Test Systems

JLG Automation has successfully build and deployed test systems for manufacturing assembly lines over a period of more than 25 years. We back up our systems with superior customer support, training and maintenance.

End-Of-Line Test Stations

End-Of-Line Test Station

End-of-line test stations are placed at the end of a production line and are used for final acceptance testing. They perform sequences of functional tests and assist in product fine-tuning. When specifying end-of-line test stations, one must balance on the one hand complete testing to make sure no faulty products are accepted and on the other hand fast testing to match short production cycle times.

Monitoring Test Stations

Monitoring Test Station

Monitoring stations and vehicle start-up stations are used in product start-up areas, burn-in areas and engineering test bays. In product start-up areas, they enable the documented execution of Standard Operating Procedures (SOPs) and in burn-in areas, they control duration tests to screen-out early-life failures. In engineering test bays, monitoring stations with data acquisition functions and digital signal processing capabilities help improve product design.

Cabin Test Stations

Cabin Test Station

Test stations for cabins of trucks, off-highway vehicles, cranes and other manned equipment are often more complex than test stations for the complete equipment. To test a cabin without the rest of the equipment, it may be necessary to simulate electrical and other equipment functions. If the cabin controls the equipment through communication connections such as the CAN bus, the hardware requirements for a cabin test system can usually be reduced.

Software Flashing

Software Flashing

Software flashing operations may be necessary during the manufacturing of products with embedded controllers. Software flashing is targeted at installing and configuring the product software of the embedded controllers. The main requirements are fast download times and the easy configuration of complex and order-specific product settings.

Test System Components

Test systems from JLG Automation are using a FlexiDIN module to interface with a unit under test. A FlexiDIN module has CAN and Ethernet ports and has an advanced test engine runtime. FlexiDIN modules perform measurements and apply control signals on a unit under test using EtherCAT based input/output devices. The electrical, hydraulic and other signals from these input/output devices are synchronized in real-time with the data from sensors of the unit under test itself. That sensor data may be available through CAN or other communication connections. The unit under test may also be controlled with diagnostics protocols over the communication connections.

Flexidin Module

On test systems from JLG Automation, the user interface for operators and the handling of test databases is provided by the FlexiCOS software. The FlexiCOS software can run on dedicated test stations, PCs and tablets. FlexiCOS performs product-specific test sequences and actions. It communicates with the FlexiDIN modules and with a central system controller. The FlexiCOS software has a Designer component for authoring test specifications, product configuration actions and software flashing operations.

FlexiCOS – Multi-Language Operator Interface

The central system controller manages the test stations. It provides test specifications to the stations and collects test results. It acts as a relay and gateway for the manufacturing IT systems. The controller gets product-specific and manufacturing-specific information from the IT systems and sends test data to the IT systems for archiving, reporting and analytics.