State-of-the-art systems are so much smarter than their forebears. That intelligence is complicating testing in development and on the shop floor. Engineers tasked to verify, validate, and test products are struggling to cope with the growing complexity of systems and increasing number of variants. We have the antidote – test bench solutions that save you time and money by automating testing and ensuring E2E traceability and reproducible results. Count on our test-bench support and services to steer you right from conceptualization and prototyping to mass production.
Taking a holistic approach to developing test systems
We take a holistic approach to development that factors individual industries and customers’ challenges into the equation. Our services cover everything from analysis, definition, and conceptualization to end-to-end systems engineering (software development and hardware) and field support. As a vendor- and systems-agnostic service provider, we always put your unique needs first.
Consistency matters, which is why we champion continuous testing from development to the production line. When we set out to develop a concept, we factor system approval processes and test procedures into the equation to assure quality and cut setup costs. We are no less diligent about taking requirements for tool qualification, standards conformity, and other engineering tasks into account when determining specifications, consulting on technologies, and conceptualizing machines and tests.
Our experts rely on modular software architectures and state-of-the-art data management when engineering the overall system. Traceability and scalability are just as important aspects as our “smart data instead of big data” approach. Once the system is up and running, we will be happy to provide follow-on services and support to cover maintenance, lifecycle management, and the like. Whatever you need – a development or a manufacturing test bench – your requirements are always our focal point.
Do you have a specific idea or project in mind?
Count on us to help you optimize your testing environments. Our vendor- and system-agnostic consulting and development services are yours for the asking. We can be there for you every step of the way from analysis, conceptualization, and end-to-end systems engineering to follow-on support for the up-and-running solution.
Come to us for custom and modular component test benches for integration testing
We offer end-to-end, tailored solutions for testing everything from conventional steering and braking systems to state-of-the-art steer/brake-by-wire and electric drives. The hardware’s ingenious design enables precise adjustment of the device under test and actuators for fully reproducible testing. Our powerful algorithms and an automated controller ensure high-quality control and very accurate test results. And our professional real-time software and optimized system architecture enable sampling rates up to 20 kHz.
Haptic testing without test vehicles: Tests can be conducted right there on the test bench, with no need for real test vehicles.
Savings: Test-drives cost money – less of those means far lower costs for testing.
Extended test coverage: Our test benches enable you to perform precise, non-destructive tests that would be hard to do or destructive in a vehicle.
Early validation: A model-based test bench layout enables early testing and validation of a system’s design.
Fully automated testing: Our test benches provide all the tools you need to automate entire tests.
Compliance: Our test systems are ISO 26262-compliant (if required).
Modular design for maximum flexibility
The modular design of our test benches makes it easy to connect individual systems such as an EPS rack power pack, an EPS column/steering wheel power pack, and brake control systems featuring power assist units. The test bench readily connects to a dynamic or static simulator to emulate the driver’s touch on the steering wheel and conjure an authentic driving experience with a real-world feel. This feature can also be retrofitted later on.
End-to-end service
As your general contractor, we can help you rise to every challenge. Anything goes, from optimizing legacy systems to delivering turnkey component test benches. Our end-of-line quality assurance encompasses:
Tests to assess torque, force, and other product properties
Functions to parameterize and calibrate intelligent position and other sensors for products with analog, SENT, LIN, CAN, Profibus, Profinet, EtherCAT, and many other communication protocols
Versatile testing facilities
Take advantage of our versatile testing facilities with an area of 3.00 m x 6.00 m for test specimens. They feature a 140 kW three-phase (400 V) power supply, a heavy-duty floor for test benches weighing up to 15 metric tons, a five-ton overhead crane, a 0.8 by 0.8 by 0.6-meter sump pit, and compressed air at six bar. Shutdown is via fire detection system (FDS). The cooling capacity is 90 kW with circulating air and 40 kW with cooling water. A separate control room with office workstations protects against heat, mechanical action, and noise. Video transmission from the test bench to the control room is also possible.
It is not just engineering excellence and innovation that set us apart. We also take a holistic view to see customers’ needs from every perspective. Able to think outside the box, we provide solutions that far exceed standard expectations. Our partners have come to appreciate the broad perspective we bring to each task. That and our commitment to customer satisfaction make us a valuable ally for your every project.
Severin Roderer, Senior Manager Test Systems Development, ITK Engineering
Innovation
Hardware-agnostic, scalable software for measurement systems and testing processes
Looking to optimize measurement and testing processes and make the most of the data you obtain? Then it is time to tackle the challenge of integrating diverse measuring devices into your processes. ITK’s Measurement and Testing software is here to help you do that – and turn data capture, systems surveillance, and device management into an exercise in convenience regardless of source.
