Inline Systems

INLINE TEST SYSTEMS

INLINE TEST SYSTEMS

Inline systems from MCD Elektronik integrate testing and automation stations directly into existing production lines, thereby increasing efficiency, cycle time, and process reliability. Whether for PCB testing, EOL testing, or assembly lines: MCD develops custom inline solutions that are precisely tailored to the product, manufacturing environment, testing requirements, and level of automation—featuring conveyor technology, intelligent barcode recognition, and automated handling.
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INLINE TESTS

Inline tests are automated quality controls that are directly integrated into the production process. The test specimen is contacted, stimulated, measured and evaluated within the line without being separately transported to an external testing location.

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Blinker, Kamera, Heizung und Assistenzsysteme.

Inline Systems

Außenspiegel

INLINE TEST SYSTEMS

Integrated testing solutions for the ongoing production process

Inline test systems connect the testing process directly with material flow, cycle time, handling, process control and data management. This means that errors can be identified at an early stage, test results can be documented directly and faulty parts can be specifically rejected.

The close integration into production supports reproducible quality, reduces manual interventions and creates the basis for complete traceability.

Quality control
100 percent testing in series production
Process integration
directly in the ongoing production flow
Traceability
Complete documentation of the test results

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 %

TYPICAL TESTING METHODS AND APPROACHES

Inline test systems connect testing and process steps directly with the production flow. Depending on the application, functional tests, circuit board tests, electrical measurements, communication tests, optical inspections as well as programming and documentation processes can be integrated.

Testing of Electrical Assemblies
Close-Up View
Inline Test System
Barcode Scanning in the Inline Test System
Detailed View of the Inline Test
Component Identification and Traceability

Electronic assemblies are tested within the line under defined conditions and relevant electrical and functional measurements are automatically evaluated.

  • Functional tests of electronic assemblies
  • Board checks
  • Current and voltage measurements
  • Signal and communication tests

Depending on the testing task, additional procedures can be integrated directly into the inline process.

  • Optical inspections
  • Leak tests
  • Load tests
  • Partial identification and barcode recognition

In addition to the actual testing, production-related process steps can be carried out and documented automatically within the inline system.

  • Programming and flash processes
  • Assembly processes
  • Label printing
  • PASS/FAIL sorting
  • Handover to subsequent process steps

Measurement and process data can be transferred directly to higher-level systems and used for traceability within series production.

  • Digital result documentation
  • Database connection
  • MES connection
  • ERP connection
Bauteilaufnahme im EOL-Prüfstand
Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

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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.

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Flexible inline concepts for different production processes

Inline test systems can be designed as linked test stations, fully automatic test lines, rotary transfer or transport systems, robot-supported cells or integrated assembly and testing systems.

Test Methods and Approaches Used

In-line test systems are integrated directly into the ongoing production flow. The entire sequence—from the test specimen’s entry through contact, measurement, evaluation, and documentation to further processing within the line—is viewed as a single, continuous process.

Functional and Electrical Tests
Functional Testing of Electronic Assemblies
Circuit Board Testing
Current and Voltage Measurements
Signal and Communication Tests
Visual and Physical Inspections
Visual Inspections
Leak Tests
Stress Tests
Barcode Recognition and Part Identification
Production-Oriented Process Integration
Programming and Flash Processes
Assembly Processes
Label Printing
PASS/FAIL Sorting
Line and Data Integration
Interlinked Test Stations
Rotary Transfer and Conveyor Systems
Robot-Assisted Cells
Database, MES, and ERP Integration
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

INLINE TESTS

INLINE TESTS

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Inline inspections are automated quality control processes that are directly integrated into the production process. The test item is not transported separately to an external testing station; instead, it is contacted, stimulated, measured, and evaluated within the production line. This allows defects to be detected early, test results to be documented immediately, and defective parts to be specifically removed from the line.

Unlike individual test stations, inline test systems are closely integrated with material flow, cycle time, handling, process control, and data management. They support 100-percent inspection in mass production and lay the foundation for reproducible quality, fewer manual interventions, and complete traceability.

TYPICAL TESTING METHODS AND APPROACHES

TYPICAL TESTING METHODS AND APPROACHES

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Inline test systems can be configured in various ways depending on the product, quantity, cycle time, and test task. Possible configurations include linked test stations, fully automated test lines, rotary transfer or conveyor systems, robot-assisted cells, integrated assembly and test systems, as well as combinations of functional testing, end-of-line testing, and process control.

Unlike general automated test systems, inline test systems are directly integrated into the ongoing production flow. While automated test systems can also operate as standalone test stations outside a production line, inline systems directly link the testing process to material flow, cycle time, handling, line control, and traceability.

Typical testing tasks include functional tests of electronic assemblies, PCB testing, current and voltage measurements, signal and communication tests, optical inspections, leak and stress tests, programming and flash processes, as well as the transfer of measurement data to a database or an MES system. In addition, assembly processes, label printing, barcode recognition, part identification, sorting of PASS and FAIL parts, and data transfer to databases or ERP systems can be integrated.

For MCD, the focus is not only on the individual test step but on the entire process: from the arrival of the test item through contact, measurement, evaluation, and documentation to further processing within the line.

Test Methods and Approaches Used

Test Methods and Approaches Used

Procedure

Inline Systems

1

INSERT

The test specimen is fed into the system via conveyor technology, a workpiece carrier, or a handling system and is uniquely identified.
2

POSITIONING

The system positions the DUT, locks it in place if necessary, and establishes electrical, mechanical, or signal connections in a reproducible manner.
3

STIMULUS & MEASUREMENT

The test object is specifically stimulated with defined signals, voltages, load profiles, and control commands. Inputs and outputs are stimulated, and the system’s responses are evaluated.
4

DIAGNOSIS & RESPONSE

Measurement results are compared with target values and tolerance limits; parts that pass inspection are sent on. Defective parts are marked or rejected.
5

RESULTS & TRACEABILITY

The system digitally stores test results, measured values, and process data. Optional: label printing or data transfer to MES, ERP, or customer systems.

FREQUENTLY ASKED QUESTIONS

FAQS

An inline test is a testing procedure that takes place directly within a running production line. The test item is automatically transported, identified, contacted, tested, and evaluated without unnecessarily interrupting the production flow. This allows function, quality, and process data to be monitored and documented directly during mass production. Inline testing is particularly well-suited for automated manufacturing with high production volumes, short cycle times, and requirements for complete traceability.
In-line test systems are suitable for electronic, electromechanical, and mechatronic products. These include printed circuit boards, control units, infotainment components, communication modules, sensors, actuators, industrial electronics assemblies, and mass-produced products with high testing and documentation requirements. Furthermore, inline testing is well-suited for the product validation of components that are typically manufactured on a production line.
Typical tasks include functional tests, end-of-line inspections, current and voltage measurements, signal and communication tests, optical inspections, leak tests, flash and programming processes, barcode recognition, labeling, sorting, and database and ERP integration.
An inline test system is useful when high production volumes, short cycle times, repetitive test sequences, automated handling, or complete traceability are required. It is particularly useful when testing, assembly, identification, and process data need to be integrated into a continuous manufacturing process.
Traceability ensures that every test result can be uniquely linked to a product, a serial number, or a barcode. This makes quality data traceable, allows the causes of errors to be identified more quickly, and enables production processes to be evaluated more effectively over the long term.

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REFERENCE PROJECTS

Inline Systems

Inline test system for mechatronic components