Test & Measurement Case Studies

 Using LabVIEW and PXI to Develop a DQT system for DAB Technologies

When Frontier Silicon, the world leader in Digital Audio Broadcast solutions, wanted to create an automated version of their DQT system, they turned to Product Technology Partners Ltd, a National Instruments Alliance Member, to design and implement a solution using off-the-shelf National Instruments hardware and the LabVIEW graphical software environment.
A layered functional framework was designed as the architecture definition to provide the key features of the software requirements, inculding:

  1. The ability to perform a large number of similar and disparate tests
  2. The ability to perform a number of tests on multiple devices in sequence or in parallel
  3. The ability to work with a test and measurement hardware architecture that is in concurrent development
  4. The ability to accommodate changes and additions to tests and instrumentation hardware with the minimum change to the software

You can read the full article here  

 Automatic FPGA Reprogramming in an Expandable Data Acquisition System

With an interest in improving their existing industrial product range our client came to us for the development of a new versatile high-performance data acquisition system. We conceived a product based upon their existing system that uses commercial off-the-shelf NI hardware and software. We employed National Instruments' CompactRIO technology, incorporating the Xilinx FPGA chip for high-speed digital and analogue signal acquisition coupled with the determinism of a Real-Time operating system for data collection, processing, storage and analysis. We developed a module-detection algorithm that matches the operator’s chosen arrangement of modules to a suitable FPGA bitstream. The final product provides operators with a highly versatile high-speed acquisition system that automatically adapts to changes in the hardware configuration, allowing an operator to expand their system capabilities by inserting a further module into an empty CompactRIO slot without the need to redefine any program configurations or settings.
Coupled with this was the design of a powerful LabVIEW application for control of the CompactRIO system. Using LabVIEW server, the PC application allows the operator to create any number of fully customisable control and indicator layouts on the interface panels, tailoring the user interface to suit their individual requirements. From their customised layouts, the operator can launch acquisition processes, inspect data graphically and compare data from separate runs, as well as design and publish PDF reports for test certification purposes.

Full article available here

 Vision inspection for pharmaceutical packaging

A world-leading pharmaceutical company had a requirement for a new test system to evaluate different types of drug packaging. Based around the customer's proprietary pressure/vacuum cycling technology, PTP developed a control system with camera inspection and associated data acquisition & analysis software. One of the key design challenges for this project was to minimise the time between when the picture should be taken and when it is actually taken. Validation of the inspection process was also an important consideration. Additionally the control system needed to:

  • calibrate all sensors on the rig
  • pressurise/depressurise the chamber in fixed steps over a definite time period.
  • schedule pictures to be taken when the pressure passes a threshold, either rising or falling
  • schedule pictures to be taken at a given time
  • analyse and display the data captured in Real Time

 Upgraded Data Logging System

Our customer had a data logging system which had been developed many years previously. Although still functional, there were concerns about the reliability of the system and PTP was contracted to develop and build a more robust alternative. The core functionality needed to mimic the original system but there were additional requirements in terms of User Interface development and modes of communication. The aim was to enhance and modernise the application without alienating those customers who were accustomed to the older system. The salient points of the development included:

  • design & development of a funtional and intuitive user interface that guides the operator through the test process.
  • communications with custom hardware
  • validation of newly developed hardware designs
  • display of test data in a manner which allowed the operator a high degree of customisation whilst maintaining the look and feel required by our customer
  • modular software design to facilitate the addition of new features in subsequent product releases

The resultant application - which was written in National Instruments LavVIEW and LabWindows/CVI - was both innovative with respect to addressing the issues above and robust in producing a solid test platform.

 Functional Test Equipment (FTE) for Carbon Monoxide (CO) sensors

PTP were contracted to design and build a bespoke piece of FTE for the customer's new range of CO sensors. These sensors comprise a CO cell and amplifier and are for use in intelligent bases. The functional testing of the sensor was carried out in two parts:

  1. In-Circuit Testing of the sensors to confirm basic functionality (a continuation of the customer's ATE testing)
  2. Gas Testing to confirm the performance of the sensors in clean ari and in CO gas at specified concentration levels.


Key technical requirements included:

  • the ability to test six sensors simultaneously
  • a mechanical design which ensured that the FTE was gas-tight but also provide suitable venting so that forced gas extraction could be applied to the cabinet.
  • highly configurable software to allow users of the right level to adjust the test schedule and pass criteria


The system was developed using National Instruments' LabWindows/CVI with data aquisition cards and bespoke electronics.

 Performance Test Software for Semiconductor Manufacturer

We developed a comprehensive test architecture, using NI TestStand and LabVIEW, for a specialist semiconductor manufacturer in order to enable performance and pre-production testing of a new range of semiconductor devices.

 Bespoke Software Development for Gas Sensor Analysis

A leading manufacturer of industrial gas sensors approached Product Technology Partners Ltd (PTP) to seek assistance with automating part of their sensor testing. They needed to ensure that their pellisors (small wire coil sensors) had been properly processed during the manufacturing stage and gave the correct output voltage when in use. Their existing system was entirely manual and they were looking to improve test throughput time as well as increase productivity. With automated logging to a new centralised database, test data manipulation and analysis became much easier and the amount of time needed for the subsequent matching process was cut drastically. The system also allowed full traceability for Quality Control purposes. Key aspects of the development were:

  • Design & development of a functional and intuitive User Interface to guide the Operator through the test process.
  • Communication with custom hardware developed by a third party.
  • Communication with a producion database across a corporate network to read test limits and record test results

 Software Upgrade for Fluke

When Fluke Precision Instruments wanted to upgrade the software component of their 7000 Series Automated Voltage Measurement System, they turned to Product Technology Partners for help.
The instrument uses a LabWindowsTM/CVITM software application for the configuration of and download to the 7000S Reference Modules with a bespoke Excel add-in that allows the user to view and manage the data collected. Fluke needed the software to be compiled under the latest version of CVI and they had a number of support issues with the newer versions of Excel. They were also looking for advice on how to connect the instrument to a PC via USB.
The combination of our extensive experience in LabWindows/CVI programming and the robust nature of the development platform from National Instruments ensured that the upgrading was achieved in a cost effective and timely manner. We were then able to address the support issues in Excel and make recommendations for the USB connectivity.
A full report was generated which detailed all the code changes carried out and listed the alternative ways for the equipment to be connected by USB. This was then followed by a site visit to Norwich to hand over the completed software and ensure that all issues had been satisfactorily addressed.

 Automated Test Equipment (ATE)

A well-known international manufacturer of fire detection systems required automated functional test equipment for a new range of fire detectors. We worked with mechanical and electrical designers to provide a turnkey solution for their immediate requirements and continue to work with the client as the product line develops. Other ATE projects include test sequencing and monitoring equipment that interface with our clients' works order databases for full integration in the production process.

 Specialised Measurement and Data Logging Systems

A railway maintenance company required automated equipment to be mounted on a rail grinding train to measure longitudinal corrugations in rail, both for audit purposes and for interactive use when grinding rail in situ. In collaboration with the client's mechanical engineering consultant we developed a PC-based on-board system for measuring, analysing and recording corrugation that functions accurately even in the hostile environment of a rail grinding train.

Other case studies to be added soon!