A dedicated desktop control and DAQ application that configures endurance routines, commands the rig’s PLC, and records cycle-by-cycle articulation and rotary torque.
The Challenge
Endurance qualification hinges on consistency: verifying whether a component maintains mechanical integrity across thousands of repetitive cycles under thermal stress. To deliver defensible compliance data, the rig must execute identical motion profiles every time while capturing high-fidelity torque values without signal drift. Manual parameter entry and periodic logging introduce human error, inconsistent cycle timing, and gaps in traceability.
What We Built
We engineered a desktop control and real-time monitoring suite tailored for the machine’s architecture. Test engineers configure profiles—such as test group, cycle count, and temperature setpoints—and trigger the run with a single click. The software coordinates motion and interlocks via Modbus TCP over Ethernet directly with the onboard PLC and HMI, capturing live telemetry and automatically formatting the run into analytics curves and compliance reports.
Key Capabilities
- Configurable Test Profiles: Define target cycles, thermal thresholds, and operational limits once; recall and execute repeatable test recipes on demand.
- Deterministic PLC Coordination: Native Modbus TCP integration bridges desktop execution with PLC safety routines and machine kinematics.
- Bi-Directional Torque Acquisition: Synchronous logging of articulation torque, rotary torque, and CW/CCW peak values across every cycle.
- Dynamic Waveform Visualization: Real-time plotting that reveals micro-yields, friction changes, and torque degradation during the run.
- Instant Report Generation: Zero-touch report compilation packaging pass/fail criteria, cycle statistics, and high-resolution curves upon cycle completion.
Outcome
Eliminated setup variance and manual logging entirely. Every endurance run now executes identically against specification, delivering continuous cycle-by-cycle torque data and an audit-ready compliance certificate the moment the cycle halts.