Assembly and leak testing

The first station assembles the sealing ring and then tests the component for leaks under defined conditions. Assembly of sealing rings Leak testing using the vacuum method Leak testing using the differential pressure method

Mechanical functional testing

Mechanical movement and actuation parameters are recorded precisely and evaluated to assess component function. Measurement of the travel angle (< 0.1°) Torque measurement Simulation of different loads

Electrical and sensor testing

Electrical profiles and sensor data are recorded, compared and evaluated automatically. Recording the current profile Hall sensor calibration and adjustment Evaluation of sensor data

Process integration and traceability

The test data is processed centrally and assigned to the production process via the MES connection. MES connection Automated material flow via feeding, sorting and transfer systems Flexible adaptation to different types of test specimens

Inline Systems

Inline test system for mechatronic components

Q: Electrical and sensor testing

Electrical profiles and sensor data are recorded, compared and evaluated automatically. Recording the current profile Hall sensor calibration and adjustment Evaluation of sensor data

Q: Process integration and traceability

The test data is processed centrally and assigned to the production process via the MES connection. MES connection Automated material flow via feeding, sorting and transfer systems Flexible adaptation to different types of test specimens

Q: What tasks does this inline test system perform?

This test system is an automated system for assembling mechatronic components and subsequently performing leak tests and electrical functional tests within the production line. The individual components are supplied via conveyor systems, assembled by a handling system and tested for leaks. For the electrical functional test, the test specimen is contacted via specimen-specific adapters and then tested automatically.

Q: Which parameters are recorded during the test sequence?

Typical parameters measured by the test system include differential pressure, torque, angle of rotation, current profiles, and signal and sensor data. The integrated assemblies are also programmed during the test process.

Q: What measurement accuracy is achieved for torque measurements?

The measurement accuracy is within a tolerance of 2%. A specially developed load machine also achieves an angular measurement and repeatability accuracy of < 0.1°. This makes it possible to reliably test and reproducibly comply with customer-specific limits.

Q: What distinguishes the system from a conventional test bench?

The system is more than a single test station: it is an inline solution that combines assembly, leak testing and functional testing in one continuous process. The test specimens are automatically transported to the stations on workpiece carriers and a transfer conveyor, tested, and the results documented. This directly links assembly quality with the test result.

Q: What particular challenges arose during the development of the system?

The system was developed for use in Canada with CSA compliance in mind. These requirements include statutory safety standards for almost all electrical or electronic equipment connected to the power grid or operated commercially. A Field Evaluation Service inspected the entire system in detail and, despite the stringent safety-related requirements, the test system received the required label for delivery and commissioning.

The inline test system for mechatronic components combines automated assembly, leak testing and functional testing in a single system

The end-of-line tester reliably safeguards quality in series production. Precise leak tests, comprehensive functional tests and flexible changeover options enable use with different test specimen variants and sustainably increase efficiency and process reliability.

Challenges and concept

The inline test system was developed specifically for the automated assembly and testing of mechatronic components. It combines the precise assembly of sealing rings with leak and functional testing in a continuous process and, as an end-of-line system, enables seamless quality control directly in production.

Blinker, Kamera, Heizung und Assistenzsysteme.

Inline Systems

Außenspiegel

Inline test system for mechatronic components

Automated assembly and testing in a continuous process

At the first station, a sealing ring is assembled and then leak-tested using vacuum and differential pressure methods. The second station performs the functional test and records electrical and mechanical parameters such as torque, angle, current profiles and signals.

Automated feeding, sorting and transfer systems ensure a continuous material flow. Flexible adaptation to different types of test specimens supports efficient and reliable series production.

Test process

Assembly & functional testing

Angle measurement

< 0.1°

Traceability

MES connection

Scope of testing and functions

The inline test system combines assembly, leak testing and functional measurements into an automated testing process for mechatronic components:

Inline test system for mechatronic components

Overall view of the test system

Feeding, test station and transfer system

Test station with measurement and operating technology

Detailed view of the test station

Mechanics, sensors and operator monitor

Inline test station with conveyor system

Side view of the test system

Feeding, test module and transfer system

The first station assembles the sealing ring and then tests the component for leaks under defined conditions.

Assembly of sealing rings
Leak testing using the vacuum method
Leak testing using the differential pressure method

Mechanical movement and actuation parameters are recorded precisely and evaluated to assess component function.

Measurement of the travel angle (< 0.1°)
Torque measurement
Simulation of different loads

Electrical profiles and sensor data are recorded, compared and evaluated automatically.

Recording the current profile
Hall sensor calibration and adjustment
Evaluation of sensor data

The test data is processed centrally and assigned to the production process via the MES connection.

MES connection
Automated material flow via feeding, sorting and transfer systems
Flexible adaptation to different types of test specimens

Continuous inline testing in series production

The coordinated assembly, testing and handling process combines automated component feeding, leak testing and functional testing within a continuous production solution.

Test methods used and results

MCD test software records all measurement and test results, evaluates them against defined limits and uniquely assigns them to the respective test specimen. This ensures documentation and traceability of test data in series production.

Leak testing

Testing using the vacuum method

Testing using the differential pressure method

Evaluation according to defined test parameters

Mechanical and electrical measurements

Precise measurement of travel angle and torque

Recording and evaluation of current profiles

Simulation of different load conditions

Sensors and calibration

Calibration and adjustment of the Hall sensor

Evaluation of sensor data

Evaluation of measured values against defined limits

Process and quality evaluation

Unique assignment of test results to the respective test specimen

Complete documentation and traceability via MES

Short cycle times through automated handling

High repeatability and stable test conditions in series production

FREQUENTLY ASKED QUESTIONS

FAQS

This test system is an automated system for assembling mechatronic components and subsequently performing leak tests and electrical functional tests within the production line. The individual components are supplied via conveyor systems, assembled by a handling system and tested for leaks. For the electrical functional test, the test specimen is contacted via specimen-specific adapters and then tested automatically.

Typical parameters measured by the test system include differential pressure, torque, angle of rotation, current profiles, and signal and sensor data. The integrated assemblies are also programmed during the test process.

The measurement accuracy is within a tolerance of 2%. A specially developed load machine also achieves an angular measurement and repeatability accuracy of < 0.1°. This makes it possible to reliably test and reproducibly comply with customer-specific limits.

The system is more than a single test station: it is an inline solution that combines assembly, leak testing and functional testing in one continuous process. The test specimens are automatically transported to the stations on workpiece carriers and a transfer conveyor, tested, and the results documented. This directly links assembly quality with the test result.

The system was developed for use in Canada with CSA compliance in mind. These requirements include statutory safety standards for almost all electrical or electronic equipment connected to the power grid or operated commercially. A Field Evaluation Service inspected the entire system in detail and, despite the stringent safety-related requirements, the test system received the required label for delivery and commissioning.

KEY FACTS

Key facts at a glance

Test system

Inline test system / Automated test system / EOL test system

Handling

Automatic, with manually interchangeable components for different variants

Concept

Assembly system / Inline test system with two stations and single-unit testing – 1 DUT per test sequence

Test methods & scope

Leak tightness: pressure test / leak test
Mechanical: loads, torques, angle measurement
Electrical: currents
Programming / signal testing: PWM and Hall signals

Components

TestManager CE, Toolmonitor DataManager, Toolmonitor PLC, MCD brushed motor controller, MCD Controller MIO1616, ULC multifunction card