IPC for Test Management
  • Piece related ECU and load wiring harnesses
  • 10x current measurement with different measuring ranges
  • 16x voltage measurement (-50 V to +50 V, resolution 10 mV)
  • 3x communication interfaces (CAN)
  • 4x wheel speed simulation (Programmable sensors eg. DF11, OH223)
  • All ECUs pins can optionally be switched to 2 FailRails
  • 1x ECU power supply (0 V to 30 V / 0 A to 127 A)

Function tester for gearbox control units

By functional testers individual function modules of the ECU hardware and software are tested. For this purpose, different simulation and measurement components are built into the test system. If the complete control of the tester via the CAN bus.
In Tester a central power supply for the device under test is installed, which is both controlled manually via a potentiometer on the front panel or automatically using internal analog voltage input. The control of the supply relay (KL30, KL15) may also be manual or automatic. The integrated separation adapter signals can be separated in the laboratory or picked for measurement purposes. Special loads are connected directly via a load connector. About an additional, also independently mobile use fault simulation module (TCFS-BOX), the ECU signals automatically disconnected, shorted together or are connected to two fault paths. The potentials of the error paths can be freely selected.

Functional Tester

Control Unit for Gears

  • 70-channel function tester
  • Signal tapping on integrated separation Adapter
  • Manual operation of the power supply incl. KL30 / KL15 connection
  • Control of Funktionsstesters via CAN
  • Integrated ECU power supply
  • Piece related ECU and load wiring harnesses
  • Direct connection for automated Fehlersimulationsbox
  • 35x current measurement with different measuring ranges
  • 35x voltage measurement (-50 V to +50 V, resolution 10 mV)
  • 3x communication interfaces (CAN)
  • 4x wheel speed simulation (Programmable sensors z. B. DF11, OH223)
  • 18x voltage Simulation (0 V to 5 V / 0 V to 10 V)
  • 1x ECU power supply (0 V to 45 V / 0 A to 20 A)
  • ...

HiL test system for fuel cell control systems

System that allows developers to test fuel cell control systems based on SIMATIC S7 without requiring a real fuel cell. The test system is based on the Hardware-in-the-Loop-principle – the voltages of the fuel cell stack als well as all relevant environmental parameters are simulated.

The test environment combines the MCM-IntelliProbe modules for monitoring and simulating cell voltages with the I/O modules of the MCM productfamily. The latter simulate relevant environmental factors such as pressure, temperature or certain switching states and measure the output values of the control unit.

Diagnostic Tester

Diagnostic Tester

  • 2-channel modular fully parallel softwate tester for SIMATIC-S7
  • Automatic switching between different analog inputs of the SIMATIC
  • Testcontrol via LabView
  • Expandable
  • Expandability
  • Signal tapping at the front
  • Build-in IPC for Test Management
  • Communication via Profibus / CAN

Each channel has the following data:

  • 32x digital input
  • 32X digital output
  • 12x current simulation (source) (0 mA to 50 mA)
  • 6x current simulation (source) (-20 mA bis +20 mA)

MCM-LabCar - Environmental simulation for engine control units

The MCM-LabCar is a flexible test system for testing the hardware and software of a control unit. For the software test, the environment of the control unit is simulated with the aid of the test system. The system is used in development-accompanying hardware function tests, system tests, production tests or in the diagnostics of field returns.

Due to the modular design, the test system can be easily adapted to later applications. This is done by installing additional test components.

Functional Tester

Control Unit for Engine Control

  • Expandable due to modular design
  • Hard- and software function test
  • Signal tap via honeycomb panel
  • Automatable via Python scripts

Monitoring of Redox Flow Batteries

The system consists of two modules. The power supply module and the measurement module. In supply module, the system is connected to the 230 V mains and provided the supply voltages for the measuring module.

In metrology module measuring channels of CVMpro-G4 MCM IntelliProbe are performed on secure terminals that provide the interface to the system under test. The Ethernet interface can be communicating with the measuring system. For a Modbus gateway is used, which assumes the implementation of system-side CAN on the user-side Modbus TCP protocol.

  • Supply voltage is disconnected from the metrology
  • Communication via MODBUS
  • Fast scanning max. 1000 PLC
  • Expandability
  • Measuring range -1 V to +5 V
  • Resolution 16 bit
  • Channel isolation 1.400 VDC
  • Configurable channel suppression

Plug 'n Play fuel cell monitoring for the test bench technique

The key requirements for measurement technology in the field of test bench applications are optimized handling properties. The integration of the system within a test rig environment has to occur easily with respect to assembly and disassembly. Moreover, a large variability concerning the test samples to be examined is required. This is especially true in the field of functional mock-up interfaces (FMI).
In the implemented solution, the measurement modules (MCM-IntelliProbe) and the process module (MCM-MasterModule) are housed within a 19"-rack, which allows simple integration or removal. Thus, the cell voltage monitoring units (CVM) can be exchanged between the FMI in any order. The connection of the measuring lines occurs via HV-qualified connectors. Moreover, additional taps for HV-- and HV+-signals are present. A wide range of test samples can be connected with the cell voltage monitoring unit via the customized harnesses.
The manifold blocks for power supply and communication lines may be placed either at the system side walls or at the back. Concerning this topic, we can react flexibly to customer-specific requirements. The cell voltage monitor is therefore characterized by a test bench suitable, strictly customer-oriented technology.
The system concept is modular to allow applications with up to 430 channels. The application of the MCM-MasterModule enables a monitoring of the individual cell voltages with sample rates up to 1000 sps full parallel. Applications with more than 400 channels can be scanned up to 500 sps. For the disclosure of the data, free configurable Ethernet, CAN and GPIO interfaces are included.

