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Functional testing involves applying operational power to a PCBA to ensure it performs its designated functions. This type requires custom-built test equipment. PCBACheck™ Printed Circuit Board Test Equipment Industrial Reference Design Our AUTOMATED PCBA TEST Equipment Reference Design is 90% Standardized and 10% Custom. Home > Services > Automated Test Systems > PCBACheck PCBA Functional Test Solution Businesses depend on Cyth Systems' expertise in functional test fixtures. Functional testing involves applying full operational power to a printed circuit board (PCBA) to ensure it performs its designated functions. This type of test often requires custom-built test equipment and fixtures. Cyth Systems provides support for all types of functional test strategies. Starter PXI Instruments Customize PXI Devices as Needed Pre-Designed Bed-of-Nails Customize Probes Locations Pre-Designed Interposer Board Customize Probes & Other Circuitry Software Environment Customize Sequences & Measurement Instruments Drivers Customize Measurements Top PCB Test Equipment Solution. Bed-of-Nails Functional Tester Preconfigured Database Preconfigured PXI System Budget & Schedule Preconfigured Test Cart Preconfigured Reports Automate complex tasks faster Speak to Engineer Perform complex and rapid tasks and measurements that are impossible for human manual tests. Test multiple boards simultaneously, even share time-expensive equipment. Conduct Stress or Life Testing of boards by repeating tests hundreds or thousands of times. Bed-of-Nails Functional Tester PCBA Bed of Nails Functional Tester Predesigned fixture ready for custom modifications for any board: Customize width & depth Customize Pin Placement Customize front and rear panel Customize Interposer Board Speak to Engineer Preconfigured PXI System Preconfigured PXI System Standard PXI Modules suits 90% of applications needs as-is: Power Supply Oscilloscope Digital Multimeter Configurable Switch Matrix Add additional modules, signals, and inputs as needed to expand your application. Speak to Engineer Preconfigured Test Cart Preconfigured Test Cart Standardized Test Cart serves most applications as-is without modification! Internal Rack Mounting Customizable worksurface Bar Code Scanner or Badge Reader Power Systems included Customization not required, but... fully customizable if necessary Speak to Engineer Preconfigured Database Preconfigured Database Standardized database Schema serves 90% of most applications as-is without modification: Speak to Engineer Store any test results, pass fail results Store images, waveforms, raw data Customization not required, but... Fully customizable if necessary Preconfigured Reports Preconfigured Reports Preconfigured Reports suits most applications as-is with CUSTOMIZATION INCLUDED Most common report fields already setup Fully customizable graphics and layout Fully customize graphs, tables, images Export to PDF already included Premade Excel or Word Templates you can customize and modify Speak to Engineer Budget & Schedule Budget & Schedule Preconfigured Budget for all included features: Most projects within 10% of standard budget and schedule Automatically adjusts for project size and features Budget INCLUDES customizations Speak to Engineer We know the ins and outs of PCB's Power supply voltage levels (VCC, VDD, etc.). Clock signals (system clock, peripheral clocks). Analog input signals (e.g., sensor inputs). Digital control signals (e.g., reset, enable signals). Serial communication inputs (UART, SPI, I2C). External trigger inputs. User interface inputs (buttons, switches). PWM (Pulse Width Modulation) signals. Temperature sensor inputs. Voltage reference inputs. Digital output signals (data lines, control lines). Analog input signals (ADC inputs). Analog output signals (DAC outputs). LED indicators. Display outputs (LCD, OLED, LED display segments). Relay control outputs. Voltage regulator outputs. Power-on indicator outputs. Current sense inputs/outputs. Power-up sequence testing. Power-down sequence testing. Voltage tolerance testing. Clock frequency and accuracy testing. Data integrity testing (checksum, CRC). Communication protocol testing (UART, SPI, I2C). Uploading Firmware or other files. Overvoltage protection testing. Undervoltage lockout testing. Logic functionality testing (gate-level/functional logic). Memory read/write testing (RAM, Flash). Sensor calibration and accuracy testing. ADC/DAC functionality and accuracy testing. Motor control functionality testing. Audio output quality testing. Display content and pixel testing. Communication protocol testing. Button/switch functionality testing. Temperature sensor accuracy testing. All these I/O's and much more. Speak to Engineer Prototype Form Why Cyth? Cyth Systems has over two decades of providing the technology and expertise you need to be successful on Automation, Measurement, and Controls projects. Our engineers will work alongside your team to design the system to meet your specifications. We develop your solutions with reduced risk, cost, and schedule. Need PCBA testing help or advice? First Name Last Name Email How can we help? [attributer-channel] [attributer-channeldrilldown1] [attributer-channeldrilldown2] [attributer-channeldrilldown3] [attributer-landingpage] [attributer-landingpagegroup] Let's talk PCBA Solutions Menu

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Project Case Study Using LabVIEW to Develop a Weld Inspection System Aug 29, 2023 a92c7602-53c5-4c31-9fc1-1d86677e85b0 a92c7602-53c5-4c31-9fc1-1d86677e85b0 Home > Case Studies > *As Featured on NI.com Original Authors: Arev Hambardzumyan, RAFA Solutions LLC Edited by Cyth Systems Using LabVIEW to develop a pipeline weld inspection system. The Challenge We needed a software application to assess the integrity of electrofusion joints of plastic pipes with a non-destructive technique using ultrasonic sensors. The software is needed to deliver comprehensive results through a green light/red light system that would give the operator a clear picture of the joint’s welding on the fly. The Solution We used the LabVIEW graphical programming environment to develop an easy-to-use software application to inspect a plastic pipe’s weld. The application uses a third-party ultrasonic transceiver to acquire ultrasonic sensor signals, analyze them and provide real-time information about defects and the overall quality of welds. About RAFA Solutions RAFA Solutions is a systems integrator company that specializes in smart machines and data acquisition/control systems. We deliver robust and flexible advanced solutions for machinery control and automation. We provide electronics design and software development services for material testing and semiconductor testing industries. Our clients are machine builders who are innovative in their technologies and build the smartest machines in their fields of application. RAFA Solutions holds CSIA Certified status in the CSIA Best Practices and Benchmarks certification program. This is the highest level of certification available in the control systems integration industry, and we are one of the first companies to receive this recognition in the region. The company is also awarded ISO 9001:2015 quality certification, which is the latest revision of the world’s most recognized quality management systems standard. Field Tests of the Software Application on the Plastic Pipes Problem Background In any pipeline system, the weakest point is the weld. Joint quality greatly affects the overall safety of the pipeline system, and if not properly checked, failures can lead to significant monetary losses and long downtimes. One of the most popular methods of joining plastic pipes in the field is the butt fusion process. But whether using electrofusion or butt fusion welding techniques, operators must properly perform quality checks of the welds to avoid future failures. Currently, operators use visual examination and pressure testing to check the quality of joints, but these methods do not offer any assurance about long-term performance. Proper quality checks and continuous monitoring after pipe installation helps to avoid long downtimes and decreases rework or replacement costs. The availability of a cost-effective and accurate nondestructive test method of monitoring a plastic pipe weld condition is important. Our customer, Impact Solutions, developed a simple-to-use, patented, cost-effective, and highly accurate method of nondestructive inspection based on A-scan ultrasonic technology. Impact Solutions approached us to help develop a software application to build an inspection system based on the new method. The idea behind the new method is in the analysis of ultrasound waves propagating through the weld substrate. The inspection system consists of an ultrasonic sensor, a transceiver, and a software application. The software application is responsible for the control and data acquisition from the ultrasonic transceiver, real-time data analysis, provision of inspection results, and creating a report based on the test results. Live Test Screen of the Software Application We used the LabVIEW graphical programming environment to build an application that satisfied all customer requirements. LabVIEW helped us develop the software in a short time, which was also one of the customer’s key requirements. A third-party company developed the hardware platform (ultrasonic transceiver). We used a special DLL provided by the hardware vendor to control it using LabVIEW. We built the software application with special requirements to be fully customizable and able to configure almost every section and feature of the software. We can use the software platform to configure the pipe parameter, joint/coupler type and parameters, ultrasonic transceiver settings, and more. We intend for the software to be an easy-to-use application, so it features a clear user interface with real-time information on inspection results by means of a traffic light system. The system assesses each joint as green (no anomalies detected), yellow (some anomalies detected), or red (significant anomalies identified). Original Authors: Arev Hambardzumyan, RAFA Solutions LLC Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Project Case Study Increasing Washing Machine Reliability with Hardware in the Loop Aug 23, 2023 811eb230-8c15-4008-9d59-e8c725bfcb8c 811eb230-8c15-4008-9d59-e8c725bfcb8c Home > Case Studies > *As Featured on NI.com Original Authors: G. Paviglianiti - Whirlpool Fabric Care, Advanced Development Edited by Cyth Systems Washing Machine The Challenge Increasing reliability standards and testing capabilities of our washing machine electronic control boards and implementing an automatic system for embedded firmware validation to save time and resources. The Solution Using NI VeriStand real-time testing software and NI PXI hardware to create a stand-alone system that tests and validates electronic control boards and automatically tests, calibrates, and validates smart algorithms that support Whirlpool 6th Sense Advanced Technology in domestic washing machines. Hardware-In-The-Loop simulation is a technique used for testing complex control systems. It is a system that can simulate scenarios for the testing of an electronic control board. HIL must be able to perform a test with high-speed analog and digital I/O data acquisition to ensure a boards proper function before deployment. We developed the 6th Sense smart control algorithms using rapid control prototyping systems based on the NI LabVIEW Real-Time Module and the LabVIEW Simulation Interface Toolkit. With our company-wide use of this system, we can test new concepts developed with simulation tools directly on a real washing machine. The development process also requires validating engineered control algorithm firmware on the production control board. Algorithm complexity is growing exponentially due to higher quality requirements and challenging cost targets associated with energy label, washing performance, low noise, and advanced features. To handle these new requirements, we designed and implemented a hardware-in-the-loop (HIL) system. Our system serves two main purposes: fast, automatic testing of the low-level signals processed and provided by the production control board for algorithm functionality and minimizing calibration and validation effort with considerable time and resource savings. Performance First We developed a washing machine mathematical model to simulate the main control loops inside the home appliance, such as mechanical, hydraulic, and thermodynamic subsystems. We adapted the I/O interfaces of the model to comply with production control boards. In conjunction with the mathematical model, we designed an external I/O board to act as a bridge and signal processor between the control mainboard and the PXI I/O interfaces. Simulating a whole washing machine requires real-time performance. To achieve this determinism, we chose a 2.2 GHz NI PXI-8110 Intel Core 2 Quad controller combined with an NI R Series Virtex-II multifunction reconfigurable I/O (RIO) module for high I/O capabilities and flexibility. We used NI VeriStand software to integrate our washing machine model. We developed the main part with MathWorks, Inc. MATLAB® and Simulink® software so it is possible to compile, deploy, and run the model on the PXI real-time controller. NI VeriStand performs all I/O mapping. Due to special requirements such as time constraints and numeric integration issues, we designed a specific part of the model directly on the field-programmable gate array (FPGA) RIO module using the LabVIEW FPGA Module. We used NI VeriStand to see and log all low-level signals coming from the control board. With the model inline parameters, we can simulate the behavior of different washing machine models with various external conditions. Beyond Rapid Prototyping As our next step, we integrated the HIL test system in our previously developed algorithm calibration system. This system, developed with LabVIEW, automatically drives the washing machine to perform specific tests and prompts the user with instructions to configure the washer load condition. Moreover, it performs defined test plans and automatically computes algorithm calibration parameters. To integrate the two systems, we implemented a LabVIEW application that remotely configures the NI VeriStand environment according to the test plan executed by the calibration system. This way, we can use plug and play architectures to integrate our HIL system with actual algorithm calibrations set up to rapidly scope how different sources of noise affect algorithm calibration. Conclusion We designed our system using LabVIEW and NI VeriStand for several reasons. First, Whirlpool and NI have a long history of more than 10 years that has successfully delivered high-performance features to customers. NI instrumentation and technology are flexible, so we can use the development environment in other product categories. Whirlpool used NI VeriStand for the first time with this project and found it modular and intuitive. Even nonsoftware-expert resources agreed. Furthermore, the backward compatibility and easy customization of NI VeriStand helped us reuse VIs already developed for algorithm calibration applications. With LabVIEW software and NI hardware, we can store technical data in an easy, suitable way, such as the Technical Data Management Streaming (TDMS) format. In addition, laboratory resources can preliminarily manage test data files thanks to user-friendly NI DIAdem software. This has a big impact on the day-by-day task scheduling between engineers and lab tech resources, resulting in overall team efficiency. The MATLAB and Simulink environments can also process the TDMS format, which facilitates synergy between company departments and easy, quick, specific data analysis. The powerful combination of the NI VeriStand platform, LabVIEW FPGA, the real-time PXI module, and years of fast prototype development and experience with NI products helped us quickly and easily design and develop the whole HIL system. Original Authors: G. Paviglianiti - Whirlpool Fabric Care, Advanced Development Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Project Case Study Validation of Italian Naval Maritime Radar System Using PXI Aug 29, 2023 250d97f6-dbaf-45ad-9c32-81a9c917a723 250d97f6-dbaf-45ad-9c32-81a9c917a723 Home > Case Studies > *As Featured on NI.com Original Authors: Rossella Stallone, Seastema SpA Edited by Cyth Systems Maritime Naval War Ship The Challenge Seastema, a provider of naval electronics equipment and integration, needed to develop a validation test system for their new Omega 360 radar for an accelerated path to market. The Solution Using NI PXI hardware and LabVIEW software they were able to use variable signal attenuators to verify the radar’s range, strength, function, and reliability during test. The Need for Ubiquitous Radar Seastema SpA, a company owned by Fincantieri, designs, develops, and supplies integrated automation systems for different areas of the marine industry. In April 2014, the company established an Innovation Division in Rome to verify the feasibility of an radar system built using commercial off-the-shelf (COTS) devices. Seastema onboard PLC and relay cabinet Currently, multifunctional phased array radars (MPAR) are centered around a monostatic architecture based on planar antennas that form a high-resolution single beam in transmission and in reception. Modern MPARs employ Active Electronically Steerable Arrays (AESA) that allow each radar antenna in the system to act as a small computer, giving the radar system a wider range of simultaneously operational frequencies, which makes it harder for opposing systems to detect. However, conventional AESA radars normally scan ±45° so that the entire round angle is covered by means of four faces or by a rotating single face. This implies that the different tasks assigned to them are sequentially fulfilled, leaving a limited amount of time to accomplish dedicated tasks such as low-angle surveillance and tracking very fast and very small targets. The first type of target needs a rapid formation of the track to be counteracted in time. Both types require long observations to be properly extracted from the surrounding clutter. These operational needs require a continuous observation of the interested area, which only staring beams can obtain. Vessels currently employing Seastema naval automation technology. Omega 360 instead realizes an array of simultaneous staring beams that are received with a single omnidirectional beam on transmit. This solution recalls the concept of “ubiquitous radar” that “looks everywhere all the time”. The architecture is then bistatic in the sense that transmission and reception use different antenna beams. We form the receiving beams by digitally combining the signal received from radiating columns distributed over the frustum of a cone. Building D.Ant.E on the NI Platform We designed D.Ant.E with an overall requirement of rapid and reliable detection of small moving targets at low altitudes, from extremely high to very slow speed, in severe clutter. Typical targets to detect include sea skimmer missiles, small boats, periscopes, and drones. We obtained the surveillance feature by means of a group of staring antenna beams formed around a cone. This solution offers very long times on target, so we needed to make the radar capable of selective Doppler filtering with consequent fine separation between real targets and clutter. D.Ant.E comprises 216 columns of radiating elements evenly distributed along the surface of a frustum of a cone. Each column connects to a receiving channel through which the received RF signal is amplified, filtered, downconverted, and digitally sampled. We physically group the receiving channels by four into 54 modules called Q-Packs. The sampled digital signals in baseband transfer in real time to a central processing unit that applies eight sets of coefficients to obtain eight simultaneous beams. We used an NI chassis that with an embedded controller and PC and a number of specialized modules (Figure 4) to implement all the radar signals and timings. We chose NI because we needed a reliable, configurable, and ready-to-use solution for all the non-innovative aspects. NI PXIe-1085 Chassis We selected the PXIe-1085 chassis and the following modules: PXIe-8135 controller to command and control all modules in the chassis PXIe-5673E module to generate the IF signal PXIe-6674T module to generate the sampling and system clocks and route all radar timings PXI-7841R device to generate all radar timings PXIe-5654 to generate the Stable Local Oscillator (STALO) signal PXIe-6592R to acquire the beams after digital beamforming, perform pulse compression, and transmit the elaborated data to the PC processor by means of optical fiber The IF signal is upconverted to the X band (in the frequency range 9-10 GHz) thanks to an upconversion unit, amplified by means of a solid-state power amplifier module, and then transmitted. We use the sampling clock by Q-Packs to sample the received signal and by DBF to synchronize Q-Pack data links. The system clock constitutes the time base of the entire demonstrator. The unit is locked by a 10 MHz reference oscillator. We can control the NI chassis remotely with a radar management computer (RMC) that allows the choice of all the operative parameters of the test to be done. The RMC also controls the radar processor, console, and tracker units. We took advantage of NI training and technical support to help tailor the system software to our specific needs. During the experimental validation in our laboratory in Rome, we presented the DBF output, after pulse compression, in real-time on a display and recorded it for analysis. We obtained the beams through a digital combination of the signals received by the columns when an RF chirp waveform is transmitted by a horn and the antenna platform is mechanically rotating in a sector from -180 to 180 degrees with a sampling step of 0.2 degrees (see Figure 5). Results The results confirm that the innovative nature of the Omega 360 architecture powers the implementation of algorithms capable of exploiting the advantages of the multiple simultaneous beams and their inherent benefits, such as a long time on target and a seamless surveillance. This affects the reduction in reaction time after the first target detection, the filtering capability of all types of clutter, and the cancellation of passive and active interferences. Introducing Sea Omega 360 The results obtained with the D.Ant.E demonstrator in a lab test, and then test on a real vessel, confirm the validity of this new and “ubiquitous” approach. Based on this, we configured a product called Sea Omega 360 that supports the anti-sea skimmer missile defense of modern vessels. Seastema SpA firmly believes that with NI hardware and software the Sea Omega 360 system can integrate the surveillance capabilities of a modern ship with an outstanding performance against surface and low-angle threats at a competitive price with other existing systems in the naval industry. Original Authors: Rossella Stallone, Seastema SpA Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Project Case Study Proton Therapy Cancer Treatment Controlled using NI Single-Board RIO Apr 1, 2024 89e44ffe-6791-43ca-abd4-a8175b558952 89e44ffe-6791-43ca-abd4-a8175b558952 Home > Case Studies > *As Featured on NI.com Original Authors: Jacob McCulley, ProNova Solutions Edited by Cyth Systems ProNova SC360 Proton Therapy System The Challenge Developing a highly accurate and precise proton beam control solution to deliver a prescribed radiological dose to a specific location within a tumor. The Solution Implementing intensity-modulated pencil beam scanning in the ProNova SC360 by using Single-Board RIO solutions to meet the monitoring and control requirements to safely and effectively deliver the radiological dose to treat a tumor. About ProNova More than 1.6 million people will be diagnosed with cancer this year in the United States, with 320,000 of those cases eligible for proton therapy. However, with just 24 existing proton therapy centers, only 5 percent of eligible patients can receive this treatment. ProNova aims to make proton therapy a widely available cancer treatment option by delivering a lower-cost, more compact, and more energy-efficient proton therapy system without sacrificing clinical capabilities. About the SC360 We designed the SC360 proton therapy system to provide the flexibility required to support 1 to 5 treatment rooms, allow for different treatment room configurations, meet individual customer needs, and enable easy integration with future R&D projects. This modular approach lends itself nicely to the design of a distributed control system with NI reconfigurable I/O (RIO) technology. This technology, in conjunction with the LabVIEW Real-Time Module and the LabVIEW FPGA Module, provide the hardware flexibility and programming capabilities needed to rapidly develop advanced embedded monitoring and control solutions for the SC360 without sacrificing the performance requirements of a proton therapy system. Consequently, we used CompactRIO and Single-Board RIO solutions extensively throughout the SC360 for magnet control, vacuum control, beamline diagnostics, and dose delivery. The SC360 offers a highly accurate and precise method for targeting tumors by using intensity modulated proton therapy (IMPT) with pencil beam scanning (PBS). This technology helps doctors treat large, non-contiguous targets with improved local control; thus, sparing sensitive organs and normal tissue from unnecessary radiation exposure. This allows proton therapy to provide a dosimetric advantage in more than 80 percent of all external beam radiation treatment cases. Left: Simplified diagram of dose delivery system, Right: Dose Delivered to a Target Along Z-Axis (left) and XY-Axis (right). SC360 Dose Delivery System The Dose Delivery System, or DDS, is the SC360 subsystem that accurately and precisely delivers protons from the beamline to a specific target in the patient. We implemented IMPT with PBS in the DDS using three sbRIO-9626 embedded controllers. The individual controller responsibilities include: · dose monitoring · beam control · beam position monitoring (Figure 2). A PBS treatment plan contains a set of locations, or spots, in 3D space (horizontal-X, vertical-Y, depth-Z) that are each prescribed a specific radiological dose. The spot produced by the proton beam is between 4–8 mm depending on depth and must be delivered within 1 mm of the prescribed location. Modulating the intensity of the proton beam adds a time dimension to the treatment plan by controlling the beam current to deliver each spot in ~5 ms. We used the Single-Board RIO FPGA and LabVIEW FPGA Module for each of these applications to meet the timing requirements for spot delivery and the response times required to safely remove the beam from the treatment room during spot transitions or following a safety interlock. Additionally, hard-wired signals pass between the FPGAs of each of the control components to trigger spot completion, spot advancement, and treatment faults. Each DDS module uses LabVIEW Real-Time to receive treatment plans, process spot treatment results, and report treatment results back to the treatment room master control component. Beam Control We control the vertical and horizontal position of the proton beam from the beamline to the patient using specialized scanning magnets. The Single-Board RIO device dedicated to beam control is responsible for controlling the magnetic fields required to deflect the proton beam to the desired spot location. Additionally, this controller provides the beam intensity set point required to maintain spot durations of 5 ms. We can sample the analog I/O available on the sbRIO-9626 at 10 kHz to continuously monitor critical feedback signals (control signals, load voltages, currents, fields, temperatures, and water flow) related to vertical, horizontal, and intensity control. The beam control system safely removes the proton beam from the treatment room if any of the monitored signals fall outside set point tolerances. The beam control module is triggered to adjust the magnet fields for the next spot when the dose has been delivered for the current spot. Upon verification that the monitored signals have settled at the new set point, the treatment can continue. We can complete and verify this spot transition process in <800 µs. Dose Monitoring We monitor the amount of charge collected on two redundant dose planes located between the output of the beamline and the patient to control the dose delivered to a spot. We used the sbRIO-9626 to meet the analog I/O and digital I/O requirements for sampling the dose plane signal conditioning circuits. Additionally, we use the onboard FPGA to monitor the delivered dose at frequencies up to 1 MHz, and provide the response time required to safely remove the proton beam from the treatment room upon fulfilling the prescribed dose or in the event the delivered dose falls outside of treatment tolerances. This level of precise control makes it possible to deliver a radiological dose within 1 percent of the prescribed dose. The dose monitoring module also synchronizes spot advancement with other DDS modules upon the delivery of a prescribed dose. We accomplish this by 1) removing the beam from the room when the prescribed amount of dose is delivered, 2) triggering the beam control and beam position monitoring modules once the spot has been completed, 3) receiving notification from the beam control and beam positioning monitoring modules upon successful spot transition, and 4) completing the spot by verifying the delivered dose is within treatment tolerances. Once the spot transition has completed (<1 µs), the treatment plan resumes on the next spot if all components are confirmed ready for safe beam delivery. This process incrementally advances the control components through a treatment plan until a dose has been delivered to all prescribed spots. What’s Next? ProNova received FDA approval for the SC360 earlier this year (2020) and plans to start treating the first patients later this year at the Provision Center for Proton Therapy in Knoxville, Tennessee. We have planned future SC360 installations for cities across the United States, Europe, and Asia. ProNova strives to improve upon the clinical advantages of proton therapy and introduce advanced technologies that help make this treatment option a reality for more cancer patients. Original Authors: Jacob McCulley, ProNova Solutions Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

