Transmission Axle Test System
The Challenge: Design, develop and deploy NI-PXI-RT-based 150HP Transmission Test System.
The Solution: Developed Windows™ XP based application using NI LabVIEW 8.0 and RT Express to store test, run test, acquired data in text file for that particular test and generate process reports.
Introduction: Customer has a 150 HP Transmission Rig to perform endurance tests on various transmission axles. The rig has a control panel for manually operating the tests and no provision to store the test data. They wanted a way to better control the system log all the test related parameters in a test file. We developed a PC-based system using the NI-PXI-RT in LabVIEW along with MS Access and Text file to control the test rig, store all the test related data and generate reports.
What is 150HP Transmission Test Rig? 150HP Transmission Test Rig is used to test different Axles under various loading conditions. Based on the test results decision is taken whether the axle design will work. And if at all the design fails what was the reason for its failure. 
System Requirements: NI-PXI-RT based 150HP Transmission Test System should meet the following requirements:• Provide user-friendly interface for operating the 150HP Transmission Test Station• Facility to operate the Test Station in Auto and Manual Mode• Read Speed, Current and Torque (Analog Inputs) from Front Drive, Rear LHS and Rear RHS DC   drives • Read Speed and Torque Analog inputs from the AC Drive• Read Temperature inputs from 6 RTDs• Send reference signals (Analog Output) to AC drive, Front DC Drive, Rear LHS DC Drive and Rear   RHS DC Drive• Monitor the status of all the drives using various digital input lines• Send signals to Start/Stop all the drives and Emergency Stop• Incorporate safety interlocks in the Real Time System• Run un-interrupted test cycle• Data Acquisition and Logging of all the test parameters for future analysis and calculations • Store test parameters• Historical trending Hardware Design: NI-PXI-RT-based 150HP Transmission Test System consists of the following equipment:• 150HP Transmission Test Station: AC Drive, DC Drives, Mechanical Rig to load the Transmission,    Control Desk• NI-PXI-RT-based Real-Time System Controller. This Controller interfaces with all the analog and    digital I/Os • Industrial PC (P4 2GHz, 512MB RAM, 40GB HDD • NI PXI Data Acquisition Card for acquiring analog inputs and driving analog outputs• NI PXI Temperature Input module 
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

Embedded Systems Most of our solutions are PC-based. Some times application demands include space constraints and for the amount of intelligence required, a PC could be an over-kill. Embedded Systems solve both these issues by providing an appropriate platform to incorporate as many features as desired while keeping the space requirements low. One major advantage of embedded systems is reliability and consistency of operations. Embedded systems are best suited for applications where failure is not an option.

Driver Development Operators, technicians, engineers and scientists all are familiar with reading measurements from instruments. Sophisticated instruments have the capability of interfacing with a computer using either serial, parallel, GPIB or other communication protocol. A generic Application software is often shipped with such instruments to configure the equipment, make measurements and store results for further analysis. A customized software solution for improved data visualization, processing and storage capabilities would require drivers to communicate to the equipment. Our expert Artisans have adequate experience to develop drivers for various measurement instruments.

The Challenge: Design, develop and deploy a Vision-based System for Preform Thickness Control.The Solution: Developed Windows™ XP based application using NI LabVIEW and NI Vision that controls the thickness of the extruded preform.
System Requirements Specification: Optical Fiber manufacturer has a Preform Extrusion Machine. This machine is used for uniformly and accurately reshaping the 80mm (±10mm variation) wide Fiber Optic Preform into a 20mm wide Preform. The process is however, performed manually, where the 80mm preform first melts through a furnace, and then it is stretched by controlling the Capstan (Omron) AC Drive and Motor manually. This crude method does not guarantee uniform thickness of 20mm for the finished output rod. A gauging system is required to constantly monitor the thickness of the output preform and provide corrective signal to the Capstan (Omron) AC Drive and Motor for maintaining the output preform thickness to 20mm ± 0.3mm.The Vision-based Preform Thickness Control system should meet the following requirements:• Determine thickness of the output preform.• Provide appropriate control feedback to the Infeed and Capstan AC Drive & Motor to control the    Preform Thickness to 20mm ± 0.3mm• Log control parameters • Quick Setup and User-friendly operator interface Technical Design Approach: Extruded Preform thickness depends on several factors • Infeed Diameter: Variation in the diameter of the infeed Preform along its length• Infeed Speed: Rate at which the Preform is fed to the furnace from the top• Temperature: Furnace temperature• Draw Speed: Capstan motor speed• Output Preform Diameter: Diameter of the resulting PreformAll the above parameters need to be monitored and controlled in order to achieve uniform thickness along the length of the Preform. Two cameras would be used to measure the diameter of the Infeed Preform as well as the output rod. Appropriate control signals would be sent to the Infeed and Capstan motor through the InTouch Wonderware server.
Hardware: Hardware for the vision based Preform Thickness Control system includes the following:• PC for acquiring and processing images• Two Cameras, lenses and power supply• Image Acquisition Card• Appropriate illumination (Light Source)• Camera mounting fixture• Cables and connectorsAn operator friendly Graphical User Interface is designed using NI LabVIEW. The NI VISA Serial VIs provided easy interface of the Serial Data from the Temperature Controller and Weighing Balance to the Data Acquisition PC. The graphical display is designed such that the operator can interpret all the inspection information easily in a single glance. The operator also has a facility to open the stored data in other applications for further detailed mathematical analysis.
Software Application: Vision based Preform Thickness Control Software provides adequate controls to the operator for producing rods with consistent thickness. Automated Preform Thickness Control System has the following advantages: • Non-contact• Greater accuracy• Better control• Greater Resolution (0.3mm)A dedicated PC with Image acquisition card constantly acquires images from the two cameras, as the preform drawing process begins. The images are analyzed online for extracting the thickness information. Software control loop provides appropriate signals to the two motors and the furnace for controlling the Preform Thickness at 20mm ± 0.3mm. Auto and Manual modes of operation are programmed for the thickness control mechanism.
Summary: Vision-based System for Preform Thickness Control provided the accuracy of 20mm ± 0.3mm. The system automatically controls the motors, which gives accurate Preform thickness as per required.