Embedded Software Automation Testing

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Automation & Test

DISTek’s approach to test ensures the development of extensible, configurable, modular, and scalable test systems that serve customers over time. We are a premier HIL (Hardware-in-the-Loop) solution service provider for mobile equipment manufacturers. Our dedicated team of experts pulls from 50+ combined years of HIL system experience and 30+ combined years of control and plant modeling knowledge.

Past DISTek projects include applications that leverage the power of tools like FPGA, CAN, NI LabVIEW, NI VeriStand, and NI TestStand. To provide the best and most up-to-date expertise available, DISTek engineers attain and maintain certifications, and the DISTek staff includes more than 15 National Instruments Certified Architects, LabVIEW Developers, TestStand Architects, Professional Instructors, and, proudly, home to one of the world’s few LabVIEW Champions.

HIL Platform Extension

Customer Challenge: Improve and support the ability to test many different ECUs and simulate full vehicle systems for several different vehicle models.

DISTek Solution: Built upon a HIL testing platform that includes extensive vehicle software simulations with a proprietary hardware interface to allow loading and unloading of different vehicle hardware on demand. This allows the customer to test a particular vehicle ECU configuration, in-vehicle display, or the full vehicle system with the HIL, and easily swap to other vehicle models as needed.

Additional Projects	Dev. Platform	Industry	Project Type	Project Summary
Modular HIL	LabVIEW, Veristand, cRIO, FPGA	Agricultural, Construction, Forestry	ECU Tester	Expand Summary
DISTek developed a HIL system to improve embedded solution testing. This HIL was designed to be both flexible and fast by simulating a wide array of signals and allowing the user to configure software channels based on their hardware inputs. This HIL was designed to be portable and uses NI cRIO chassis with FPGA.
Planter Simulator	LabVIEW, Veristand, MXI, FPGA	Agricultural	System Simulator	Expand Summary
Designed and built a HIL test stand with reconfigurable I/O for testing a variety of controllers. The system used National Instruments MXI-Express hardware, Veristand Real-Time engine and LabVIEW FGPA. Reconfigurable hardware interfaces and LabVIEW FPGA personalities were employed to accommodate various controller setups and provide a high channel count for testing.
Remote Simulation Manager	LabVIEW	Agricultural, Construction, Forestry	Simulator Support	Expand Summary
Provided customer with a software application written in LabVIEW utilizing VI Server that could remotely connect to and control multiple SILs and HILs in a testing lab.
Portable Rugged HIL	cRIO, LabVIEW	Agricultural	System Simulator	Expand Summary
Designed and assembled a portable rugged HIL for a customer to be used for training and marketing purposes. We also provided a GPS Simulation custom device developed for NI Veristand.

Transmission Control

Customer Challenge: Specify and integrate controls for a transmission remanufacture end of line test aimed to detect improper assembly or defective parts in the transmission.

DISTek Solution: Used a National Instruments cDAQ and LabVIEW to create an application capable of shifting through gears via CAN communication to the transmission control unit, monitoring for proper torque characteristics at the input and outputs of the transmission, precisely controlling the VFD speed and torque commands via Ethernet I/P, and doing a full FFT analysis of vibration present in the system.

Additional Projects	Dev. Platform	Industry	Project Type	Project Summary
Dyno Control Systems	cDAQ, LabVIEW	Automotive	Instrumentation, Controls	Expand Summary
Upgraded instrumentation and dynamometer control systems for customer including portable data acquisition systems capable of synchronized high speed data capture over numerous signal types.
Fuel Injection System	NI PXI, NI LabVIEW	Off-highway	DAQ, Control	Expand Summary
Simulated an eight-cylinder diesel engine with microsecond fuel delivery control and measurement to test the functionality of fuel injectors in a real-life system. Created a test bench that uses NI DRIVVEN tools to test the electrical profile for each injection and the rail pressure control and measurement of delivered fuel per injection.
Hydraulic Cylinder System	PXI, EtherCAT, NI VeriStand, NI LabVIEW	Agricultural	Automation, DAQ	Expand Summary
Designed test stand that can perform Calibrated Accelerated Life Testing (C.A.L.T.) on hydraulic cylinders. This solution is fully extensible with modeling capabilities, customizable test scenarios & supports a wide range of sensors. The design allows for re-creating in a test lab dynamic field conditions the cylinders encounter. Future capabilities will include a test profile to be recorded at a mobile machine and then played back in the test lab.
Robotic Module Swapper	LabVIEW, cRIO, FPGA	Agricultural, Construction, Forestry	Test Automation	Expand Summary
Used a National Instruments cRIO, FPGA, and LabVIEW to control a system comprised of a rack that housed different hardware assembly modules and a moving shuttle underneath the modules with high density connectors mounted on it. The RT application controlled the shuttle, moving it up and down the module rack connecting to modules as decided by the client HIL system. The system had robotic grade cabling and precision, and the customer has since purchased two more of these units due to their high level of performance, quality, and time savings in an automated test environment.