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The RIO platform provides reconfigurable I/O within an off-the-shelf control system that can be customized for any control or monitoring application. Reconfigurable I/O (RIO) Real-Time Embedded Platform NI Authorized Distributor and System Integration Partner Home > Products > NI Multifunction I/O A Single Real-Time PLATFORM with WORLD-CLASS credentials Our solutions are based on the Reconfigurable I/O (RIO) platform from NI. The RIO is a versatile solution with infinitely customizable I/O configurations, making it suitable for various industrial applications, including monitoring, automation, and machine control. Two Convenient Formats, Same Embedded PLATFORM The RIO platform is built on Intel processors, Linux Real-Time OS, and Xilinx FPGA's, which gives industry-standard credentials and flexibility. The RIO platform is a versatile solution with infinitely customizable I/O configurations, making it suitable for various industrial applications, including monitoring, automation, and machine control. CompactRIO (cRIO) Packaged Ready-To-Use INDUSTRIAL CONTROL SYSTEM The CompactRIO (cRIO) is arguably the most flexible and powerful Industrial Controller for industrial and scientific machinery, facilities, instrument, or equipment applications. The cRIO has hundreds of available I/O modules so that they can be customized for any application with NO custom development. The cRIO is not a PLC - - it’s much more than a PLC. With the power of LabVIEW and Linux, the RIO platform can take high-speed measurements, analyze images from cameras, read from and write to databases, and even send email or text messages. Learn about cRIO Single-Board-RIO (sbRIO) Industrial SINGLE-BOARD COMPUTER designed for integration into your product The RIO platform is also available in the Single-Board RIO (sbRIO) or System-On-Module (SOM) form factor. These two controllers can perform any task by the development of Mezzanine Boards to customize the I/O as needed for a project. Yet to make that process simpler, Cyth also offers Circaflex - a family of ready-to-use mezzanine boards with swappable I/O modules to help prototype all the I/O for a project without any PCB development. After successful prototyping, Circaflex boards can be used as-is, or customized further to optimize connectors, packaging, or size. Learn about sbRIO Both formats designed to INTEGRATE all your SENSORS & COMPONENTS For cRIO, NI offers a wide variety of versatile and rugged modules designed to meet a wide range of industrial and embedded control and data acquisition needs. These modules offer analog and digital I/O options, enabling users to precisely monitor and control various processes and systems. With seamless integration into the CompactRIO chassis, they facilitate rapid deployment and customization of real-time control solutions, simplifying development and maintenance. For the sbRIO, mezzanine boards address the need for custom I/O interfaces and functionality. Integrators can design mezzanine boards with any signal needs. Yet Cyth offers a wide variety of Circaflex Reference Designs for sbRIO. Some Circaflex boards include built-in I/O, as well as module sockets for Circaflex I/O Modules. With Circaflex, developers can tailor their Single-Board RIO systems to a wide range of unique use cases, extending the platform's flexibility allowing projects to start with . Motors & Motion DC Motors Steppers Servos Syringes Pneumatics Sensors Gripper Pistons Slides Solenoids Actuators pH Flow Weight Strain Oxygen/DO Current Current CO2 Pressure Temperature Presence Position I/O Devices Displays Buttons Knobs LEDs Traffic Lights Fludics Peristaltic Pumps Valves Syringes Both formats powered by LabVIEW for easy development of algorithms and applications LabVIEW is a graphical programming environment engineers use to develop automated research, validation, and production test systems. Both formats are designed for Quick Prototyping of Automation and Control Projects The RIO platform is the perfect starting point for industrial factories and facilities or low-volume industrial and scientific machines. Either platform is a great choice for designing the internal control system of an industrial or scientific product to be manufactured in the hundreds or thousands.

Project Case Study Fast and Precise Laser Engraving with CompactRIO Mar 27, 2024 f42611fa-081e-472d-a134-75a2feb9e0a4 f42611fa-081e-472d-a134-75a2feb9e0a4 Home > Case Studies > *As Featured on NI.com Original Authors: Christopher Farmer, Wired-in Software Pty Ltd Edited by Cyth Systems Laser Etching using an NI CompactRIO controller. The Challenge Develop a reliable, embedded, high-speed laser engraving control and positioning subsystem within eight weeks. The Solution Develop, integrate, and test the application using CompactRIO hardware and the LabVIEW Real-Time and LabVIEW FPGA modules to control the output signals with transition times between 100 ns and 10 us. Background Manufacturing processes include critical components to be tightly synchronized within the 100 ns to 10 us range. In the case of laser engravers, timing, and positioning is controlled within the manufacturing system and is a critical part of the process. The customer in question has had a previous solution based on custom hardware; however, this has become outdated and can no longer be serviced and maintained. Being a crucial part of their system failure will lead to great risk to production. Solution Process We designed and developed the high-speed laser engraver control subsystem based on CompactRIO technology. It produces patterns of analogue and digital output signals, all within tight transition times (of 100 ns and 10 us). We rapidly developed this reliable and expandable solution in eight weeks. Because we used the CompactRIO platform, the solution was purely a software development effort—no custom hardware was required. This resulted in a much faster solution than if a custom electronic solution had been developed. Application Overview This embedded system application consists of a single controller running in a headless configuration. We designed it to run 24/7 without any user interaction. The PROFINET slave receives commands from a PROFINET master. The controller transmits its status back to the master and returns a fault if the received parameters are invalid, or if an issue is present (such as input is missing or nonresponsive). On receiving a trigger signal (via a digital input), the encoder counter (via digital inputs) is reset. A sequence of control events is derived from the PROFINET parameters. It is used to position both the motor (via an analog output) and enable the laser (via a digital output) at specific encoder counts and must carry out each change within less than 0.1 ms. The sequence is restarted upon every trigger received. Left: Remote Panel Access to RT_Main.vi, Right: Trace from a Tektronix Oscilloscope Software Design The software involves both the LabVIEW Real-Time and LabVIEW FPGA modules, which ensure deterministic code for this application with strict timing requirements. The control algorithm, written with LabVIEW FPGA, runs on the FPGA inside the CompactRIO system. The FPGA code has a state machine architecture within a Single Cycle Timed Loop. The control system has two modes of operation: auto and manual. During auto mode, the FPGA controls the motor position and laser signals based on the combination of encoder counts, trigger signal, and PROFINET parameters. The PROFINET parameters sent by the master can be changed dynamically, which the FPGA code can read at the start of each trigger. In manual mode, the received PROFINET parameters can change only the position of the motor. The real-time code is used for setting up the simulation and provides remote panel access for diagnostic purposes only. The real-time panel can be easily viewed through a web browser. CompactRIO During Development Simulation During development (with the system offline and disconnected from the PROFINET master, encoder, and trigger), the PROFINET parameters were simulated in the real-time front panel. This allowed us to test the conversion of 128-byte numeric arrays into meaningful parameters. The FPGA code has some simulation functions that can be turned on/off from the real-time panel. With the existing I/O available, we connected wires in a loopback type configuration (that is, wire some digital outputs straight back into digital inputs for the encoder and trigger signals). Then, within the FPGA software, we can generate encoder and trigger pulses to stimulate the system inputs. We developed an independent LabVIEW application to take readings from a Tektronix 1 GS/s oscilloscope to verify the system operation (that is, check the timing of the trigger, encoder, motion, and laser). Using the Tektronix device drivers downloadable from ni.com, it was simple to assemble an application for test data acquisition that didn’t disrupt the core application development. We saved the files in TDM Streaming file format, allowing for post-analysis in another independent LabVIEW application. Hardware We based the system on cRIO-9035 to meet the following requirements: 6 C Series slots (PROFINET slave requires an empty slot beside it Ample FPGA resources High-speed timing requirements—need to act within 0.1 ms or less Configurable I/O simplifies hardware design Modules Description CompactRIO-9035 CompactRIO Controller and Chassis CompactRIO PROFINET Slave Module Receives commands from the PROFINET master NI-9401 DIO Reads the encoder pulses NI-9263 AO Controls the motor NI-9423 DI Receives the trigger signal NI-9474 DO Enables the laser Benefits The LabVIEW graphical dataflow programming environment makes the development process easier and faster. With the add-on toolkits and modules, such as LabVIEW FPGA and LabVIEW Real-Time, we can use LabVIEW for domain-specific industrial applications. The client’s system to be replaced was a custom-designed embedded PC-based solution that is no longer supported. After an extensive search, CompactRIO was the only off-the-shelf solution that did not require custom hardware to meet the system requirements. LabVIEW FPGA is easy to develop, and abundant resources are available to fast-track development (such as the CompactRIO Developer’s Guide, and online real-time and FPGA training for valid subscriptions), and thus enabling us to meet the timeline. Conclusion By adopting an NI software and hardware solution, we designed and built a high-speed control subsystem using LabVIEW Real-Time and LabVIEW FPGA within a tight timeline. The PROFINET controller gave us a sophisticated interface to the factory’s distributed control system. The spare I/O was leveraged to be used as simulation outputs. The FPGA code’s deterministic nature ensures that every encoder pulse change was captured. CompactRIO is a reliable and robust solution for the application, which is required to run continuously for extended periods of time. Original Authors: Christopher Farmer, Wired-in Software Pty Ltd Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Project Case Study CompactRIO Controls Fuel-Cell Hybrid Train Sep 17, 2024 2c864fcd-47f4-4945-9341-5619566e1124 2c864fcd-47f4-4945-9341-5619566e1124 Home > Case Studies > *As Featured on NI.com Original Authors: Tim Erickson, Vehicle Projects LLC Edited by Cyth Systems Fuel-Cell Hybrid Train The Challenge Controlling the operation of a 250-kW fuel-cell hybrid locomotive. The Solution Using an NI CompactRIO controller to monitor and control the safety and operation of a fuel-cell locomotive and controller area network (CAN) bus to communicate the engine status to the operator via a touch panel programmed with NI LabVIEW software. The prime mover of a traditional switch locomotive is a diesel engine between 1 and 2 MW driving an alternator that supplies power to the traction motors and locomotive auxiliary systems. These traditional switch locomotives require a high-power diesel engine, which typically is not fuel-efficient and has limited emission control. Subsequent design iterations of switch locomotives have transitioned to a hybrid-electric design, which reduces the overall emissions and fuel consumption because the engine can be downsized while the battery stores energy for high-power transients. However, a large source of diesel particulate pollution in urban areas still comes from diesel-powered locomotives in rail yards. To help alleviate this pollution, a North American public-private partnership is prototyping a fuel-cell hybrid switch locomotive for urban rail applications and replacing the diesel engine with a 250-kW net fuel-cell power plant, creating the world’s largest fuel-cell hybrid locomotive. Vehicle Projects LLC of Denver, Colorado, engineered the control system for the fuel cell using a CompactRIO embedded controller and LabVIEW graphical design software. Our goals are to reduce air pollution in urban rail applications, including yard switching associated with seaports, and to serve as a mobile backup power source for critical infrastructure during military base grid failures or civilian disaster relief operations. Fuel Cells and Hybrid Power Trains Fuel cells are electrochemical power devices that directly convert the chemical energy of a fuel into electric power. The cells produce electricity and water from hydrogen fuel and oxygen, which is the reverse process of water electrolysis. While fuel cells share principles of operation with batteries, they differ in that the electrochemically active materials, hydrogen and oxygen, are stored or available externally and continuously supplied to the device rather than stored in the electrodes. They are periodically refueled, like an engine, rather than recharged electrically. Like batteries, individual cells are grouped together into “stacks” to provide the required voltage or power. A fuel-cell hybrid power train uses a fuel-cell prime mover plus an auxiliary power/energy-storage device to carry the vehicle over power peaks in its duty cycle and recover kinetic or potential energy during braking. For steady-state operation, the continuous net power of the prime mover must equal or exceed the mean power of the duty cycle. Preliminary research has shown that a hybrid-switch locomotive can reduce capital and recurring operation costs. NI Compact RIO Figure 1. Top: NI Compact RIO 4 Slot Chassis. Bottom: NI CompactRIO 8 Slot Chassis. Designing a Control System Using CompactRIO We faced several design and integration challenges while developing the large hydrogen fuel-cell vehicle including weight, packaging, and safety considerations. Harsh operating conditions, especially the shock loads that occurred during coupling to railcars, required highly rugged component systems. Additionally, the fuel-cell control system is needed to communicate with the existing commercial vehicle controller to interpret operator demand and adjust fuel-cell power plant parameters to meet the power requirement. The CompactRIO embedded controller provided an ideal form factor to meet these specifications with the right I/O combination for this application. This programmable automation controller (PAC) managed and executed all power plant functions and continuously monitored the performance and safety of the hydrogen storage and fuel-cell power systems. Software Architecture Based on LabVIEW A CompactRIO embedded controller running the LabVIEW Real-Time and LabVIEW FPGA modules controls the fuel-cell power plant operation. The user monitors the control system via a touch panel installed in the locomotive cab. The control application consists of modular control algorithm VIs that communicate with each other and the field-programmable gate array (FPGA) I/O system using a tag-based architecture so that we can refer to each I/O point by the assigned name within the LabVIEW application. Each tag has properties associated with it including alarm limits, scaling (converting from voltage to engineering units), and events such as when the user wants it to log to a disk. We implemented a programmable logic controller (PLC) mentality into our PAC-based system. Developing the Perfect Control Platform with LabVIEW and CompactRIO We chose LabVIEW and CompactRIO because the NI C Series modules with integrated signal conditioning helped us implement fast monitoring of the various I/O points while connecting to a wide range of specialty sensors such as flowmeters and pressure sensors. Additionally, we performed complex control algorithms beyond simple proportional integral derivative control at very fast loop rates. Some of our control algorithms included mathematical models that we implemented with LabVIEW, which we could not have developed using less flexible environments such as a PLC platform. Furthermore, we achieved the fast loop rates that we required because we had the ability to place some of the control algorithms on the field programmable gate array (FPGA). Technical Specifications LabVIEW 2020 NI CompactRIO 8-slot Chassis Author Information: Tim Erickson Vehicle Projects LLC Talk to an Expert Cyth Engineer to learn more

