• Acquisition of four length, force and temperature signals, separately for each one of the four belt pre-tensioners
• Measurement of supply voltage and current consumption in different measurement ranges, from min. 1mA to max. 50A for each one of the four belt pre-tensioners
• Implementation of specific firmware on the NI-CAN board in order to simulate realistic environment conditions in the vehicle
• Logging for all arising data
• Control for a climate chamber
• Porting of all existing sequences from NI LabVIEW to NI TestStand as well as parameter-based test steps
• Script-Editor based on tables for the simplest creation of endurance test sequences
• Sequential control of the two pre-tensioner pairs, so that one GPIB-controlled 20V/120A power supply adapter is sufficient for peak currents of up to 50A per pre-tensioner 

The endurance test system consists of one 19" rack, 40U tall, which include

• The industrial PC with data acquisition board
• CAN interface and GPIB controller
• Keyboard and mouse are also integrated into the rack, through a keyboard drawer, as well as the 17" touch screen monitor.
• Further space is occupied by the Konrad power supply unit, the Agilent 20V/120A adapter and the UPC.
• Additional custom made hardware was integrated in a 6U 19" slot module, including four Konrad current measurement modules and the signal conditioning system NI SC-2345 with measurement transducers for force and temperature signals.
• All plugs for the pretension and sensor power supply have been integrated into the front panel of this slot module. The rack also offers the possibility of extension by a second industrial PC, if the user wishes to add a CAN-rest bus simulation. If necessary, the unused space in the rack may be used for controlling a third pair of belt pre-tensioners.
• The 24 analog values are acquired at a maximum sample rate of 1 kHz; the 36 CAN signals at 100Hz.
• The measurement values are time-synchronized, so that signal variations from the external sensors can be compared to the pre-tensioner sensors. A Measurement Server-PC collects the data of all three test rigs and presents these for evaluation, while data acquisition is still active.

• NI TestStand: Sequence control Editor, Debugger
• NI LabVIEW: Test Step libraries
• KT-Operator Interface: Operator interface Debugging
• KT-Project: Test step library Functional test
• Custom developments: Konrad Endurance Test Software, Konrad Climate Chamber Software

PCI-based test system

Instrumentation

• NI PCI-6259 16Bit, 1MS/s, 32 single-ended analog inputs
• 48 Digital-I/O, 4 analog outputs
• Signal conditioning system NI SC-2345:
• SG-24 for force sensor acquisition
• TC-02 for temperature acquisition
• 4x KT current measurement modules,
• measurement range: 1mA to 50A
• Measurement range change via 4 TTL digital inputs
• Output voltage: 0 to 5V
• Measurement accuracy: 1% full scale.
• Custom-specific hardware control
• NI PCI-6528 24 digital I/O.

Communication

• 2 x NI PCI-8461/2 Series 2, high-speed CAN 2 port, 1MBit/s
• NI PCI-GPIB interface.
• Power adapter and energy supply
• Agilent 6031A 20V / 120A, controlled via GPIB
• KT power supply unit.

Adaption

• Pretensioner-specific recording for force and length measurement, suitable for operation within a climate chamber.

Interface

Customer-specific hardware interface with all electronics and connections for the original cable tree of the pretensioner, connections for length, force and temperature sensors