Testsysteme

We provide specific, turnkey, fully automated test systems for customers around the world.

FROM A SINGLE SOURCE

Conception, project planning, design, manufacturing, assembly, programming, commissioning, training, service and support under one roof – hand in hand.

MODULAR CONCEPTS

By reusing assemblies and software as well as the project-specific use of standard components, implementation times are shortened and costs are reduced.

USABILITY

Special emphasis is placed on the user-friendly, intuitive and multilingual design of human-machine interfaces.

EXAMPLE TEST
SYSTEMS

Robot-based door module test system

  • Testing of all door module components (window regulator, lock, speakers, KG antenna, crash sensor, etc.)
  • Universal, automatically adjusting receptacle for different door module variants
  • Robots for variant changeovers and camera-based tests
  • 3D positioning systems for individual receptacle assemblies
  • Image processing integrated into the control software (online/offline configuration)
  • Communication with LIN/CAN control units
  • Control of the robot and multiple servo drives via the PC system software
  • Connection to order control system
  • Labeling of the door module
  • Documentation of the test results, incl. photos

LED module test/parameterization/
calibration system

  • Use of different module ICs (Melexis, Elmos, etc.)
  • 5 processing stations, panel loader, panel unloader
  • Automatic feeding of panels from the magazine
  • Flashing of module software
  • Serial number allocation (unique across multiple systems)
  • IC function tests (auto-addressing, temperature sensor, etc.)
  • Burning-in (up to approx. 60 seconds)
  • Spectrometer measurement of the color and brightness of the color chips
  • Calculation of parameters for calibration and writing to IC
  • Control of 26 servo drives, 8 LIN channels, 2 spectrometers, etc.
  • Cycle time per module ‹ 2 seconds
  • Documentation of all module data

Robot-based
UNI light test system

  • Lighting evaluation of light conductors and assembly components
  • Automatic adjustment of the robot gripper for different test object variants
  • Manual feeding or direct connection to injection molding process
  • Test objects are identified on an infeed conveyor and their position is determined
  • Gripping and positioning (LED or contacting by the first robot)
  • Image recording by camera on the second robot
  • Wide variety of evaluation methods
  • Marking of the light conductor or assembly component
  • Sorting and depositing in customer-specific packaging
  • Documentation of the test results, incl. photos

Seat rail test system

  • Crack testing on seat rails immediately after the stamping process
  • Automatic changeover for different variants (incl. feed-through mode)
  • 3D measurement and evaluation of cracks
  • Recording of bending radii using nine 2D profile laser systems
  • Image processing and image evaluation in 120 ms
  • OK/NOK sorting, incl. documentation
  • Processing time per seat rail ‹ 1.3 seconds

UNI window regulator/door module test system

  • Tests on different window regulator and door module variants during series production
  • Programmable real-time control for position-dependent window regulator load (electrical weight, NI cRIO)
  • Control via LIN and CAN (CANoe remaining bus simulation)
  • Servo drive for moving manual window regulators
  • Fast measurement technology via NI DAQ
  • Force measurement by means of window regulator stroke
  • Laser measurement for form testing
  • Programmable button control (resistance‐coded, time‐coded)
  • Universal receptacle thanks to manually adjustable receptacles for different window regulator/door module variants
  • Documentation of test results,
  • Generation of test/measurement log (PDF)

UNI lock test system

  • Tests for different lock variants during series production
  • Intuitive and reproducible positioning of the receptacle (x, y, z, incline)
  • Servo drive for positioning the load/measuring unit
  • Control via time-coded outputs or LIN
  • Servo drive pressure and tension measurement
  • Force measurement
  • Fast measurement technology through NI components
  • Manually adjustable variant-specific receptacles
  • Individually configurable test sequences
  • Documentation of test results,
  • Generation of test/measurement log (PDF)

Bumper test system

  • Optical presence test for integrated components (sensors, clips, …)
  • Safe DUT jig for different variants
  • Automatical transport
  • Automatical surface inspection
  • Automatical photo documentation
  • Type/variant identification via RFID
  • Documentation of the test results

Seat backrest test system

  • Structure-borne sound and electrical function test of the metal structure
  • Head rest adapter/simulation
  • Weight simulation with weights or motor
  • Automatic positioning of the acceleration sensors
  • Environment decoupling
  • Sound analysis
  • PWM motor control
  • PLC/PC controlled
  • Labelling and documentation of test results

Seat comfort test system

  • Function tests for pneumatic seat comfort modules (lordosis, lateral support, massage, etc.)
  • Load application on the individual air cushions
  • Path and time measurement for the aeration and ventilation of individual air cushions
  • High-precision pressure measurement
  • Pump simulation
  • Communication to the control unit via LIN/CAN/CANoe remaining bus simulation
  • Reading out and checking of control unit data (type, version, serial number, status, error information, etc.)
  • Exchangeable receptacles for different module variants
  • Labeling of the seat comfort module
  • Documentation of the test results

Door module test system

  • Series test of all door module components (window regulator, lock, speakers, KG antenna, crash sensor, etc.)
  • Two door modules can be tested in parallel in two receptacles
  • Communication with LIN/CAN control units
  • Reading out and checking of control unit data (type, version, serial number, status, error information, etc.)
  • Multiple vision sensors for installation tests
  • Connection to order control system
  • Labeling of the door module
  • Documentation of the test results, incl. photos