Project Case Study Automating the Test of High-Current Circuit Breakers Using NI CompactRIO Mar 27, 2024 a068a8d7-489e-4d63-8d49-2fd1c51ab513 a068a8d7-489e-4d63-8d49-2fd1c51ab513 Home > Case Studies > *As Featured on NI.com Original Authors: Xavi Salada, Techna International Ltd Edited by Cyth Systems Circuit breakers The Challenge Increasing the ease of mechanical and electrical testing of circuit breakers. The Solution Automating the safety test processes of testing circuit breakers by using pneumatics to test their mechanical operation and using high-accuracy sensor inputs/outputs to read the voltage status of the device’s electrical circuit. Introduction Circuit breakers are an essential safety feature of every building—key to preventing fires and protecting people and their belongings. Such devices must pass a number of safety tests before distribution. Electrical tests ensure the proper functionality of the device and mechanical tests guarantee the mechanisms can operate repeatedly for a long period of time. Completing these tasks manually is labor intensive and time consuming as tests are run in large quantities and can last for hours. We needed an automated test machine to make it safer to test new products in the development stage and practical to test a large a quantity of devices during production. With this automatic system, an operator can control the test machine through a computer program instead of being in direct contact with the devices. Left: Frame of automated circuit breaker testing system with DUT (Devices Under Test) Right: NI cRIO-9063 & cRIO 9038 Controller Chassis Application Overview The test machine consists of two sections. The first section includes a pair of pneumatic pistons used to power cycle each unit under test (UUT) a number of times specified by the operator, as well as sensors to determine current levels and pin position. The second section has the UUT connected in parallel to a relay that acts as a bypass in case the device trips. A voltage sensor determines whether the UUT is still engaged or malfunctioning because of fatigue. LEDs indicate the test pass status for each power cycle. We repeat this schema using a programmable power supply to increase the number of devices that we can simultaneously test. Running the test with the circuit breakers arranged in series runs the risk that some of the devices may trip due to heat generated by the amount of current passing through them. In this case the system needs to recover and activate the specific relay to bypass the tripped device so the test can continue. To do that, the program continuously scans all voltage sensors placed after each device to determine which UUT has tripped. When the program identifies the tripped UUT, it stops the power supply, activates the appropriate relay, and switches an LED to display this to an operator. The system then resets the power supply and the test continues. On the front panel, the operator can view the status of each UUT, the current used, and the remaining time for the test. Control of the system, including the pistons, relays, LEDs, and binary sensors, requires a large number of digital inputs provided by the NI 9375 and USB-6509. We use the USB-6509 with MOSFETs for voltage regulation and the NI 9375 to serve as a 24 V source, which keeps our system design simple because we do not need extra circuitry. We connected a current clamp to the NI 9205 analogue input module using its 16 differential inputs for measuring the current levels passing through the UUTs. Original Authors: Xavi Salada, Techna International Ltd Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

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Project Case Study Identifying Noise Sources on In-Flight Aircraft with LabVIEW & PXI Mar 27, 2024 08963015-630e-457a-b96f-192656dbfc91 08963015-630e-457a-b96f-192656dbfc91 Home > Case Studies > *As Featured on NI.com Original Authors: Dr. Kenichiro Nagai, Japan Aerospace Exploration Agency (JAXA) Edited by Cyth Systems A private jet undergoing takeoff The Challenge Developing a measurement system to identify noise sources on in-flight aircraft. The Solution Building an application based on NI LabVIEW software that uses NI PXI hardware to acquire data from a phased microphone array on a runway. Investigating Noise Sources on Passenger Aircraft To develop quieter passenger aircraft, we must identify all noise sources to improve our understanding of the noise generation mechanisms. While designing an aircraft, we can predict noise levels through numerical analysis and model tests. However, the properties and characteristics of actual aircraft noise can only be obtained by actual flight tests. Noise source localization through acoustic beamforming is a powerful tool to accomplish this. Beamforming is a method of mapping noise sources using a phased array of microphones and displaying their amplitude. Although we at JAXA have developed and improved this technique through both wind tunnel tests and flight tests using small-scale model airplanes, we haven’t applied this technique to actual aircraft in flight. In recent years, we acquired a small Mitsubishi MU-300 Diamond business jet. We set up a phased microphone array on a runway and began conducting noise source localization measurements to verify our current technology and to determine areas of improvement. Phased Microphone Array Measurements The phased array consists of many microphones distributed over a large diameter. Using the slight time lag for the sound waves emitted from the noise sources to arrive at each microphone, we can estimate the location and strength of each noise source. In this test, we designed the phased array to distinguish between two separated 1 kHz tones in 4 m distance on an aircraft flying at 120 m altitude. We designed an array consisting of 99 microphones arranged over a circular area with a 30 m diameter. Left: Phased array of line scan cameras installed on the runway. Right: Phased microphone array installed on the runway. In-flight noise source localization tests must include the state of the jet engine; acoustic measurements; and the aircraft’s position, altitude, and speed while it flies over the phased array. We also record meteorological data such as wind direction and speed, temperature, and humidity, since the noise generated from the aircraft is attenuated by the atmosphere before reaching the microphones on the ground. A key feature of our system is the simultaneous measurement of flight parameters with acoustics. We accomplish this using two line-scanning cameras placed with the phased array on the ground. These two cameras are directed upright and are staggered both in flight direction and in lateral direction, as shown in Figure 1. The cameras capture synchronized images of the passing aircraft, providing us 3D information that allows us to analyze the flight speed and flight altitude of the aircraft. The noise localization process is simultaneously executed with the acquired acoustic data on another computer. This data is combined together shortly after the aircraft flies over the phased array and is visualized as noise source maps overlapping the aircraft image. Visualized noise sources Figure 2. Visualized noise sources for 1,000 Hz and 2,000 Hz on the aircraft in a landing configuration (flaps down, landing gear down, engine idling, altitude 60 m, flight speed 60 m/s, level flight). Measurement System We chose an NI PXI system with a variety of modules to meet our requirements for a compact system. Our system contains an embedded controller and an NI 8260, a 4-drive, in-chassis, high-speed data storage module. LabVIEW, the NI Vision Development Module, and the NI Sound and Vibration Measurement Suite provided an effective tool for developing our solution. The system provided quick setup, data logging, real-time monitoring, and data review. We mounted it on a mobile platform for portability. The NI PXI-4498 dynamic signal acquisition (DSA) modules provide power to the microphones via integrated electronic piezoelectric (IEPE) conditioning and simultaneously acquire high-resolution data from them. Since each module can handle up to 16 channels, the seven modules can simultaneously sample 112 channels with room for expansion. The NI PXI-1428 image acquisition modules allow line-scan digital imaging from line-scan cameras. These acquired images are processed automatically by the application we developed using the NI Vision Development Module. In addition, the NI PXI-6682H timing and synchronization module provides synchronization via GPS to timestamp the data and coordinate with avionics onboard the aircraft and on the ground. NI PXIe-1095 We conducted flight tests November 16–18, 2010, at Taiki Aerospace Research Field in Hokkaido Prefecture. While the MU-300 business jet executed a series of repeated approaches and climbs to simulate takeoff and landing at various flight altitudes and speeds, we took measurements simultaneously on the ground and in the aircraft. Figure 6 shows the typical results of noise localization maps for 1,000 Hz and 2,000 Hz on the aircraft in a landing configuration. At 1,000 Hz, we confirmed noise sources with higher amplitudes (shown in red) near the main landing gear, outside edge of the flaps, and the engine nozzle. At 2,000 Hz, we observed noise sources near the engine nozzle, main landing gear, and nose landing gear, but no longer at the outside edge of the flaps. Through this test, we demonstrated the technology to localize multiple noise sources on an in-flight aircraft. We are continuing to improve our technology to locate noise sources more accurately and to enable a more detailed evaluation of noise source properties such as noise spectra. Original Authors: Dr. Kenichiro Nagai, Japan Aerospace Exploration Agency (JAXA) Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

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In embedded applications like industrial controllers and robotics, precise timing and predictable execution are crucial for smooth operations. < Back The Most Important Considerations of an Embedded System Design The NI RIO Platform solves each of these design challenges Previous Next

Project Case Study Developing a SONAR System Using PXI and LabVIEW Mar 27, 2024 f5f43da5-02b4-481a-8343-00a6eaf99425 f5f43da5-02b4-481a-8343-00a6eaf99425 Home > Case Studies > *As Featured on NI.com Original Authors: Arun Joy, Captronic Systems Pvt Ltd Edited by Cyth Systems SONAR System Using PXI and LabVIEW The Challenge Developing a real-time monitoring system to accurately detect and analyze the vibrations and movements an object undergoes using a noncontact inspection technique. The Solution Using NI PXI Express hardware and the NI LabVIEW Real-Time Module to create a SONAR data acquisition and processing system that sends ultrasonic pulses and analyzes the echo from the object to capture the minute variations in the distance to the object caused by vibratory movement. In the system we created for this application, the critical component is accurately detecting the minute vibratory movements (on the order of a few millimeters) in real time for objects where in-contact measurement methods, such as using a linear variable differential transformer (LVDT), is not possible. SONAR describes the technique of sending ultrasonic pulses and listening to their echoes from an object. By analyzing the echoes, we can obtain details such as distance to the object, size, shape, and structure. We chose a SONAR system for this application because it delivers more accurate results than other methods such as LVDT, and it provides a noncontact inspection method useful for inspecting objects on which we cannot mount sensors. In this application, ultrasonic transducers repeatedly pulse at a pulse repetition frequency of 40 Hz to 100 Hz. The system captures corresponding echoes and precisely measures the time taken to receive each echo for an accurate distance calculation. Any vibration or movement introduces a variation in the time intervals. For our solution, we needed to: Develop a high-speed data acquisition system to simultaneously acquire ultrasonic frequency signals from four ultrasonic transducers (multiple transducers are mounted at different angles to the object of inspection) Create a high-speed bus to handle the large amount of data acquired at high sampling rates (on the order of MS/s per channel) Design a real-time processing unit to implement the algorithm for precise time and distance measurement Synchronize the pulsing of all transducers Ensure precise synchronization to detect each pulse or echo SONAR System System Architecture System Overview The system is made of an ultrasonic transducer, a pulse receiver, a digital output module, a digitizer, a real-time controller, and application software. The ultrasonic transducer is pulsed, sending out an ultrasonic wave. The subsequent echoes generate a voltage in the transducer, which is sent back to the pulser-receiver. The pulser-receiver provides the high-voltage pulses necessary to excite the transducer. It receives the echo signal from the ultrasonic transducer and amplifies it before feeding it to the digitizer. The digital output module provides digital output signals to synchronize the pulser-receiver instrument, and the digitizer converts the waveform sent from the pulse-receiver from voltage to bits using an analog-to-digital converter. The real-time controller controls the acquisition and processing and sends the data to the monitoring station (user interface) for display. The application software processes analyzes, and presents the data from the digitizer according to the user-defined parameters. We completely developed the application software in LabVIEW. It has two parts: the GUI running on the monitoring station PC (host PC) and the processing unit running on the NI PXIe-8133 real-time controller. A LabVIEW TCIP/IP protocol facilitates communication between the real-time controller and the host PC (user interface). The user can configure and control the system using the software GUI. The NI PXIe-1071 chassis contains the real-time controller, digitizers, and digital output module. The real-time controller controls all module operations. The digital output module provides digital outputs for the synchronized pulsing of pulser-receivers. The ultrasonic echo signals amplified by pulser-receivers are acquired using NI high-speed digitizers. The acquired signal undergoes signal processing, such as averaging and filtering, to remove any waveform degradation. Left: Ultrasonic Pulse and Echo , Right: Acquisition and Processing—Result Display The algorithm for measuring the time of flight (time taken to receive the echo) of the ultrasonic signal is implemented using the LabVIEW Real-Time Module and the LabVIEW Advanced Signal Processing Toolkit. The processing unit in the real-time controller executes this algorithm deterministically, to detect the vibration with high accuracy. The application also provides a data-logging feature for future data analysis. The results as well as acquired data are transmitted to the host PC in real time for monitoring. The system measures the time and distance for each pulse. The monitoring is simultaneously carried out for signals from four ultrasonic transducers located at different angles to the object under inspection. It can even precisely measure the minute vibratory movement of the object this way. Application Software The system has an easy-to-use GUI for the host PC, developed in LabVIEW. Users can configure the system per their requirements and give commands to control the acquisition. It also provides a feature to record the acquired data and results to analyze later. With a configuration utility, users can enter the signal parameters and digitizer settings to configure the acquisition. The acquisition and processing panel contains the controls to start and stop acquisition, and to record data and results. The graphical display indicators make monitoring and analysis easy with the help of LabVIEW analysis tools. The display and analysis options include A-Scan and B-Scan display of digitizer data and the frequency and time domain analysis of results. Advantages of the SONAR System The SONAR system we created provides a noncontact method to monitor the object characteristics. There are no limitations on the surface, object shape, or environment where the object is kept. The system gives far more accurate results than other methods, such as LVDT, even for vibration with a maximum 1 mm peak-to-peak amplitude. By simultaneously acquiring data from multiple transducers, the system can capture movements in more than one axis. The system also has a feature to record data and results for future analysis. We used NI hardware and software to develop a precise monitoring system to monitor the vibratory movements of objects in real time. NI products such as the LabVIEW development environment and real-time PXI hardware made it easy and efficient. With the real-time PXI controller and the LabVIEW Real-Time Module, our system can simultaneously acquire and process from all channels with a high degree of determinism. The NI PXIe-1071 chassis gave us sufficient bandwidth to handle the large amount of data acquired by the digitizers, and the digitizer’s NI-TClk feature gave us precise synchronization. The built-in advanced signal processing tools in LabVIEW offer an efficient way to implement the algorithm for measurement and calculations. We used the built-in communication protocols, such as LabVIEW TCP/IP, for data transfer between the real-time target and the host PC. Efficient file options, such as technical data management solution data storage, helped us manage our large amount of data, and the LabVIEW platform made development easy, fast, and effective with a powerful GUI. Original Authors: Arun Joy, Captronic Systems Pvt Ltd Edited by Cyth Systems

NI’s sound and vibration products acquire acoustic and vibration signals for audio test, condition monitoring, and more. Choose your form factor today. NI Sound & Vibration Measurement Products NI Authorized Distributor and System Integration Partner Home > Products > Sound and Vibration Sound and Vibration Sound and vibration products interface with microphones and accelerometers to acquire acoustic and vibration signals. Use these products for audio test; machine condition monitoring; and noise, vibration, and harshness (NVH) applications. Easily take sound and vibration measurements with NI hardware and software NI’s sound and vibration products integrate with the software of your choice for dynamic signal acquisition (DSA) applications. You can use interactive measurement panels in DAQExpress, create custom applications in development software like LabVIEW, and more. Available in the Form Factors You Need NI offers sound and vibration measurement hardware that works with the system you use: PC-based, PXI, CompactDAQ, or CompactRIO. If you need additional features for extreme environments, consider FieldDAQ™ hardware. Sound and Vibration-Specific Software for Quick Analysis All NI sound and vibration hardware is programmable with NI-DAQmx software and compatible with the LabVIEW Sound and Vibration Toolkit, which includes easy-to-use power spectrum, swept sine, octave analysis, and other functions. PLATFORM MODULES Platform modules integrate with modular hardware platforms that allow you to combine different types of modules in a custom system that leverages shared platform features. NI offers three hardware platforms—CompactDAQ , CompactRIO , and PXI —though all platforms may not be represented in this category. CompactDAQ Sound and Vibration Measurement Bundle The CompactDAQ Sound and Vibration Measurement Bundle includes the C Series Sound and Vibration Input Module and a CompactDAQ Chassis. PXI Sound and Vibration Module Provides dynamic signal generation and acquisition in sound and vibration applications for PXI systems. Feature Highlights: Platform: PXI Bus: PXI, PXI Express C Series Sound and Vibration Input Module Provides dynamic signal acquisition in sound and vibration applications for CompactDAQ and CompactRIO systems. Feature Highlights: Platform: CompactDAQ, CompactRIO C Series Universal Analog Input Module Provides analog input channels for voltage, current, temperature, and strain measurements in CompactDAQ or CompactRIO systems. Feature Highlights: Platform: CompactDAQ, CompactRIO Sound and Vibration Input Device for FieldDAQ Provides dynamic signal acquisition in rugged environments. FieldDAQ™ devices are dust- and water-resistant and offer TSN technology for simplified distribution. Feature Highlights: Bus: Ethernet STAND-ALONE OR COMPUTER-BASED DEVICES Stand-alone or computer-based devices either integrate with standard desktop and laptop computers or allow you to use them without the need for other modular hardware. Sound and Vibration Device Provides dynamic signal generation and acquisition in sound and vibration applications for computer-based systems. Feature Highlights: Bus: PCI, USB

