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Automated Test Stand Design

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Multiplexing: Reduce Cost and Complexity

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Circuit Design, Custom Software and Hardware Development, Energy and Utilities, Green Technology, LabVIEW Programming, Telecommunications, Test and Measurement, Test and Measurement Automation

Multiplexing (Muxing) is an operation that selects one of many electrical signals and forwards the input into a single line. Demultiplexing (Demuxing) does the same operation, but in reverse, taking one electrical signal and outputting it onto one of many different wires depending on a selection. Muxing is an effective and relatively inexpensive wiring strategy that could reduce your circuit complexity and save you money. DMC has helped to implement muxing schemes on multiple projects and has witnessed...

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Consumer Product Turnkey Appliance Test System with Power Measurements using LabVIEW

Posted in Automated Test Stand Design, Consumer Goods, Data Analysis, Data Mining, and Reporting, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, Test and Measurement, Test and Measurement Automation

DMC developed a complete turnkey appliance test lab for a major manufacturer. The lab consisted of several custom-designed test-stands for conducting a variety of tests on ovens, cooktops, microwaves, clothes washers and dryers, dishwashers, and refrigerators. Several transducers were attached to the appliances and data was collected using custom software written by DMC. Both the hardware and software were designed to the customer’s specifications in order to facilitate comparisons to other...

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NASA Battery Simulation System

Posted in Aerospace, Automated Test Stand Design, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC leveraged our established Battery Management System (BMS) Testing Platform to deliver an automated Battery Simulator System to a NASA research group. NASA needed this system to facilitate development of highly specialized battery devices. These battery systems were designed to provide mobile power for advanced electromechanical systems such as Robonaut 2, a dexterous humanoid robot created to perform a wide range of tasks to assist astronauts on the International Space Station. The Battery Simulator...

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EV/HEV Battery Pack Environmental Exerciser/Monitor System

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC designed, built, and programmed a set of automated test stands for charging and discharging electric vehicle battery packs. The test stands also monitor the performance of these battery packs while exposed to harsh environmental conditions for extended timeframes. To provide the necessary testing bandwidth and flexibility required by the customer, DMC's solution included five test stands designed to test a single battery pack, and two test stands designed to test up to six battery packs at...

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Turnkey Solution for Food and Beverage Product Testing

Posted in Automated Test Stand Design, Business Intelligence, Data Analysis, Data Mining, and Reporting, Food and Beverage, LabVIEW Programming, Microsoft Consulting Services, SQL Server BI, Test and Measurement, Test and Measurement Automation

DMC designed and developed a custom test station and software for a beverage carbonator line to check for pressure leaks. The client needed a pressure decay test for a sub-assembly valve manifold in a restaurant-grade consumer appliance. DMC worked with the client to replicate and improve upon the manual test procedure, including interactive control and retesting ability. The product delivered was a complete, custom turn-key solution, involving mechanical, electrical and software engineering. Pressure...

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Pediatric Hospital Test Chamber with LabVIEW FPGA

Posted in Automated Test Stand Design, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, Pharmaceutical & Medical, Test and Measurement, Test and Measurement Automation

DMC was approached by the Ann & Robert H. Lurie Children’s Hospital of Chicago to develop the world’s only Thermoregulatory Chamber designed and built from the ground up specifically for children. DMC worked with the hospital clinicians, researchers, architects, and construction crews to deliver this one-of-a-kind solution.

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Battery Control Unit Tester for Remanufacturing and Warranty Servicing Process

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Energy and Utilities, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC utilized the DMC Battery Test Platform to develop a Test Control Panel software application to perform automated testing of the Battery Control Unit (BCU) for a Client's automotive lithium ion battery pack. This test system allowed the Client to instate an efficient process for evaluating the operating state of the Battery Control Units in battery packs returned under warranty claims, and thereby greatly reduced the cost of servicing these warranty claims.

