End-of-Line: Measurement Robot for Wire Modules

Customer: Rosenberger Hochfrequenztechnik GmbH & Co. KG
Sector: High-frequency, fiber-optic, and high-voltage connection solutions
Requirement: Upgrade of test bench software for high-frequency measurements with robots and vector network analyzer
Implementation: Custom solution (NI/LabVIEW)

Data Management and Automation Enable Full Transparency

The Initial Situation

Test bench with robotic arms and a large monitor. © RosenbergerRosenberger Hochfrequenztechnik is a leading international manufacturer of connection solutions. A key focus is on custom-specific high-frequency solutions for demanding high-tech applications. As part of the zero-error strategy, all wires and wire modules are comprehensively tested at the end of production. In particular, modules with hundreds of contacts are automatically tested on test benches using measurement robots and vector network analyzers (VNA).

The Task

Rosenberger required a new high-frequency measurement robot (HFR) with centralized, database-driven test bench software. This software had to be capable of mapping measurement devices, test procedures, and protocols that vary depending on the customer and test object. measX was selected as the partner. The measurement data management system, which had been developed and proven for other test specimens, was expanded for use with the measurement robot.

The Solution

The HFR software consolidates all customer- and product-related data and controls the entire testing process: from setting up the test configuration to documenting the measurement results. It enables automated workflows with minimal manual input, communicates with PLC and VNA, records measurement values, evaluates them against stored limit values, and visualizes the results in high-frequency-specific graphs. All measurement data and test results are stored in the Rosenberger database along with the test order information. Upon request, the measurement data is also made available to the customer. A particular strength of the system is the easy integration of new measurement instruments and functions.

In Practical Use

The updated test bench software, featuring centralized measurement data management and a direct integration into the Rosenberger database, reliably prevents data entry errors and ensures a high level of process and result reliability for the tests. Complete transparency down to the measurement value level facilitates collaboration with customers regarding specifications or complaints. New measurement and testing requirements can even be flexibly implemented for individual parts at any time. Seven HFR test benches are already in successful use. In the future, the automated high-frequency tests will take place using only the new system.