• simultaneous test of up to eight valves over various periods
• file-based automatic and manual control
• cyclic storage of test state for resumption of aborted tests
• online error diagnostics, logging and emergency stopp based on variable parameters
• bus connection and dynamic control via interface card PEAK System-Technik PCAN-PCI
• analogue data acquisition and digital control via multifunction board Goldammer MultiChoice light PCI
   
• created using DIAdem 11

The plausibility check of measured data, as described here, is done in the context of the long-term acquisition of meteorological climate data at measuring stations of Bavarian national institute for forest and forestry.
Meteorological series of measurements are not only affected by weather variations, but frequently also by non weather-related factors, e.g. malfunctions or aging of sensors and data loggers. This leads to not plausible meteorological data and missing values during the recording. The plausibility check differs between so-called limit errors (e.g. exceedance of measuring range), timing errors (wrong logger time) and consistency errors (e.g. constant measured value over a longer period).

• automatic validation of measuring data
• database-based definition of validation methods
• automatic PDF report generation in case of failures
• interactive investigation of incorrect measuring data using "quality bits"
• integration of National Instruments DataFinder for comfortable data search
• validation of approximately 800.000 measured values using more than 50 validation procedures within approx. 45 seconds
   
• created using:
  - DIAdem 11
  - data base: Microsoft Jet Engine

• separately adjustable two-channel signal generation for control of hydraulic control valves
• generation of trapezoid (parameters: frequency, minimum, maximum, slope), sine, rectangle and triangle signals (parameters: signal form, frequency, amplitude, offset, phase and duty cycle)
  frequency range 0.001 - 100Hz
• parameterization of signal generation by function blocks within DIAdem
• simultaneous acquisition of temperature signals
• signal generation and data acquisition via National Instruments cRIO-9073 with analogue output module NI 9263 and analogue input module NI 9217
• PC interface alternatively via Ethernet or RS-232
   
• created using:
  - controller application: LabVIEW Real Time / FPGA 8.6
  - user interface: DIAdem 10

• selection within a measured or imported characteristic diagram
• contour display of the characteristic diagram
• cursor marking of measure point
• setpoint calculation by 3D interpolation
• setpoint transfer and measurement of characteristic diagram point
   
• created using DIAdem 11

Check of mine hoists in accordance with the legal provisions for transport of material. Acquisition and inspection of horizontal acceleration values affecting the tracking devices.

• integrated solution for automated acquisition and evaluation of horizontal accelerations
• automatic calculation of acceleration values in accordance with the prescriptive limits
• data acquisition via National Instruments CompactDAQ
   
• created using DIAdem 8

• generation of a failure rate report and reports for machine capability and process suitability analysis
• automatic database import of customer-specific production data (Continental- / CONTITECH data) into a Microsoft SQL Server database
• interactive retrieval of production data - narrowing queries to production specific characteristics like test-plan, revision, work shift, date, serial number
• automatic data reduction of production data
• automatic report generation by user-specific batch processes
   
• created using:
  - Microsoft SQL Server database
  - DIAdem 10

• sensor administration
• linear and nonlinear calibrations
• formula administration for real time and offline calculations
• acceptance of test pre-settings and automatic or manual test performance
• transfer of set points to the test rig controller (PLC with Profibus communication)
• acquisition of stationary (200 Hz) and dynamic (up to 4.8 kHz) measurement data
• online calculation and visualisation
• quasi online calculation of characteristic maps and diagrams
• recalculation of test results with modified test parameters
   
• created using DIAdem 10

• integrated solution for administration, control, measurement (see also here) and analysis
• different test rig types supported
• database based parameter management
• event-triggered user information
• automatic and manual analysis algorithms
   
• created using DIAdem 10

• automatic stress test (up to 2 million cycles) of brake applications
• test rig control and data acquisition via real-time system Jäger ADwin-Pro
• automatic report generation (graphs)
• determination of characteristic parameters (level crossing) for attrition analysis
   
• created using DIAdem 10

• ad hoc CAN measurement data evaluation based on pre-defined configurations
• data import using DIAdem CAN converter
• state identification by means of up to 10 freely definable events
• state isolation by single file storage
• determination of load currents
• report generation (graphs)
   
