It is the policy of OMNI Engineering Services Inc. not to disclose customer names and/or proprietary details of projects without the client’s release to do so.

Design a test system that will test the electronics, connections and wiring of an "Electric Car Control Module". The system under test is the panel of components including Drive, motor, charger, dc/dc converter, contactor and other support components.

A custom interface board was used along with a DAC board. The project's software was developed using Labview. Labview was a good choice and allowed custom reporting, logging and full automated testing with one button. The report lists any failures with suggested solutions. Also included was a back end interface to run the test manually that was used for software development and would be used to troubleshoot system failures. The system can easily be expanded for component testing, barcode reader, serial communications for new ECU models.

One of the main challenges was to minimize test time as a multitude of connections need to be made by the operator. The customer especially likes the way we implemented the hardware to help with this challenge. The product integrated well with there new automated build process. It allow a product that was not tested until it was being driven off the line to allowing pre-testing of the electronics to minimize rework.

Labview development system
Custom interface board with 72V interfacing
DAQ Board 32 IO, 16AI, 1 counter, 1 AO
Robust mechanical connections