Cell Monitoring

  • Plug 'n play design for a flexible system integration
  • Communication via LAN, CAN and GPIO
  • Fast sampling with 1000 sps maximum
  • Internal data pre-processing within the MCM-MasterModule
  • Scalable
  • HV-qualified connectors
  • Switchable measurement range -1 V up to +5 V or -3 V up to +3 V
  • Resolution 16 bit
  • Channel isolation 1.400 VDC
  • Configurable channel suppression

QA Test for wobble deviation

With the EOL tester functions of the ABS sensor and the associated sensor wheel are checked on a vehicle axle. The tester can be determined whether or not the air gap between the sensor and trigger wheel is too big or too small. With a suspension of a tester both axes can be checked.

Diagnostic Tester

ABS-Wobble-Ring

  • Both sides of an axis can be checked simultaneously
  • Speed independent evaluation of the sensor signal
  • Result Display via LEDs
  • Transmission of results to a control center computer
  • Input resistance typ. 5 kΩ

TCFS Box - error simulation on ECU PINs

The TCFS box is used for error simulation on control unit pins. It is usually used in conjunction with a test system.

Various errors can be applied to signals:

  • Open
  • Short circuit between pins
  • Short circuit to Failrail 1 (eg BAT +)
  • Short circuit to Failrail 2 (eg BAT-)

All signals which are applied to the connected test system can be subjected to these errors. In addition, further signals can be fed in via jacks on the front panel or permanently bridged.

  • Applicable also in the vehicle

Test system for hardware and software functions of automotive ECUs

Test system for development-accompanying hardware function tests or system tests on embedded automotive control units (ECUs).

Functional Tester

  • Signal tap via honeycomb panel
  • ECU adaptation is done by two ZIF connectors

Test system for system frost tests on urea injection systems

The test system verifies the freezing robustness of urea injection systems. It provides the necessary control of the injection systems in a connected climate chamber and the associated measurement technology.

Up to 12 test pieces can be connected to the test system. It does not matter if it is DUT with or without EDU (Electronic Dosing Unit). The system can control both types of devices under test. The selection of the test object is made via the user interface.

The test system is divided into two parts for six test pieces each. Such a unit is called a BANK. Each BANK is controlled by a control computer (MCM MainControl). Each examinee has its own, controllable power supply. Furthermore, each test specimen has its own hose heater. The test procedure is controlled by scripts.

Universal tester for automotive control units and components

The diagnostic tester is much more in the OEM quality assurance for various automotive control devices and components in the powertrain, driver assistance, driver safety used. All resources of the tester (500 channels) are performed on a centralized test adapter interface with high contact service life on which the specimen-test adapters are connected via the quick-change mechanism. In the test adapter, the actual allocation of system resource occurs. The specimen itself is typically contacted via a needle bed adapter with separate Kipphebelmechanik. If another controller to be tested, the test adapter is changed and the appropriate software configuration loaded. This takes only a few minutes. Through an adapter detection mating between hardware and software is checked. The control computer contains no aware test system-specific hardware and can be easily exchanged.
If the complete control of the test sequences on PROVEtech:TA under a Basic-based scripting language. The software already includes an automatic script and version management of all Prüflingsvarianten- and equipment.
In order to solve customer queries faster a global remote access and remote maintenance has been established.

Diagnostic Tester

Control Unit for Airbag, Control Unit for Anti-Lock Brake System, Control Unit for Bodycontroller, Control Unit for Electronic Ignition Lock, Control Unit for Engine Control

  • 500 channels with varying degrees
  • Quick-change mechanism for for the device under test
  • Conversion time between two specimens max. 3 min.
  • Control testing over PROVEtech:TA
  • System computers without specific fittings - exchangeable at any time
  • Extendable through modular design
  • Tap important signals to the front
  • Included all major communication buses (eg. CAN, LIN, FlexRay)
  • 6x power supply (high and low current max. 40 V / 60 A)
  • 64x measuring signal relay matrix (max. Schaltsrom 1 A)
  • 192x switching channels (max. Schaltsrom 1, 5, 10, 25 A)
  • 24x current measurement (max. -25 A to +25 A)
  • 4x quiescent current measurement (-10 mA to +10 mA)
  • 24x current measurement (-50 V to +50 V)
  • 8x analog signal detection (0 V to 10 V, 16 bit resolution)
  • Communication with the control unit (4x CAN, LIN 2x, FelxRay, OBD, Ethernet)
  • . . .