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Partnered Test Solutions

CIMTEK has a history of partnering with leading edge companies to develop a cost effective solution that ensure product quality and an on-time product launch. By way of example, CIMTEK was approached by a leading manufacturer of truck brake systems to facilitate the supply and support their complete Computer Integrated Manufacturing (CIM) solution, right from the start of their work with Antilock Brake Systems (ABS) with integral Electronic Control Units (ECU) for heavy vehicles.

The end product was a state-of-the-art automated production system featuring a large number of networked cells running our Test Executive. A high performance network server with custom SQL database ensures that the security, quality, and flexibility demanded is not only met, but exceeded. The result is a medium product volume/high product mix "flexible manufacturing" production line designed by CIMTEK in cooperation with the customer.

The CIMTEK Systems included:

· Network Server

- All work cells networked to the central server

- Centralized control of parts, orders, test scripts, limits, and data

- Revision control system

- SQL database

- Paperless repair

- Trend analysis

- SPC data collection and reporting (Pareto charts, histograms, Xbar and R)

- Secure data storage utilizing Raid technology

- Remote support and monitoring capability

· ABS ECU Creation Station

- Part configuration and PC Board Part creation in the part Database

- CimTest configured to burn an Eprom, create the part in the database, and create a bar code label

· ABS ECU Assembly Stations

- ECU powerup and communication allowing recall of Serial Number, Part Number, Software Revision, etc

- Database verification

- Integration of ECU and housing

· ABS ECU Functional Test Stations

- Full functional testing of ABS ECU's - 100% of the production line's output

- Includes "mistake-proofing" interlocks to prevent operator intrusion on the testing process

- Acuity® vision system to verify proper operation of LED status lights

- Interchangeable product mounting nests for different product configurations

- Verification of both product and process

- Manipulation and component insertion using Adept Robotic Systems

· ABS ECU Test Fixtures

- Untested parts are conveyed into the test cell

- Bar code confirmation of module type

- Automatic identification of appropriate test nest

- Automatic full functional test including machine vision and operational simulation

- Result dependent transfer to fail conveyor or potting station

· ABS ECU Potting / Curing

- Database lookup of module specific capacity

- Transfer to cure conveyor with programmable cure time

· ABS Assembly Final Test

- Works in conjunction with a simulated airbrake system to test a complete anti-lock module and ensure proper operation of control valves

- Tests multiple styles and configurations of ABS modules

- Automatic configuration of test stand (i.e. voltage, current, etc.) via LAN from upstream CIMTEK test stations

- Verification of both product and process

· Finalization / Shipping Preparation

- Database lookup ensuring all processes complete

- Process control by customer order

- Configuration to specific vehicle type

- Packout with custom labeling

- Full scale Plant Production Systems by CIMTEK