Virtual Instruments in LabVIEW

for SCADA systems, Factory automation, Laboratory tests and PC based test equipments.

Here are Virtual Instruments and Supervisory Control & Data Acquisition Systems. Most of these are PC / PAC based SCADA systems for industrial control & automation. Others are for automated, multi-parametric laboratory tests. Most are developed & deployed using LabVIEW.

PC based Virtual Instrument for Instantaneous (magnetic) trip test of circuit breakers


PC based Virtual Instrument for Short Circuit test of circuit breakers

This PC based VI is a test & measurement instrument for conducting Instantaneous (magnetic) trip test on circuit breakers as per IEC 60898. The VI is designed in LabVIEW primarily for factory automation of the test process. Also, there's a 'Type-Test' mode for laboratory tests. The type test measures more parameters than the normal mode of test. The test sequence is fully automatic and ensures total operator safety. The VI utilizes a SCR ELEKTRONIKS high-current source for current injection. This VI is completely designed in LabVIEW and runs on a standard PC with Windows or Linux.


LabVIEW based complete SCADA system: Virtual Instruments for test on Electrical Contactors as per IEC 60947

SCADA main screen

SCADA - contactor flashing test

SCADA contactor coil current and wattage measurement

SCADA -  High Voltage or Hipot Test

LabVIEW SCADA for pick-up and drop-off test


SCADA screen showing data acquired & prompt
 

These are a set of virtual instruments designed in LabVIEW to run on a Windows PC or a Real-Time PAC. They make a complete and fully automatic SCADA system for test on electrical contactors as per IEC 60947. These VI take highly accurate measurements, collect all the test results securely in test database (RDBMS) and provide for reports including yield calculation, pareto analysis and daily/monthly production reports in various formats. The SCADA supports secure web based supervisory control and monitoring. In case multiple of such SCADA systems are used with many equipments inside factories at different geographical region, all the DUT parameters and test data can be stored and collected respectively on a web server. Supervisors can set alarms and triggers on events, such as an e-mail alert on low yield.


PC based Virtual Instrument for Time-Current characteristics of circuit breakers


PC based virtual instrument - Time Current Characteristic of Circuit Breaker

Virtual Instrument for Time Current Characteristics of Circuit Breaker for Verification as per IEC 60898

This PC based VI is a measurement instrument for plotting the Time v/s Current characteristics of a circuit breaker as discussed in IEC 60898, UL 508 and various other standards. The VI is designed in LabVIEW primarily for use by design engineers to optimize the design of circuit breakers at test laboratories as well as for certification purpose by assessment agencies. The VI runs on a standard PC and uses an electrical test setup for circuit breakers made by SCR ELEKTRONIKS. This VI is completely designed in LabVIEW and and can check all curves of the circuit breaker.

Quality Test of Circuit Breakers - Measurement of time current characteristics

Thermal-trip test sequence in the time current characteristics' plotting process is shown in the above VI


PC based Virtual Instrument for Thermal Calibration & test as per IEC 60947 of MCCB


Test Bench virtual instrument

MCCB Test Equipment Virtual Instrument for production test 

This PC based VI is a production test equipment for Thermal Calibration & test of MCCB as discussed in IEC 60947, UL 508 and various other standards. The VI is designed for use by manufacturers of Molded Case Circuit Breakers. The VI utilizes a customised test bench and associates every breaker with a barcode for life-time traceability. It controls test current & other parameters, conducts simultaneous tests on multiple breakers and executes multiple test sequences automatically as programmed by the supervisor.

 

User Management Virtual Instrument

This VI provides for user management with multi-level security.


Test Bench
Main menu of the Test Bench for Test, Measurement & Calibration

virtual instrument SQL report generation
VI to generate production reports (sample screen) is shown above.

