Automotive sub-assemblies such as bumpers, spoilers and door modules typically contain an array of electronic components, such as parking assist sensors, pedestrian sensors, gesture equipment, fog lamps, telecommunications amplifiers and receivers.
Following the manufacture of these sub-assemblies, it is important to ensure that the correct components have been fitted, fully connected, and with the specific correct engineering revisions.
As technology advances, each of these components will evolve, such that sometimes separate engineering revisions come to exist that are incompatible with each other.
Given that components of the same generic type often share a form factor, in-line electrical testing may be required to distinguish devices that have different engineering revisions but are identical to the naked eye. Furthermore, just-in-time manufacturing requires that sub-assemblies arrive in a guaranteed functional state.
“You can quite comfortably use the Genix Test Unit, knowing that tests will be completed correctly.”
Clive Sims, Director, Sims Engineering Ltd
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The Genix Test Unit provides a means of performing a number of electrical and communications tests on products at assembly stations during manufacture. The system has been designed for testing a range of electronic components within sub-assemblies, such as bumpers, spoilers and door modules, at the end of the production line.
The test unit has a high I/O count supporting a wide range of simultaneous tests and includes PLC interfaces for test control, result capture and handshaking. It’s capable of providing both advanced continuity and functionality testing via LIN, CAN and PSI5 and optional other protocols, such as SENT.
Typically, test results are fed back to the PLC. Custom handheld devices can be provided for monitoring of test results or alternatively, these test results can be monitored via our real-time systems interface creation software, VISUALCONNX, with a custom GUI. The unit can be mounted in a wide variety of locations within the manufacturing environment. Plugable screw terminal blocks for I/O and power are provided with each test unit.
How does testing work?
The GTU is a system designed for testing a range of electronic components within sub-assemblies, such as bumpers, spoilers and door modules, at the end of the production line. The unit comprises a micro-controller based test system, including instrumentation electronics, power supply, communications test channels, PLC signalling and custom firmware to provide a turnkey solution to performing a number of sequential tests.
Tests are initiated via digital inputs driven from an externally connected PLC. During these tests the outputs of the unit will be driven to indicate a pass or fail condition via solid state, volt-free relay outputs. These tests happen in a matter of seconds, resulting in a short takt time.
At the end of the test, an output changes state to indicate test complete to the PLC, which should then confirm whether the item being manufactured has passed all relevant tests.
All test output lines, such as voltage and current outputs and supplies are protected against short circuit to 0V, such as might occur with a damaged harness or connector. Each channel on the GTU is protected against overload. Connection is provided to the unit under test via Zero-Insertion Force (ZIF) units that allow connections to the test system with minimal wear and tear to sub-assembly connectors, which can be replaced with easily-replaceable inserts, to minimise downtime.
ZIF units are available to fit a wide range of automotive standard electrical connectors.
What can the GTU do?
The GTU allows organisations to mitigate against the risk of faulty equipment that may otherwise only be detected at vehicle end-of-line testing or even result in commercial recalls. It allows OEMs and Tier 1 suppliers to verify continuity for the correct engineering revision of sub-assembly electronics across multiple vehicle programs. It allows sub-assemblies to be tested within a production environment, either directly at an assembly station or other test bench.
Example tests the GTU can perform in the workshop or production line
|• AK Parking Assistance Sensor
||• AK Parking Distance Sensor
|• Airbag Testing
||• HP Parking Distance Sensor
|• Single Gesture Sensor
||• Parallel Gesture Sensor
|• Continuity Test, Low Current
||• Continuity Test, High Current
|• Low Side Voltage Divider Test
||• Pedestrian Sensor Testing
|• Camera Presence Test
||• Tweeter Speaker Testing
|• Ambient Lighting Testing
||• HP Parking Assistance Sensor
Pluggable screw terminals
Easy disconnection and reconnection in the workshop
PLC industrial interface
Integrate with industry-standard PLCs easily
A rugged housing protects against workshop risks
Test outputs are protected against short circuit to 0V
Relay lines are protected against short circuit to 24V
Rubber mounting blocks are fitted to absorb vibration
16 measurement channels are available
Predefined test sequences
Sequences can be performed quickly and easily
A range of LEDs provide various user alerts
Quick and easy testing
The unit takes 2-3 seconds for all tests in total
Special testing applications in manufacturing
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The challenges involved in testing airbags
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PSI5-based pedestrian sensor testing
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Applications for advanced continuity testing
Continuity testing is often used to ensure parts are correctly connected during manufacture of sub-assemblies,...
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