Platform development for EOL testing of intelligent sensors
The challenge: Test field for assessing sensors with many variants This project pursued two key objectives. For one, the customer wanted a flexible software platform that could handle the most diverse requirements for devices under test. The other challenge was to establish a test standard for functional safety (ISO 26262) in various factories around the world. The customer had bespoke software for testing each variant, but it lacked the consistency necessary to trace and retrace tests and tested sensors. On top of that, the software had quality, maintenance, and extensibility issues.
The solution: Deliver a platform-based solution ITK Engineering chose to go with in-process control (IPC) and industrial measuring systems based on COTS hardware. On the software side, ITK developed a host of platform functions. These include user, configuration, and variant management as well as hardware abstraction for measuring instruments, external devices, actuators, devices under test, and the like. It also features test sequencing, event logging, and measurement data storage capabilities as well as a plug-in concept for new sensor types.
Added value for the customer: By building an architecture with plug-ins for the various application components, ITK was able to minimize the verification and validation effort for tool qualification. Only the affected plug-ins have to be qualified in the event of changes or extensions. Throughout the project, ITK struck the right balance between development overhead and testing effort for tool qualification.
Optimizing quality control for manufactured mechanical components
The challenge: Tame complexity in quality assurance Our customer faced a range of challenges. Shipping defective parts out from a factory is a no-go. This is why the quality assurance bar is set so high – and rises with increasing complexity. Another key challenge was to keep the company’s factories in Germany competitive with components manufactured on various shop floors in several plants and countries. To further complicate matters, the customer was still running many systems with outdated hardware despite having to contend with challenging cycle time demands.
The solution: Deliver camera- and sensor-driven end-of-line control ITK Engineering took a two-pronged approach to satisfy the customer’s quality demands: Our experts developed a camera- and sensor-based solution for end-of-line inspection of mechanical components, and subsequently upgraded, extended, and retrofitted 25 legacy machines. Several 1D, 2D, and 3D laser sensors were used to this end.
Added value for the customer: Featuring cutting-edge algorithms and sensors, the overall solution delivered by ITK Engineering works with replicable accuracy. We also provided operation and management software for the entire test bed. The customer now has all the capabilities needed to perform measurement system analyses (MSA) and test systems’ behavior. A virtual MSA also minimizes the effort involved in testing new software variants.
Professional software development with LabVIEW in an industrial environment
The challenge: Prototype software jeopardizes production Highly modular and flexible, CESA³R hardware requires robust yet versatile control software. Although our customer, Robert Bosch GmbH, had a software solution, it was merely a prototype, so fail-safe production was far from guaranteed. An adaptation would have taken a great deal of disruptive retooling time and cost a lot of money if the system had to be shut down.
The solution: Flexible and modular application development with LabVIEW ITK Engineering used LabVIEW to develop the entire application for Bosch GmbH. To this end, our experts determined key requirements with the customer, developed back-office software, and tested on location in the customer’s plant. The engineering team went with a flexible, modular design to build a solution that readily accommodates software plug-ins when it comes time to upgrade and extend the hardware.
Added value for the customer: Putting its extensive industrial application development skills to work in this project, ITK Engineering brought the CESA³R system up to industrial maturity. The Robert Bosch GmbH is now able to run fully functional, robust software without risking production downtime. Designed to accept plug-ins, the software is easy to extend yet meets the rigorous demands of a manufacturing plant.
A software suite for parameterizing and running test systems and tests
The challenges: Error-prone measurements, hard-to-compare readings The customer had a solution for parameterizing and running test systems and tests, but it was outmoded. Simple text files served to configure testing setups. These foggy instructions were causing errors. Disparate software and tests made it impossible to compare readings taken in tests and on the production line. And because of the incomplete documentation, engineers had no way of knowing which parameters were used to take readings.
The solution: Deliver E2E software to cover everything from initial testing to validation in production Determined to tailor the software for a perfect fit, the ITK Engineering team collected and aligned the requirements for tasks ranging from product development, validation and the test bay to manufacturing and quality assurance. Drawing on this information, ITK developed a configuration tool and a corresponding test bench software. The configuration tool serves to parameterize and manage testing stations, configurations, and instruments. It also renders system setups and executable functions. Designed to access an SQL database in the background, it can be run entirely from the back office. This way, setups can be configured ahead of time without disrupting operations on the shop floor. The software enables manual and fully automated testing. It also features measurement system analysis (MSA) and test bench characterization functions as well as user and permissions management tools.
Added value for the customer: The customer now has an end-to-end software suite for testing, from development through product validation to production. On the one hand, this ensures consistency and comparability of readings. On the other hand, engineers can pre-test configurations in the test bay. The on-board configuration tool minimizes setup errors. Its database-supported configuration capabilities and links to measurement data makes it so much easier to analyze rejects. The result: This mitigates the risk of disruptions and downtime. It reduces the amount of misconfiguration-induced scrap and rejects. And it accelerates cycle times.
Benefits
Custom test bench development
Cross-industry expertise
Vendor- and systems-agnostic
Unsolved challenges? We look forward to your inquiry.
