Case Studies

Automotive Sensor Testing and Programming

Posted in Automotive, LabVIEW, Manufacturing Automation and Intelligence, Test & Measurement Automation


DMC developed a new end-of-line test station for an automotive sensor manufacturing line. This system has shifted over the years from using a CAN Box system to using a system with TCP/IP communication. The new system tests and programs a wide range of different parts.

Sensor Part


DMC implemented modifications to the original CAN Box end-of-line tester to adapt to the new AJKA Reader/Programmer box that uses TCP/IP communication.

The new system waits for the PLC to send the part number of the sensor under test and the start request.  Using the part number, the LabVIEW program looks up the sensor in a text file where all the necessary information about the sensor is stored. This information includes the sensor type, how many channels it has, and how to program it if applicable.

Once the test starts, the LabVIEW program sends requests, using the built-in LabVIEW TCP functions, to the AJKA box. The box performs high resolution measurements of the sensor’s baud rate, high and low currents, and PAS data.  Also, if the sensor type can be programmed and the test station is a programming station, the AJKA box writes the necessary information to the sensor. If the test station is a verification station instead, then the AJKA box will read the information stored in the sensor and verify that the sensor has been programmed successfully.

Depending on the preset tolerances for these measurements, the test will either pass or fail, and the program will send the information back to the PLC so that the factory can keep track of what parts fail and what measurement caused the failure.  If the test fails, the LabVIEW program stops and sends the PLC a signal which alerts the operator to check the part in case it was a false reject.

Customer Benefits

  • Reduces cost and part production time due to automated end-of-line testing.
  • Increases quality and testing accuracy as a result of standardized automated testing.
  • Part tracking and statistical analysis allow process improvements and identification of most common failure modes.


  • NI LabVIEW
  • AB SLC 500 series PLC
  • Genesis Automation AJKA Reader/Programmer