Project Case Study Hybrid Battery Life Cycle Testing Using CompactRIO Mar 27, 2024 90cdf694-e3d9-409e-8cee-26514f9904c7 90cdf694-e3d9-409e-8cee-26514f9904c7 Home > Case Studies > *As Featured on NI.com Original Authors: Abedalsalam Bani-Ahmed, Center for Sustainable Electrical Energy Systems, University of Wisconsin–Milwaukee Edited by Cyth Systems Hybrid battery life-cycle testing The Challenge Developing an automation system to evaluate the performance and cycle life of a hybrid lithium-ion/lead-acid battery. The Solution Combining CompactRIO FPGAs and processors to create a rugged, reliable automation system that charges/discharges a lithium-ion/lead-acid hybrid battery to evaluate performance and cycle life. The controller monitors the system's voltages, currents, and temperatures and commands the source, load, and relay to maintain continuous charging/discharging cycles in an unsupervised manner. The controller also runs a protection algorithm and streams data to the HMI client for logging. Introduction A part of the Center for Sustainable Electrical Energy Systems at the University of Wisconsin-Milwaukee, the Power and Electronics and Electric Drives Lab focuses on electrical energy generation and conversion. We integrate multiple energy conversion and storage devices to design systems that provide the most effective, efficient, and reliable means of providing power to loads. These research projects develop technologies for multiple industries and build a talent pipeline for companies in Southeastern Wisconsin. Battery cycle life testing is time-consuming and the most important procedure in battery qualification test. The battery/system under test is subjected to repeated charge/discharge cycles to determine its cycle life. For our lithium-ion/lead-acid hybrid battery, there are two cycling and capacity check tests. The cycling test includes charging/discharging the combined batteries 1,000 times at a 0.3 C rate. After every 50 cycling tests, we perform a capacity check to measure the capacity of the combined system. The capacity check test includes one cycle of fully charging and discharging the system at 0.1 C. Moving from charging to discharging circuit can take up to one hour and involves disconnecting the source and reconnecting to the load. Additionally, safety hazards arise because we must perform this operation manually and close to the system approximately every three hours. The goal of the tests is to evaluate the performance and cycle life of the combined batteries to find the feasibility of this combined energy storage for use in multiple utility level applications, including energy harvesting, peak shifting, and frequency regulation. We have conducted several lab scale tests and examined different combined configurations to evaluate the charge and discharge characteristics and cycle performance of the combined batteries. Left: Schematic of the combined batteries: 7 Lithium-ion batteries and 2 Lead-acid batteries are connected in parallel. Right: NI CompactRIO hardware. System Overview The combined batteries are seven lithium-ion batteries (LIBs) connected in series and two lead-acid batteries (LABs) connected in series. The seven LIBs are connected in parallel with the two LABs, as Figure 1 shows. Table 1 summarizes the electrical characteristics of each battery cell under test. Figure 2 illustrates the electrical connection of the source and load to the strings along with the voltage, current, and temperature sensors. During the charging cycle, the CompactRIO hardware triggers the relay and the relay energizes the contactor to connect the source to the combined batteries. During the discharging period, CompactRIO discharges the relay, which leads to disconnecting the source from the terminals. Then the digital load is turned on to perform the discharging cycle. Advantages of Using NI Products Without NI products, we would have to perform many time-consuming and hazardous operations manually. For example, disconnecting the source from the circuit and connecting the load, and vice versa. Programming the source and the load, if needed at each cycle, can be time-consuming. Average testing time for one cycle is seven hours. Handling the circuit exchange manually takes about one hour (two hours per cycle). We used CompactRIO hardware for system automation. We programmed the FPGA with the NI 9215, NI 9220, and NI 9480 analog input modules for acquiring three different types of signals (voltages, currents, and temperatures). We used LabVIEW software for programming. An NI real-time target runs the control and automation algorithm and communicates with the source and load over serial communication lines using the NI 9870 modules. Data logging runs on the HMI client and communicates with the controller over TCP/IP. The flexibility to add different modules to CompactRIO, based on the project needs, is what makes it the best candidate at the design stage. LabVIEW block-based programming is easy to learn and does not require extensive programming experience. In addition, we can monitor the whole system remotely, which minimizes the hazard of being around the running system of batteries, which is under intense testing. Because NI products have been used for years in our lab, NI hardware and programming software became viable platforms in many project setups. We can use FPGA for data acquisition and computational purposes to meet the processing requirements. For example, our system requires data logging every one second. At the same time, data acquisition cannot be interrupted, because CompactRIO is busy with the control algorithm that also includes a hard real-time protection mechanism that requires the system to shut down within milliseconds in case of emergency. CompactRIO was a good choice because the real-time controller receives the data from the FPGA target and runs the algorithm separately, and transmits the collected data to the logging VI running on the computer as a network variable. This makes the system distributed over three different processing units without interruption. We programmed our system exclusively with LabVIEW and using the LabVIEW Real-Time and LabVIEW FPGA modules. We programmed the FPGA to acquire continuous data acquisition and faster responses for possible battery faults. Also, because the system runs unsupervised, we programmed it to send any emergency reports through our email server directly from CompactRIO. Original Authors: Abedalsalam Bani-Ahmed, University of Wisconsin–Milwaukee Edited by Cyth Systems

Project Case Study Precision Rotor Balancing for Turbomolecular Pumps Dec 5, 2025 5f3f28eb-09c8-4f2c-8d06-bd19292c247c 5f3f28eb-09c8-4f2c-8d06-bd19292c247c Home > Case Studies > Ultra-high vacuum equipment manufacturer developed high-precision rotor balancing system in five weeks using the NI USB-9234 DSA, LabVIEW, and the NI Sound and Vibration Measurement Suite. *As Featured on NI.com Original Author: Gerard Johns, Edwards Edited by: Cyth Systems Edwards turbomolecular pump CAD rendering Project Summary Ultra-high vacuum equipment manufacturer developed high-precision rotor balancing system in five weeks using the NI USB-9234 DSA, LabVIEW, and the NI Sound and Vibration Measurement Suite. System Features & Components Integrated IEPE signal conditioning of NI USB-9234 enabled direct accelerometer connection without external amplification NI sound and vibration measurement software included signal reconstruction and analysis functions that facilitated quick implementation of custom processing algorithms LabVIEW software enabled rapid prototyping , automated code generation, and implementation of parallel processing architecture Parallel processing architecture balancing of two pumps simultaneously per station enhanced balancing operation throughput capability through Interactive operator guidance tools translating phase angle and magnitude calculations into correction mass assembly instructions Outcomes Complete system development from concept to production deployment in under five weeks Dynamic input range exceeding all commercially available balancing systems Parallel balancing and correction operations per NI USB-9234 increased production throughput at a fraction of the cost of a typical commercial system Class-leading vibration measurement performance enabled successful product launch Technology at-a-glance Hardware: NI USB-9234 Dynamic Signal Analyzer (obsolete – comparable NI C Series module NI-9234 ) Accelerometers Digital photo sensor for rotor position detection Software: NI LabVIEW NI Sound and Vibration Measurement Suite (obsolete – replaced by LabVIEW Sound and Vibration Toolkit) Ultra-High Vacuum Pumps Laboratory mass spectrometers and electron microscopes require ultra-high vacuum environments where even minimal vibration compromises measurement accuracy. Edwards, a leading manufacturer of vacuum equipment serving semiconductor and pharmaceutical industries, faced a critical challenge when developing their nEXT Turbo Molecular Vacuum Pump. They wanted to achieve world-class vibration performance, which required rotor balancing tolerances that were impossible to measure with existing solutions available on the market. Edwards needed a custom balancing system that could measure vibration with unprecedented precision for rotors spinning at high velocities. Measurement & Data Analysis Challenges The nEXT Turbo Molecular Vacuum Pump utilized a turbine rotor spinning at 60,000 rpm, with blade-tip velocities approaching 90% of the speed of sound. These unparalleled capabilities of this technology presented a few critical manufacturing challenges for Edwards. Inaccessible measurement location: Rotor assembly contained within sealed pump housing prevented direct vibration measurement at the source, deviating from standard balancing methodology Manual calculatios: Off-the-shelf balancing solutions required operators to perform manual calculations and balancing compensation, which greatly slowed production and increased the potential for human error Compressed timeline: Product launch was weeks; Edwards needed to take their concept through validation to production deployment relying only on their internal teams for development Measurement precision: Dynamic input range required for the detection of minute vibrations and high rotor speeds exceeded all commercially available rotor balancing solutions Due to technical and timeline constraints, Edwards knew they could not rely on the conventional balancing solutions commercially available. They decided to leverage an NI-based technology stack to accelerate development while staying within budget. Need help deciding where to start? Left: OEM vacuum pumps by Edwards, Right: the inside fan blades of a turbomolecular pump. High Measurement Accuracy Edwards' engineering team selected the a few key pieces of NI platform to prototype and deploy a custom balancing solution. Core Platform Selection: NI LabVIEW software: Graphical programming environment enabled rapid prototyping and robust application development into production environments NI Sound and Vibration Measurement Suite: Domain-specific libraries with signal reconstruction functions and vibration analysis algorithms NI USB-9234 dynamic signal analyzer: Precision measurement hardware with 51.2 kS/s sample rate per channel, 24-bit resolution, and 102 dB dynamic input range Integrated IEPE signal conditioning: Direct connection from USB-9234 to the accelerometer simplified system architecture and reduced potential signal degradation points This development approach enabled Edwards to accelerate prototyping and application development without sacrificing the high measurement accuracy critical for this application. Rapid Prototyping Through Production The NI Sound and Vibration Measurement Suite signal reconstruction functions enabled interfacing a digital photo sensor with analog inputs for rotor position detection. An accelerometer attached to the pump body captured vibration data. The Sound and Vibration Assistant automatically generated LabVIEW code from the prototype configuration, eliminating weeks of manual coding and providing a validated foundation for production application development. Edwards built production-ready features on the LabVIEW foundation: Automated calibration functions to maintain measurement accuracy across multiple balancing rigs Proprietary calculation algorithms for measuring pump imbalance through the housing rather than directly at the tip of the rotor Interactive operator guidance tools to translate phase angle and magnitude calculations into straightforward instructions for rotor balancing Using LabVIEW's parallel processing architecture, Edwards configured the USB-9234's remaining channels to balance two pumps simultaneously. This effectively doubled production capacity from a single hardware platform at a fraction of the cost of purchasing two commercial systems. Explore another rapid prototyping solution In less than five weeks, Edwards took their proof of concept through validation and into production deployment. Increased Production & Enhanced Sustainability Edwards’ augmented technical capabilities far exceeded commercially available balancing equipment. The key technical features enabled by the NI USB-9234 included: Detection and correct of vibrations in rotors spinning at 60,000 rpm 102 dB dynamic input range enhanced measurement flexibility and enabled quick accommodation for variations in pump models and rotor configurations Leveraging the NI technology stack, Edwards increased their rotor balancing operation efficiency: Cost Savings: Parallel, dual-pump rotor balancing capability delivered two complete balancing rigs at fraction of the price for a single commercial system Improved cycle time: Automated imbalance calculations and operator guidance tools reduced balancing cycle time and training requirements Operational control: Internal solution support eliminated vendor dependencies and enabled direct implementation of system enhancements as product line expanded Platform standardization: LabVIEW and NI hardware as accepted standards across Edwards’ production test, global service centers, and R&D laboratories, resulting in reduced training complexity and enhanced knowledge transfer In five weeks, Edwards used LabVIEW, the USB-9234, and the Sound and Vibration Measurement Suite to rapidly develop a custom solution for high-speed rotor balancing that outperformed commercial alternatives. Original Author: Gerard Johns, Edwards Edited by: Cyth Systems

Project Case Study Embedded Monitoring System for Measuring Natural Gas Emissions Mar 30, 2025 83d943ef-f3d1-4522-99ea-a70ec6161271 83d943ef-f3d1-4522-99ea-a70ec6161271 Home > Case Studies > Remote natural gas emission sensing instrument. The Challenge Developing a remote sensing instrument for real-time detection and quantification of fugitive natural gas emissions that must also adapt to evolving customer requirements driven by emerging industry regulations. The Solution Using the timing and synchronization capabilities of the NI PXI platform, the integrated high-throughput I/O of a FlexRIO digitizer, and a LabVIEW-programmable FPGA to create the signal processing embedded system in a sophisticated differential absorption lidar product. Introduction The significant growth in the production, usage, and commercialization of natural gas is placing unprecedented demands on the nation’s pipeline system. The Pipeline and Hazardous Materials Safety Administration (PHMSA) develops and enforces regulations for the safe operation of the nation’s 2.6 million mile pipeline transportation system (U.S. Department of Transportation, 2016). Through PHMSA programs, serious pipeline incidents have decreased by 39 percent since 2009, according to the Department of Transportation (DoT). Recent incidents such as the 2010 San Bruno, California pipeline explosion and the 2015 Aliso Canyon gas leak are only two of more than 250 serious pipeline incidents since 2009. Left: Real-world methane plumes discovered by Methane Monitor, Right: Spectral features of the most common atmospheric gasses (above), with methane shown on an expanded scale (below). Natural gas consists primarily of methane. Methane is the second most prevalent greenhouse gas emitted in the United States and accounted for about 11 percent of all US greenhouse gas emissions from human activities in 2014. Methane is emitted naturally and by human activities such as leakage from natural gas systems. The US Environmental Protection Agency says that the comparative impact of methane on climate change is more than 25 times greater than that of carbon dioxide over a 100-year period. Continued natural gas pipeline incidents and leaks, the associated impacts, and oil and gas industry regulations drive the need to promptly detect, classify, and resolve fugitive methane emissions. Under funding from the PHMSA and Ball Aerospace, Ball used more than 50 years of remote sensing expertise to develop a system called Methane Monitor. Methane Monitor identifies methane emissions on the ground from a fixed-wing aircraft. Unlike existing methods of aerial leak survey, Methane Monitor operates from a single-engine, fixed-wing aircraft for lower cost than sensors mounted on helicopters. It images the full plume of methane gas as a more precise method of monitoring leaks, it can notify facility operators immediately of large emission sources, and it provides full reports within hours of the end of the flight. Development of these advantages placed large demands on high-throughput signal acquisition, synchronization, and processing. Lidar Background In light detection and ranging (lidar) systems, a laser source emits a pulse of light. The pulse interacts with targets such as the ground or structures. Some of these interactions result in backscattered photons, which are collected and recorded as a function of time. This time-of-flight data directly corresponds with the range at which the scattering occurred, allowing generation of a 3D model of the illuminated topology. DIAL Background Lidar range measurements are inherently part of differential absorption lidar (DIAL) measurements. DIAL operates at two laser wavelengths: one on-resonance and one off-resonance of a molecule of interest. Since the on-resonance wavelength is more strongly absorbed by the molecule, the difference between the two signals correlates to the amount of the molecule in the laser’s path. Thus, DIAL systems can measure the range and quantity of target molecules in the atmosphere (U.S. Department of Commerce, 2016). Challenges DIAL systems look at sharp absorption lines in the spectrum, and Methane Monitor targets the methane molecule (CH4). We designed Methane Monitor so we could compare the resonance features uniquely from other molecules that might confuse the measurement. These measurements require a signal-to-noise ratio approximately 500 times better than what’s needed to establish range alone. Methane Monitor system hardware. The environment imposes challenges because return signals are subject to changes in ground reflectivity. Imperfections in the laser impose challenges because the pulse energy and wavelengths of the two pulses vary independently across firings. Hence, Methane Monitor calibrates every measurement for background reflectivity and normalizes the received energy to the transmitted energy. Methane Monitor also measures a calibrated methane sample before each target measurement. We can use the calibrated methane measurement to correct shot-to-shot instabilities in laser wavelength by reverse calculating the absorption constant. Methane Monitor performs the background, reference, and receive measurements each time the laser fires. The on-resonance and off-resonance pulses are separated non-deterministically by a few hundred nanoseconds. The range depends on the customer’s survey objectives and the aircraft’s altitude and is generally 500 m to 1 km above ground level (AGL). Timing and Synchronization Methane Monitor’s timing and synchronization centers on the PXI-6683H module, which includes a GPS-aligned system reference clock to the laser and PXI embedded systems. The system reference clock is available to all PXI Express peripherals. The PXIe-6341 X Series DAQ uses reference clock synchronization to synchronize analog commands and telemetry. A PXIe-7965R FlexRIO FPGA module runs the custom digitizer and DIAL algorithms. The FPGA block diagram is synchronized to the system reference clock out of the box. The PXI-6683H also generates asynchronous counter-reset signals for the FPGA through PXI trigger lines. Counter values are packaged with each measurement. They can verify, geo-locate, and interpolate the measurements against data obtained from a position and orientation system (POS) and steering mirror controller. Custom Triggering Pulses from each serialized signal are precisely acquired about the peak A/D converter count using level-triggered circular buffers. The serialization, custom triggering, and custom acquisition reduce the data throughput. Timestamps are assigned to each peak for the lidar range measurement. DIAL Analysis The FPGA performs several quality checks on the data. For example, it verifies that ground pulses were received, and it sets various flags based on pulse parameters. The FPGA reshapes each pulse to correct deterministic electrical effects. It executes Methane Monitor’s methane concentration algorithm every time the laser fires and streams telemetry to a LabVIEW application running on a PXIe-8135 controller. The LabVIEW application provides the operator with an instantaneous view of the captured pulses, measurements, performance, system health, and more. The LabVIEW application serves as the final data product to Ball Aerospace’s lidar visualization software that overlays the range and concentration measurement on the context camera image. All data is logged to an NI 8260 1.2 TB PXI SSD. We used DIAdem software to post process Methane Monitor’s data for quality assurance and continuous improvement. Benefits and Impacts Over 100 hours of flight time have been logged, and the methane detection threshold has been determined as a function of wind speed. We have detected methane flow rates as low as 50 standard cubic feet/hour (SCFH). We can configure Methane Monitor’s sensing swath width up to 200 meters wide. The system has a spatial resolution and geo-location accuracy of better than 2 meters each. Methane measurements are color-coded and superimposed on co-bore sighted context images to provide a real-time view of methane emissions to the operator. Original Authors: Steve Karcher, Ball Aerospace & Technologies Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Functional testing involves applying operational power to a PCBA to ensure it performs its designated functions. This type requires custom-built test equipment. PCBACheck™ Bed of Nails Test Fixture Industrial Reference Design Our AUTOMATED PCBA TEST Equipment Reference Design is 90% Standardized and 10% Custom. Home > Services > Automated Test Systems > PCBACheck PCBA Functional Test Solution Businesses depend on Cyth Systems' expertise in functional test fixtures. Functional testing involves applying full operational power to a printed circuit board (PCBA) to ensure it performs its designated functions. This type of test often requires custom-built test equipment and fixtures. Cyth Systems provides support for all types of functional test strategies. Starter PXI Instruments Customize PXI Devices as Needed Pre-Designed Bed-of-Nails Customize Probes Locations Pre-Designed Interposer Board Customize Probes & Other Circuitry Software Environment Customize Sequences & Measurement Instruments Drivers Customize Measurements Top Our Solution. Bed-of-Nails Functional Tester Preconfigured Database Preconfigured PXI System Budget & Schedule Preconfigured Test Cart Preconfigured Reports Automate complex tasks faster Speak to Engineer Perform complex and rapid tasks and measurements that are impossible for human manual tests. Test multiple boards simultaneously, even share time-expensive equipment. Conduct Stress or Life Testing of boards by repeating tests hundreds or thousands of times. Bed-of-Nails Functional Tester Bed of Nails Functional Tester Predesigned fixture ready for custom modifications for any board: Customize width & depth Customize Pin Placement Customize front and rear panel Customize Interposer Board Speak to Engineer Preconfigured PXI System Preconfigured PXI System Standard PXI Modules suits 90% of applications needs as-is: Power Supply Oscilloscope Digital Multimeter Configurable Switch Matrix Add additional modules, signals, and inputs as needed to expand your application. Speak to Engineer Preconfigured Test Cart Preconfigured Test Cart Standardized Test Cart serves most applications as-is without modification! Internal Rack Mounting Customizable worksurface Bar Code Scanner or Badge Reader Power Systems included Customization not required, but... Fully customizable if necessary Speak to Engineer Preconfigured Database Preconfigured Database Standardized database Schema serves 90% of most applications as-is without modification: Speak to Engineer Store any test results, pass fail results Store images, waveforms, raw data Customization not required, but... Fully customizable if necessary Preconfigured Reports Preconfigured Reports Preconfigured Reports suits most applications as-is with CUSTOMIZATION INCLUDED Most common report fields already setup Fully customizable graphics and layout Fully customize graphs, tables, images Export to PDF already included Premade Excel or Word Templates you can customize and modify Speak to Engineer Budget & Schedule Budget & Schedule Preconfigured Budget for all included features: Most projects within 10% of standard budget and schedule Automatically adjusts for project size and features Budget INCLUDES customizations Speak to Engineer We know the ins and outs of PCB's Power supply voltage levels (VCC, VDD, etc.). Clock signals (system clock, peripheral clocks). Analog input signals (e.g., sensor inputs). Digital control signals (e.g., reset, enable signals). Serial communication inputs (UART, SPI, I2C). External trigger inputs. User interface inputs (buttons, switches). PWM (Pulse Width Modulation) signals. Temperature sensor inputs. Voltage reference inputs. Digital output signals (data lines, control lines). Analog input signals (ADC inputs). Analog output signals (DAC outputs). LED indicators. Display outputs (LCD, OLED, LED display segments). Relay control outputs. Voltage regulator outputs. Power-on indicator outputs. Current sense inputs/outputs. Power-up sequence testing. Power-down sequence testing. Voltage tolerance testing. Clock frequency and accuracy testing. Data integrity testing (checksum, CRC). Communication protocol testing (UART, SPI, I2C). Uploading Firmware or other files. Overvoltage protection testing. Undervoltage lockout testing. Logic functionality testing (gate-level/functional logic). Memory read/write testing (RAM, Flash). Sensor calibration and accuracy testing. ADC/DAC functionality and accuracy testing. Motor control functionality testing. Audio output quality testing. Display content and pixel testing. Communication protocol testing. Button/switch functionality testing. Temperature sensor accuracy testing. All these I/O's and much more. Speak to Engineer Prototype Form Why Cyth? Cyth Systems has over two decades of providing the technology and expertise you need to be successful on Automation, Measurement, and Controls projects. Our engineers will work alongside your team to design the system to meet your specifications. We develop your solutions with reduced risk, cost, and schedule. Need PCBA testing help or advice? First Name Last Name Email How can we help? [attributer-channel] [attributer-channeldrilldown1] [attributer-channeldrilldown2] [attributer-channeldrilldown3] [attributer-landingpage] [attributer-landingpagegroup] Let's talk PCBA Solutions Menu

