Control and Functional Testing

Mechanical controls and programmable device functions are tested and verified automatically. Mechanical testing of button functions and controls Testing of rotary controls and other operating functions Programming of test and end-user firmware Verification of programmed firmware

Display and Electrical Testing

Optical and electrical functions are tested reproducibly under different operating conditions. Optical display inspection using a camera system Current measurements in different operating states Voltage measurements and simulations Execution of defined audio tests

Traceability and Production Process

Modularity, data connectivity and automated labeling support an efficient, traceable production process. Connection to the customer database for complete traceability Automated printing of product and packaging labels Creation of failure labels for repair and analysis processes Quick-change system for interchangeable cassettes and different device configurations

Reliable communication in the most demanding conditions:

Reliable multifunction units that connect radios and headsets by cable or Bluetooth are essential for law enforcement, emergency services and industry. MCD Elektronik develops end-of-line test systems for comprehensive testing of Bluetooth and DECT interfaces (radio interfaces) and audio quality, delivering maximum reliability, reproducibility and quality in series production.

Challenges and Concept

End-of-line testing of modern headset control units requires high flexibility across variants, reproducible test conditions and reliable quality control in series production. Functional, electrical, mechanical, audio and communication functions must all be evaluated reliably in one continuous test process.

Blinker, Kamera, Heizung und Assistenzsysteme.

EOLT Systems

Außenspiegel

Headset Control Units

Flexible EOL Test Bench for Communication and Control Units

MCD Elektronik developed a flexible, modular test bench for three different product variants. Interchangeable cassettes and quick-change systems let the test process adapt to different device configurations without affecting production speed.

The integrated MCD AudioAnalyzer precisely evaluates voice and audio signals. Integrated instruments also enable current and voltage simulation, while connection to the customer database supports complete traceability of devices under test and test results.

Product Variants

Test Areas

Function, Audio & Communication

Traceability

Customer Database

Ein flexibler End-of-Line-Prüfstand

MCD entwickelte hierfür einen flexiblen End-of-Line-Prüfstand, der sämtliche Varianten innerhalb von weniger als 30 Sekunden prüft. Das System kombiniert optische, mechanische und elektrische Prüfverfahren zu einem durchgängigen Prüfkonzept.

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Testing and Functional Scope

The EOL test bench checks the relevant control, communication, audio and electronic functions of headset control units under defined, reproducible test conditions:

EOL Test Bench for Headset Control Units

Front View of the Test Bench

Test Fixture in the EOL System

Test Fixture for Headset Control Units

Detailed View of the Test Fixture

Contacts, Wiring and Actuators

Label Printer for Product Identification

Detailed View of the Identification

Product and Barcode Labels

Mechanical controls and programmable device functions are tested and verified automatically.

Mechanical testing of button functions and controls
Testing of rotary controls and other operating functions
Programming of test and end-user firmware
Verification of programmed firmware

Voice, audio and communication interfaces are evaluated using integrated test equipment.

Precise evaluation of voice and audio signals with the MCD AudioAnalyzer
Testing of Bluetooth functionality, including audio transmission
Validation of wireless and wired interfaces
Testing of DECT interfaces

Optical and electrical functions are tested reproducibly under different operating conditions.

Optical display inspection using a camera system
Current measurements in different operating states
Voltage measurements and simulations
Execution of defined audio tests

Modularity, data connectivity and automated labeling support an efficient, traceable production process.

Connection to the customer database for complete traceability
Automated printing of product and packaging labels
Creation of failure labels for repair and analysis processes
Quick-change system for interchangeable cassettes and different device configurations

Bauteilaufnahme im EOL-Prüfstand

Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

Spiegeleinstellungen

Kamerasysteme kontrollieren Lichtfunktionen und Spiegelstellungen, während Antriebe, Klappmechanismen und elektrische Funktionen automatisiert getestet werden.

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Lichtfunktionen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

Kamerafunktion

Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Kamerafunktion

Länderspezifische Varianten

Auch das Nichtvorhandene zählt.

Die Negativprüfung stellt sicher, dass sich nicht verbaute Ausstattungsmerkmale nicht aktivieren lassen. Geprüft wird auch, was fehlen muss.

Modular Design for Different Product Variants

Interchangeable sets stored directly in the system and a quick-change system reduce changeover times. This allows the test bench to adapt efficiently to different device configurations and supports a high degree of flexibility across variants in series production.

Test Methods and Results

To test safety-critical communication devices, the EOL system combines mechanical, optical, electrical and acoustic test methods with software programming and digital traceability.

Mechanical and Optical Testing

Testing of button functions and rotary controls

Optical display inspection using a camera system

Device-specific contacts and hardware

Test bench validation as part of a Measurement System Analysis (MSA)

Audio and Communication Testing

Analysis of voice modules and audio input and output signals

Testing of radio, Bluetooth and DECT interfaces

Speech recognition and evaluation with the MCD AudioAnalyzer

Testing of wired communication interfaces

Electrical and Software Testing

Current and voltage measurements in different operating states

Current and voltage simulation using integrated instruments

Programming of test software and device-specific production software

Verification of programmed device functions

Process and Quality Assurance

Complete traceability of devices under test and test results

Automated printing of product, packaging and failure labels

Rapid adaptation with interchangeable cassettes and modular test equipment

Reproducible test conditions for consistently high communication quality

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

Optische Prüfungen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Kamerabasierte Erkennung von Lichtfunktionen

Analyse von Spiegelstellungen

Kontrolle des Spiegelglases

Mechanische und elektrische Prüfungen

Antriebe und Klappmechanismen werden mechanisch geprüft, während Winkelpositionen bestimmt sowie Spannung und Stromaufnahme gemessen werden.

Bewegungsprüfung der Antriebe

Winkelmessung der Klappfunktion

Stromaufnahme der Motoren

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

FREQUENTLY ASKED QUESTIONS

FAQS

These control units extend headsets with functions for managed voice communication. These include selecting and separating communication channels, volume control, push-to-talk functions, and pairing with different communication devices.

The end-of-line (EOL) test system is used at the end of the production line to ensure that headset control units are fully functional. It checks all relevant electrical, mechanical and functional characteristics, as well as communication signals, before the product is shipped.

End-of-line testing ensures that every control unit operates fully and reliably over time. This is particularly important because headsets are used in safety-critical environments where voice communication must be reliable, easy to operate and robust. Typical applications include police, emergency services, fire departments, defense, aviation, control centers, logistics and manufacturing.

Yes. EOL testers are designed for straightforward integration into existing manufacturing environments, including connections to MES or ERP systems.

Yes. The end-of-line test system can be partially or fully automated, for example with automatic loading, operation and unloading systems. This improves test accuracy and process reliability while reducing cycle times. Complete documentation also helps ensure consistently high product quality.

KEY FACTS

Key facts at a glance

TEST SYSTEM

End-of-Line Test System

Handling

Semi-automatic

Concept

Single test station with one test specimen per test cycle

Test Methods & Scope

Electrical: voltage, current
Audio / communication: audio signal, communication signal
Temperature: temperature measurement or testing
Haptic / mechanical: force-displacement measurement

COMPONENTS

MCD TestManager, MCD Toolmonitors, VTS 2030 rack system, MCD AudioAnalyzer, MCD USB hub,
MCD Controller MIO1616, multiplexer, barcode scanner