Elevate Controls was contracted to design and implement a comprehensive End-Of-Line (EOL) Test System that automated all quality assurance, compliance and traceability procedures for a Gas Engine Control Unit (ECU) for medium duty commercial vehicles.
The EOL Test system was deployed to an offshore manufacturing facility in India.
Every ECU required full verification to ensure reliable and safe operation before release to the customer. The EOL Test solution had to automate the entire process – from hardware and embedded software validation to compliance documentation and data archiving to support warranty management and long-term product support.
Key requirements included:
Elevate Controls delivered a custom End-of-Line Test System built on the National Instruments (NI) PXI/PXIe hardware platform, with NI TestStand and NI LabVIEW software providing the test automation framework.
The system was supplied in a compact rack-mount enclosure featuring a custom wiring harness and load box, and flexible 12/24V power distribution. It was designed to manage a single test line with software-configurable support for multiple ECU versions.
The modular NI PXI/PXIe hardware and tightly integrated NI software frameworks ensured that the Test system was scalable and flexible to support any future changes to the test requirements.
Key Solution Features:
By combining NI’s industry-leading PXI/TestStand platform with custom circuitry and robust mechanical fixturing, Elevate Controls delivered a flexible and scalable automated ECU End-of-Line Test System tailored to the client’s needs.
The system has been in continuous operation for over a decade, supporting four different ECU variants, and has helped our client to maintain leadership in alternative fuel technologies.
Every control, monitoring, or test system project is unique. Elevate Controls follows a consistent development process that adapts to the unique requirements of your project and delivers a quality outcome every time. We use industry-standard tool chains that ensure consistent and efficient application of resources across every stage.
We offer a full-cycle development service from concept to deployment, and every stage in between. Whether you’re starting from a blank page or optimising an existing system, our team brings deep industrial experience, technical know-how, and a problem-solving mindset to every project.
Elevate Controls offers full-cycle development of embedded controllers. Our consistent development process adapts to the unique requirements of your project and ensures a quality outcome every time. We use industry standard tool chains that ensure efficient use of resources, and design protect to allow for future variation and scalability.
We supply custom measurement and automation systems for application in technology-based industries including mining & materials handling, renewable energy & power, transport, and manufacturing.
Our systems deliver superior performance for demanding applications that push the limits of traditional data loggers and PC/PLC controllers.
We are expert integrators of the Mathworks MATLAB/Simulink software toolchain for system modelling, simulation and control design of complex engineering applications.
We design, develop, validate and certify high-volume Vehicle/Engine Control Units.
We are a proven partner for VCU/ECU development with over 100,000 units currently in service.
Elevate Controls can partner with you to develop your control, measurement, or automation product. We can manage the entire process to the point of handover or work as an embedded part of your product development team.
We develop products using fully documented industry-standard processes and toolsets that ensure that your product can be maintained, evolved, and supported for it’s projected commercial life.
We employ a consistent development methodology that delivers successful outcomes every time.
Elevate Controls develops custom test systems that are integral to every successful industrial or manufacturing business. Test guides and validates product development, tracks and maintains product quality, and is an essential element of post-production support and warranty management.
Elevate Controls specialises in custom solutions to industrial automation challenges that push the limits of traditional PLC/SCADA systems. We target challenging industrial R&D or test applications, specialised sub-systems within a traditional DCS, and process control for niche or pilot-scale manufacturing.
We have supplied systems to industries that include mining and materials handling, electrical power, transport, manufacturing, process industries, agribusiness, and engineering services.
We do not compete directly in the large-scale DCS or SCADA space.
Traditional data management lags behind the exponential growth in the volume and variety of data collected in modern engineering workplaces.
Elevate Controls’ Engineering Data Management Solution is designed to meet the needs of small to medium-sized engineering groups that must manage, analyse, and report large quantities of mixed-signal data.
Elevate Controls is an NI Systems Integration Partner with over 30 years’ experience deploying NI-based systems into Australian industry.
We are one of Australia’s most awarded integrators of NI systems at leading industry events.
We have hands-on experience with all NI’s current & legacy hardware lines, and all NI software applications & frameworks. We are one of Australia’s leading LabVIEW software development houses, having worked with every version of LabVIEW since its initial release.
Fibre Optic Measurement delivers some unique benefits that complement the functionality of traditional electro-mechanical sensing systems.
Elevate Controls can deliver measurement and automation systems that seamlessly integrate Fibre Optic Measurement into traditional electro-mechanical sensing systems. This can address issues that may be challenging or impossible to meet with electro-mechanical sensors alone.
