ECU Field Tester

Background: Supporting In-Service ECU Maintenance

Elevate Controls was engaged to design and deliver a robust Field Test System to support in-service maintenance and fault diagnostics of Gas Engine Control Units (ECUs) for medium-duty commercial vehicles.

This project extended our long-standing partnership with the ECU manufacturer, which began over a decade ago when we developed their original End-Of-Line (EOL) Test System. Over time, the manufacturer discovered that ECUs returned under warranty were often fully functional or failed due to external factors not covered by warranty. This increased warranty support costs and reduced production capacity, as returned units competed for access to the in-factory EOL Test system.

The Challenge: Portable ECU Testing in the Field

The challenge was to replicate around 95% of the original factory-based EOL Test System functionality in a portable, DC-powered ECU test unit. The goal: enable accurate on-site ECU fault diagnosis and generate reliable test reports directly comparable to factory test data.

Key requirements for the portable ECU Field Test System included:

  • Comprehensive functional test coverage for over 90 physical I/O points, with real-time monitoring and control of high-speed CAN bus protocols.
  • Verification of embedded ECU software versions and functionality, with capability to update or reload software in the field.
  • Provision of all necessary system loads.
  • Reliable operation on DC power in remote conditions.
  • Secure archiving of test results, with immediate comparison to ex-factory reports.
  • Remote access and technical support, anywhere in the world.
  • Rapid testing, reporting, and analysis to minimise vehicle or equipment downtime.

The only major element not required in the field unit was the original factory shipping and conformance documentation.

ECU Field Tester – Elevate Controls, Como WA

The Solution: A Rugged, Portable ECU Field Test System

Elevate Controls delivered a rugged, portable ECU Field Test System built on advanced National Instruments (NI) hardware and software technology.

Thanks to advances in hardware since the original EOL system was deployed, multiple PXI/PXIe modules could be consolidated into a single bus-powered multifunction I/O module and CAN interface. While overall test time was slightly longer due to reduced parallelism, it remained well within practical field test requirements.

Software developed for the original EOL Test System was seamlessly adapted to the new portable hardware, retaining full compatibility with all current and future TestStand test sequences. The local operator interface mirrors the factory system — streamlined by removing shipping documentation — allowing test engineers to switch between the factory EOL system and the Field Test unit with zero additional training.

The Field Test System supports remote connections via WiFi or GPS and automatically uploads ECU test reports for centralised analysis.

In the field, suspected faulty ECUs can now be fully tested on-site, confirming in less than 5 mins whether an actual ECU failure has occurred or if the issue is due to external factors. This has significantly reduced unnecessary ECU returns, cut warranty support costs, and freed up the factory EOL Test System for production testing.

The Outcome: Support for Full Life Cycle ECU Test

This project demonstrates Elevate Controls’ commitment to designing robust, flexible test and measurement systems that evolve with our customers’ needs.

We design and deliver custom test, measurement, and automation solutions that provide reliable performance throughout their lifecycle. By planning for flexibility and scalability, we help manufacturers and service teams meet new technical and business challenges with minimal cost and disruption.

In this case, our customer’s need to tighten warranty management and protect production capacity within a complex supply chain drove the requirement for a portable ECU Field Test System. By building on the proven factory-based test solution previously developed by  Elevate Controls, we delivered a cost-effective, high-performance portable ECU test system that protects production capacity, reduces support costs, and provides peace of mind — wherever in the world it’s deployed.

Our Approach

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.

Concept Validation

System Architecture

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Deployment & Scaling

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Our Services

Embedded Controllers

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.

Measurement & Automation

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.

MatLab/Simulink Services

We are expert integrators of the Mathworks MATLAB/Simulink software toolchain for system modelling, simulation and control design of complex engineering applications.

Vehicle/Engine Control Units

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.

Product Development and Supply

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.

Test Systems

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.

Specialised Industrial Automation

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.

Engineering Data Management

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.

NI Alliance Partner

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

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.

Contact Us

Our solutions leverage industry-leading platforms, including National Instruments hardware and software, ensuring reliability, scalability, and faultless integration with your existing infrastructure.

We partner with clients throughout the entire project lifecycle—from proof of concept to system development, deployment, and long-term support— with the added flexibility to integrate at any phase of your project.

Elevate Controls helps businesses accelerate innovation while optimising performance and cost.

Contact us today to discuss your specific requirements and discover how Elevate Controls drives efficiency, accuracy, and competitive advantage in your operations.



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