Combining our technical capabilities in automation, machine design and data acquisition systems has allowed us to develop a considerable number of systems for measuring the quality of manufactured products and processes.

Our capabilities include:

  • Machine design to create the mechanical, structural and electrical infrastructure required to conduct quality control tests.
  • Automation of the testing machines to execute the tests, capture and analyze the data, archive the test results and produce reports on those results.
  • Integrating sensor technologies for a wide variety of measurements including temperature, load, pressure, flow, speed, displacement and many other common and unique sensing technologies.
  • Database integration to archive test results and to exchange information with other plant database systems.
  • Custom software development allows us to create the best solutions for our clients for each specific application.
  • Integration of third party test equipment with our systems. We frequently need to collect data and/or control test equipment from other suppliers. As long as the equipment has a serial port, Ethernet port or analog output, we can probably communicate with it.

Compressor Tester

A client needed a Quality Control (QC) testing system for their new line of portable air compressors. The QC system needed to perform a complete operational test of each air compressor produced at the plant. The test data had to be archived and the test station operator had to be alerted to the results of each test. One test needed to be completed every two minutes in order to keep pace with production capacity. Each station collects data consisting of electrical current draw, line voltage, power consumption, power factor, pump pressure and pump-up-time for each compressor. This data is stored in a SQL database for each compressor tested.

Electrical Panel Tester

In order to reduce the manufacturing cost for their HVAC and building automation control panels and to insure a high quality, defect free product, Creative Control Designs, Inc. (CCD) needed to find a faster and more efficient method for testing the functionality of their products before they were shipped to the customer.

REAL Controls developed an automated panel testing system for CCD. The new system automatically performs six (6) diagnostic tests on each panel, compares the panel configuration with the customers design specifications, downloads the correct program to the panel controllers and prints a report summarizing the results of the tests. Along with the new panel tester, a barcode system has been implemented for tracking the panels, and the various subsystems within the panel, as they are processed through the CCD manufacturing plant.

Electronic Device Tester

REAL Controls developed software for the clients burn-in test system using National Instruments LabVIEW programming software. The software provides three operator interface screens which allow an engineer and an equipment operator to set up the desired testing parameters, execute the test and collect data from each device under test. Temperature data from thermocouples installed in the test system are also acquired. The system tests diodes, transistors and other electronic components under elevated temperature conditions.  Approximately 1000 components are tested simultaneously over an extended period of time. The test results needed to be organized into spreadsheet data files by product type and lot number for each component.

HiPot Tester

A manufacturer of insulating mats for use in high voltage applications needed to test the electrical insulation properties for their product. The mat is used to protect electrical personnel working on high voltage electrical panels and switchgear. Various width and length mats must be tested at voltages approaching 50,000 volts. REAL Controls provided the integration services for this system. We obtained drawings of the manufacturing process and of the new high voltage test equipment. We developed a set of demolition drawings to remove equipment that would not be reused with the new system and we prepared a set of installation drawings for the new equipment. We also made changes to the process Programmable Logic Controller (PLC) software that were needed for the integration.

Low Cycle Fatigue Sensor

A manufacturer required a low cycle fatigue testing system to measure the long term effects of applied loads to its products. As varying loads are applied to the parts being tested a load cell and a displacement sensor are used measure the effects on the part. The test is run over several days until the part fails. The data is then analyzed and a report is generated with the test results.

Pipe Thickness Measurement System

A manufacturer of welded steel pipe required a testing system to measure and analyze the wall thickness and the roundness of the pipe as part of their quality testing system. A LVDT sensor is used to measure both of these parameters simultaneously. A short section of pipe is loaded into the test machine and rotated using a small servo motor. The LVDT rides on the inside of the pipe as it rotates. Data is acquired using a low cost National Instruments board and a custom program automatically analyzes the data to calculate the required parameters.

Sample Measurement System

Using high accuracy laser measurement technology, this machine was custom designed to accurately measure the size of pressed powdered metals parts. It is part of the quality testing system for a manufacturing plant which produces the powder and helps to insure repeatable compaction density among different batches of the product. Seven parts are tested simultaneously and a calibration is automatically performed just prior to each test. Data is acquired and analyzed for each test part in real time and the results are stored and printed onto a test report.