End of Line Vehicle Test

Customer Challenge: End of line vehicle test that prompts an operator through the test while assuring that all test conditions are met as well as log the test data for analysis.

DISTek Solution: LabVIEW and TestStand on a tablet PC and NI cDAQ hardware in a portable rugged enclosure. Channels, variables, and memory can be monitored for out of range conditions. The test pauses and prompts to return parameters to their in range state. DTCs can be monitored. Vehicle options are pulled from a database based on the serial number and test sequences are run automatically.

Additional Projects	Dev. Platform	Industry	Project Type	Project Summary
EtherCAT Controller Tester	cDAQ	Agricultural	ECU Tester	Expand Summary
Utilized a National Instruments cDAQ to read sensor data and broadcast over EtherCAT to a controller under test as well as read outputs from the controller for troubleshooting purposes.
Modbus Waveform Tester	LabVIEW, TestStand	Industrial	Test Stand	Expand Summary
DISTek implemented a LabVIEW and TestStand based test application that allowed the customer to create "normal" waveforms as well as non-standard waveforms with induced errors in timing, amplitude, phase, and missing or extra pulses. The controller's status was monitored via Modbus and by analyzing the controller's analog and digital outputs.
Wi-Fi Sniffer	LabVIEW	Agricultural	Analysis	Expand Summary
A Wi-Fi "sniffing" device was used to capture communications between two devices without interruption. The captured data was processed live to look for traffic specific to the two devices. The packets were parsed and specific data was displayed to indicate the quality of the communication as well as any errors that were detected.
Vehicle Simulators	LabVIEW	Agricultural, Construction, Forestry	Simulator	Expand Summary
Developed multiple vehicle simulators for a customer that communicated via J1939 CAN wirelessly to their external application for testing. Vehicle controls and parameters were able to be manually changed as well as scripted. Manual GPS driving was also simulated as well as basic scripted angular navigation.

Sub-Assembly and Motor Tester

Customer Challenge: Design an end of line sub-assembly tester capable CAN communication to and testing of a DC motor drive enclosure for proper wiring and functionality.

DISTek Solution: Designed a mobile test bench using a National Instruments PXI chassis, controlled with LabVIEW and TestStand components. The system was capable of verifying all wiring, communicating shorts, improper connections or voltages,and able to control the UUT via CAN communication, setting parameters, and verifying the unit was capable of running through all states of normal operation.

Additional Projects	Dev. Platform	Industry	Project Type	Project Summary
Automated Testers	PXI, TestStand	Agricultural, Construction, Forestry	Test Automation	Expand Summary
Created multiple automated test solutions for a customer using NI PXI and NI TestStand to test various subassemblies, saving time and money by eliminating the need for manual operator verification testing.
Display Tester	cDAQ, .NET	Construction	Test Automation	Expand Summary
Used a National Instruments cDAQ and a .NET application to control a system complete with XY Table, pneumatic plungers, and Cognex smart camera. The XY Table maneuvered the display into position, the pneumatic plungers were triggered to simulate button presses, and the camera was used to effectively identify any problems with the screens.
Extensible HIL Tester	LabVIEW	Agricultural	HIL System	Expand Summary
Design and implementation of an extensible HIL test system for the testing of agricultural transmission systems. End user requirements stated the need for being able to develop code in house for use in the final application. Extensibility of the final system was realized through the use of a software architecture based around the loading and executing of compartmentalized code modules. By allowing the application to load code modules, and developing the application in code modules itself, the end users were capable of modifying the final system as well as receiving a library of already built and functional code modules to use as templates.
Process Control Application and Database	SQL, Access, SAP	Agricultural	Database	Expand Summary
Designed and created an SQL database to upgrade an existing process control application that was written in Access. Added additional functionality and support to the application, including programmatic integration with SAP.

Modeling
& Simulation Embedded
Software Automation
& Test

Featured Case Study

Developing a reconfigurable ECU Test System

Using FPGA technology, DISTek developed a reconfigurable ECU test system.

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Featured DISTek Expert

Name:

Gene

Title

Senior Test Engineer

Technical Strengths:

Test Systems Engineering, Industrial Automation, Hydraulics, Electro-Hydraulic Control Systems, Reliability Engineering, Quality Engineering, Electronics, Mechanical Systems, Sensor Technologies, PAC's, PLC's

Past Experience

20+yrs as a Test Systems Engineer for various industries and Regional Reliability Laboratories Management for a Fortune 500 Company.

DISTek Employee Since:

2006

What I love about my job:

The broad range of project technologies that I get exposed to at DISTek call on and expand the technical strengths I've attained over my career. As technology grows, engineers are challenged with coming up with new ways to test their products. Designing the test solutions for these products is an extremely rewarding experience.

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DISTek Integration, Inc.