PC based Virtual Instrument for Short-circuit trip test as per IEC 60947 of MCCB


Magnetic Trip Test Bench Virtual Instrument

This PC based VI is a production test equipment for Short-circuit trip test of MCCB as discussed in IEC 60947, UL 508 and various other standards. The VI is designed for use by manufacturers of Molded Case Circuit Breakers. The VI utilizes a customised test bench and associates every breaker with a barcode for life-time traceability. It controls short-time high current & other parameters, conducts simultaneous tests on multiple breakers and executes multiple test sequences automatically as programmed by the supervisor.


Magnetic Trip Test Bench Virtual Instrument - Magnetic Trip Test MCCB IEC 60947
As per the user's pre-selection, the production testing is performed with associated test parameters to the breaker's catalog. The test sequence is programmed in the VI.

Test Bench Virtual Instrument - Short Circuit Test MCCB IEC 60947
Although the VI is designed for production test to be used by manufacturers and OEMs, it can be used for quality control purpose at test laboratory or sample type test in factory with more rigorous test sequence and additional parameters.

IEC 60947 short circut test molded case circuit breaker VI
Automating the entire test sequence drastically reduces time of the test process.

Calibration of Current Source
Calibration process of high current source is shown above.

PC based SCADA for Thermal Calibration test bench (multi-station simultaneous test)


This SCADA is designed to conduct thermal calibration of multiple Molded Case Circuit Breakers of same or different ratings simultaneously by a single operator. The HMI is designed to accomodate expansion of the test system, as and when required. The control system VI, that works with each current source & corresonding measurement devices, is controlled using the HMI thus providing the operator to conduct simultaneous thermal calibration of circuit breakers on a single test bench!

SCADA HMI
HMI of the SCADA is seen above.

vi for calibration of current source and measurement devices
The SCADA helps the calibration of current source & measurement devices.


SCADA system for Quality Test Bench - for quality control, assessment agencies & certification bodies


 

This PC based SCADA enable quality & performance testing as normally required by quality control department, assessment agencies & certification bodies. The software eliminates the labor of setting parameters for testing devices, generating reports & other meticulous tasks that the quality engineers otherwise have to manually work for each test job.

Quality Test SCADA

The above screen is the general look & feel of the SCADA for Quality Test. There's an energy saver-mode that puts the test bench in stand-by, all devices off & screen blackened to save energy.

SCADA guides the operator to do the appropriate on-bench connections for Quality Test

SCADA guides the operator to do the appropriate on-bench connections for each Quality Test.

Virtual Instrument for Insulation Resistance Test

Once the connections are done, the SCADA calls the appropriate VI and picks up the corresponding quality test parameters from the test database. The above VI performs insulation resistance test.

HIPOT test virtual instrument

The above VI performs the hipot test.

Total Harmonic Distortion measurement by virtual instrument

For each quality test, the control & measurement devices are selected & fed the programmed parameters first and then the test is conducted automatically. This helps to achieve user safety, lesser fatigue and speed. The above VI conducts power factor & on-load test on a ballast and measures the Total Harmonic Distortion and other set measurements.

Test laboratories and quality controllers often enforce report format to print & view test results. The below are extracts of report format for luminary test by a leading manufacturer. The SCADA has a dedicated module that generates reports in the desired format directly.

Test Report format

The above is a programmed template that eliminates the need to make reports manually after the test results are obtained.


Virtual Instrument to automate the factory process of electrical safety testing.

Electrical Safety testing is the most widely implemented test process world-wide; being a mandatory assessment in most countries enforcing safety standards such as CEI 60335 for all devices that utilise electricity. This PC based VI automates the electrical safety test, using a SCR ELEKTRONIKS make Safety Test Equipment. This VI is completely designed in LabVIEW and runs on a standard PC with Windows or Linux.

Virtual Instrument for Electrical Safety Test

Similarly, these virtual instruments are tailored for Automatic Test Equipments for LED based Luminary, Luminary LED Assembly & Luminary Driver.

Login for Automatic Test Equipment for LED Luminary

The above VI is a login to the secure TestWare.

Virtual Instrument for LED Luminary ATE

The above is the VI for conducting tests on an assembly line of LED Luminaries.