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Project Case Study Using CompactRIO to Automate the Hydrophobic Coating of Cartridges Mar 27, 2024 683a37d6-d1d5-4bab-a06e-3205865cc18e 683a37d6-d1d5-4bab-a06e-3205865cc18e Home > Case Studies > Hydrophobic Coating of Cartridges The Challenge A company that supplies scientific instrumentation approached us with the need for a system to automate the hydrophobic coating of cartridges. The Solution Using NI CompactRIO hardware, precision motors, and a LabVIEW motor control architecture, we built the customer an industrial six-station assembly fixture to increase their manufacturing throughput and quality assurance. The Modularity of the System Stack Dispenser: The plastic cartridges were loaded in left and right stacks of 250. Escapement Mechanism: A mechanism that uses pneumatic actuators to give the controlled release of a left and right half to the plastic cartridge. Hydrophobic Coater: The machine used a custom brush attached to a pneumatic slide to evenly apply the plastic with a hydrophobic (water-resistant)resin coating. Oven & UV Curer: The left and right halves would travel on a conveyor through an oven and high-strength UV curing light. Camera Vision Inspection: The cartridge halves would be positioned via conveyor on a zebra-striped background. A camera conducting a vision inspection using machine vision algorithms to ensure the translucent coating was even and free of bubbles. Restacker: The left and right halves were restacked into hoppers. CompactRIO: 3 x NI-9145 8 Slot Chassis, EtherCAT bus connector, used to control the system I/O. Left: A variable frequency drive (VFD) sets the programmable speed of the conveyor carrying cartridges. Right: Stack dispensers using Sick proximity sensors to detect stack levels. System Highlights Stack Dispenser & Escapement Mechanism: Four pneumatic actuators that programmatically released cartridges one by one. Hydrophobic Coater: A two-part peristaltic pump released a precise amount of hydrophilic coating which was evenly applied using a brush attached to a pneumatic slide. Oven & UV Curer: UV Curer set the coating under high heat and the oven (500± ºF) vaporized any residual solvent leftover from the coating. Camera Vision Inspection: Used two Basler cameras with Edmund Optics lenses in two different positions. Spectral position, direct reflected light, which was used to spot potential defects, second camera positioning with zebra lines were used to determine imperfections (bubbles in coating, etc.) Restacker: Pneumatic restacker Left: A pneumatic on the assembly line pushes cartridges to the side that are determined rejects by the camera vision inspection. Right: A Vexta DC brushless motor powers the conveyor belt. Technical Specifications Stack Dispenser 4 x Neumatic Actuator Release Cylinder & Valve 4 x Custom Escapement Fitting Hydrophic Coater 2 x Watson Marlow Peristaltic Pump 2 x Custom Brush 2 x Pneumatic Linear Slide Oven & UV Curer Camera Vision Inspection System 2 x Basler Running Line Scan Camera 2 x 75 mm Focusable Double Gauss Lens Conveyor 4 x SICK Variable Frequency Drive 8 x Sick Proximity Sensor 4 x Solenoid Operated Pinch Valve 1 x Acer Operator Monitor 4 x CompactRIO NI-9145 8 Slot Chassis, EtherCAT bus connector 1 x LabVIEW 2020 Talk to an Expert Cyth Engineer to learn more

This course teaches you how to use common design patterns to successfully implement and distribute LabVIEW applications for research, engineering, and testing environments. LabVIEW Core 2 Training Course Start Date | End Date Duration ENROLL < Back NI Course Overview The LabVIEW Core 2 Course is an extension of the LabVIEW Core 1 Course. This course teaches you how to use common design patterns to successfully implement and distribute LabVIEW applications for research, engineering, and testing environments. Topics covered include programmatically respond to user interface events, implementing parallel loops, manage configuration settings in configuration files, develop an error handling strategy for your application, and tools to create executables and installers. The LabVIEW Core 2 Course directly links LabVIEW functionality to your application needs and provides a jump-start for application development. NI Course Objectives Implement multiple parallel loops and transfer data between the loops Create an application that responds to user interface events Manage configuration settings for your application Develop an error handling strategy for your application Package and distribute LV code for reuse Identify Best Programming Practices for use in LabVIEW NI Course Details Duration: Instructor-led Classroom: Two (2) days Instructor-led Virtual: Three (3) days, five-and-a-half-hour sessions On-Demand: 4 hours (exercises as a supplement) Audience: New users and users preparing to develop applications using LabVIEW LabVIEW Core 1 Course attendees Users and technical managers evaluating LabVIEW in purchasing decisions Users pursuing the Certified LabVIEW Associate Developer certification Prerequisites: LabVIEW Core 1 Course or equivalent experience NI Products Used: If you take the course On-Demand: LabVIEW 2021 NI-DAQmx 21.0 NI PCI-6221 or NI USB-6212, BNC-2120 Simulated NI-PCI-6221 If you take the course in an instructor-led format: LabVIEW Professional Development System 2023 or later NI-DAQmx 23.0 or later USB-6212 BNC-2120 Training Materials: Virtual instructor-led training includes digital course material that is delivered through the NI Learning Center NI virtual instructor-led training is delivered through Zoom, and Amazon AppStream/LogMein access is provided to participants to perform the exercises on virtual machines equipped with the latest software Cost in Credits: On-Demand: Included with software subscription and enterprise agreements, or 5 Education Services Credits, or 2 Training Credits Public virtual or classroom course: 20 Education Services Credits or 6 Training Credits Private virtual or classroom: 140 Education Services Credits or 40 Training Credits NI Course Outline LESSON OVERVIEW TOPICS Transferring Data Use channel wires to communicate between parallel sections of code without forcing an execution order. Communicating between Parallel Loops Exploring Channel Wires Using Channel Templates Exploring Channel Wire Interactions Transferring Data Using Queues Creating an Event-Driven User Interface Create an application that responds to user interface events by using a variety of event-driven design patterns. Event-Driven Programming User Interface Event Handler Design Pattern Event-Driven State Machine Design Pattern Producer/Consumer (Events) Design Pattern Channeled Message Handler (CMH) Design Pattern Controlling Front Panel Objects Explore methods to programmatically control the front panel. VI Server Architecture Property Nodes and Control References Invoke Nodes Managing Configuration Settings Using Configuration Files Manage configuration settings with the help of a configuration file. Configuration Settings Overview Managing Configuration Settings Using a Delimited File Managing Configuration Settings Using an Initialization (INI) File Developing an Error Handling Strategy Learn how to develop an error handling strategy for your application. Error Handling Overview Exploring Error Response Exploring Event Logging Injecting Errors for Testing Packaging and Distributing LabVIEW Code Learn how to package and distribute LabVIEW code for use by other developers and end-users. Preparing Code for Distribution Build Specifications Creating and Debugging an Application (EXE) Creating a Package for Distribution Programming Practices in LabVIEW Explore recommended practices for programming to develop readable, maintainable, extensible, scalable and performant code. Recommended Coding Practices Writing Performant Code in LabVIEW Software Engineering Best Practices Identify some key principles of software engineering best practices and the benefits of implementing them when working in LabVIEW. Project Management Requirements Gathering Source Code Control Code Review and Testing Continuous Integration Enroll

Events ||NI Connect 2025| NI Connect 2025 NI Connect 2025 April 28, 2025 Fort Worth, TX NI Connect 2025 was a technical conference held in Fort Worth, Texas . It was hosted by National Instruments (NI) , which is now part of Emerson. Here's what NI Connect 2025 was all about: Focus: The conference focused on advancements in test and measurement systems, showcasing integrated hardware and software solutions used in various industries. Key Themes: Attendees explored the latest developments in areas like data acquisition (DAQ), AI-enhanced LabVIEW, and software-defined RF platforms. Target Audience: It gathered engineers, researchers, and business leaders interested in test and measurement technology. Event Features: The event featured:Technical sessions: Over 90 sessions covered topics such as Python, LabVIEW, AI, and machine learning integrations. Keynotes: Industry leaders shared insights and real-world success stories. Networking opportunities: Attendees connected with peers, industry experts, and thought leaders. Tech demos: The latest NI and test technologies were showcased. Product announcements: New product updates for NI DAQ, LabVIEW, and PXI were announced. Location and Date: The event took place at the Fort Worth Convention Center in Fort Worth, TX , from April 28th to 30th, 2025 .

Control & monitoring instruments & devices for industrial, scientific, medical, & biotech. We offer two powerful tools to deliver success to your project. Thank you for submitting your request Home > Services > Thank You Our industry needs expertise and direction more than ever before! We make it our mission to convert our experience and knowledge into help and assistance for our clients. An Embedded Control Systems Engineer will contact you soon. If you urgently need assistance regarding: Discuss your requirements. Evaluate feasibility. Tailored technical proposal. Please call us at (858)-537-1960. Click to learn more about: Cyth Systems NI Integration Case Studies Cyth Systems LabVIEW Consulting Engineering Consulting Automated Test Equipment Machine Vision Systems Industrial Automation We're Trusted By Automated Test Equipment | Embedded Systems | Machine Vision Systems | Industrial Automation | Engineering Consulting Since 1999

Project Case Study Synchronizing High-Speed Cameras to Improve Golf Performance Aug 25, 2023 357a12be-7a9d-402d-a467-18b8f031312b 357a12be-7a9d-402d-a467-18b8f031312b Home > Case Studies > 10 High-Speed Cameras to Improve Golf The Challenge Helping a golf research and development company improve their video feedback system for an indoor driving range. The Solution Synchronizing 10 high-definition cameras together with a weight plate using LabVIEW to improve an existing system’s function and performance. The Story//The Cyth Process Ironically, the object of golf is to play the least amount of golf. As a golfer's game improves, they're able to complete a hole with fewer and fewer strokes. The quickest way to a golfer’s improvement is by making continual adjustments to their stroke technique. In the San Diego area, a prominent R&D facility for high-end ironwoods approached us for help. At this facility, the client performs club fittings and video recordings of the golfer's swings. Our engineering team was tasked with the synchronization of 10 high-definition cameras together with a weight plate to help provide improvements to a state-of-the-art indoor driving range. Additionally, the client needed custom functionality added to their software to provide playback or annotations required for the analysis of a golfer’s swing. This was a repeat system with which the client desired a few major upgrades. These were the addition of higher resolution cameras and a pressure mapping mat that tracked the golfer’s stance and weight distribution. Our engineering team was able to provide the synchronization of these upgrades using LabVIEW RealTime (RT) capabilities, which allowed for high-speed communication between multiple hardware and software inputs and outputs. There was a total of 10 cameras, all synchronized together, for the client's system. All the cameras filmed in 4K resolution, at 60 frames per second. For the video’s large data files to be processed an industrial computer used LabVIEW and Ethernet communication protocol. The facility was set up in such a way that a golfer would hit a ball down a long dark driving range with lights shining illuminating them from the left and right. Before the golfer began, he or she would fill out relative information about their height and weight, club, and whether they were right or left-handed. Their information would be saved and logged alongside all users dating back several years. This was extremely valuable as an instructor had the ability to select past recordings to demonstrate different aspects of the golfer’s swing over time using a touch screen monitor. Further, the instructor could mark the screen showing the ball’s curve, rotation, flight path, and golfer's form. To assist the client in adding more user features our development team built an open software architecture, allowing for future tools and customizability to be added as needed. Several of these were drawing tools, side-by-side playback, and efficient file management. The software graphical user interface incorporated designs the client provided to give a seamless and customized user experience. Overall, we were able to assist the customer in the synchronization of 10 high-definition cameras together with a weight plate using LabVIEW to improve an existing indoor driving range’s function and performance. The customer’s ability to provide the high-quality video analysis necessary for a golfer’s continual stroke improvements was a task our engineering team was glad to be able to help with and fulfill. Talk to an Expert Cyth Engineer to learn more

