The Challenge: Develop a PC-based system for Pneumatic Drill Test Station. The Solution: Develop Windows based application using NI LabVIEW to perform final functional quality test on pneumatic drills.  Introduction: Customer manufactures pneumatic drills for various applications. Each has a different design to meet specific application need. For final functional testing, they needed a PC-based test system, which can be easily configured to test different variety of pneumatic drills. We developed a PC-based system using the NI-PCI6014 DAQ card and SCC-2345 Signal Conditioning Interface. Software developed using NI LabVIEW was capable of guiding the operator through a series of steps to configure the system, test the part and store appropriate test related data in a database. Later it can also generate test parameter print out and shipping labels.  What is Pneumatic Drill? Pneumatic drill is a tool used for heavy digging operations. It is powered by compressed air. Depending upon its mechanical design it can produce a fixed number of strokes for a particular air flow rate. The PC based test system thus controls the air flow rate and measures the number of strokes in a fixed interval of time to qualify the drill functionally. They even have rotary tools where the supplied air generates rotation in the tool. For these tools we measure the rotation for a fixed air flow rate. 
 System Requirements: The Pneumatic Drill Test System is required to test a variety of pneumatic drills: Non-rotary and rotary. Each drill has a particular design specification of air flow rate and number of strokes/rotation. These are available in a master drill data file. The PC based test system should confirm acceptability of the part being tested based upon the specification. Test data must be stored in appropriate tables in a database for future statistical analysis. 
 Hardware Design: A vertical test rig is fabricated inside a sound-proof chamber for mounting the pneumatic drill under test. Pneumatic actuators controlled by digital signals are used to activate the lever on the drill. Air flow to the drill is controlled using a flow meter. The number of strokes it generates is gauged using the knock sensor fitted on the rig. Optical sensors are used to measure the number of rotations of rotary tools. A pressure transmitter is used to indicate air pressure on the PC monitor while the test is running. 
 Software Design: The Data Acquisition software is designed to perform the following tasks:• Select test configuration parameters for particular drill under test from a list of stored types• Run the test for a fixed time and display the results of Air Flow, Pressure and Number of    strokes/rotation• Evaluate whether the drill qualifies the specification• Maintain a database of test related parameters An operator friendly Graphical User Interface is designed using NI LabVIEW. The NI DAQ VIs provided a complete interface to measure the Air Flow rate, Pressure and output of the knock sensor. The graphical display is designed such that the operator can interpret all the inspection information easily in a single glance. All the data is stored in MS Access file. Even the component-specific tolerance levels are stored in a separate table in the same file. While generating the reports the system compares the inspection values with the component specific tolerance levels to determine whether the component is accepted or rejected. The operator also has a facility to generate reports shift-wise, day-wise, month-wise or year-wise for a particular component type. Operator can even Print any report for production records outside the department.
Summary: Pneumatic Drill Test Station provides an efficient platform for validating production drills for final acceptance and/or rework.

Transmission Axle Test System 50 HP
The Challenge: Design, develop and deploy NI-LabVIEW-based 50HP Transmission Test System.
The Solution: Developed Windows™ XP based application using NI LabVIEW to operate a 50HP Transmission Test Rig. Allows operator to configure an automated test cycle, run the test cycle multiple times and store acquired test data in text file for report generation and future analysis.
Introduction: Customer has a 50 HP Transmission Test Rig, for endurance testing of new axle designs, which can be manually operated from a control panel. It has no provision to store test data. They wanted a system to log all the process related test and measurement data for the automotive axle, tested on the rig. We developed a PC-based system using the NI-LabVIEW along with MS Access and Text file to control the test rig, store all the inspection related data and generate test reports. What is 50HP Transmission Test Rig? 50HP Transmission Test Rig is used to test different Axles under various loading conditions. Test results help design engineers confirm their axle design. And if at all the axle under test fails, design engineers are able to analyze the failure and improve upon the design. 
System Requirements: NI LabVIEW based 50HP Test System should meet the following requirements:• Provide user-friendly interface for operating the rig• Provide control for motor start/stop and speed up/down• Provide analog output for proportional control valve• Monitor the speed in RPM at three places• Monitor temperatures from 6 Thermocouples• Monitor 2 load signals• Emergency Push Button for immediate shut down of the system in case of emergency• Digital input for Feed Pump ON signal• Data Acquisition and Logging of all the test parameters for future analysis and calculations• Provide manual and automated modes of operation• Historical trending
Hardware Design: NI-LabVIEW based 50HP Test System consists of the following equipment:• Industrial PC (P-IV, 1 GHz, 512 Mb RAM, 20GB HDD minimum)• NI PCI Data Acquisition Card• SC Signal Conditioning Box with appropriate modules• SCC Analog input modules for RTD and load• SCC Analog output module for proportional valve control• SCC Digital input for speed measurements, Feed Pump ON and Emergency Push Button• SCC Digital output for Motor start/stop and Speed up/down
Software Design:• Operator can configure various test cases in the form of a recipe• Recipe defines various speed and load conditions for different time intervals• Operator can view various test parameters graphically as the test progresses• All the data is stored in test specific Text files• The operator has the facility to retrieve test related data for previously tested axles• All the analog and digital parameters are available to the operator for manually controlling the test 
Summary:• Automated Test System provides an efficient platform for the operator to control 50 HP Transmission Rig• The Operator can store various Test Cycles and recall them as needed, thus saving time on writing the test again• In Auto mode the system controls the rig, performs the selected test and stores test data without further operator intervention• Safety: The system generates alarm caused due to various fail safe conditions, thus avoiding accidents• With the help of all the data stored user can analyze the behavior of the axle and if required redesign it

SPOTWELD STRENGTH TEST MACHINE

INTRODUCTION:

The machine is designed to test the SPOT WELD STRENGTH of STRIPS of various thickness from 0.2mm to 2.0mm. The machine has self standing structure with integrated ELECTRICAL CONTROLLS, PRINTER, MICROCONTROLLER UNIT, MOTOR & SWITCHES. The platen movement is achieved through 03phase AC motor with reduction gear, limit switches.

MACHINE SPECIFICATIONS:

POWER: 415V AC, 50Hz, 3 Ø

DISPLAY: 6 Digits 7 Segment LED for PEAK LOAD Detection

PRINTER: PK R 250 Thermal Printer

LOAD MEASURMENT:  2Kg to 100Kg

MINIMUM DISTANCE BETWEEN PLATTER: 100mm

MAXIMUM DISTANCE BETWEEN PLATTER: 400mm

ATTACHMENT PROVIDED: Tensile Testing Hook

MACHINE SPEED: 05mm per Minutes, Two way, Up & Down.

ELECTRICAL REQUIRMENT:

Machine requires STABLE (±05v) electrical supply of 3 Ø, 415V AC with INDEPENDENT & EFFECTIVE NEUTRAL.

CONTROLL PANEL:

All controls are given on control panel IN FRONT of the machine. They are governed by SWITCHES & MICROCONTROLLER given on the panel.

Tamperature Analysis Instrument

To measure change in weight of a sample w.r.t. rise in temperature. This information allows material scientists to study thermal properties of a chemical/mixture.