Inline Systems

Inline test system for mechatronic components

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.
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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.

Inliner-Ringmagnet-EOLT-scaled-1024x768

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

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

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil
Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

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
Bauteilaufnahme im EOL-Prüfstand
Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

INLINE SYSTEM mechatronic components_mcd-003 (2)-2468x2521
INLINE SYSTEM mechatronic components_mcd-002 (1)-1200x1500

Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

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

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

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.

mcd_plus_white
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
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

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

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