Thanehall’s approach to Test Programming and Test Engineering
Thanehall leverages decades of experience in test programming and test engineering to deliver comprehensive testing solutions. From early work with ATLAS™ to modern tools like C, LabWindows / CVI™, LabVIEW ™ and Python™, we’ve developed numerous Test Program Sets (TPS) for diverse industries. Our innovative approach includes script interpreters that simplify development, allowing programmers to focus on high-level engineering. By combining legacy knowledge with cutting-edge practices, we ensure efficient, reliable testing processes tailored to client needs.
Enhancing Engineering Test Capabilities with Rugged, Bespoke Solutions
A client faced challenges with unreliable engineering test setups and low-level DC current measurement inaccuracies during a development program. Thanehall designed rugged, bespoke test boxes with custom interface cables and integrated automation using National Instruments DAQmx™ drivers, ensuring standardised and reliable testing. To address measurement issues, specialised calibration test boxes with precision resistors and custom software were developed, enabling accurate calibration and extended power supply calibration intervals. These solutions streamlined the client’s testing process, improved measurement reliability, and reduced operational costs.
Innovative Test Fixtures for Diverse Applications
Thanehall has developed a range of tailored test fixtures for diverse client needs, from military-grade solutions with precise air cooling and specialist connectors to advanced "Bed of Nails" fixtures integrating firmware programming, data acquisition, and RF testing up to 6 GHz. Additionally, economical fixtures were created to support unit programming and bring-up with simple cooling solutions. These innovations have provided reliable, efficient, and cost-effective testing capabilities across industries, meeting both complex and straightforward requirements.
Advanced RF Switching Units with Bespoke Communication Solutions
Thanehall designed a 10-channel RF switching unit for a client, enabling connections from DC to 6 GHz for devices like RF Power Meters, Vector Network Analysers, and Spectrum Analysers. The unit integrated optical switching for managing optical power, converting optical to RF signals, and generating modulated optical power at 1310 nm. Featuring optical splitters for multi-channel monitoring and a 3U rack-mounted design with e-cal integration, it ensured precise calibration and seamless measurement capabilities. This versatile solution exemplifies Thanehall's expertise in delivering advanced, tailored systems for complex RF and optical signal management.
Advanced Test Racks and Systems for Environmental Stress Testing
Thanehall developed advanced test systems for environmental stress testing, including ESS test racks for Eurofighter Typhoon units adhering to Mil. Std. 4370, a portable HTOL tester, test harnesses, and compact end-of-line ESS systems. These solutions supported synchronised multi-unit testing, remote monitoring for Mil. Std. 810 compliance testing, and precise control over extreme temperature cycles and vibrations. Thanehall’s innovations ensured reliable, efficient, and compliant testing for critical components across the diverse applications.
Delivering Comprehensive Documentation and Test Requirement Solutions
Thanehall provided comprehensive technical documentation for a military client, including multi-volume handbooks for installation, calibration, repair, and fault diagnosis, adhering to evolving standards including NES 40, Defense Standards, and JSPs. Detailed installation diagrams derived from survey data helped the client secure a major infrastructure project bid. For the Eurofighter program, Thanehall created Test Requirement Documents (TRDs) to Mil. Std. 1519, along with Acceptance Test Procedures, Environmental Procedures, and diagnostic guides. These solutions ensured compliance, operational efficiency, and project success across diverse military and engineering needs.
Portable Rugged Test Equipment for Aircraft Ground Equipment (AGE)
Thanehall developed a portable test system for Aircraft Ground Equipment using Commercial Off The Shelf (COTS) components and a durable laptop controlling bespoke interfaces and cabling. The system, housed in a custom case within a transport-compliant enclosure, passed Mil. Std. 810 tests for durability. This cost-effective solution ensured reliable field testing and maintenance while meeting stringent operational and transport requirements.
Production Test Process using National Instruments LabVIEW™, Sequences and Scripts
Thanehall upgraded their LabWindows /CVI™ test sequencer to a versatile LabVIEW™ based system, featuring a bespoke scripting language with variables, loops, and device commands. The text-based approach allowed engineers to maintain tests without costly licenses. Cloud-based reporting enabled easy access to test results in Excel and other formats, delivering a scalable and cost-efficient solution for production testing.
Shop Floor Control System with Integrated BoM, MRP, ERP, and Test Process
A client transitioning to manufacturing in-house required a robust solution to replace their Excel based BoM management. Thanehall developed a custom database for components, sub-assemblies, and high-level assemblies with CAD import capabilities, integrating it into a comprehensive Shop Floor Control System. The solution included checkpoints for kitting, assembly, testing, packing, and dispatch, linked to bespoke Material Requirements Planning (MRP) and Enterprise Resource Planning (ERP) systems. Transitioned to the cloud as React™ applications on Amazon Relational Database Service (Amazon RDS), it enabled real-time monitoring and automated reporting, offering startups similar to our client an accessible, scalable system for reliable manufacturing and traceability.
Supporting ISO 9001 Quality Management System with Documentation and Audits
Thanehall used its expertise in quality management, which originated from experience with BS 5750 through to ISO 9001 standards, to assist a client in implementing an ISO 9001 Quality Management System. This included defining processes, drafting procedures, and conducting surveillance audits to ensure compliance and effectiveness. The collaboration resulted in a practical, fully compliant QMS that improved operational efficiency and positioned the client for successful certification.
Power Inverter Testing
A Cambridge-based client designed and manufactured micro solar inverter equipment with integrated Zigbee communication for gateway monitoring. A simulator was developed in LabVIEW, interfacing with Python scripts to facilitate verification and validation (V&V) activities and simulate large inverter installations to assess capacity and scalability. A robust test system was built and maintained for a contract manufacturer in Poland and expanded to include a US manufacturing site, with both systems linked to Python scripts for streamlined automation. Inverter testing included functional evaluations using Solar Power Simulator Power Supplies. Key tests involved islanding detection (ensuring output shutoff when mains power is disconnected), frequency and voltage limits, power factor performance, and Maximum Power Point Tracking (MPPT). Comprehensive testing was conducted to ensure compliance with BS EN 50438:2007 standards.