• created using DIAdem 10

• server-based application for automatic collection and evaluation of data
• local application for manual data analysis
• data transfer from PLCs through VPN and FTP as well as from distributed PCs through Ethernet
• database-based configuration
• generation of daily, weekly, monthly and annual reports as Excel sheets
• error, operating time and event reporting
   
• created using DIAdem 10

• companywide (development, test and production control) all-in-one solution for large volume data management
• easily expandable by methods and configurable by favorites
• statistical evaluation and data enhancement
• Quality Control Charts
• individual user profiles
• multi language support
• automatic software updates
   
• created using DIAdem 10

Automotive static structure test
Design, dimensioning and testing of car bodies are subject to official regulations by governmental agencies assessing static push-in and pull-out tests of especially relevant parts of the car body.
According to the US-American regulation FMVSS 216 the roof crush resistance test is performed to evaluate the stability of the car roof and the A-pillar by applying a static pressure by means of a flat metal plate. The aim of the test is to ensure that in case of a roll-over accident there is enough space for the passengers to survive.

• automatic test according to US regulation FMVSS 216
• database-based test parameterization TEDS
• data acquisition and control via HBM MGCplus
• PC-based automatic evaluation
• data filing in ISO accredited ISO-TS 13499 Format
   
• created using DIAdem 10

• automatic testing of piston and pistonless hydraulic accumulators
• database-based test parameterization
• Data acquisition and control as well as protective and safety functions via a distributed automation system National Instruments compact FieldPoint
• PC-based automatic evaluation and protocol generation (diagrams)
   
• created using DIAdem 10 and LabVIEW RT 8

• database-based analysis of production test data
• continuous transfer of test data to the database
• pre-defined and variable queries
• automatic pdf report generation (diagrams) via server-based DIAdem application
• Excel export functions
   
• created using:
  database: Oracle 10
  report server: DIAdem 10
  user interface: hta (html) application

• test data analysis based on pre-defined configurations
• definition of report layouts with up to 10 pages, 10 diagrams and 100 curves each
• DataPlugIn import filter for various application specific data formats
• numerous pre-defined (mean values, sums, differences, spans) and freely definable calculation functions as well as generation of complex setpoint functions
   
• created using DIAdem 10

• automatic and manual test
• bus connection via interface module PEAK System-Technik PCAN-USB
• simultaneous acquisition of analogue signals via digital multimeter Fluke 45 connected via RS-232
• database-based test programme management
   
• created using DIAdem 10

• automatic mode for cyclical load / unload of wheel suspension (force or position controlled, single or double sided, synchronous or asynchronous) with simultaneous force and position recording
• manual mode (step mode) for free run of drives as well as for force or position controlled target move
• test rig control via GFC Milan drive MDA 63.1 with Profibus interface, connected via Profibus board applicom PCI-1500 PFB
• parameterization according to Profibus profile for variable drives PROFIDRIVE
• data acquisition via multifunction board National Instruments PCI-6221 and HBM Spider 8
• mathematic and graphic analysis (e.g. calculation of axis module characteristics, graph of measured force versus calculated wheel center position)
• database-based configuration parameter management (scaling, limits, geometrical data)
   
• created using DIAdem 9

• determination of characteristics and long-term test of DC motors, transformers and power supplies.
• load test of motors via hysteresis and eddy-current brakes, controlled by Magtrol DSP6001 controller with GPIB interface, connected via National Instruments interface board PCI-GPIB
• test rig control and data acquisition via multifunction board National Instruments PCI-6221 and signal conditioning National Instruments SC-2345
• programmable power supply with analogue interface
• load test of transformers and power supplies via DC load with analogue interface
• speed-controlled determination of characteristics of DC motors
• long-term test of DC motors by application of freely definable motor voltage and load torque characteristics
• current-controlled determination of characteristics of transformers and power supplies
• manual test modes with free definition of setpoints
• automatic report generation
   
• created using DIAdem 10

• serial acquisition of climate data via hardware components by Lufft company
• database-based parameterization of measurement hardware
• local "fallback database" to backup the central database
• import of measured data from central database into DIAdem
• external supervision of measurement equipment
   
• created using DIAdem 9

• database-based server application with distributed data acquisition and control
• acquisition and output of texts via barcode scanner and ELECTRONIC ASSEMBLY LCD displays, connected via Wiesemann & Theis COM server
• acquisition and output of analogue and digital signals via Beckhoff bus coupler BK9000
   
