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.
Background: Delivering a Comprehensive ECU End-of-Line Testing Solution
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.
UUT
The Challenge: Deploying and Maintaining an ECU End-of-Line Test System Offshore
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:
- Verifying ECU hardware functionality across 90+ physical input/output (IO) points, via real time monitoring of high-speed CAN-based protocols
- Automated deployment and verification of the final ECU embedded software.
- Automated generation of compliance documentation, serial number assignment and tracking, and shipping/release paperwork.
- Secure archiving of ECU test data to support warranty traceability and quality management within a multi-level supply chain.
- Remote access and maintenance of the EOL Test System from global locations.
- Minimisation of overall test time to maximise throughput.
- Scalability to address increased production volumes, and flexibility to support future ECU variants.
The Solution: A Custom NI-Based ECU Test System
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:
- CAN-based communication with the ECU for command/control and dynamic load configuration.
- Real-time monitoring of more than 90 I/O points, ensuring precise measurement of expected vs. actual responses.
- Automated deployment and validation of shipping-ready embedded ECU software.
- An easy-to-use graphical operator interface with real-time status display, plus detailed pass/fail reporting for full traceability.
- Automated generation of serial numbers, barcodes, and compliance certificates.
- Archiving of all ECU test reports in a searchable database, enabling audit trails and continuous process improvement across the manufacturing lifecycle.
- Fully tested and delivered as a ready-to-run unit for quick installation and commissioning at the offshore site.
Outcome: A Flexible and Reliable ECU End-of-Line Test System in Continuous Service
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.