Tailgate test system

  • Endurance test of mechanical and electric tailgates
  • Damage-free adaption of the tailgate using vacuum
  • Direct testing of the complete tailgate on the vehicle possible
  • Testing of individual tailgate components using dummy structure
  • Two climate-proof servo drives
  • Servo‐controlled learnable movement curve
  • Actuation of the tailgate up to a speed of 2 m/s
  • Force and angle measurement
  • Tests performed at ‐40 °C to +85 °C
  • Remote control with emergency stop function

Dashboard test system

  • Presence check of all attachment parts on the dashboard
  • 8 industrial cameras for testing 25 characteristics
  • Infrared lighting for independence from daylight
  • Connection to order control system
  • Labeling of the dashboards
  • Documentation of the test results, incl. photos

Motor actuator test system

  • Series tests integrated into assembly line
  • Bosch transport system, incl. branches to various test systems
  • Automatic contacting and pinion adjustment
  • Reading out and checking of actuator data (type, version, serial number, status, error information, etc.)
  • Dynamic load control
  • Leak test
  • Establishing the delivery position
  • Automatic labeling of the actuator
  • Automatic removal of NOK tested actuators
  • Documentation of the test results

Interior lighting test system

  • Series test of lighting components for a homogeneous appearance in the vehicle
  • Evaluation of direct and indirect light
  • Test for components without LED modules (light is coupled in the system) and with LED modules or LIN LED modules
  • 3D printed parts to simulate the radiating surfaces of the vehicle (simulation of the installation environment)
  • Reading out and checking of LIN LED module data (type, version, serial number, status, error information, etc.)
  • Specially developed evaluation methods for optimal analysis
  • Graphic representation of the measurement data
  • Generation of reports about individual test objects, selectable time periods, statistical evaluations, etc.
  • Exchangeable disk system for multiple variants
  • Presence check of various attachment parts
  • Labeling of the lighting components
  • Documentation of the test results, incl. photos

Air conditioner test system

  • Functional test of all flaps within an air conditioner
  • Automatic contacting of all actuators (stepper)
  • Control of the LIN stepper
  • Standardization of the positions
  • Tests for reachability of the end positions
  • Establishing the delivery position
  • Reading out and checking of stepper data (type, version, serial number, status, error information, etc.)
  • Presence check of various attachment parts
  • Automatic transfer for further transport
  • Connection to order control system
  • Documentation of the test results

Bumper test system

  • Testing of all electrical components on a bumper (parking sensors, radar sensors, lights, etc.)
  • Position detection on cable harness
  • Reading out and checking of component data (type, version, serial number, status, error information, etc.)
  • Electrical height-adjustable shelf (if necessary, type-specific)
  • Cabinet system with 19“ flat surface and control cabinet
  • Type/variant identification via RFID
  • Labeling of the bumper
  • Documentation of the test results

Clutch master teach-in/test system

  • Linearization of the measurement curve and storage of parameters in the electronics of the clutch master
  • Precise positioning
  • Automatic fixing and contacting of up to 6 variants
  • Reading out and checking of clutch master data (type, version, serial number, status, error information, etc.)
  • Dynamic load application
  • High-precision measurement to record the actuating travel
  • Real-time control system (NI cRIO, Bosch drives)
  • Documentation of the test results

20 YEARS OF
TESTING EXPERIENCE

OVER 550 SYSTEMS
INSTALLED WORLDWIDE

ENDURANCE TEST SYSTEMS
60
QUALITY ASSURANCE SYSTEMS
70
END-OF-LINE TEST SYSTEMS
420

CUSTOMER SYSTEMS
IN THE AUTOMOTIVE SECTOR

Comprehensive solutions for wide-ranging test requirements

DECORATIVE ELEMENTS
DISPLAYS
ELECTRIC MOTORS
CENTER CONSOLES
WINDOW REGULATORS
SEAT BELT BUCKLES
GLOVE COMPARTMENTS
TAILGATES
DASHBOARDS
AIR CONDITIONING SYSTEMS
CLUTCH MASTER CYLINDERS
LIGHT CONDUCTOR ASSEMBLIES
AIR VENT SYSTEMS
REARVIEW MIRRORS
CONNECTING ROD DRIVES
SEAT COMFORT MODULES
SEATS
SPINDLE DRIVES
BUMPERS
DOORS
DOOR PANELS
DOOR MODULES
DOOR LOCKS

We develop innovative requirement-based solutions for variant-rich and demanding test objectives, test requirements, and test conditions. Ask us about the customer systems that we have provided for leading international industrial partners.

WHAT DISTINGUISHES US?

Superior software, interface and operating concepts

DRIVE.STUDIO

With Drive.Studio, we offer our customers an easy-to-operate, effortlessly expandable development system for your individual test environment. Functionality, interfaces, image processing, and visualization are combined in a single tool, and a wide variety of task can be performed easily and economically. Thanks to the integrated simulation mode, the software can be developed and operated without hardware and mechanics, which enables parallel implementation, thus saving time and money.


INTEGRATED SERVICE & SUPPORT

All of our systems contain functions that enable easy and cost-effective worldwide service and support.

WORLDWIDE REMOTE MAINTENANCE

ALL SYSTEM ACTIVITIES TRACEABLE FOR 31 DAYS

AUTOMATIC E-MAIL DISPATCH IN CASE OF FAULTS

SIMPLE SYSTEM UPDATES

CONTACT

How can we help make your project a success?
Let’s find out together!