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Battery Test System for Pack Remanufacturing and Warranty Servicing Process

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Data Analysis, Data Mining, and Reporting, Energy and Utilities, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC utilized the DMC Battery Test Platform to develop a Test Control Panel software application to perform automated testing of a Client's automotive lithium ion battery packs. This test system allowed the Client to instate an efficient process for evaluating the operating state of battery packs returned under warranty claims, and thereby greatly reduced the cost of servicing these warranty claims.

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End of Line Test Station for Beverage Dispensing Valves

Posted in Automated Test Stand Design, Business Intelligence, Consumer Goods, Data Analysis, Data Mining, and Reporting, Food and Beverage, LabVIEW Programming, Microsoft Consulting Services, SQL Server BI, Test and Measurement, Test and Measurement Automation

DMC supplied a fully automated end-of-line tester for high-end beverage dispensing valves. The system tests and calibrates each valve to ensure that it meets the client's stringent manufacturing standards. The test stand supplies varying pressure water to the valve throughout the test to simulate different real-world conditions. During each phase of the test, extremely accurate coriolis flowmeters within the test stand continuously monitor the flowrate through each section of the valve to...

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Relay Multiplexer Module with .NET Driver Library

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Circuit Design, Custom Software and Hardware Development, Embedded Development and Embedded Programming, Energy and Utilities, Green Technology, LabVIEW Programming, Product Development, SDK, API, and Driver Development, Test and Measurement, Test and Measurement Automation

DMC delivered a low cost, high density Relay Multiplexer Module for a high channel count test application for a client in the performance racing automotive sector.  DMC provided the client with multiple methods for controlling and operating the device, including a soft front panel interface, a library of LabVIEW drivers, and a DLL package of .NET drivers.

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Custom Relay Multiplexer System for High Channel Count Data Acquisition

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Embedded Systems, Energy and Utilities, Green Technology, Product Development, Test and Measurement, Test and Measurement Automation

DMC designed and developed a relay-based multiplexing system for a Client's large-channel-count data acquisition system. For this project DMC was required to produce a reliable, yet low-cost, system to make current and voltage measurements using a high accuracy Digital Multi-Meter (DMM) on over 200 signal lines with 1kV isolation.

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Portable Battery Management System (BMS) Testing Demo

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

An international partner requested a small scale Battery Management System (BMS) Test Station for demonstrating the basic battery simulation functions of a much larger test system. DMC responded by building a Demo Test Station that is easily transportable while still fully capable of simulating all the input signals (voltage, current, temperature) to a 6-cell battery pack BMS.

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Battery Stack Simulator for Hardware in the Loop (HiL) Testing of Electric Vehicles

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Energy and Utilities, Green Technology, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, Product Development, Test and Measurement, Test and Measurement Automation

 A battery stack simulator for hardware-in-the-loop (HiL) test systems is being produced by DMC to augment the capabilites of battery management systems (BMS) HiL test systems.  This system leverages DMC's vast hardware and software experience in Electric Vehicle (EV, HEV, PHEV) Battery Pack and BMS Testing.

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Battery Management System (BMS) Test Stand (2nd Generation)

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Energy and Utilities, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC built upon its previous Battery Test Platform design experience to produce a completely automated test system specifically designed for Battery Management System (BMS) validation, verification, environmental, and Hardware in the loop (HWIL/HIL) testing. Numerous new features and functionalities were implemented in this second generation version of DMC's BMS Test Stand to meet the customer's latest testing requirements. To fully evaluate a BMS, the first challenge is to simulate all...

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Hydrogen Fuel Cell Customizable Test Platform

Posted in Automated Test Stand Design, Automotive, Building Technology, Energy and Utilities, Green Technology, LabVIEW Programming, Product Development, Test and Measurement, Test and Measurement Automation

Through continued research, fuel cells are developing into a very efficient and clean production method to satisfy future electrical energy needs.  Fuel cells provide a number of critical benefits not present within many of the conventional energy production methods in use today.  Most notably, the energy provided by fuel cells is produced from hydrogen, a conversion which releases only air and water and creates no harmful emissions.  This characteristic is one of many reasons that...

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