Segmented  Cell Test Stand 

Software:             LabVIEW™ 2015
Core Hardware:   National Instruments™: PXI-1042, PXI-8192, PXI-6251, PCI-6244, PCI-6723
                            GRandalytics^®: Custom Designed Active Signal Conditioning

Description:
For in-depth research on current distribution, impurity impacts and flow field analysis, segmented fuel cells are a valuable tool. This research system consists of a PXI-based current analysis unit with the ability of static impedance tests, sequenced step tests and sweeps, and a specialised test station with a multitude of feed gases, wide range, parallel mass-flow-controllers, impurity injecting, scripting, etc. 

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HiL and High dynamic Fuel Cell Test Stand 

Software:             LabVIEW™ 2015, Real-Time, FPGA
Core Hardware:   National Instruments™: CompactRIO
                            GRandalytics^®: Modular Signal Conditioning and Drivers, Measurement and Diagnosis Systems

Description:
Hardware-in-Loop fuel cell testing is relatively new and classic test stands are not fast enough to run vehicle simulations and reliably measure fuel cell transient behaviour without interfering with the unit under test by restricting flows, or delaying set points. Aim of this project was to modify an existing state-of-the-art fuel cell test stand and push the envelop of responsiveness and speed to the absolute limit. A CompactRIO real-time controller works as the master control unit of the test stand avoiding the breach of determinism by eliminating any PCs and non-real-time component in the chain of controllers. External systems like GUI or simulation targets communicate via UDP sending set points and receiving measurements. Multiple external machines can run in parallel to distribute the overall simulation. The inherently fast and reliable FPGA back plane of the CompactRIO sounds out the measurements. It checks for lowest-level alarms and initiates countermeasures without involving the CPU. Specially designed signal conditioning hardware allows the use of one 8-slot chassis to run the whole test stand.

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Static Fuel Cell Test Stand 

Software:             LabVIEW™ 7.1 DSC
Core Hardware:   National Instruments™: AT-MIO, SCXI

Description:
To increase productivity and reliability of static fuel cell test stations, a new GUI has been designed. The hardware platform a SCXI system could remain in place while completely new software was written (or actually drawn) from scratch. Based on  the DSC toolkit and LabVIEW™ 7.1, the software boosted performance (increase of sampling rate), productivity (adding scripting capability, data set logs, variable units, gas mixing and more) and reliability (powerful alarm and safety checks) along with an intuitive and easy to use front panel. External instruments could be added and seamlessly integrated by running software servers.

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Optimization of a control system in a CIP cleaning plant

Software:             LabVIEW™ 6i
Core Hardware:   National Instruments™: FieldPoint™ 1000

Description:
The CIP (Clean-in-Place) method is used for the cleaning of pipes and process equipment. It's based on a special design of pipes, valves, etc., which eliminates the places where residue accumulates.
The developed software manages the controlling of various pumps (like for dispensing) as well as the monitoring of flow and pressure sensors and a photometer, which is used for proportional control of the dispensing pump. All monitored data are logged and graphically displayed. Fieldpoint 1000 (with modules FP RLY-422, FP TB-10) had to be implemented as already existent platform.

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Wall Thickness Measurement System for Bearing Shells

Software:             LabVIEW™ 7.1 
Core Hardware:   Solartron RS232 linear encoder

Description:
The new testing system acquires, analyzes and evaluates data from testing the dimensional accuracy of bearing shells. A convenient LabVIEW™ interface appears following the user selection of the operation mode in the menu bar. Input masks for tolerances, calibration values as well as analog, digital and graphical display of the current test data, etc. are features of the front panel.
The application is list-controlled; parameters for initializing, executing, event-driven starts can be set by the user in an ASCII initialization file. A special algorithm was developed and implemented in the program which filters invalid values and is user-adjustable. Results are handed over to an existing evaluation software what required a complicated adaption of the data format. The program is currently used for the measurement of wall thickness and is expected to be expanded for the measurement further properties like roundness, diameter of curvature, surface lines, etc.

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Watermanagement System for Combustion Engine Test Stands

Software:             LabVIEW™ 6.1 Real-Time
Core Hardware:   National Instruments™: FieldPoint™ 2000

Description:
In the course of this project, the monitoring and controlling of two coolant circulation systems for engine test benches has been automated. All operations of the water treatment plant are to be logged and controlled by the system. This includes, e.g., surveillance of the water level by a plausibility check, water refill, switching of the softener container and initiating the regeneration as well as initiating desalination.
An easy expendable setup based upon LabVIEW™ Real-Time modules has been developed. Due to the need for operational safety, controlling is done centrally and the FieldPoint™ system ensures the indispensable system stability. The capability of FieldPoint™ to directly integrate a variety of sensors (like temperature, pressure, etc.) without signal conditioning also enhances safety and compactness of this arrangement. The continuous data acquisition provides a complete documentation without interruption. It can be monitored at any workstation via Ethernet and web browser.

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This project was published 

Automatic Cable Testing System

Software:             LabVIEW™ 6.1
Core Hardware:   National Instruments™: PCI-6024E, PCI-DIO-96 DAQ Boards
                             FUG: HCE 7-1250 POS High Voltage Power Supply

Description:
An automated system for cable testing has been developed, by which continuity checks of wires and their shielding as well as the electric strength between the wire insulation can be tested at high voltages up to 1250 V. The software application is an easy-to-use, still highly versatile, list-controlled program that ensures a safe and fast operation by a minimized user interface. A printed circuit board with a high standard of safety has been designed. Also part of the system hardware are two PCI-DAQ cards from National Instruments™, which allow setting up a rather cost-effective and compact system.
The LabVIEW™ based system enables a convenient, timesaving handling of end-of-line testing by a PC. The Software 'CaTe 1.0', together with the PCI-DAQ technology, reveals a high grade of flexibility. The implementation of parametric controlling of the program flow ensures an adaptation to various testing procedures. The results are being stored in a log file. A report or barcode can be generated optionally.

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Automated data analysis system for engine test bench

Software:             LabVIEW™ 6.1, SigmaPlot 8.02
Core Hardware:   None

Description:
A huge amount of data is produced by a large number of engine test benches (e.g., in the course of endurance run or functional tests). With this application, they are processed and visualized in a user-friendly manner. Various types of presentation are possible by an easy-to-use tool. Great looking graphic pages for reporting, etc. can be created in no time and an easy adaptation of the layout is provided for upcoming requirements.

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Diagnosis Tool for Engine Control Units

Software:             LabVIEW™ 6i
Core Hardware:   None

Description:
This easy-to-use application for a PC or notebook replaces the cost-intensive diagnosis box. Typical data (like engine speed, oil temperature, booster pressure, etc.) are being recorded at a high sample rate and processed for further evaluation. The display of errors stored within the ECU and clearing them as well as calibration of engine instruments was provided. A graphical display with a simulation of the car dashboard ensures a clearly arranged user interface. Several parameters like user level or language are loaded from a file. This service tool is secured by a special algorithm, which protects from unauthorized manipulation.