Page 17 - Rail Supplies 2020 Edition

company News
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Just the Ticket: Instant Test Validation for Faster Production
As the rail industry moves towards standardisation, OEMs must source future-ready equipment - technology that supports digitisation and big data.
The latest ‘Real-Time Scanning’ (RTS) testing technology enables instant validation of harnesses and connections as they are constructed. It captures test data, identifying recurrent faults so they can be resolved. And in the present day? RTS enables faster production processes, achieving valuable time savings.
The Status quo
Rail OEMs have always tested their installed electrical systems, typically including tests for continuity, low voltage isolation, high voltage insulation, electrical bonds, and a degree of function testing of components such as switches, breakers, and relays. Unfortunately, in many instances the reporting is limited to a simple pass/fail.
Manufacturing teams are commonly seeking ways to reduce the amount of testing to improve productivity. The challenge is how to test more efficiently to reduce the production bottleneck.
a Future-Ready Solution
Production testing can be integrated using MK Test’s RTS solution, which reduces bottlenecks by fitting testing modules earlier in the build. Miniature switching modules – nanoSatellites – are fitted to the ends of harnesses prior to installation; typically, during harness manufacture. MicroSatellites and active switching LRUs are used where
there is high test point density or where multiple interconnects merge. Main control modules (MCM) are located around the Unit Under Test (UUT) and connected to the input ends of the harnesses. These MCMs generate current, measure volt drops, and control the various active switching modules, creating a high speed, miniaturised and inobtrusive test system connected to all harnesses and interconnects. As harnesses are fitted into the UUT and connected to form complete wiring network legs, the MCM detects the nanoSatellites and microSatellites and instantly
measures the resistance of each connection. The result is compared to the netlist (in real time) and reported as a ‘completed connection’ and continuity resistance pass, or it will show as a failed connection. Each switching module has an integrated LED that shows the Pass or Fail status of each connection, in real time, enabling “on the fly” rework and immediate retest and validation. The MCM scans at up to 5,000 measurements/second, providing true ‘real-time’ scanning. Multiple MCM modules can work in parallel, scanning thousands of connections per second.
MK’s systems enable all data to be collated as a measured value, in a database that can be interrogated using a range of custom analysis tools including the Report Analyzer. This data supplies an in-depth understanding of the regularity of specific types of failure and an opportunity to design out the causes. The effect of moving specific tests to other production stages can be accessed, so a rail harness fully tested in the shop may not need tests repeated at installation stage.
The MK Results Database and Report Analyzer toolset uses statistics and data to quickly find common faults and changing trends. This can highlight material batch issues, changes in supply chain quality, and specific training needs. The tool also shows tests that never fail, enabling decisions on whether tests are stringent enough or even required.
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Rail SuPPliES & SERvicES 2020