In this course you will explore the fundamentals of data acquisition using sensors, NI data acquisition hardware, and LabVIEW. Certification Program Start Date | End Date Duration ENROLL < Back NI Course Overview In the Data Acquisition Using NI-DAQmx and LabVIEW Course, you will explore the fundamentals of data acquisition using sensors, NI data acquisition hardware, and LabVIEW. The first part of this class teaches the basics of hardware selection, including resolution and sample rate, and the foundation of sensor connectivity, including grounding and wiring configurations. The second part of this class focuses on using the NI-DAQmx driver to measure, generate, and synchronize data acquisition tasks. You will learn about programming finite and continuous acquisitions, as well as best practices in hardware/software timing, triggering, and logging. In this class, you will get hands-on experience configuring and programming NI data acquisition hardware using NI-DAQmx and LabVIEW. NI Course Objectives Develop integrated, high-performance data acquisition systems that produce accurate measurements Acquire data from sensors, such as thermocouples and strain gages, using NI data acquisition hardware Apply advanced understanding of LabVIEW and the NI-DAQmx API to create applications Eliminate measurement errors due to aliasing and incorrect signal grounding Initiate measurements using hardware and software triggering Acquire and generate single-point and buffered analog waveforms Acquire and generate digital signals Use signal conditioning to improve the quality of acquired signals Synchronize multiple data acquisition operations and devices NI Course Details Duration Instructor-led Classroom: Two (2) days Instructor-led Virtual: Three (3) days, five-and-a-half-hour sessions On-Demand: 4.5 hours (exercises as a supplement) Audience Developers using LabVIEW with NI data acquisition hardware to create data acquisition applications Users familiar with the DAQ Assistant or basic NI-DAQmx code that want to expand their programming capabilities Users new to PC-based data acquisition and signal conditioning Prerequisites LabVIEW Core 1 LabVIEW Core 2 NI Products Used: If you take the course On-Demand: -NI DAQmx 2022 Q3 -LabVIEW 2022 If you take the course in an instructor-led format: -LabVIEW -NI-DAQmx -CompactDAQ Chassis -C Series analog input, analog output, and digital I/O modules Training Materials Virtual instructor-led training includes digital course material that is delivered through the NI Learning Center. NI virtual instructor-led training is delivered through Zoom, and Amazon AppStream/LogMein access is provided to participants to perform the exercises on virtual machines equipped with the latest software. Costs in Credits On-Demand: Included with software subscription and enterprise agreements, or 5 Education Services Credits, or 2 Training Credits Public virtual or classroom course: 20 Education Services Credits or 6 Training Credits Private virtual or classroom: 140 Education Services Credits or 40 Training Credits NI Course Outline LESSON OVERVIEW TOPICS Measuring Analog Input Select and connect to the hardware, configure the DAQmx task appropriately, and validate an analog signal. Simulating the Hardware Selecting the Right Hardware Considering Signal Conditioning Connecting the Signal Validating the Measurement Measuring Current Generating Analog Output Select and connect to the hardware, configure the DAQmx task appropriately, and validate an analog signal. Selecting the Hardware Connecting the Signal Validating the Signal Generating Current Generating and Reading Digital Signal Select and connect to hardware, configure the DAQmx task appropriately, and validate a digital signal. Selecting the Hardware Exploring Signal Conditioning Connecting the Signal Validating the Signal Exploring Counter Signals Choosing a Signal to Explore Choose a specific signal and configure the DAQmx task, including any special signal conditioning needs. Measuring Temperature Measuring Sound, Vibration, and Acceleration (IEPE Measurements) Measuring Strain, Force, and Pressure (Bridge-Based Measurements) Measuring Position with Encoders (Counter Input) Measuring Edges, Frequency, Pulse Width, and Duty Cycle Generating a Pulse Train Programming with the NI-DAQmx API Use NI-DAQmx API in LabVIEW to automate data communication between a DAQ device and a computer. DAQmx Code Structure Overview Reading and Writing Finite Amount of Data Communicating Data Continuously Programming Multiple Channels Examine various methods for multi-channel task creation and their applications. Communicating with Multiple Channels Creating Multidevice Tasks Using Multiple Lines of a DAQmx Code in a Single VI Triggering on a Specific Condition Acquire data on a specific condition and explore how to use hardware sources as triggers. Triggering Overview Types of Hardware Triggers Sources of Hardware Triggers Exploring Advanced Timing and Synchronization Methods Use an appropriate method for synchronizing multiple DAQ tasks. Synchronization Overview Synchronizing a Single Device with a Shared Trigger Identifying Limitations of Shared Trigger Synchronization Synchronizing Multiple Device Synchronizing Specific Hardware Series Logging Measurement Data to Disk Log data to a TDMS file to store and analyze post-acquisition. TDMS File Overview Logging Data with the DAQmx API Organizing the TDMS Data Viewing the TDMS Data Exploring System Considerations Explore additional aspects of building a data acquisition system. Exploring System Considerations for Hardware Determining the Accuracy of a System Exploring Bus and Computer Considerations Where to Start the DAQ Application Enroll

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Certified LabVIEW Architect (CLA) The Certified LabVIEW Architect (CLA) is the final step in the three-part LabVIEW certification process. The exam verifies the user’s ability to build a sensible VI hierarchy and project plan for delivering an application that fulfills a set of high-level requirements. Certified Architects provide technical leadership, helping ensure the developers on their team follow best practices and become more competent and efficient developers. 1 Review the Requirements 2 Prepare for the Exam 3 Schedule an Exam 4 Share your Success 5 Recertify Review the Requirements Step 1. The Certified LabVIEW Architect (CLA) certification is the highest level of LabVIEW certification that is valid for 4 years. Recertification is required to maintain credentials. Benefits include the use of the professional certification badge logo and related digital credentials. NI recommends that you have 36 months or more experience of developing medium to large applications and that you have mastered the content in the Software Engineering for Test Applications Training Courses. Exam Details Prerequisite: An active Certified LabVIEW Developer (CLD) certification Format: VI and application architecture development Duration: 4 hours Location: Online Prepare for the Exam Step 2. Preparing for Your Exam CTA Exam Topics TestStand Advanced Architecture Series Step 3. Schedule the Exam Once you have completed your exam preparation and have met all prerequisite requirements, you are ready to schedule your exam. For in-person exam registration, please email us at solutions@cyth.com Share your success Step 4. 1. When you complete the CLA exam, your exam will be graded by engineers at NI. 2. You will be advised if you passed or failed. -If you passed you will receive a notification email with your digital credential. -If you have not received your notification email within 3 days of receiving the notification that you passed the assessment, email services@ni.com 3. To share your badge, please follow these instructions: a. Log into your account at Credly b. Click on the profile icon at the top right-hand corner of the page and go to “Badge Management” c. Click on the badge you are looking to share d. Scroll down and click “Share” e. You will be brought to the “Share Badge” screen where you can find different tabs directing you to connect your social media accounts and share your badge Recertify Step 5. Certified professionals can recertify using one of two methods: -Recertification exam -Recertification by points Recertification Interval 4 Years Recertification Exam Details Format: Multiple Choice Duration: 1 hour Location: Online Prepare: CLA-R Exam Preparation Resources Recertification by Points -By participating and completing approved activities, certified professionals can earn and accumulate points redeemable toward recertification. For information on recertifying with points. Enroll

Project Case Study Load and Torque Testing of Cargo Drive Trains Using CompactRIO Mar 27, 2024 9466c09d-8d4e-48c6-9a68-117360b99c9e 9466c09d-8d4e-48c6-9a68-117360b99c9e Home > Case Studies > *As Featured on NI.com Original Authors: Paul Riley, Computer Controlled Solutions Limited Edited by Cyth Systems Testing the drive trains of shipping container loading cranes using CompactRIO. The Challenge Overland and maritime transport of shipping containers using railways and cargo vessels is the most fuel-efficient shipping method relative we have today. To load railcars and cargo vessels requires colossal drive trains capable of safely moving shipping containers several tons in weight. To ensure the success of these drive trains, we needed to create an equally colossal test rig capable of safely applying hundreds of kilonewtons of torque and move a 25-ton positioning platform with submillimeter accuracy. The Solution Creating a data acquisition and control system using LabVIEW and CompactRIO for deterministic control so that one can safely handle and test a 30-ton drive train with high accuracy. We used the CompactRIO platform, with its user-reconfigurable FPGA and real-time deterministic operating system, to develop a solution that would not have been possible using existing programmable logic controllers (PLC). Left: Hydraulic load and torque testing rig, Right: Container cranes (also known as gantry cranes) contain drive trains tested using CompactRIO. Finding the Best Electronic Solution Maritime transport is crucial to the world’s economy. With 90 percent of the world’s trade shipped by sea, it is the most cost-effective way to move bulk cargo across the globe. Ocean freight services also have a smaller carbon footprint than air freight. Efficiency continues to improve with the newer, larger generation of container ships exceeding 400 m in length and weighing up to 200,000 tons. Moving these giants requires a power plant the size of a three-story office building to drive gearing and propellers of huge proportions. To ensure this drive train succeeds, we needed a colossal test rig. With a rig of these proportions and vast power capabilities, we needed an approachable development platform that keeps all aspects of control, acquisition, and safety in one system. Normally, when a rig like this is designed, there is a logger from one supplier, multiple PID control systems from another, and logic handling from yet another. The downside with this approach is that it can end up separating responsibilities and skills across suppliers with each expecting to work on their own specialty as there is no commonality between the tools. Integrating the individual components can be complicated and costly, in both time and budget. Identifying the root cause of problems can take time as everyone oversees only their specific area of specialty. Many different vendors are used, which limits scalability due to the time spent on integration when any single component changes. This makes future proofing a design challenging. We chose LabVIEW and CompactRIO as they have simple integration and expandability. Because they are part of the same platform, everyone can be familiar with every part of the system. This makes fault finding significantly easier. Scalability becomes straightforward too as CompactRIO features an expandable chassis for new I/O and sensible programming in LabVIEW makes adding new features a quick process. Left: Electronics Control Cabinet, Right: NI-9038 & NI-9063 cRIO Controllers Why CompactRIO? We use CompactRIO and its I/O because the platform is: Modular—Off-the-shelf hardware is available quickly and worldwide. Parallel—All logic is efficiently coded in FPGA firmware with a 25ns response. FPGA use is a key decision; it means all the critical control and acquisition is handled at the same time instead of using microprocessors that must execute all logic in a series where one process can hang all the others. A Single Development Environment—The whole project is self-contained in a LabVIEW project file, so no third-party add-ons can upset maintenance in future years. Expandable—The modular nature and rack mounting of the CompactRIO product means we can easily expand the system in the future. Here, we used three CompactRIO systems all synchronized and handling hundreds of I/O with a high-bandwidth acquisition of data. Moving 25 Tons and Applying Large Load The test rig has a 25-ton platform that supports the 30-ton drive train. We raise and lower this with submillimeter accuracy to engage splines and then apply up to 400 kN of tensile or compressive load. We also accurately apply 300 kNm of torque to the unit whilst it is rotating at constant speed. Considering the average sports car can produce 0.5 kNm of force, we were dealing with considerable torque. We applied the load using two large actuators precisely synchronized and able to swap between a displacement and load control mode. We based our solution on custom-written closed-loop control code on the FPGA. Based on standard PID control loops, the CompactRIO platform helped us design more complex algorithms to account for precise dual control of load and displacement. For accurate and noise-free measurement, we used digital devices wherever possible wired directly to the FPGA. We measured the torque frequency signal and absolute encoder data, which results in total calibration accuracy, 100 percent linearity, and high-speed measurement for critical feedback channels. Flexible Software Design Criteria: How DIAdem and TDMS Are Essential As this was a new machine for testing units at the end of production, we still faced questions about how to apply the high loads and torques, rather than just simply testing, analyzing, and reporting. Our engineers needed ultimate flexibility in using this rig for research, quality testing, and production test processes. The solution was to design the software with a clear status ribbon along the main screen. This ribbon clearly indicated the full range of loading, installing, and testing the unit in such a way that the operator could step forward and backward at any time along the process. If required, the operator could then go once through a whole test process or skip parts or perform retests at will. The issue with this approach is: how do you acquire all this data in a tidy format, in one file, and analyze it with any popular package when you don’t know what data you will collect and in what order until runtime? This is where saving in a Technical Data Management Streaming (TDMS) format helps. We open a new file when the unit under test is loaded and can then save separate data blocks at will, with full calibration information, varying channel count, and frequency as required. Data is grouped by type so that if an engineer performs a retest, the new data can be logically stored next to the data of the first test. This data is in a compact, single file that can easily be loaded into Excel, DIAdem, The MathWorks, Inc. MATLAB® software, and more with very clear metadata for analysis and reporting. Fast Fault Detection Detecting a transducer fault quickly is critical with a test rig of this power and size. Writing algorithms in LabVIEW on the FPGA allowed us to constantly monitor all critical transducers. Any failure instantly puts the rig into a controlled and safe shutdown procedure and clearly indicates the nature of the fault and its location to the operator for quick repair. Original Authors: Paul Riley, Computer Controlled Solutions Limited Edited by Cyth Systems

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At Cyth Systems we empower Life Science innovators to rapidly design, prototype, and test advanced systems, bringing life-saving technologies to market faster. Product Engineering & Test Solutions for Life Sciences Explore Our Life Sciences Portfolio As an experienced machine builder and test equipment provider, we help Life Science innovators design systems, develop prototypes and software, and test products so that they can deliver their life-saving technologies sooner. Scientific & Medical Instrumentation Evolve your ideas to lab-ready products. Whether you're developing next-generation diagnostic platforms, analytical instruments, or specialized research equipment, our solutions expedite time-to-productization while meeting demanding technical and regulatory requirements. Learn More Bioprocess & Therapeutics Optimize bioprocess IP and equipment development with a ready-to-use, customizable platform capable of supporting your entire development cycle, from upstream process design to downstream recipe refinement. Learn More Manufacturing Automation & Test Maximize production efficiency, product quality, while minimizing cost of ownership. From automation tooling to test fixtures, we help you scale operations while maintaining the precision required in regulated enviroments. Learn More Solutions for Life Sciences Bioprocess Reference Design Explore our ready-to-use, customizable platform for developing lab and industrial bioprocess applications, built for sensor integration, control automation, and data capture. Learn More Battery Test & Simulation BatteryFlex is a platform for evaluation and characterization of a wide range of battery cells and modules for applications where quality and regulatory compliance are non-negotiable. Learn More PCBA Functional Test Platform Our automated PCBA functional test platform provides instrumentation, fixturing, and software that can be customized to your test requirements. Learn More Related Case Studies Bioprocess Biotech startup accelerates funding with scalable reference design for control and automation. Learn More Microfluidics Biopharmaceutical machine builder exceeds production yield and quality metrics using Cyth and NI platform technology. Learn More Interested in designing with us? Enter to win a free consultation and proof of concept build First Name Last Name Email How can we help you? [attributer-channel] [attributer-channeldrilldown1] [attributer-channeldrilldown2] [attributer-landingpage] [attributer-channeldrilldown3] [attributer-landingpagegroup] Get Started Join the NI Technology Accelerator Program (NI TAP) Accelerate your innovation journey with the NI Technology Accelerator Program (NI TAP). NI TAP offers access to discounted hardware and software, and expert support to help you bring your products to market faster. Apply

Functional testing involves applying operational power to a PCBA to ensure it performs its designated functions. This type requires custom-built test equipment. PCBACheck™ Bed of Nails Fixture Industrial Reference Design Our AUTOMATED PCBA TEST Equipment Reference Design is 90% Standardized and 10% Custom. Home > Services > Automated Test Systems > PCBACheck PCBA Functional Test Solution Businesses depend on Cyth Systems' expertise in functional test fixtures. Functional testing involves applying full operational power to a printed circuit board (PCBA) to ensure it performs its designated functions. This type of test often requires custom-built test equipment and fixtures. Cyth Systems provides support for all types of functional test strategies. Starter PXI Instruments Customize PXI Devices as Needed Pre-Designed Bed-of-Nails Customize Probes Locations Pre-Designed Interposer Board Customize Probes & Other Circuitry Software Environment Customize Sequences & Measurement Instruments Drivers Customize Measurements Top Bed of Nails Fixture Solution. Bed-of-Nails Functional Tester Preconfigured Database Preconfigured PXI System Budget & Schedule Preconfigured Test Cart Preconfigured Reports Automate complex tasks faster Speak to Engineer Perform complex and rapid tasks and measurements that are impossible for human manual tests. Test multiple boards simultaneously, even share time-expensive equipment. Conduct Stress or Life Testing of boards by repeating tests hundreds or thousands of times. Bed-of-Nails Functional Tester Bed of Nails Functional Tester Predesigned fixture ready for custom modifications for any board: Customize width & depth Customize Pin Placement Customize front and rear panel Customize Interposer Board Speak to Engineer Preconfigured PXI System Preconfigured PXI System Standard PXI Modules suits 90% of applications needs as-is: Power Supply Oscilloscope Digital Multimeter Configurable Switch Matrix Add additional modules, signals, and inputs as needed to expand your application. Speak to Engineer Preconfigured Test Cart Preconfigured Test Cart Standardized Test Cart serves most applications as-is without modification! Internal Rack Mounting Customizable worksurface Bar Code Scanner or Badge Reader Power Systems included Customization not required, but... fully customizable if necessary Speak to Engineer Preconfigured Database Preconfigured Database Standardized database Schema serves 90% of most applications as-is without modification: Speak to Engineer Store any test results, pass fail results Store images, waveforms, raw data Customization not required, but... Fully customizable if necessary Preconfigured Reports Preconfigured Reports Preconfigured Reports suits most applications as-is with CUSTOMIZATION INCLUDED Most common report fields already setup Fully customizable graphics and layout Fully customize graphs, tables, images Export to PDF already included Premade Excel or Word Templates you can customize and modify Speak to Engineer Budget & Schedule Budget & Schedule Preconfigured Budget for all included features: Most projects within 10% of standard budget and schedule Automatically adjusts for project size and features Budget INCLUDES customizations Speak to Engineer We know the ins and outs of PCB's Power supply voltage levels (VCC, VDD, etc.). Clock signals (system clock, peripheral clocks). Analog input signals (e.g., sensor inputs). Digital control signals (e.g., reset, enable signals). Serial communication inputs (UART, SPI, I2C). External trigger inputs. User interface inputs (buttons, switches). PWM (Pulse Width Modulation) signals. Temperature sensor inputs. Voltage reference inputs. Digital output signals (data lines, control lines). Analog input signals (ADC inputs). Analog output signals (DAC outputs). LED indicators. Display outputs (LCD, OLED, LED display segments). Relay control outputs. Voltage regulator outputs. Power-on indicator outputs. Current sense inputs/outputs. Power-up sequence testing. Power-down sequence testing. Voltage tolerance testing. Clock frequency and accuracy testing. Data integrity testing (checksum, CRC). Communication protocol testing (UART, SPI, I2C). Uploading Firmware or other files. Overvoltage protection testing. Undervoltage lockout testing. Logic functionality testing (gate-level/functional logic). Memory read/write testing (RAM, Flash). Sensor calibration and accuracy testing. ADC/DAC functionality and accuracy testing. Motor control functionality testing. Audio output quality testing. Display content and pixel testing. Communication protocol testing. Button/switch functionality testing. Temperature sensor accuracy testing. All these I/O's and much more. Speak to Engineer Prototype Form Why Cyth? Cyth Systems has over two decades of providing the technology and expertise you need to be successful on Automation, Measurement, and Controls projects. Our engineers will work alongside your team to design the system to meet your specifications. We develop your solutions with reduced risk, cost, and schedule. Need PCBA testing help or advice? First Name Last Name Email How can we help? [attributer-channel] [attributer-channeldrilldown1] [attributer-channeldrilldown2] [attributer-channeldrilldown3] [attributer-landingpage] [attributer-landingpagegroup] Let's talk PCBA Solutions Menu

