Case study

Automotive Test System

intro

QESTIT helped Backer to develop a mobile test system designed to meet the rigorous demands of truck heater testing. The project addressed challenges such as handling high voltages and currents, integrating LIN communication, and ensuring coolant flow during testing to prevent overheating. With operator safety and robust data logging as top priorities, the system served as a critical component in Backer’s End of Line (EOL) test suite. This custom-built solution provided a safe, efficient, and adaptable platform to calibrate and validate heaters before release.

Ensuring Safety and Optimizing Heater Performance

This system was a simple but important part of a larger test routine conducted by Backer for a truck heater. It was integrated with other components to form an End Of Line (EOL) test suite, checking the heater's safety and performance. This system was a unique challenge, as it was not a typical EOL test system and was used (in part) to calibrate units to perform better before release.

Result capture and operator safety were the top priorities. Users needed to capture as much useful information as possible to improve the heater before launch and before releasing produced heaters to Backer's customers. Substantial failures (failures which cannot be fixed) in units would generate data which would be used to improve future designs.

From this description of the problem, we built a custom program which recorded all the data from high voltage sensors, other sensors and LIN communication from the Unit Under Test (UUT). Usually when making EOL or production test systems, we rely on our testing platform QATS. This speeds up development and ensures reliability. However, this use case necessitated a new custom program.

Our work

Pictures from the project

Containing High Voltage Electronics

VeriVolt High Voltage Sensors

Program

Several Mobile Logging Systems

Protecting Operators in High-Risk Testing Environments

Safety in our systems is always important. When operating with products that can go over 800V, the consequences of a unresponsive system can be severe. All our products are CE Certification Marked and conform to industry standard safety regulations. Operator Safety was assured by:

Placing all high voltage components inside of boxes to prevent electrocution
Using safety signals from the UUT and other system components, to stop testing if the user is at risk
Securing all cables and other hazards
Performing Risk Analysis calculations as determined by EU regulations
Proving a detailed set of documentation including a specification, user manual and extra external documents

From the team

A tailored, robust solution designed to meet Backer's needs

“ As QESTIT are customer driven, we want to ensure that customers receive the best solution and sometimes that requires building from the ground up. The program was designed to be simple but powerful. Its safety features were extensively tested for failures.”

QESTIT Systems Team

Summary

In summary Backer received an easily movable and safe test system which stores information into a readable file format. The software was configurable and can easily expanded on in the future.

About

Backer

What does Backer do?

Backer develops and manufactures heating, measurement, and control solutions, specializing in advanced components for laboratory testing, design, and certification.

How?

By combining cutting-edge technology, extensive product knowledge, and a global presence, Backer ensures high-quality, cost-effective solutions tailored to customer needs.

What does it result in?

This results in optimal, reliable, and competitive heating solutions with expert support available worldwide, meeting the diverse needs of customers across industries.