• created using LabVIEW 7

• test rig control (moving table and normal force) via multifunction DAQ card
  National Instruments PCI-6221
• data acquisition via HBM Spider 8
• various test modes (single, continuous, manual, autocalibration)
• test parameterization via and result transfer from / to materials database via XML files
• automatic test evaluation and report generation (graphs)
   
• created using DIAdem 9

Application description

• static and dynamic (leak) tests with more than 50 parameters per step
• test configuration and parameterization via data base
• database storage of test results
• automatic print of failure labels
   
• created using LabVIEW 7

• ASi-Bus interface Bihl+Wiedemann ASi Master
• data acquisition and control via
  Phoenix Contact ASi input / output modules and Nolek leak testers
   
• created using LabVIEW 7

• automatic long-term test (up to 2 mill. cycles) of gear linkage operation
• test rig control and data acquisition via amtec robotics PowerCube and HBM Spider 8
• extensive system setup and configuration functions
• implemented test modes:
  - position-controlled gear operation with closed-loop-controlled counteraction force
  - parallel position-controlled double operation with uncontrolled counteraction force
  - gear linkage operation with force-controlled shift of direction
   
• created using DIAdem 9

The bumper test rig is used to check the impact and bending strength of bumper systems within a vehicle. By means of the test rig conformity to US standard regulation 49 CFR Part 581 as demanded by the legislator and optimizations of bumper systems design are tested.

• customized automatic database-based parameterization of measurement hardware HBM MGCplus
• integration of Hentschel velocity measurement system via RS-232 interface
• automatic assignment of measurement signals by TEDS sensor identification (Sensors Plug&Play)
• test result storage and management in Oracle database
   
• created using DIAdem 8

Pedestrian safety is evaluated by tests according to the regulations defined by European Enhanced Vehicle Safety Committee (EEVC). Different impact bodies simulate pedestrian's head, body and legs. Behavior of vehicle's front section is assessed by measurement results and optimized by design.

• implemented tests:
  - adult and child head to bonnet impact according EEVC WG 17
  - lower leg impact to front-end
  - thigh impact to bonnet front-edge
  
• database-based configuration of measurement hardware MiniDau by Kayser-Threde
• automated analysis according EEVC WG 17 in DIAdem and a-dam
   
• created using DIAdem 8

• data acquisition via HBM MGCplus
• static and und dynamic measure of angle, path, force and torque
• automatic data sheet and graph generation
   
• created using DIAdem 10

• defined application of load cycles on foam parts over various periods under configurable climatic conditions (dynamic fatigue test according DIN 53574 / ISO 3385)
• automatic hardness test (indentation test according DIN 53579)
• test rig control and data acquisition via amtec robotics PowerCube
• control of a CTS climatic chamber via RS-232
• automatic weigh (determination of residual humidity) via Sartorius weighing platform
• automatic report generation (graphs)
   
• created using DIAdem 9

• test rig control via Bosch Rexroth HNC100 (interface: Profibus-DP via applicom PCI-DPIO) and Seng AnaDigIO
• analogue data acquisition of forces, pressures and distances
• automatic test sequences and report generation for function test, reaction and release time test, tightness test
• device management, sensor calibration, test management, manual test rig control via PC
   
• created using DIAdem 9

• test definition as sequence of pre-defined tests steps in any order
• database based parameter management and test rig configuration
• parameterization of the tested devices via RS-232
• data acquisition and dynamic control via:
  - variant I: Goldammer MultiChoice light PCI 16/B board (analogue and PWM) as well as applicom PCI-DPIO and Bosch-Rexroth DDL module (PROFIBUS DP)
  - variant II: National Instruments CompactRIO (analogue, PWM and PROFIBUS DP)
• simultaneous digital test rig control
• analysis of test step results according to static and dynamic criteria
• automatic report generation (tables, graphs)
• integrated measurement system check (repeat accuracy)
• test time reduction from 15 minutes to below 80 seconds
   
• created using DIAdem 9

• continuous (for years) acquisition of pollutants in waste water (via OPC from Siemens S5), storage in day and year files
• several data acquisition points, remote access to data acquisition PC (via Ethernet, distance between data acquisition points and analysis PCs a few kilometers)
• manual input of analysis data and synchronization with continuous measured data
• calculation of characteristic values for selectable time intervals
• display of results for any period of time (1h - 1a) in tables and graphs
   
• created using DIAdem 8 / 9