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GTU brochure final email Flipbook PDF
GTU brochure final email
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GTU MICROGen VISUALCONNX LVTGO-VBS SENS-X Sens-X DTB DTB
Genix Test Unit • Parking sensors • Gesture units • Vehicle cameras
www.add2.co.uk/gtu | [email protected] | +44 [0]1889 574400
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• Automotive sub-assembly electronics continuity testing
GTU
Enhance sub-assembly electrical testing Perform advanced continuity testing with the Genix Test Unit
Production line bumper and spoiler test solutions Automotive sub-assemblies such as bumpers and spoilers
electrical and communications tests on products at assembly stations
typically contain an array of electronic components, such as
during manufacture. The system has been designed for testing a range
parking assist sensors, pedestrian sensors, gesture equipment,
of electronic components within sub-assemblies, such as bumpers and
fog lamps, telecommunications amplifiers and receivers.
spoilers, at the end of the production line.
Following the manufacture of these sub-assemblies, it is important to
The test unit has a high I/O count supporting a wide range of
ensure that the correct components have been fitted, fully connected,
simultaneous tests and includes PLC interfaces for test control, result
and with the specified engineering revisions.
capture and handshaking. It’s capable of providing both advanced continuity and functionality testing via LIN, CAN and PSI5 and optional
As technology advances, each of these components will evolve, such
other protocols, such as SENT.
that sometimes separate engineering revisions come to exist that are incompatible with each other.
Typically, test results are fed back to the PLC. Custom handheld
“The Genix Test Units integrated into our existing machines easily and we had no negative feedback from our supplier base. I personally went around every machine in the UK when they were installed last summer and it was pretty clear how they were functioning and that the HMI controls were very positive.” Nick Towers, Manufacturing Group Leader, Plastic Omnium
Given that components of the same generic type often share a form
devices can be provided for monitoring of test results or alternatively,
factor, in-line electrical testing may be required to distinguish
these test results can be monitored via our real-time systems interface
components that are identical to the naked eye. Further more, just-in-
creation software, VISUALCONNX, with a custom GUI. The unit can be
time manufacturing requires that sub-assemblies arrive in a
mounted in a wide variety of locations within the manufacturing
guaranteed functional state.
environment. Plugable screw terminal blocks for I/O and power are provided with each test unit.
The Genix Test Unit provides a means of performing a number of
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GTU: Introduction
GTU
What can the GTU do? 12 example tests the GTU can perform in the workshop or production line The GTU allows organisations to mitigate against the risk of faulty equipment that may otherwise only be detected at vehicle end-of-line testing or even result in commercial recalls. It allows OEMs and Tier 1 suppliers to verify continuity for the correct engineering revision of sub-assembly electronics across
AK Parking Distance Sensor A test for a parking distance sensor powered with a non LIN-based interface.
HP Parking Assistance Sensor Tests for the presence of a standard LIN interfaced parking assistance sensor.
HP Parking Distance Sensor Tests for the presence of a standard LIN interfaced parking distance sensor.
Single Gesture Sensor Checks and confirms the presence of a single gesture unit in the wiring harness.
Parallel Gesture Sensor Tests for the presence of two gesture units and if they are connected in parallel in the wiring harness.
Continuity Test, Low Current Tests for the presence of devices such as antennae in the wiring harness using a limited current.
Continuity test, High Current Tests for the presence of the devices such as fog lamps in the wiring harness using a high current.
Camera Presence Test Tests to see whether a front or rear view camera has been plugged into a loom.
Low Side Voltage Divider Test A test for components or sub-assemblies that exhibit fairly high resistance to 0V, such as antennae.
Airbag Testing Tests for the presence of the vehicle airbag in a safe and thorough manner.
Pedestrian Sensor Testing Tests for the presence of pedestrian sensors initiated by acceleration or pressure.
A wealth of flexible I/O
Pins
Description
24V IN
2
Power supply
PLC Inputs 1-8
9
8 inputs commoned to C1
vehicle program sub-assembly testing
PLC Inputs 9-16/Outputs S-Z
9
8 inputs commoned to C2
The GTU is supplied with a wide range of electrical
PLC Outputs A-H
16
8 volt-free contact pairs
communications totalling 108 multipurpose I/O.
PLC Outputs J-R
16
8 volt-free contact pairs
Supply Outputs 1-4
8
4 switched supplies to test harness
Measurement I/O 1-8
16
8 Genix I/O test pairs
assemblies under test, as well as PLC interfaces
Measurement I/O 9-16
16
8 Genix I/O test pairs
for test control, result capture and handshaking.
HOST CAN
8
CAN accessibility
Optional RS232
8
Optional interface for PLC
The GTU provides support for complete
These include all communications to sub-
Available connections are as follows:
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Connector
VISUALCONNX
AK Parking Assistance Sensor A test for a parking assistance sensor powered with a non LIN-based interface.
