ADwin Systems for Test Automation in Development & Production

Test systems are used to determine the dynamic characteristics and parameters of components and sensors. WithADwinsystems, an analog and/or digital stimulus is applied to the Device Under Test (DUT), using single or multiple channels of actuators or amplifiers. In addition to the stimulation, the response of the components is acquired by reading the analog and digital input channels of the ADwinsystem. ADwin systems are capable of evaluating the response in real time. Thus, the system can immediately calculate how well the test component matches the required specifications. The stimulation and acquisition can be performed over a very wide range of frequencies, from a few hundred Hertz to several hundred kilohertz. By very precisely timing stimulation, acquisition, and on-line evaluation, ADwinsystems can accurately calculate the dynamic parameters of the test component.

Test systems for R&D acquire component parameters as well as characteristics of prototypes and preproduction models. The endurance of components is determined by testing them over thousands of test cycles. For this, ADwinsystems connected to a PC perform all of the test functions, in real-time. The measurement data is then displayed on the PC through a graphical user interface (GUI).

On production lines, test benches ensure a higher level of quality through random sample or individual component testing (CAQ). Test information and data is transferred to a control system (PC or programmable controller) via Ethernet or a Fieldbus interface. This information can then be stored as quality records in the production database. ADwinsystems perform all tests and evaluate the data. Only the results are sent to the control system.

The figure below shows how an ADwintest system is connected to a PC or programmable controller. The ADwinsystem (green) stimulates the device under test via analog and/or digital outputs, measures the responses via analog and/or digital inputs, and performs an on-line calculation of the dynamic parameters of the DUT. A PC connected via Ethernet or USB displays the test results. On production lines, a programmable controller is typically connected via Profibus, Interbus, CAN, etc.

Typical applications for ADwinsystems are test systems used for sensors, actuators, control devices, shock absorbers, combustion engines, electro motors, gears, ball bearings, engine bearings, injection pumps, lamps, relays, switches, CAN bus devices (e.g. for automotive), field bus systems, ... , and many more.

The ADwinsystem is the only one which can realize flexible, fast testing, as described:

ADwinapplications always run in real time. Every sampled value or event can be evaluated in the same step; a control function or on-line analysis, etc., can be performed immediately. This is made possible by the design of ADwinsystems, which feature a local CPU, additional analog and digital interfaces, as well as various expansion options. The local CPU is a fast, 32-bit floating-point DSP, equipped with internal memory for executing real-time code and external SDRAM for data. In conjunction with the real-time development tool ADbasic, this DSP allows fast, deterministic program execution, with a guaranteed reaction time of less than 1 μs.

For operation with a PC, Ethernet and USB interfaces are available. For industrial use with a programmable controller, there are field bus interfaces, such as Profibus, Interbus, CANbus, etc., and serial interfaces. There are three ADwinseries: ADwin-light-16, ADwin-Goldand ADwin-Pro. The ADwin-light-16and ADwin-Goldsystems are low cost solutions for applications with few I/O channels and limited expansion or configuration requirements. The modular, expandable ADwin-Prosystem is recommended for applications with many channels and flexible configurations.

Capabilities of the ADwinsystem:

• Intelligent data acquisition: On-line evaluation of measurement data, performed immediately after each sample is taken; complex triggering conditions, high sampling rates, freely programmable mathematical operations/functions, such as RMS values, Min/Max, mean, integral, derivative, correlation, digital filters, FFT, signal analysis, etc.
• Signal/waveform generation: Multi-channel signal generator, analog and/or digital, periodical or non-periodical signals, random; on-line adjustable (frequency, phase, amplitude, offset, timing); values can be user supplied or calculated based on measured inputs and/or other variables.
• Control functions (open/closed loop): PI, PID, cascade, adaptive; e.g. PID speed: max. 500 kHz at 100%, typically 500 Hz … 50 kHz; independent of PC load; multiple controllers simultaneously; various control algorithms and cycle times; quick and simple controller development; standard control algorithms can be easily adapted to optimized applications, digital I/O control, etc. ADwinsystems are very powerful and flexible. They can be configured individually, in order to meet all test specifications. This brief application note provides basic information on the potential ofADwinsystems.

Please contact Computer Aided Solutions for further information.