Case Study Title: Electric Oil Pump Validation Testing
Client Type: Global Tier 1 Automotive Supplier
Scope and Capabilities:
The project involved the design and delivery of a modular end-of-line (EOL) test system for validating electric oil pumps in a high-volume production environment. The system simulated electrical, thermal, hydraulic, and mechanical loads to replicate real-world vehicle conditions, while supporting automated loading and unloading for seamless integration into the client’s assembly line footprint and workflow. It was capable of testing multiple pump variants through the use of exchangeable fixtures and featured a temperature-controlled lubrication system with both heating and cooling functions. Built-in diagnostics, barcoding, safety interlocks, and traceability tools ensured reliability and compliance, while PID loop control supported testing with standard SAE engine and transmission oils. The system operated fully automatically with integrated fault-handling and message code compliance for production-grade robustness.
Key Features:
The system featured a multi-station test bench equipped with hydraulic clamping to support efficient and repeatable part setup. Control and data acquisition were built on a PXI-based architecture with National Instruments hardware, incorporating LIN and CAN communication, high-speed DAQ, and custom analysis modules. Thermal conditions were managed through a circulation heater and chiller with ±3°C control accuracy, while vacuum-assisted pre-fill and purge subsystems ensured reliable fluid management. The setup also included automated pass/fail sorting with integrated label printing to streamline production workflows.
Deliverables:
The project delivered a fully integrated end-of-line (EOL) test bench powered by a custom ECT software suite, enabling flexible and automated validation of components in a production setting. Configurable test scripts and built-in fault management ensured adaptability to different product requirements while maintaining reliability and traceability. The scope included complete mechanical, electrical, and software documentation to support long-term operation and serviceability. Commissioning support and operator training were provided on-site, with provisions for ongoing remote maintenance to maximize system uptime and efficiency.
