Development and Production of  Switch-Disconnector Testing Unit

Customer
ABB OY (Finland)

Completion Date:
01.08.2024

At the client’s request, we developed a new product functionality tester platform for a product series: switch-disconnectors. It is a modular platform used to test products of various sizes by simply changing the product fixture attached to the table.

In total, we developed and produced 5 testers for the client for testing products of different sizes within the same family.

Key functionalities of the testing system:

• Servo-driven product manipulation for performing various switching operations;
• Feedback from a force sensor to measure switching forces (up to 20 Nm), to verify the product’s compliance at the end of the production process;
• QR code scanning from the product to ensure traceability and to switch recipes (different switching procedures are performed depending on the product);
• Logging of all tested products (in .csv format) and storing data (generation of a new .csv file once a day to ensure traceability);
• Machine vision control to check the mechanism’s functionality;
• “Golden Sample” procedure for validating the tester;
• For ergonomic purposes, the tester is built on a height-adjustable workbench.

The project included the following:

• Development of the tester platform in collaboration with the client;
• Development and design of mechanical systems;
• Development and design of electrical and automation systems for the device;
• Manufacturing and assembly of the mechanical systems of the device;
• Assembly and construction of electrical and automation systems for the production line;
• Design and production of the electrical cabinet;
• Full development of the control system, PLC programming;
• CE certification (risk analysis, compliance assessment).

Hardware used:

• All automation is based on the Beckhoff control system;
• Beckhoff servo motor for performing tests;
• Datalogic scanners for reading product QR codes;
• Cognex camera system for mechanism validation.