Automated Inverter Test Rig On Labview Environment

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Parameter	Details
DC Input Voltage	0–50 V programmable; precision ±0.01 V via NI PXI-4110 supply
AC Output Voltage & Frequency	0–300 VAC, 45–65 Hz; measured with ±0.1% accuracy
Load Control	0–100% resistive (P.F. >0.98), inductive (P.F.≥0.8), capacitive; switching <10 ms
Current Measurement	Up to 30 A per channel; isolated Hall-effect transducers
Efficiency & THD	IEC 61000-3-2 compliance; THD measured across 2–50 kHz; efficiency at varied loads
Protection Tests	Over/Under-Voltage, Over/Under-Frequency, Short-Circuit, Overload trip times
Transfer Time	<1 ms resolution; max load 25% for UPS-to-mains transfer
Data Logging	SQL Server backend; raw datapoint storage at up to 1 M samples/s
Communication Interfaces	Ethernet, RS-232, USB; OPC UA compatible
Software Platform	LabVIEW 2024 Q3; Windows 10/11; optional remote web dashboard
Report Formats	PDF, CSV, XML; auto-email capability

Manufacturing QA/QC, R&D Characterization, Field Service & Maintenance, Certification & Compliance, and Automotive & Industrial end-of-line testing. The bench ensures batch consistency, compliance with industry standards, rapid prototype validation, on-site health checks, and streamlined certification processes.

Details

Introduction
Modern power electronics demand rigorous, repeatable validation to guarantee inverter reliability, efficiency, and compliance with industry standards. The Automated Inverter Test Bench builds upon the core LabVIEW®-based framework to deliver a turnkey solution that streamlines over 140 distinct tests—spanning DC/AC performance, protection thresholds, dynamic response, and power quality metrics—into a single, tightly orchestrated workflow. By leveraging graphical “G” programming, integrated NI hardware, and SQL-backed data management, the system transforms what traditionally required hours of manual intervention into a rapid, error-resistant process.

Key Features
▹ Modular Test Sequencer: LabVIEW logic checks 146 parameters with prompts and auto pass/fail decisions.
▹ High-Speed Data Acquisition: PXI & CompactDAQ sample at 1 MS/s to capture microsecond transients.
▹ Adaptive Load Control: 4–20 mA-driven loads switch from no-load to full-load without rewiring.
▹ Role-Based User Management: Tiered access with encryption, permissions, and audit logs.
▹ Automated Calibration Tracking: Alerts per ISO 17025; locks tests until calibration is valid.
▹ Flexible Limit Configuration: Limits editable by model or serial number for fast test updates.
▹ Comprehensive Reporting: Exports PDF/CSV with graphs, results, waveforms, and full traceability.

Applications
Manufacturing QA/QC, R&D Characterization, Field Service & Maintenance, Certification & Compliance, and Automotive & Industrial end-of-line testing. The bench ensures batch consistency, compliance with industry standards, rapid prototype validation, on-site health checks, and streamlined certification processes.

Technical Specifications

Parameter
Details

DC Input Voltage
0–50 V programmable; precision ±0.01 V via NI PXI-4110 supply

AC Output Voltage & Frequency
0–300 VAC, 45–65 Hz; measured with ±0.1% accuracy

Load Control
0–100% resistive (P.F. >0.98), inductive (P.F.≥0.8), capacitive; switching <10 ms

Current Measurement
Up to 30 A per channel; isolated Hall-effect transducers

Efficiency & THD
IEC 61000-3-2 compliance; THD measured across 2–50 kHz; efficiency at varied loads

Protection Tests
Over/Under-Voltage, Over/Under-Frequency, Short-Circuit, Overload trip times

Transfer Time
<1 ms resolution; max load 25% for UPS-to-mains transfer

Data Logging
SQL Server backend; raw datapoint storage at up to 1 M samples/s

Communication Interfaces
Ethernet, RS-232, USB; OPC UA compatible

Software Platform
LabVIEW 2024 Q3; Windows 10/11; optional remote web dashboard

Report Formats
PDF, CSV, XML; auto-email capability

System Architecture
- Industrial PC & HMI: Windows® workstation with touchscreen running LabVIEW core.
- PXI Chassis & Modules: NI PXI-1045 chassis with PXI-4110, PXI-4071, PXI-6229, PXI-8536 modules.
- Power Analyzer: Third-party analyzer (e.g., EY Qalibre) via IEEE 488 and LXI.
- Electronic Load Bank: PLC-controlled resistive/inductive banks with safety interlocks.
- I/O & Switching: Solid-state relays and contactors; integrated emergency-stop.

Principle of Operation
The test bench operates via a LabVIEW state-machine: initialization (self-tests and calibration checks), parameter sequencing (instrument settings, data capture, limit validation), operator interaction (setup prompts), error handling (fault detection and retries), and automated report generation (PDF summary with graphs).

Workflow & Test Procedure
- User Login → Role-based dashboard
- Test Selection → Proβile or CSV import
- Pre-Check → Calibration and safety veriβications
- Automated Execution → Sequential test nodes with real-time visualization
- Review & Sign-off → Digital signature capture
- Archival → SQL database storage and network backup
- Notification → Email summary to QA manager

Software Interface
- Dashboard: Real-time KPIs and calibration alerts.
- Test Console: Live waveform plots and operator controls.
- Configuration Panel: Editable test sequences and limit tables.
- Report Manager: Search, bulk export, and auto-email setup.
- Remote Access: Secure web-based status and report viewer.

Calibration & Maintenance
Instrument registry auto-imported from NI MAX, tracking serials and calibration dates.
Alarm engine issues email/pop-up alerts 7 days before due. Maintenance logs capture tasks and attach certificates. Service mode allows maintenance with audit logging.

Conclusion
By consolidating manual procedures into an automated, LabVIEW-centric framework, the Neometrix Automated Inverter Test Bench achieves consistent, standards-compliant results while drastically reducing test times. This translates to improved manufacturing yield, accelerated R&D cycles, and faster certification turnaround, delivering clear ROI in diverse power electronics applications.