Certified LabVIEW Embedded Developer (CLED) A Certified LabVIEW Embedded Systems Developer (CLED) demonstrates proficiency and expertise in designing, developing, debugging, and deploying reliable mission-critical embedded control and monitoring applications based on CompactRIO, Single-Board RIO, and/or R Series hardware. A CLED efficiently uses the LabVIEW Real-Time and LabVIEW FPGA modules in accordance with best practices and software engineering principles to design modular, scalable, and maintainable embedded systems. 1 Review the Requirements 2 Prepare for the Exam 3 Schedule an Exam 4 Share your Success 5 Recertify Review the Requirements Step 1. The Certified LabVIEW Embedded Systems Developer (CLED) certification demonstrates the ability to develop and deploy reliable embedded control and monitoring applications. This certification requires passing the exam in two parts: first the multiple-choice CLED-1 and then the performance based CLED-2. This certification that is valid for 5 years. Recertification is required to maintain credentials. Benefits include the use of the professional certification badge logo and related digital credentials. NI recommends that you have 18 to 24 months of experience in developing medium- to large-scale LabVIEW control and monitoring applications with CompactRIO, Single-Board RIO, and/or R Series hardware or that you have mastered the content in the Developing Embedded Applications using CompactRIO and LabVIEW FPGA and Developing Embedded Applications Using CompactRIO and LabVIEW Real-Time Training Courses. Exam Details Prerequisite: CLED-1: Active Certified LabVIEW Developer (CLD) or Certified LabVIEW Architect (CLA) certification CLED-2: Passing grade on CLED-1 exam. Format: CLED-1: Multiple choice CLED-2: Application development using Single-Board RIO hardware Duration: CLED-1: 1 hour CLED-2: 5 hours Location: CLED-1: Online CLED-2: Onsite only (At your location with minimum 5 or more attendees) Prepare for the Exam Step 2. Preparing for Your Exam CTA Exam Topics TestStand Advanced Architecture Series Step 3. Schedule the Exam Once you have completed your exam preparation and have met all prerequisite requirements, you are ready to schedule your exam. For in-person exam registration, please email us at solutions@cyth.com Share your success Step 4. 1. When you complete the CLED-1 exam, you will be advised if you passed or failed. -If you passed, and after any flags have been reviewed by our certification team, you'll receive a notification email that includes information on how to schedule the CLED-2 exam. This email may come within a few minutes of passing, but it can take 24 hours. -If you have not received your notification email within 3 days of passing the assessment, email services@ni.com 2. When you complete the CLED-2 exam, your exam will be graded by engineers at NI. Once the grading process is complete, you will be advised if you passed or failed. -If you passed you will receive a notification email with your digital credential. -If you have not received your notification email within 3 days of receiving the notification that you passed the assessment, email services@ni.com To share your badge, please follow these instructions: a. Log into your account at Credly b. Click on the profile icon at the top right-hand corner of the page and go to “Badge Management” c. Click on the badge you are looking to share d. Scroll down and click “Share” e. You will be brought to the “Share Badge” screen where you can find different tabs directing you to connect your social media accounts and share your badge Recertify Step 5. Certified professionals can recertify using one of two methods: -Recertification exam -Recertification by points Recertification Interval -5 Years Recertification Exam Details Format: -CLED-1: Multiple choice -CLED-2: Application development using Single-Board RIO hardware Duration: -CLED-1: 1 hour -CLED-2: 5 hours Location: -CLED-1: Online -CLED-2: Onsite only (At your location with minimum 5 or more attendees) Recertification by Points By participating and completing approved activities, certified professionals can earn and accumulate points redeemable toward recertification. For information on recertifying with points. Enroll

NI Authorized Distributor. If you need genuine human support for your order, there are two flexible ordering options: submit your quote request and shop online Shop / Store NI Online Ordering Options Three Flexible ORDERING OPTIONS to suit your needs. Submit order documents or build a Shopping Cart. Review the options below and choose the method that is right for you. Get genuine HUMAN support for your order if you need. If you have any questions, or need support, we're here to help. Send us a message, or use the Chat feature to speak to us LIVE (M-F 8AM-5PM PST) Option 1 - Submit your Quote Request or Purchase Order Send a Purchase Order or Request For Quote in any format - PDF, Word Document, Excel, even a screenshot or a Text. We'll process your quote or order and confirm by email. First Name Last Name Company Email How can we help? Upload your order Upload File Upload supported file (Max 15MB) [attributer-channel] [attributer-channeldrilldown1] [attributer-channeldrilldown2] [attributer-channeldrilldown3] Submit [attributer-landingpage] [attributer-landingpagegroup] Option 2 - Build a Cart, Shop Online * Browse our Online Store * Use the Search Bar to find parts * Build Cart and Print Quote * Checkout and Purchase Browse Store Option 3 - Enter Part Numbers directly into the cart As you enter part numbers, you will build your own quote and see confirmation as the cart populates - - COMING SOON - - Part Number SKU Quantity Add to Cart Added: Qty 1 - 777012-05 - PXI-5422 PXI Waveform Generator, 80 MHz, 16 bits, 200 MS/s, 1 Channels, 512 MB

Project Case Study Rapid Prototyping of an Integrated Starter Generator Using cRIO Mar 26, 2024 69c48cdc-2230-4bfd-a8f4-14e0f8eee257 69c48cdc-2230-4bfd-a8f4-14e0f8eee257 Home > Case Studies > *As Featured on NI.com Original Authors: Bipin Adaki, Varroc Engineering Ltd. Edited by Cyth Systems Starter Generator Using cRIO The Challenge We needed to develop a prototyped controller to validate the algorithms with the physical assembly of the integrated starter generator (ISG) while the actual controller was designed and developed. The Solution We used the modular CompactRIO platform, which gave the flexibility of changing the input and output signals, along with LabVIEW and the LabVIEW Model Interface Toolkit to import custom simulation models and tune the algorithms by advanced signal processing. A key segment of Varroc group is the electrical-electronics business. Its key electrical-electronics products include magneto, lighting, starter motors, CDI, handlebar assemblies, RR, and instrument clusters. Varroc group works on the design and development of the integrated starter generator assemblies and its controller. Internal combustion engines rely on the inertia of each cycle (or stroke) for its next stroke. For a typical four-stroke engine, the power for the movement of the piston comes through the power or combustion stroke, which is one of the four strokes of a four-stroke engine. An ISG is a device used to rotate or crank an internal combustion engine to compress the charge for the first combustion. This combustion process then generates enough inertia for the engine to run on its own. After the engine is started, the same ISG works as the generator and supplies power to the vehicle auxiliary and to charge the battery. Although this system can be used in conventional engine-powered vehicles, one of the key contributors to the hybrid’s fuel efficiency is its ability to automatically stop and restart the engine under different operating conditions. A typical hybrid vehicle uses an ISG on the engine crank shaft. The ISG performs functions such as fast, quiet starting, automatic engine stops/starts to conserve fuel. It also recharges the vehicle batteries. Our team is responsible for the testing of ISG assembly. In the past, once the ECU and its low-level driver software were developed, the high-level algorithm needed to be integrated with the ECU. It was only after this integration, that the process of algorithm validation was initiated, leading to a longer time to market. For this project, our strategy was to quickly validate our high-level algorithm on a prototyping platform while the design and development of the actual ECU happened in parallel. Left: The ISG Assembly Connected to the Drive Board Being Controlled by the Prototyped ECU, Right: Integrated Starter Generator Validating the Control Algorithm on a Prototyping Platform Our control algorithms were written in The MathWorks, Inc. MATLAB® and Simulink® software. We wanted to accelerate the process of validation of these algorithms by moving forward from software simulations to hardware implementation without waiting on the actual controller development cycle. The challenge was to look for a prototyping platform that was flexible and scalable to allow integration of additional I/Os during the process of validation but at the same time allows us the ease of programming and signal processing to tune our control algorithms. We used the CompactRIO platform to prototype our controller. We used the LabVIEW FPGA Module to write the low-level driver IP without going into HDL programming languages. Our FPGA IP allowed us to generate PWM signals for the inverter or motor drive, acquire speed sensor pulses and calculate RPM, control relays, and so on. Using the LabVIEW Model Interface Toolkit, we were able to compile our control algorithm from The MathWorks, Inc. Simulink® software and seamlessly integrate it into our LabVIEW code and run it deterministically on an ARM Cortex-A9 processor (Xilinx Zynq-7000 SOC) on the CompactRIO running the NI Linux Real-Time OS. This model communicates with the FPGA to generate PWMs according to the set point as well as capture the feedback from the system. The NI-9401 module allowed us to provide high-speed switching signals of 5 kHz to 10 kHz to our power inverter board. We used NI-9403 to capture feedback using a Hall effect sensor for motor position sensing as well as to capture other signals like the wheel speed, ignition, clutch, and so on. We also monitored parameters like the three-phase motor voltages and current and the battery voltage through the NI-9229. With the inherent UI capabilities of LabVIEW, developed the user interface for our project without putting in any additional efforts. The UI allowed us to visualize the signals in real time and proved handy for debugging as well. Digital Signal Processing to Improve Effectiveness of Algorithm The development of such a system that needs to be deployed in a noisy environment requires additional signal-conditioning and signal-processing techniques like adaptive filtering and averaging of samples. With the ready-to-use libraries within LabVIEW along with the signal processing toolkit, we easily designed and tuned our filtering parameters like windowing, averaging, and so on to enhance the quality of the signal before providing it to the control algorithms. Real-Time Parameter Logging A major challenge in control algorithm development is to have the insight of how various parameters in the control algorithm are changing according to the stimulus as well as the real-world conditions. The Technical Data Management Streaming (TDMS) file writing capability in LabVIEW gave us the ease to implement parameter logging. We could derive insights from this data that helped us tune or modify our control algorithms. Results By following this approach of rapid prototyping and using the NI platform, we validated our control algorithms within a time span of four to six months. Using LabVIEW and user-programmable FPGA-based hardware, we quickly prototyped our controller and validated the control algorithm without waiting for the design and development of the actual controller. The ease of use of the NI platform helped us reduce the development and validation time of our control algorithms by 50 percent and gave us insights to modify them. We are looking to build on this approach and continue using our expertise on the CompactRIO platform and LabVIEW for our future projects as well. Original Authors: Bipin Adaki, Varroc Engineering Ltd. Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Project Case Study Designing the World’s Fastest Pathogen Detection Platform using CompactDAQ Mar 27, 2024 fa293d0b-587f-4d93-8e2f-5ddfb2fe6b43 fa293d0b-587f-4d93-8e2f-5ddfb2fe6b43 Home > Case Studies > *As Featured on NI.com Original Authors: Dr Maël Le Berre, CTO and Cofounder, Elvesys Edited by Cyth Systems Pathogen Detection Platform The Challenge Public health crises are, unfortunately, no longer just plot points of apocalyptic novels or Hollywood thrillers. Diseases like Ebola and influenza, and pathogenic threats such as anthrax, are very real consequences of a growing and mobile world population. Establishing detection methods that can quickly and reliably diagnose these threats has true lifesaving potential. The Solution Elvesys, a small French startup on the forefront of pathogen detection, used NI data acquisition hardware and LabVIEW software to create the world’s fastest pathogen detection platform to inexpensively diagnose patients. Taking On a Grand Challenge and Battling Pandemics Time and accuracy are critical elements when attempting to effectively detect pathogens. That’s why the National Academy of Engineering identified the advancement of health informatics as one of its grand challenges for engineering in the 21st century. The primary motivation behind this grand challenge is to improve preparation for, and response to, public health emergencies such as pandemics and chemical or biological weaponry. Seamless integration of NI DAQ hardware with LabVIEW to control the Fastgene system and greatly reduced development time. A Record-Breaking and Lifesaving Response Today’s pathogen detection technologies require considerable amounts of time and costly laboratory equipment to achieve accurate, reliable test results. When it comes to preventing an outbreak of life-threatening pathogens like Ebola and anthrax, minutes matter. That’s why Elvesys developed Fastgene, the world’s fastest technology for detecting any pathogenic agent in a drop of blood or saliva. Using Fastgene, healthcare workers can detect Ebola in six minutes and anthrax in seven minutes. That’s respectively 7 and 14 times faster than the world’s best current technologies. This buys treatment time for patients and minimizes further exposure that could lead to an outbreak. Technology Fastgene is based on Elvesys microfluidic technologies. Microfluidics is a technology born of microelectronics that allows for precise control of fluid samples. By drastically reducing the sample size to a single drop of blood or saliva, multiple diagnostic operations can be incorporated into a single “lab-on-a-chip.” The Fastgene lab-on-a-chip pathogen detection technology rapidly multiplies a specific portion of DNA to increase the number of copies present in the sample, making it much easier to detect pathogens. There are three key components that make this microfluidics platform successful: the microfluidic sample management system, a fluorescent marker detection and measurement system, and a software interface to control the entire process. As the DNA is multiplied, the total quantity of pathogens present in the sample is determined by detecting a fluorescent spot in each DNA duplicate. Given the rapid pace of DNA multiplication, it is critical that the fluorescent marker detection system keep pace without sacrificing accuracy. To accomplish this, Elvesys created and commercialized, through the Elveflow brand, a custom fluorescence reader using the NI USB-6003 low-cost multifunction DAQ device. Scaling down a complex laboratory procedure required software-integrated hardware with 100 kHz acquisition speed and the ability to detect small variations in the DNA amidst high background noise, with 16-bit resolution to ensure an accurate count of DNA samples. Reducing Development Time With LabVIEW and NI Data Acquisition With a small team of 20 individuals, Elvesys has brought to market, through Elveflow, the technologies used to develop the Fastgene pathogen detection system. As a highly innovative startup with accelerated development cycles and no external financial investment, having fully customizable DAQ hardware that could be programmed in a high-level development environment was essential in the success of this and other Elveflow instruments. In fact, Elvesys designed, developed, and prototyped its entire pathogen detection platform in less than two years, which drew the attention of the French State Procurement Agency (SAE). The SAE further commissioned Elvesys to develop another prototype that could be deployed with French troops for operational use in the field. While this prototype can help protect troops or towns, its principal application remains rapid, low-cost diagnosis of patients during a medical consultation. Their use of cutting-edge microfluidics and a reliable measurement system from NI also won Elvesys the Worldwide Innovation Challenge award from the French Government. Original Authors: Dr Maël Le Berre, CTO and Cofounder, Elvesys Edited by Cyth Systems

Due to the unique nature of machine vision solutions, they require a different form of thinking & problem-solving to implement accurate & repeatable results. SERVICES Machine Vision Systems Home > Services > Machine Vision Systems MACHINE VISION SYSTEMS Machine vision solutions are typically used for automated inspection and process control across a wide range of industries. Our machine vision lab enables us quickly prototype proofs of concept to demonstrate the feasibility of meeting your needs through a machine vision application. MACHINE VISION SYSTEMS Service Areas Area Scan & 2D Inspection 2D Inspection subcategories ↑ Cell counting and recognition Customize your "flat" image testing needs The most common form of machine vision is 2D vision and area scan solutions. Our broad experience ensures that we know how to ask the right questions and integrate the correct solution for your needs - no matter what industry you are in or what you need to inspect. End-of-line manufacturing inspection Sub Pixel Presicion Measurement Guiding assembly Barcodes & Optical Character Recognition Microscopy 3D Inspection 3D Inspection subcategories ↑ Confirming molded part shapes 3D Machine Vision uses a laser and camera to collect the full 3D profile of an object as a shape instead converted to either an image or a point cloud. 3D data can then be analyzed using typical image analysis techniques to look for bumps, scratches, measure holes, or compute volumes. Applications include regulating the volume of a bar of soap, analyzing microstructures in a material, or finding defective molded parts. Measuring volume Scratches, cracks, or imperfections Confirming presence or absence Machine Learning - NeuralVision Machine Learning Vision subcategories ↑ Machine Vision involves teaching a machine to recognize and classify images and is now available for industrial inspection and automation. It can be extremely useful when traditional vision inspection solutions are too complicated to program, or simply not accurate or consistent. NeuralVision is a cloud-based AI software that bypasses traditional machine vision programming. NeuralVision learns by studying images to learn to classify images or detect problems.... just like humans do! Classifying organic items Recognizing defects in assemblies Hard-to-define inspections MACHINE VISION SYSTEMS Case Study Portfolio Robotic Automation Triples Sample Preparation Throughput Circaflex & NI Single-Board RIO Power Syringe Lubrication Inspection Demo Machine Vision Solution Enables Steel Surface Defect Detection Inspecting Dinner Plates Using LabVIEW & Vision Integration A Mobile Platform for Road Inspections Using LabVIEW Machine Vision Inspection of Implantable Electrode Wire to Combat Parkinson's Disease Synchronizing High-Speed Cameras to Improve Golf Performance Cyth Pairs AI Software with Robotic Arm to Sort Organic Seedlings Machine Vision System Inspects Medical Guide Wire Electrode for Surgical Safety System 1 2

Cyth Systems | Whitepapers | Automated Printed Circuit Board Testing | Implementing Automated Testing in Your PCBA Manufacturing Process Implementing Automated Testing in Your PCBA Manufacturing Process Assess Your Testing Needs Start by assessing your specific testing needs and requirements. Consider the types of tests you need to perform, the performance criteria, and the desired level of quality control. This will help you determine the scope and complexity of your automated testing system. Research & Select the Right Equipment Research and select the right equipment and software for your testing process. Consider factors such as test accuracy, test speed, ease of use, scalability, and compatibility with your existing manufacturing process. Consult with experts in the field, attend trade shows and conferences, and request demonstrations or trials to evaluate different options. Design Test Fixtures Design test fixtures that securely hold the PCBs, provide proper alignment and contact, and allow for easy insertion and removal of the boards. Consider the specific requirements of your PCB designs and ensure that the test fixtures can accommodate different board sizes and configurations. Test the fixtures with sample PCBs to ensure proper functionality. Develop Test Sequences & Parameters Develop test sequences and parameters that accurately reflect your testing requirements. This includes defining the order of tests, the specific measurements and analysis to be performed, and the pass/fail criteria. Consider the complexity of your test procedures and ensure that the automated testing system can handle them accurately and consistently. Test the sequences and parameters with sample PCBs to ensure accurate and reliable results. Deploy and Validate Develop test sequences and parameters that accurately reflect your testing requirements. This includes defining the order of tests, the specific measurements and analysis to be performed, and the pass/fail criteria. Consider the complexity of your test procedures and ensure that the automated testing system can handle them accurately and consistently. Test the sequences and parameters with sample PCBs to ensure accurate and reliable results.

