Summary
DMC’s Test and Measurement team upgraded and standardized legacy LabVIEW code across a dozen test stands for a manufacturing client. The original code had been developed by an internal team member who had left the company, leaving the client unable to confidently make changes or maintain the codebase. With no version control system and no consistent software architecture across machines, the client’s test stands had become difficult to update and support.
The issue came to a head when the client’s IT department required an upgrade to Windows 11 in preparation for Windows 10 end of life (EOL). The client realized the existing NI FieldPoint hardware would be incompatible with Windows 11, prompting them to consider a full replacement of both test equipment hardware and software.
DMC’s Test and Measurement team took a different approach, providing expert guidance to modernize the system architecture. The updated design improved overall system performance while significantly increasing the client’s ability to maintain and evolve the system over time.
Customer Benefits
Reduced Rework
DMC’s NI hardware and software expertise enabled the right upgrade decisions upfront, meeting test requirements without unnecessary rework.
Improved Traceability
Version-controlled test stand software provides clear change tracking and reliable historical test data.
Operator Efficiency
Operator feedback drove software improvements that reduced manual effort, enabling faster testing and higher throughput.
Stronger Code Quality
DMC’s LabVIEW expertise improved development efficiency and code quality while reducing reliance on legacy systems.
Scalable Processes
Standardized software across consolidated test stands simplifies adding new procedures and ensures consistent interfaces and data logging.
Solution
Throughout the upgrade project, DMC worked closely with the client to replace NI hardware. The client had a small inventory of components remaining from a previous upgrade initiative, so the DMC team performed a cost analysis to determine the most effective way to reuse existing hardware while still meeting data acquisition requirements.
Key Technologies
- NI LabVIEW
- NI FieldPoint
- NI cDAQ
- TDMS Logging
DMC updated LabVIEW on a dozen test stands, migrating the data acquisition interface from NI FieldPoint to DAQmx. The team then reviewed the entire codebase and standardized both code structure and logging formats. As part of this effort, the team implemented TDMS logging to improve performance for long-duration tests and to support more reliable data storage. Additional code quality improvements included enhanced error handling, standardized E-Stop behavior, and more robust resource management.
To ensure the updated software aligned with current test workflows, the Test and Measurement team incorporated operator feedback into the final design. These updates included automating simple manual operations, adding controls for common processes, and expanding data visualization through additional graphing. DMC commissioned the new hardware and deployed the updated test software through a combination of on-site support and remote collaboration with the client’s team.
Result
Faced with unsupported hardware, undocumented legacy LabVIEW code, and a Windows 10 EOL deadline, the client needed a clear path to modernize their test systems without disrupting ongoing operations.
The DMC Test and Measurement team partnered closely with the client to address these challenges through a phased hardware and software upgrade. By migrating from NI FieldPoint to NI cDAQ, updating LabVIEW and DAQmx, and standardizing code architecture and logging formats, DMC delivered a more reliable, maintainable, and Windows 11–ready test platform.
As a result, the client now has a standardized, version-controlled test environment that supports traceability, reduces rework, and enables future expansion. The upgraded test stands are easier to maintain, simpler to modify, and better positioned to support a scalable and supportable foundation.
Moving from Windows 10 to Windows 11? Check out our recent guidance on updating LabVIEW for Windows 11 to ensure your test software is properly upgraded for Windows 10 EOL.
Facing a similar challenge with your test systems?
Our Test & Measurement engineers will help you scope a solution that fits your timeline, budget, and existing standards.