Background​

A client engaged in a complex development program faced significant challenges with their existing testing setups. These relied on makeshift engineering test lash-ups to interface with their Unit Under Test (UUT), which often proved unreliable and inconsistent. The situation was compounded by low-level DC current measurement accuracy issues, undermining the precision required for their operations.

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Challenges​​

The primary issue was the lack of standardized, durable testing equipment. The client struggled to achieve reliable UUT connections using partially modified test boxes, leading to inefficiencies and inaccuracies. Another critical challenge was the inability to achieve consistent low-level DC current measurements, which introduced errors and required frequent recalibration of power supplies and test systems.

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Solutions Delivered​

Thanehall addressed these challenges by designing and delivering a range of bespoke, rugged test boxes tailored to the client’s specific needs. These test boxes were built for durability and reliability, ensuring they could withstand the demands of frequent testing. To improve interfacing with the UUT, the boxes were equipped with custom-designed interface cables and included manual switches that could be duplicated for automated control. Automation was seamlessly integrated using simple DAQ cards controlled by National Instruments DAQmx™ drivers, enabling more efficient and repeatable testing processes.

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To resolve the low-level DC current measurement accuracy issues, Thanehall developed specialized calibration test boxes. These boxes featured a selection of precision resistors and a feed to a Digital Multimeter (DMM). Custom software was created to control the DC Power Supply Unit (PSU) and the DMM, facilitating the calculation and storage of calibration slopes and offsets. This approach significantly enhanced the reliability of low-current measurements and extended the calibration intervals for the PSU, reducing downtime and maintenance requirements.

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Outcome​

The implementation of these solutions resulted in a significant transformation of the client’s testing capabilities. The rugged test boxes eliminated inconsistencies caused by makeshift setups, ensuring reliable and standardized connections to the UUT. The calibration test boxes resolved the low-level measurement challenges, providing accurate and repeatable results while reducing operational costs through extended calibration intervals. Automation further improved efficiency, saving time and resources during the testing process.

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Conclusion​

Thanehall’s innovative and tailored engineering solutions enabled the client to overcome their technical challenges effectively. The combination of rugged, bespoke test equipment and advanced calibration systems not only streamlined their development program but also ensured cost-effectiveness and long-term reliability. This case highlights the value of customised approaches in addressing complex engineering requirements.​

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