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PC Based Test and Measuring (DAQ) Systems

Screenshot of Battery monitorWe design a host of customized PC based Data Acquisition (DAQ) systems. The customized hardware used in these systems is also designed and developed by us. The software is developed such that anybody with basic computer knowledge can use it efficiently. An important feature is that the software is user friendly and MS Windows based. The data can be seen as it is being generated (online) and is stored for viewing and analyzing it later on (offline).  Features like data overlays help in comparing the performances of different products under test.  Statistical analysis is also given optionally for better understanding of processes.  The acquired data can be optionally stored as Excel files or PDF documents and then can be analyzed later.

A few customized equipments that we have developed are:

 

Battery Test Equipment:

Cell Match JigThe battery characteristics (charge-discharge curves) are drawn for charging cycle and discharging cycle.  The current, voltage and battery chemistry are programmable so that user can configure it as per the battery specifications.  The configurations can be saved and recalled or edited at will.  The battery chemistry sets the charging type.  Similarly the discharging currents and the voltage level to which the battery is to be discharged is also programmable.  Multiple charge-discharge cycles can be done and the number of cycles is recorded for future use.  The discharge is usually constant current type and the current is software settable.   Battery parameters like open circuit voltage (OCV) and internal resistance can be measured and recorded right on the assembly conveyer line to ensure battery quality and consistency.  Audio-visual indication is given to generate the pass/fail signal. Various chemistries like NiCd, NiMH, Li-ion, Lead Acid, Thermal Batteries etc. are supported.

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Relay Test equipment:

Computerized relay test equipments are developed to check the parameters of electro-mechanical relays. Some of the parameters include pick-up and drop-out voltages, coil resistance, contact resistances, pick-up (actuation) time, release time, contact bounce time and number of bounces at Normally Open (NO) and Normally Closed (NC) contacts.  The bounces can be plotted graphically with respect to time for analysis.  The test parameters can be configured in the software and the limits can also be specified.  The system will compare the test values with the limits and generate the pass/fail audio-visual indication.

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Process Monitoring Systems:

Screenshot of process monitoringProcess Monitoring Systems are another type of Data Acquisition Systems wherein process parameters like temperature, pressure, voltage, current, power and any other physical quantity can be accurately measured and the read data is displayed on a PC monitor in a graphical form.  Process parameters can be set with upper and lower limits and based on these set limits a decision is taken to give alarm or give outputs for control purposes.  This data can also be stored in standard formats and analyzed later on. Process parameters can be viewed on the fly while the process is underway.  These systems are highly customized to suit the requirement of the user.

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PCB sub-assembly testing:

PCB sub-assembly testing includes voltage and current measurements at various test points as specified by the user.  We can optionally provide the mechanical jigs and fixtures to hold the PCB sub-assembly for testing.  Pressure loaded pins or spring loaded pins are used for acquiring data from the PCB under test. User-friendly software is developed to the specific customer application. The pass/fail limits for each parameter is programmable and the results are stored and can be analyzed later.

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Load Monitoring Systems:

 

Generator data for 6 load steps

Load monitoring systems are designed to be used with our load banks.  Necessary current and voltage sensors are provided in the load bank itself and the data collected is recorded and graphically plotted on the screen.

Transient response of Generator due to load application

We have also designed and developed more advanced systems, which actively control the load banks as well as passively record data. This system can be used to automate tests of the load banks, apply load steps automatically after pre-defined time periods, record data and generate automated test reports. Various generator parameters like voltages, frequency, currents, power, power factor, temperatures and pressures are monitored, and automatic pass/fail can be assigned based on tolerance limits of these parameters. A detailed and fully customized report is also generated automatically. Recorded data can also be graphically plotted and manually analysed later on after the test.

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