Optical, Mechanical, and Pneumatic Testing

Optical inspections, mechanical test tasks, as well as leak and presence checks can also be integrated into the system. Optical inspections and image processing Mechanical test tasks Leak tests Presence checks

Process Integration and Additional Functions

In addition to the actual test, further process steps can be integrated directly into the custom solution. Assembly processes Calibrations Verifications Copying and writing processes Assessment of assembly and component placement

Flexible System Configurations

The configuration depends on the test specimen, production process, and required level of automation. Manual test station Semiautomatic station Assembly and test station Validation system Verification station Optical and electrical test station Fully automated custom machine

Special Systems

Special Test Systems

Special test systems from MCD Elektronik are used when standard test benches are not sufficient. For special test specimens, new technologies, or complex process requirements, MCD develops custom solutions—featuring customized mechanical components, adaptations, measurement technology, software, automation, and data connectivity.

Special Systems

Special test systems are needed where conventional test concepts reach their limits. Specific mechanical properties, combined test methods, or new technologies require individually developed solutions for which no standardized test solution is often available.

Blinker, Kamera, Heizung und Assistenzsysteme.

Special Systems

Außenspiegel

Special Test Systems

Custom Special Test Systems for Challenging Test Tasks

A special test can combine electrical, optical, mechanical, pneumatic, acoustic, or software-based test tasks with assembly processes, calibrations, verifications, copying processes, or image processing.

MCD Elektronik views these tasks as an overall system comprising the product, test objective, production environment, operating concept, safety requirements, and data management. This results in special test systems precisely tailored to the test specimen and process.

Test Methods

electrical, optical, mechanical, pneumatic, acoustic, and software-based

System Configuration

manual to fully automatic

System Approach

Individually tailored to the test specimen and process

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 %

Typical Test Methods and Concepts

Special test systems combine different testing and process requirements in a tailor-made solution. Mechanics, contacting, measurement equipment, software, and handling are precisely matched to the specific test task.

Actuator Assembly Station

Front View of the Test Station

Pressure-Tight Test Chamber for CO₂ Sensor Cells

Exterior View of the Test Chamber

Stainless Steel Chamber with Pressure Connections and Sensors

Operator Monitor of the Validation Tester

Detailed View of the Test Software

Measured Values, Angles, and Test Result

Special Test System

Detailed View of the Test System

Depending on the application, electrical measurements, functional tests, and sensor and actuator tests are combined within the test system.

Functional tests
Electrical measurements
Sensor and actuator tests
Frequency and signal tests

Optical inspections, mechanical test tasks, as well as leak and presence checks can also be integrated into the system.

Optical inspections and image processing
Mechanical test tasks
Leak tests
Presence checks

In addition to the actual test, further process steps can be integrated directly into the custom solution.

Assembly processes
Calibrations
Verifications
Copying and writing processes
Assessment of assembly and component placement

The configuration depends on the test specimen, production process, and required level of automation.

Manual test station
Semiautomatic station
Assembly and test station
Validation system
Verification station
Optical and electrical test station
Fully automated custom machine

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.

Engineering, Mechanics, and Software from a Single Source

A special test system is created through the combination of engineering, mechanics, software, metrology, automation, and experience gained from completed customer projects.

Test Methods and Concepts Used

Depending on the application, special test systems combine electrical, optical, mechanical, pneumatic, acoustic, and software-based test methods with additional process and automation tasks.

Electrical and Functional Testing

Functional tests

Electrical measurements

Sensor and actuator tests

Frequency and signal tests

Optical and Mechanical Testing

Optische Inspektionen

Bildverarbeitung

Mechanical test tasks

Assessment of Assembly and Component Placement

Pneumatic and Acoustic Testing

Leak tests

Presence checks

Acoustic test tasks

Calibration and Process Integration

Calibrations and verifications

Montageprozesse

Copying and writing processes

Custom adaptation of mechanics, contacting, measurement equipment, software, and handling

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

Special Systems

Specialized test systems are needed when conventional testing approaches reach their limits. This can be the case when a test specimen has unique mechanical properties, when multiple testing methods must be combined, or when new technologies are being tested for which no standardized testing solution yet exists. A specialized test can take many different forms: It combines electrical, optical, mechanical, pneumatic, acoustic, or software-based testing tasks with assembly processes, calibrations, verifications, copying processes, or image processing. MCD Elektronik does not view such tasks as isolated parameters, but rather as a comprehensive system comprising the product, test objective, manufacturing environment, operating concept, safety requirements, and data management. This results in specialized test systems that are precisely tailored to the respective test object and process.

Typical Test Methods and Concepts

Depending on the application, specialized test systems can be designed as manual test stations, semi-automatic stations, assembly and test stations, validation systems, verification stations, optical-electrical test stations, or fully automated special-purpose machines.

It is crucial that the mechanical components, connections, measuring equipment, software, and handling are individually tailored to the test task. Typical testing tasks include functional tests, electrical measurements, optical inspections, sensor and actuator tests, frequency and signal tests, leak or presence tests, calibrations, verifications, copying and writing processes, as well as the evaluation of assembly or placement conditions.

For MCD, the key factor is this: A specialized test system is the result of the interplay between engineering, mechanics, software, measurement technology, automation, and experience gained from completed customer projects.

Test Methods and Concepts Used

Procedure

Special Systems

INSERT

The test specimen is placed in the customer-specific fixture, adapter, or special mechanism, and the test sequence starts automatically.

STIMULUS & MEASUREMENT

The test object is specifically stimulated with defined signals, voltages, load profiles, and control commands. System responses, measured values, and process data are automatically recorded and evaluated.

SPECIAL EXAM

Depending on the test task, different test procedures are combined, and application-specific hardware and software components are developed and integrated into the test sequence.

DIAGNOSIS & RESPONSE

Comparison of the measured test specimen responses in relation to the expected results, signal waveforms, and tolerance limits.

RESULTS & TRACEABILITY

The system outputs a clear result (Pass/Fail) and generates digital documentation. Optional: label printing, integration with a customer’s MES system.

FREQUENTLY ASKED QUESTIONS

FAQS

A specialized test system is a custom testing solution for products, processes, or technologies that cannot be fully tested using a standard system. Depending on the application, it combines additional mechanical components, specific adaptations, measurement technology, software, automation, and data connectivity.

A functional test specifically verifies that a product or assembly performs as intended. A specialized test system goes a step further when it involves complex mechanical components, unusual test conditions, specialized measurement methods, verification processes, assembly functions, or custom automation.

Yes. Specialized test systems can be implemented as manual test stations, semi-automatic stations, or fully automatic custom machines. Depending on the process, handling, locking, contact connection, image processing, robotics, database integration, or product ejection can be integrated.

A specialized test system is worthwhile when standard test benches are insufficient, multiple test procedures must be combined, or a product has specific interfaces, shapes, safety requirements, or quality characteristics. This is particularly relevant for new technologies, complex assemblies, or industry-specific special processes.

Mechanics are often a key component of special tests. They ensure that the test specimen can be securely positioned, reliably contacted, moved, loaded, shielded, or mounted. Especially with non-standard test specimens, the mechanics play a crucial role in determining measurement stability and process reliability.