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Test- and Calibration solutions

One of our main areas of activity is the testing and calibration of products, mainly electronic components of all kinds. Starting with small LEDs with a size of 5x5 mm, contact areas of 0.5 mm, and contact pins with a diameter of 0.3 mm, to components from e-mobility such as Eg batteries with a size of 1x2m and 100 kg or e-mobility control units with currents of up to 800A.

As well as tests in the optical (AOI, spectral measurement, ...) and mechanical (force, displacement, ...) area.

The devices and machines for this range from simple manual devices to fully automatic, interlinked systems in which a wide variety of processes can be integrated.

We can implement the corresponding test software in a package together with partners.

Thermal test
Screening system for a transmission control unit (TCU)

Thermal test methods are the most suitable means of qualifying electronic products for use under extreme temperature conditions. We support our customers in choosing the most suitable method. Depending on the application, we develop static run-in systems or automated transfer systems.

construction of a termperature tunel at our site
construction of a termperature tunel at our site

Stahl MB has long been a specialist in the planning and execution of fully automatic tunnel systems (DTA). Our customers benefit from optimized processes that guarantee fast throughput times and process reliability at the same time.

In addition to the main process of electrical testing, further processes (link) can be integrated into these systems, such as marking stations or cleaning, in order to map individual customer requirements.

Application example Task:Electrical testing and stimulation of sensors of a transmission control in different temperature ranges - low temperature down to -40 ° C, high temperature up to + 160 ° and at room temperature

Technical implementation:

Staggered sequence of temperature tests in integrated test adapter chambers, including corner point tests

Fully automatic throughput with a workpiece carrier transfer system

Loading and unloading takes place automatically by means of a robot

Operation area:

Electronics manufacturing for automotive / aerospace, renewable energies

Burn-in, run-in and screening systems

In order to put electronic or electromechanical components into "stress", to uncover weak points or design errors, tests are carried out under the influence of high temperatures. These can also be expanded into service life tests. For this purpose, the components are fitted and contacted on so-called run-in boards and contacted with a test system via defined interfaces. In contrast to a continuous tunnel system, continuous testing is possible while the temperature changes. The lead time can range from a few hours to several weeks.

Optical inspection, calibration and CV



Final inspection of an evaporator's valve/flange position

The final test consists of the base-machine and an interchangeable fixture. The interface between the base-machine and the interchangeable fixture is standardized through pneumatic and electrical connections via plugs.

The main task of the final inspection is to measure the valve/flange position of an evaporator using a camera system (setting according to drawing definition) and to check some other features.
The assembly of the system is semi-automated, therefore insertion and removal as well as aligning the valve/flange position of the components is done manually. The test procedures run automatically.

After setting up the interchangeable fixture on the base-machine and before the start of the actual production process, the camera system is taught the correct valve/flange position by inserting a calibration standard into the fixture and releasing it by pressing the two-hand button.

After successful calibration, the operator can insert an evaporator into the fixture.
The machine detects the part and clamps it on its reference surfaces (according to the drawing) on ​​the evaporator core. The evaporator and valve labels are scanned. Additional features such as e.g. existing "blue dots" are checked and the position of the valve/flange of the evaporator is checked using cameras. The position of the valve/flange is shown on a screen as live images with operator indicators. The operator adjusts the position of the valve/flange until it is within the correct range shown on the screen.
Now the correct position is confirmed by pressing the two-hand button.
The operator puts a protective cap on the valve/flange, which in turn is checked by the vision-system.
This step is confirmed again by pressing the two-hand button.
As a final step, the vaporizer is marked with a blue dot and ejected.
The worker takes out the finished product from the cassette.

Semi automated device for inspection of luminance and luminous intensity

The scope of the machine is to give the R&D a most flexible system to determine the luminance and luminous intensity, of their developments.

A vision system is used to locate the DUT. Then a cartesian robot moves the luminance and luminous intensity sensors to predefined test-points above the DUT in respect to the position of the DUT.

The modular design of the machine allows an easy adoption to future developments by exchanging the DUT fixture.

Test- and calibration-fixtures

Over the past few decades, mechatronics have become more and more common in many areas of technology such as vehicle construction, medical technology and aerospace. Modern computer-aided control systems evaluate a large number of sensor signals in order to operate the entire system at the optimal operating point.

With our test and calibration adaptations, we create the possibility for laboratory and production applications to test both individual components and complete systems by stimulating sensors in a targeted manner and providing the electrical connection to external test equipment.

Manifold absolute pressure sensor calibration

Our tools are used to calibrate MAP and T-MAP sensors on three continents.

A fully automated calibration line, developed and manufactured by Stahl Maschinenbau GmbH, enables our customers to calibrate and test a wide variety of MAP-sensors. Overall we enable our customers to produce over 5 million sensors per year. Due to a modular design of electrical- and pneumatic adapters, over 30 variants of MAP sensors are implemented in these production lines and the number is still increasing.