The LabVIEW Core 1 Course gives you the chance to explore the LabVIEW environment and interactive analysis, dataflow programming, and common development techniques in a hands-on format. LabVIEW Core 1 Training Course Start Date | End Date Duration ENROLL < Back NI Course Overview In the LabVIEW Core 1 Course, you will explore the LabVIEW environment and interactive analysis, dataflow programming, and common development techniques in a hands-on format. In this course, you will learn how to develop data acquisition, instrument control, data-logging, and measurement analysis applications. At the end of the course, you will be able to create applications using the state machine design pattern to acquire, analyze, process, visualize, and store real-world data. NI Course Objectives Interactively acquire and analyze single-channel and multi-channel data from NI DAQ devices and non-NI instruments Create user interfaces with charts, graphs, and buttons Use programming structures, data types, and the analysis and signal processing algorithms in LabVIEW Debug and troubleshoot applications Log data to file Use best programming practices for code reuse and readability Implement a sequencer using a state machine design pattern NI Course Details Duration: Instructor-led Classroom: Three (3) days Instructor-led Virtual: Five (5) days, five-and-a-half-hour sessions On-Demand: 7.5 hours (exercises as a supplement) Audience: New users and users preparing to develop applications using LabVIEW Users and technical managers evaluating LabVIEW in purchasing decisions Users pursuing the Certified LabVIEW Associate Developer certification Prerequisites: Experience with Microsoft Windows Experience writing algorithms in the form of flowcharts or block diagrams NI Products Used: If you take the course On-Demand: LabVIEW 2021 or later NI-DAQmx 21.0 or later NI-488.2 21.0 or later NI VISA 21.0 or later USB-6212 BNC-2120 If you take the course in an instructor-led format: LabVIEW 2023 or later NI-DAQmx 23.0 or later NI-488.2 23.0 or later NI VISA 23.0 or later USB-6212 BNC-2120 Training Materials Virtual instructor-led training includes digital course material that is delivered through the NI Learning Center. NI virtual instructor-led training is delivered through Zoom, and Amazon AppStream/LogMein access is provided to participants to perform the exercises on virtual machines equipped with the latest software. Cost in Credits On-Demand: Included with software subscription and enterprise agreements, or 5 Education Services Credits, or 2 Training Credits Public virtual or classroom course: 30 Education Services Credits or 9 Training Credits Private virtual or classroom: 210 Education Services Credits or 60 Training Credits NI Course Outline LESSON OVERVIEW TOPICS Introduction to LabVIEW Explore LabVIEW and the common types of LabVIEW applications. Exploring LabVIEW Environment Common Types of Applications Used with LabVIEW First Measurement (NI DAQ Device) Use NI Data Acquisition (DAQ) devices to acquire data into a LabVIEW application. Overview of Hardware Connecting and Testing Your Hardware Data Validation Exploring an Existing Application Explore an existing LabVIEW project and parts of a VI. Exploring a LabVIEW Project Parts of a VI Understanding Dataflow Finding Examples in LabVIEW Creating Your First Application Build a VI that acquires, analyzes, and visualizes data from NI DAQ device as well as from a non-NI instrument. Creating a New Project and a VI Exploring LabVIEW Data Types Building an Acquire-Analyze-Visualize VI (NI DAQ) Building an Acquire-Analyze-Visualize VI (Non-NI Instrument) Exploring LabVIEW Best Practices Use various help and support materials provided by NI, explore resources, tips and tricks for using LabVIEW. Exploring Additional LabVIEW Resources LabVIEW Tips and Tricks Exploring LabVIEW Style Guidelines Debugging and Troubleshooting Explore tools for debugging and troubleshooting a VI. Troubleshooting a Broken VI Debugging Techniques Managing and Displaying Errors Executing Code Repeatedly Using Loops Explore components of LabVIEW loop structures, control the timing of a loop, and use loops to take repeated measurements. Exploring While Loops Exploring For Loops Timing a Loop Using Loops with Hardware APIs Data Feedback in Loops Working with Groups of Data in LabVIEW Work with array and waveform data types, single-channel and N-channel acquisition data. Exploring Data Groups in LabVIEW Working with Single-Channel Acquisition Data Working with N-Channel Acquisition Data Using Arrays Writing and Reading Data to File Explore basic concept of file I/O and how to access and modify file resources in LabVIEW. Writing Data to a Text File Writing Multi-Channel Data to a Text File Creating File and Folder Paths Analyzing Text File Data Comparing File Formats Bundling Mixed Data Types Use LabVIEW to bundle data of different data types and pass data throughout your code using clusters. Exploring Clusters and Their Usage Creating and Accessing Clusters Using Clusters to Plot Data Executing Code Based on a Condition Configure Case structure and execute code based on a condition. Conditional Logic Introduction Creating and Configuring Case Structures Using Conditional Logic Reusing Code Explore the benefits of reusing code and create a subVI with a properly configured connector pane, meaningful icon, documentation, and error handling. Exploring Modularity Working with Icons Configuring the Connector Pane Working with SubVIs Controlling Data Type Changes Propagate data type changes using type definitions. Exploring Type Definitions Creating and Applying Type Definitions Implementing a Sequencer Sequence the tasks in your application by using the State Machine design pattern. Exploring Sequential Programming Exploring State Programming Building State Machines Additional Scalable Design Patterns in LabVIEW First Measurement (Non-NI Instrument) Use LabVIEW to connect to non-NI instruments and validate the results. Instrument Control Overview Communicating with Instruments Types of Instrument Drivers Enroll

Project Case Study Automated Test of Secondary Surveillance Radar Transponders Aug 16, 2023 36698fd7-79b8-4f62-b43a-b2ca22a0f13e 36698fd7-79b8-4f62-b43a-b2ca22a0f13e Home > Case Studies > *As Featured on NI.com Original Authors: Tomasz Marzec, Becker Avionics Polska Edited by Cyth Systems SSR transponder technology serving as an air traffic control beacon. The Challenge Creating a flexible, scalable, and automated test system that allows various test scenarios for secondary surveillance radar (SSR) transponder (XPDR), compliant with Automatic Dependent Surveillance–Broadcast (ADS-B) technology, that can perform RF communication test and simulate, monitor, and control real airborne environments, from power supply to all variants of communication buses like ARINC429, CAN, TIA-422. The Solution Using NI PXI products to facilitate the functionality tests of the SSR transponder in accordance with RTCA/ICAO required documents to develop the XPDR Test System. Becker Avionics developed the XPDR Test System using NI PXI products to facilitate the functionality tests of the SSR transponder in accordance with RTCA/ICAO required documents. Functionality tests included simulators of multiple ground stations, onboard navigation systems (real-time trajectory motion), cockpit instruments, displays, and switches (flight control and management system). We chose the NI PXI system with RIO (Reconfigurable I/O) for fast development of complex RF stimuli generation and RF response analysis. The flexibility of the hardware and software platform (LabVIEW and the LabVIEW FPGA Module) from NI allowed performing even the most complex tests described in DO-181E and DO-260B documents. The RF communication capability of the software we developed was separated and released as the XPDR Communication Library. We qualified this software tool internally according to DO-178C and DO-330. Introduction to SSR and ADS-B SSR is a radar system used in air traffic control (ATC) to detect, identify, and measure the position of aircraft. Compared with the primary surveillance radar system that measures only the range and bearing of targets by detecting reflected radio signals, SSR relies on targets equipped with an SSR transponder that replies on each interrogation signal by transmitting a response containing encoded data. The transponder is a radio receiver/transmitter, which receives on 1,030 MHz and transmits on 1,090 MHz. SSR essentially provides two-way air-to-ground data communication and operates in several modes of interrogation (for example Mode A, Mode C, and Mode S). Each mode produces a different response from the aircraft (identification, altitude, and multipurpose—flight ID, latitude, longitude, altitude). Modes A and C use simple pulse–position modulated interrogations and replies. Mode S uses differential phase shift keying modulation for encoded data in interrogation. A Dataflow Graph of the SSR’s communication protocol and library. Automatic Dependent Surveillance–Broadcast (ADS-B) technology automatically transmits, through data link, position data derived from the onboard navigation system. ADS-B provides real-time surveillance information to ATC (as a replacement for SSR) and to other aircraft for situational awareness and self-separation. Selected Technical Challenges Testing SSR transponders is an exceptionally demanding task that requires understanding various complex engineering areas and technologies that are not separate, but depend heavily on one another. Specialized knowledge and experience is crucial for success in such test development and involves: RF generation and analysis—short duration, non-periodic pulses Dynamic range considerations and weak signals of interest in the presence of strong interferers Real-time signal analysis RF multichannel timing and synchronization High bandwidth and low-latency data streaming We used commercial off-the-shelf (COTS) technologies from NI to reduce our efforts related to the aforementioned topics. System Bandwidth Total system bandwidth is one of the most important issues when dealing with RF instruments. The NI PXI Express chassis delivers a high-bandwidth backplane to meet a wide range of high-performance test and measurement application needs. NI peer-to-peer technology ensures high-throughput and low latency (~10 us) module-to-module data transfer. In the XPDR Test System, we can group the data transfers by the following links: § FPGA to VSG peer-to-peer links—100 MS/s, 4 B/S, 2X TX channel gives 800 MB/s § VSA to FPGA peer-to-peer links—50 MS/s, 4 B/S, 2X RX channel gives 400 MB/s § Host to/from FPGA DMA links—up to 16 DMA channels, depends on system load, average 10 MB/s Total system bandwidth exceeds 1.2 GB/s. System Timing and Synchronization Proper timing and reliable synchronization methods are key elements of a test system. The PXI backplane of the NI PXI Express chassis supports timing, synchronization, and triggers to meet long-term and stable RF measurements. Synchronization is achieved by sharing a PXI 10 MHz reference clock. To ease timing alignment, the NI PXI modules share start triggers. Generations and acquisitions begin at precisely the same time (strictly defined for the rest of the XPDR Test System). Example Test Procedures XPDR desensitization and recovery test procedure (2.4.2.6 from DO-181E document) checks that the XPDR receiver shall recover sensitivity within 3 dB of the minimum triggering level (MTL approximately 74 dBm), within 15 us after reception of desensitizing pulse having signal strength up to 50 dB above MTL. For example, high power Mode S interrogation signal (such as 50 dB over MTL) is transmitted to the transponder and just after that high-power signal (a few µs later), there is a Mode A interrogation signal arriving at a MTL +3 dB level. The transponder needs to react with defined reply efficiency on such dynamic range RF signals at its inputs. XPDR maximum susceptibility test procedure is a load test, in which hundreds of interrogations are generated within 4 s (Mode A, Mode C, and Mode S with varying delay, period, power, content, and interferences). After 4 s, the transponder is interrogated for 1 s with almost 2,000 ADS-B In signals. The transponder later should not only generate back RF replies, but also repeat all received ADS-B message stream by Ethernet interface. This test is very important for analyzing the behavior of the system in extreme situations, where tens, if not hundreds, of airplanes are in close proximity of the airport and collision avoidance system. These two example tests show the power of the solution based on software-defined instruments and NI RF solutions in PXI form factor. The system can schedule large numbers of signal interrogations with highly-customizable delays, powers, and shapes, including the possibility of generating interfering signals. Business Results and Next Steps We developed the XPDR Test System across multiple stages of transponder research and development. Thanks to the nature of FPGA, which are easily reconfigured, we could quickly adapt tests set to new functions. The innovative NI approach to test platforms with open, software-defined firmware (FPGA) with commercial off-the-shelf RF hardware, reduced the time needed to prepare and perform complicated test scenarios. NI delivers completely new technical capabilities to automated test systems. This enables new levels of performance and reliability confirmed by long-term development testing (a full set of tests takes two weeks 24/7, single test set works for months). Any failure of the test system would significantly prolong the test time and consequently could delay further product development. It is also worth noting that NI supported the project by providing important information, benchmarks, and LabVIEW FPGA examples of streaming capabilities between FlexRIO and RF instruments, which streamlined the process of moving into the NI PXI RF platform. Original Authors: Tomasz Marzec, Becker Avionics Polska Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

Project Case Study Real-Time Defects Mapping on Integrated Circuits Using NI PXI & LabVIEW Mar 31, 2025 fa19df2d-4cc4-4110-b895-d087c3c73781 fa19df2d-4cc4-4110-b895-d087c3c73781 Home > Case Studies > An example of an PCBA which requires specific fault testing Project Summary Creating a system to localize failure mechanisms causing abnormal electrical behavior, including those linked to complex parameters (such as frequencies, amplitudes, and digital values contained in registers), in integrated circuits (ICs). Solution & Results Improving a conventional faults mapping system using NI PXI hardware and the NI LabVIEW FPGA Module. Industry Electronics, Manufacturing Technology at-a-glance NI PXI-1036 NI PXI-8102 controller NI PXI-7852R LabVIEW FPGA Module Help with Finding Faults Fault localization is complex due to decreased individual pattern sizes, increased metallization levels, and decreased voltage supplies. We needed to localize a defect measuring less than a few micrometers in a component of several square millimeters. There are several ways to do this, including using global fault isolation methods. One method uses a laser to scan an IC surface while measuring current or voltage variations induced by the laser’s photoelectric or thermal effects. With the thermal laser (λ≈1.3 m), the beam locally heats the component to change its electrical behavior. An analog system monitors some parameters (currents or voltages) during scanning. Dedicated software running on a PC then creates a map representing the circuit’s heat sensitivity. Faults are generally localized by comparing the map obtained for a reference circuit with the one resulting from a faulty circuit. We used a Hamamatsu Phemos 1000 that can create maps with 1,024 x 1,024 pixel resolution. Left: Mapping Acquisition Using a Laser-Scanning Phemos 1000 Microscope, Right: Software Developed Using LabVIEW FPGA Conventional Method Limitations With the standard Optical Beam Induced Resistive-Change (OBIRCH) laser thermal stimulation method, we can only measure voltage or current changes under local heating. We extended this method by mapping complex variables such as frequencies, amplitudes, and digital values stored in registers. Hardware System Setup We developed and validated our solution by analyzing a failure in a component that manages cell phone energy (battery power and voltage regulation) and conversions (audio, radio frequency, and supervision). This circuit contains an A/D converter (ADC) to measure various currents and voltages during phone operation. On failing components, conversion results shifted several bits (least significant). We used an NI PXI-1036 chassis equipped with an NI PXI-8102 controller and an NI PXI-7852R field-programmable gate array (FPGA) module. This NI system is inserted between the device interface board and the fault isolation equipment (Phemos 1000). This assembly ensures the component startup and the ADC control. It initiates conversions and collects the results via serial peripheral interface (SPI) bus. It performs scale conversion and transmits data to the fault localization equipment. The laser scans the chip in 72 seconds to build an image made of 1024 x 1024 pixels. Each point must be acquired and processed in less than 65 μs (pixel clock period). We chosed NI hardware because it fully met our requirements. The NI products are low cost, fast enough to process each pixel in less than 65 μs, and programmable with the LabVIEW FPGA Module . Software System Setup We created an autonomous system without requiring expertise in complex programming languages. We used LabVIEW FPGA to program the system because it provides the developer with all the needed layers: drivers, APIs, function libraries, graphical interfaces, compilation and synthesis chains. We downloaded and customized a free SPI controller from IPNet. This block can communicate with various SPI peripherals. We simplified it by removing unnecessary options and created a cell optimized for our needs. We initiated A/D conversions into the FPGA algorithm, retrieved the results, performed a scaling, and exported data to the Fault Isolation Equipment (Hamamatsu Phemos 1000). During the mapping construction, the Phemos 1000 is autonomous; it controls the scanning laser, makes voltage and current measurements, and builds laser excitation sensitivity maps. An external signal can be monitored by using an analog input of the equipment. We connected one of the analog PXI-7852R module outputs on this input. The Phemos 1000 and PXI chassis can operate asynchronously or synchronously. We validated both methods. The asynchronous method is simple to implement, but the pixel processing must be less than 65 μs. The synchronous mode is more complex and has a longer processing time. In our tests, processing was fast enough to use the asynchronous mode. Original Authors: Sébastien CANY, ST-ERICSSON Edited by Cyth Systems Talk to an Expert Cyth Engineer to learn more

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NI source measure units are high-precision, high-accuracy DC instruments that can both source and simultaneously measure voltage and current. NI Source Measure Units and LCR Meters NI Authorized Distributor and System Integration Partner Home > Products > Source Measure Units and LCR Meters Source Measure Units and LCR Meters Source Measure Units are high-precision, high-accuracy DC instruments that can both source and simultaneously measure voltage and current. Additionally, LCR Meters can measure the inductance, capacitance, and resistance (LCR) of electronic equipment. PLATFORM MODULES Platform modules integrate with modular hardware platforms that allow you to combine different types of modules in a custom system that leverages shared platform features. NI offers three hardware platforms—CompactDAQ , CompactRIO , and PXI —though all platforms may not be represented in this category. PXI LCR Meter Bundle The PXI LCR Meter Bundle includes a chassis with a PXI LCR Meter to help you test electronic equipment. PXI LCR Meter PXI Source Measure Unit Provides precise voltage or current sourcing and measurement capabilities for PXI systems. Feature Highlights: Platform: PXI Bus: PXI, PXI Express PXI SMU Bundle The PXI SMU Bundle includes a chassis with a PXI Source Measure Unit (SMU) with up to 40 W of DC power. Provides functionality to help you measure and test the inductance, capacitance, and resistance (LCR) of electronic equipment. Feature Highlights: Platform: PXI Bus: PXI Express