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a wide range of further testing is also possible. Please see below for a selection of examples of tests possible using the GTU.
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Based upon instructions given from the PLC, the GTU performs the relevant tests according to configurations stored within its firmware -
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environment, either directly at an assembly station or other test bench.
MICROGen
multiple vehicle programs. It allows sub-assemblies to be tested at the end of the line within a production
GTU: Introduction
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Key functionality Introducing how the GTU works The GTU is a system designed for testing a range of electronic components within sub-assemblies, such as bumpers and spoilers, at the end of the production line. The unit comprises a micro-controller based test system, including instrumentation electronics, power supply, communications test channels, PLC signalling and custom firmware to provide a turn-key solution to performing a number of sequential tests. Tests are initiated via digital inputs driven from an externally connected PLC. During these tests, the outputs of the unit will be driven to indicate a pass or fail condition via solid state, volt-free, protected relay outputs. These tests happen in the matter of seconds, resulting in a short takt time. At the end of the test, an output changes state to indicate that the test is complete to the PLC, which should then confirm whether the item being manufactured has passed all relevant tests. All test output lines, such as voltage and current outputs and
Damaged wires
supplies are protected against short circuit to 0V, such as might occur with a damaged harness or connector. Each channel on the GTU is also protected against overload. Connection is provided to the unit under test via Zero-Insertion Force (ZIF) units that allow connections to the test system with minimal wear and tear to sub-assembly Example ZIF unit
connectors, which can be replaced with easily-replaceable inserts, to minimise
downtime. ZIF units are available to fit a wide range of automotive standard electrical connectors.
“You can quite comfortably use the Genix Test Unit, knowing that tests will be completed correctly.”
Clive Sims, Director, Sims Engineering Ltd.
Key features The GTU provides functionality to cater to a range of different applications. Some examples of key features are listed below:
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Multichannel measurement 16 measurement channels are available
Anti-vibration Rubber mounting blocks are fitted to absorb vibration
PLC industrial interface Integrate with industry-standard PLCs easily
Pluggable screw terminals Easy disconnection and reconnection in the workshop
Industrial enclosure A rugged housing protects against workshop risks
Predefined test sequences Sequences can be performed quickly and easily
Fully protected outputs Test outputs are protected against short circuit to 0V
Diagnostic feedback A range of LEDs provide various user alerts
Fully protected relays Relay lines are protected against short circuit to 24V
Quick and easy testing The unit takes 2-3 seconds for all tests in total
GTU: Key functionality
GTU The Genix Test Unit provides a means of performing a number of electrical and communications tests on components at assembly stations during manufacture. Common devices tested include parking sensors, gesture sensors, PED sensors, cameras and
The unit is appropriate for end of line testing of vehicle subassemblies such as bumpers and spoilers. It’s capable of providing both continuity and functionality testing using a range of protocols,
MICROGen
headlamps.
VISUALCONNX
for example using LIN, CAN or PSI5.
Selecting your system will allow us to provide the most appropriate solution to meet your requirements: Could you provide a list of all equipments that will be fitted to the harness(es) in the final vehicle?
Do you require only a connectivity test for the equipment inside the bumper(s), or a more complex test methodology?
Could you confirm how many test stations do you require for this vehicle programme?
Do you have any examples of the electrical equipment contained within the bumper(s) that you can send to us?
Will you require ZIF connectors that accept the bumper electrical connections and feed them into the GTU?
Do you have example wiring harnesses for the bumper(s) that you can send to us?
Would you be willing to share any datasheets of any electrical equipment contained within the sub-assembly?
What type of physical setup (desk-mounted or wallmounted, for example) would the GTU be situated in?
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Due to differences between automotive sub-assemblies from various manufacturers, we may request responses to a number of key questions that
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How to choose your GTU solution
Full control The GTU can deliver test results to a PLC, or a custom GUI made in VISUALCONNX
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VISUALCONNX allows powerful real-time user interfaces to be created in minutes - simplifying the logging, testing or simulation of embedded systems. It offers wide compatibility with a range of target systems, and is comfortable with a range of complex requirements, even including an open API that allows users to create new connection types.
To control the GTU, a custom GUI can be built. This can be done either by
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the user or in-house at add2. The flexibility VISUALCONNX provides allows users to make full use of all of the features that the GTU offers.
Custom, complex VISUALCONNX interfaces can be used to drill down into test results. Alternatively, a simple pass/fail interface can be used to achieve a quick and clear result, depending on requirements.
GTU: Selecting your system
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Case study: Plastic Omnium
Read how add2 helped Plastic Omnium to enhance in-line electrical testing during the manufacture of vehicle bumpers, increasing component visibility. This was achieved through the production of a fully functional, end of line production test device built on established Genix technologies.
