Modular End-of-Line Test Stand for maximum operational reliability and reproducible measurement results

With the CLEA 2 End-of-Line test stand, SPIE AUTOMATION has created a complete replica of an existing test system. The solution provides identical functions and measurement results as the previous test stand, is technically up-to-date, and creates the necessary redundancy for permanently secured production.

Challenge and Objective

The customer tests 100% of its assemblies before delivery. The assemblies are used in technically demanding systems, where they perform safety-relevant height adjustment functions. Accordingly, the demands on precision, reliability, and traceability of the test results are high. Until now, the entire production was completely dependent on a single End-of-Line tester. Every assembly passed exclusively through this system. A failure would have immediately led to a production standstill. Against this background, the customer’s goal was to implement a second, fully functional test stand to increase operational reliability and create redundancy in production. Additionally, the challenge was to replicate a test stand that was about ten years old. Numerous components of the measurement, control, and safety technology were discontinued or no longer available. At the same time, it had to be ensured that the new test stand offered exactly the same functions and delivered identical measurement results. A central goal was also to retain the existing operating and testing software unchanged, so that operating personnel could work on both systems in parallel without additional training.

Solution

The implementation was carried out by the SPIE AUTOMATION Haßfurt branch team. Initially, the requirements specification and the existing End-of-Line tester were analyzed in detail. All functional and technical requirements for mechanics, electrics, and software were recorded, especially limit values, interfaces, safety functions, and real operating conditions. Based on this, the mechanical design of the test stand was newly developed and released for production after close coordination with the customer. In parallel, modern, available electrical components were selected that meet the high demands for precision, reliability, and safety. The complete system concept – consisting of mechanics, electrics, and software architecture – was presented to the customer, coordinated, and approved. Subsequently, mechanical production, control cabinet construction, and electrical installation began. The existing PC-based test software was specifically adapted to the new hardware. The user interface, test sequences, and user guidance remained deliberately unchanged. This allowed the new test stand to be seamlessly integrated into existing production. After electrical commissioning, the PC program was integrated, and the entire system was put into operation. All functions – from the calibration of the integrated measurement technology and the testing of the servo drive with absolute encoder to the function and holding test of the electrical brake – were extensively tested. For realistic testing, a defined weight is attached to the assembly during tests, simulating the later load in use. For validation, several test specimens were measured on both the existing and the new test stand. The direct comparison confirmed identical measurement results. Only then was the system approved by the customer. All measurement and calibration data are stored and documented for each individual component. Finally, the complete technical documentation was prepared, including circuit diagrams, parts lists, software and operating descriptions, and safety considerations. The system was designed to be CE-compliant and handed over with all necessary documents.

Benefits

The customer now has a second, identical End-of-Line test stand. A failure of the existing system no longer leads to a production standstill. Production is secured, redundancies have been created, and delivery dates remain stable. At the same time, the testing technology is state-of-the-art. Discontinued components have been replaced, and the system is maintainable and future-proof in the long term. The unchanged user interface allows employees to work on both test stands without additional training. This increases operational safety, reduces risks, and sustainably secures production.

These SPIE AUTOMATION Strengths Were Applied

High flexibility in implementation and rapid adaptation to modern measurement technology
Many years of experience in testing technology
High code quality according to LabVIEW programming standards
Complete Development Service from a Single Source
Development of individual and tailor-made solutions
Simple company structure for uncomplicated project execution
Flexibility in time management to meet customer-specific deadlines

About our customer
Our customer is a leading international provider in the field of linear technology and drive systems. With decades of experience, the company is one of the globally established manufacturers of technologically sophisticated components and solutions for industrial applications, particularly in automation and mechanical engineering.

Industry
Mechanical Engineering

I am very satisfied with the project implementation. We delivered a complete test system to the customer on schedule, equipped with state-of-the-art measurement technology and providing exactly the same measurement results as the existing test stand. At the same time, the solution creates maximum operational reliability and redundancy in production.

Uwe Schweinfest
Software
SPIE AUTOMATION

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