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STIHL Retools Test Rig Automation Using TwinCAT with LabVIEW Integration By Casey Taylor, Software Product Manager, Beckhoff Automation LLC


T


est and measurement are crucial aspects of product development, where the re-


liability and accuracy of results heavily depend on the tools uti- lized. STIHL, a renowned name in power tools globally, understands the significance of employing top- tier tools. Operating from its de- velopment center in Germany, STIHL conducts a diverse range of tests on prototypes and series products, ensuring their durabili- ty and functionality. This rigorous quality control process involves round-the-clock testing in hun- dreds of cabins, each adhering to device-specific test plans.


Close Collaboration Recognizing the importance


of enhancing their testing infra- structure, STIHL collaborated with measX, a specialist in measurement technology, to de- vise a flexible and universal au- tomation solution. This system facilitates the swift implementa- tion of variable, high-quality test plans, bridging the gap between industrial automation and test engineering seamlessly. Central to this success is the efficient in- teraction between Beckhoff’s TwinCAT automation software and LabVIEW™. Headquartered in Mönchen -


gladbach, Germany, measX GmbH & Co. KG boasts a rich history of crafting tailored meas- urement, test, and evaluation systems for diverse industries since 1981. Within the realm of test rig technology, they special- ize in automated development test rigs. Commissioned by STIHL,


measX developed the DLA en- durance testing automation solu- tion, leveraging EtherCAT and Bus Terminal I/O systems along- side TwinCAT PLC from Beck- hoff. Initially designed for the state-of-the-art development cen- ter in Waiblingen, the system is now employed company-wide for endurance testing. The DLA application en-


sures reliable testing of various equipment configurations using a standardized and intuitive op- erating concept, simplifying test definition, execution, and moni- toring. Its adaptability allows seamless transition between dif- ferent test sequences, enhancing efficiency. “The DLA application is de-


signed to ensure reliable, high- performance testing of all types of different equipment with varying configurations,” explains Marco Tiskens, the measX engi- neer responsible for the STIHL project. “A standardized, intu- itive operating concept makes it easy to define, perform and mon- itor each test session. It is also very simple to switch between different test sequences.” The control systems, pow-


ered by a compact Industrial PC running TwinCAT, are connect- ed to measurement data acquisi- tion units via EtherCAT and Bus Terminals. This setup provides the flexibility required for devel- opment test rigs, eliminating the need for separate measurement systems and enabling synchro- nous data acquisition. Different test specimens ne-


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cessitate diverse requirements, such as fuel, water, or power supply. Specialized EtherCAT Terminals cater to these needs, offering precise measurement ca- pabilities for temperature, speed, and energy consumption. The system’s modularity allows for easy integration of additional or alternative terminals as re- quired, ensuring scalability.


To streamline the testing


process, STIHL’s test database precisely defines measurement channels and parameters for each endurance test. The DLA application automates the gener- ation of test programs based on this data, facilitating efficient execution and monitoring of test sequences.


Seamless Integration The seamless integration of


measurement and control tech- nology is facilitated by the Twin- CAT Automation Interface, en- abling automatic code genera-


The DLA application


ensures reliable testing of various equipment


configurations through a


standardized and intuitive operating concept,


tion and standardized test proce- dures. This approach minimizes errors, standardizes tests, and expedites the testing process. Furthermore, the DLA ap-


plication offers comprehensive visualization and monitoring functions, allowing operators to oversee multiple test rigs simul- taneously. Data analysis and re- porting are also automated, pro- viding valuable insights for fur- ther evaluation. Deployed across STIHL test


centers worldwide, the DLA sys- tem ensures consistency, reliabili- ty, and scalability in endurance testing. Its standardized approach facilitates rapid adaptation to new products and technologies, en- hancing the company’s ability to deliver high-quality equipment to customers globally. In conclusion, STIHL’s part-


nership with measX and Beck- hoff has resulted in a cutting- edge automation solution that not only improves testing effi- ciency but also ensures the relia- bility and safety of its products. By leveraging advanced meas- urement and control technolo- gies, STIHL continues to uphold its reputation for excellence in


the power tools industry. Contact: Beckhoff, 13130


Dakota Avenue, Savage, MN 55378 % 952-428-7321 E-mail: j.figy@beckhoff.com Web: www.beckhoff.com r


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