The Problem Automotive sub-assemblies such as bumpers and spoilers typically contain an array of electronic components from different suppliers, such as parking assist sensors, telecommunications receivers, pedestrian sensors, gesture equipment and fog lamps. As technology advances, each of these components evolve, such that separate engineering revisions come to exist that are incompatible with each other. Following the manufacture of these sub-assemblies, it is important to ensure that the correct components have been fitted, fully connected, and with the specified engineering revisions. Given that components of the same generic type often share a form factor, in-line electrical testing is required to distinguish components that are identical to the naked eye. Such was the situation at Plastic Omnium. Nick Towers, Manufacturing Group Leader at Plastic Omnium, explains. “As the company assembling the parts, and as the tester of the parts in our final bumper assembly, there were no visible attributes that we were able to use to detect a difference in the parts”. The consequence of this was the potential to be “operating with two different levels of parts in live production within our business across the UK”. This situation could have potentially led to incorrect configuration or parking assistance failure causing production lines to be halted or commercial recalls to be initiated after entering the marketplace.
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GTU: Case study
GTU
The Solution add2 was contacted and asked to develop a test facility in order to identify the components within bumpers under manufacture. After detailed discussions between Plastic Omnium, its suppliers and its automotive OEM customer, the Genix Test Unit was developed. “Both Plastic Omnium and add2 had a very clear understanding of what we
and very clear at all times”. The Genix Test Unit performs a number of electrical and communications tests of components at assembly stations during manufacture. It offers a high I/O count, and is easily reconfigurable through software to accommodate testing of multiple sub-assembly variants using
MICROGen
needed to do”, Towers observes; “communication with add2 was very positive
the same physical box. This allows every piece of electrical functionality within a bumper to be tested in a single unit Units are provided with a predefined set of test sequences which are requested from the PLC via the digital inputs to the test unit. At the
VISUALCONNX
end of these tests, each result is fed back via volt-free contact solid state relays. Connection is provided to the subassembly under test via zero insertion force connectors that minimise wear to consumable parts. Connection to the assembly station PLC is provided via screw terminal from the Genix Test Unit. Test results are fed to the PLC, and can be delivered to an external GUI or hand-held device, as is convenient.
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Commissioning of the Genix Test Unit is a simple matter. “We had three different suppliers of our own that were fitting and commissioning the test devices, and that appeared to be very straightforward”. add2 is happy to
Example ZIF unit with military standard connector
integrate the Genix Test Unit to ensure test procedures are in place in a timely fashion. “There was quite a bit of support from add2 on-site to ensure that the devices communicated effectively with our existing assembly
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machines”.
“Communication with add2 was very positive and very clear at all times” Nick Towers, Manufacturing Group Leader, Plastic Omnium
The Conclusion DTB DTB
Mr Towers is happy to confirm the positive impact of the Genix Test Unit.
“I personally went around every machine in the UK when they were installed last summer”, he notes; “the devices integrated into our existing machines
Looking to the future, there is ample scope for the Genix Test Unit to be utilised for a wide range of end-of-line automotive component testing. “In the future it may be relevant for gesture systems, radar systems, lane change radar, distance radar for adaptive cruise control”.
Moreover, the Genix Test Unit is currently in active use across a range of automotive OEMs and suppliers, providing both resistive and communicative testing for components including PED sensors, airbag sensors and gesture-based vehicle security sensors.
GTU: Case study
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quite easily; we had no negative feedback from our supplier base”.
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GTU: At a glance
Advanced continuity testing
Pedestrian sensor testing
Airbag testing
The Genix Test Unit performs both
The Genix Test Unit can perform
The GTU can perform airbag presence
communicative and continuity testing of
production line testing of pedestrian
testing in a safe and efficient manner
sub-assembly components. This allows
sensors via an industry standard PSI5
by taking measurements with minimal
for verification and correct engineering
interface. This ensures the operation
current at safe current levels. The unit
revision testing to take place in the
of critical vehicular safety features
then ensures that the detonator is
workshop or production line.
within sub-assemblies or vehicles.
within the correct range and is present.
Sub-assembly testing made simple Avoid recalls and production line delays with our advanced continuity test system GTU performs advanced continuity testing of automotive sub-assemblies during manufacture. It offers a high I/O count, and is easily reconfigurable through software to accommodate testing of multiple subassembly variants using the same physical box. This allows every piece of electrical functionality within a sub-assembly to be tested in a single, robust, costeffective unit. It also facilitates testing of all sub-assembly variants within
Gesture unit testing
Antennae testing
Increasingly, gesture sensor
Both the presence of radio and mobile
technology is being used in vehicles to
internet antennae (3G and 4G) can be
operate elements such as opening and
tested for by the Genix Test Unit. The
closing the vehicle, via physical
unit is able to test for the presence of
movement. The GTU can test for the
both antennae and amplifiers within a
presence and type of these sensors.
sub-assembly.
each vehicle programme.
www.add2.co.uk | [email protected] | +44 [0]1889 574 400
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GTU: At a glance