NI ATE Core Configurations: Flexible and Scalable Automated Test Equipment Solutions

Modern manufacturing and engineering environments require automated testing systems that deliver consistent performance, reliable measurements, and efficient operations. From aerospace applications to transportation production testing and electronic device validation, engineers need flexible testing infrastructure that can support increasingly complex requirements.

The NI ATE Core Configurations provide an integrated infrastructure solution for building rack-based Automated Test Equipment (ATE) systems. Designed and built by NI (National Instruments), these configurations simplify the design, procurement, assembly, and deployment of automated test systems through standardized mechanical, power, and safety infrastructure.

With multiple rack sizes, configurable power distribution, integrated monitoring capabilities, and support for NI instrumentation, ATE Core Configurations provide a flexible foundation for custom and scalable test systems.

What Are NI ATE Core Configurations?

NI ATE Core Configurations are standardized rack-based infrastructure solutions designed to simplify the development and deployment of Automated Test Equipment.

Instead of sourcing and assembling individual rack components from multiple suppliers, engineers can procure an integrated system that includes mechanical infrastructure, power distribution, safety components, and configurable I/O.

The system can also accommodate different NI hardware platforms, including:

• PXI instrumentation
• CompactDAQ
• CompactRIO
• Other compatible instrumentation

This approach allows engineers to build customized automated test systems while simplifying procurement, assembly, and future system replication.

Key Benefits of NI ATE Core Configurations

1. Complete System Procurement from a Single Source

Developing an automated test system often involves purchasing components from multiple vendors. This can increase procurement complexity, coordination requirements, and project timelines.

NI ATE Core Configurations simplify this process by providing an integrated purchasing approach.

Users can specify and purchase rack infrastructure, uninterruptible power supplies, emergency power-off systems, power distribution units, and other rack-mountable components through a single source.

Having a single source for procurement also simplifies repair and replacement coordination through NI support.

2. Integrated Rack Control Unit for System Monitoring

Every NI ATE Core Configurations rack includes a Rack Control Unit (RCU).

The RCU provides a C# API supported on Windows 10 and enables system monitoring, reporting, and control functions.

Its capabilities include:

• System health and status monitoring.
• Startup and shutdown sequence control.
• Input power and power distribution monitoring.
• Fan speed and PWM control.
• Temperature monitoring.
• Safety thermal shutdown monitoring.
• ITA pin status monitoring.
• Local system storage.
• Communication with interface devices.

These capabilities help test engineers monitor rack infrastructure and manage important system operations.

3. Reduced Hardware Assembly and Integration Effort

Preparing a rack-based automated test system can require significant engineering time for mechanical assembly, wiring, component installation, and software configuration.

With NI ATE Core Configurations, standard rack assembly, connections, and software installation are performed by NI engineers before shipment.

This helps reduce hardware preparation activities and allows engineering teams to focus on test sequence development, validation, and other critical engineering tasks.

4. Flexible Rack and Power Configurations

ATE Core Configurations are designed to accommodate different application requirements.

Users can select rack sizes, power entry configurations, power distribution options, configurable I/O, and accessories.

Custom configurations can also be referenced through a single part number, making future reordering easier.

NI ATE Core Configurations: Available Rack Sizes

NI provides three primary rack size options: 15U, 38U, and 44U.

15U Rack Configuration

The 15U rack is designed for DUT-on-top configurations and lower-power systems.

It provides a compact solution for test applications where the device under test needs to be positioned at a practical working height.

38U Rack Configuration

The 38U rack has an overall height of approximately 1,915.1 mm, including casters.

Its height is less than two meters, allowing it to fit through common door heights while providing substantial space for test instruments and other components.

44U Rack Configuration

The 44U rack provides additional equipment space within the same floor footprint.

It is suitable for test systems requiring greater instrument mounting capacity.

Rack Mechanical Specifications

All three configurations feature four swivel-locking anti-ESD casters.

ATE Power Configuration Options

Power distribution is a critical consideration when designing an automated test system.

NI ATE Core Configurations provide six power configuration options to accommodate different system requirements.

The available options provide flexibility when selecting the power infrastructure for different automated test applications.

The appropriate configuration should be selected according to the facility’s electrical supply, voltage, current rating, phase requirements, and equipment load.

Integrated Power Distribution and Safety Infrastructure

NI ATE Core Configurations integrate several power and safety components to support reliable rack operation.

Power Entry Panel (PEP)

The Power Entry Panel routes external facility power, Ethernet, and USB connections into the ATE rack.

It also provides circuit protection, thermal protection, and emergency power-off functionality.

Depending on the configuration, the PEP includes:

• IEC or hardwired power connections.
• Circuit protection.
• Line filters.
• Emergency shutoff relays.
• Pre-wired Rack Control Unit connections.
• Fan connections.
• UPS or loopback I/O.
• C19 outlets.
• External grounding connection.

Power Distribution Unit (PDU)

The Power Distribution Unit distributes incoming power to the outlets used by system components.

Single-phase PDUs feature eight IEC C13 outlets, which can be controlled by the RCU in pairs.

They also support auxiliary DC outputs, circuit protection, remote inhibit, and emergency power-off functionality.

Three-phase PDUs support both delta and wye configurations.

Uninterruptible Power Supply (UPS)

An optional UPS provides power to critical system components during power interruptions, brownouts, and normal operation.

The UPS option provided in ATE Core Configurations is APC-branded.

Emergency Power-Off (EPO)

Emergency Power-Off provides a mechanism for quickly disconnecting system power during critical situations.

When activated, the emergency power-off mechanism disconnects power to the AC and DC Power Distribution Units through switches within the Power Entry Panel.

The rack also includes a temperature controller that can shut down the system when its internal temperature reaches a user-programmable threshold through the RCU.

PXI Instrumentation for Automated Test Systems

PXI is an important platform for building high-performance measurement and automation systems.

It combines PCI electrical-bus capabilities with modular CompactPCI packaging and specialized synchronization buses.

NI ATE Core Configurations support the integration of PXI instrumentation for a wide range of measurement and testing applications.

Available PXI instrument categories described in the NI brochure include:

• Oscilloscopes.
• Digital Multimeters.
• Digital Instruments.
• Waveform Generators.
• Frequency Counters.
• Source Measure Units.
• Programmable Power Supplies and Loads.
• Switching Matrix and Multiplexers.
• Data Acquisition Modules.
• Vector Signal Transceivers.
• NI FlexRIO Custom Instruments.

With PXI instrumentation, engineers can build test systems tailored to their measurement, characterization, validation, and production testing requirements.

Software Solutions for NI Automated Test Equipment

Hardware is only one part of an automated test system. Software plays an equally important role in test development, execution, data analysis, and reporting.

NI offers several software solutions to support different engineering workflows.

LabVIEW

LabVIEW is a graphical programming environment used to develop automated research, validation, and production test systems.

It supports hardware communication, measurement acquisition, and configurable interactive interfaces.

NI TestStand

TestStand is a test executive software solution that accelerates automated test system development.

It supports test execution using LabVIEW, Python, C/C++, and .NET, as well as parallel testing and operator interface development.

DIAdem

DIAdem provides measurement data search, inspection, analysis, calculations, and automated reporting capabilities.

FlexLogger

FlexLogger is a no-code data acquisition software solution for validation and verification applications.

It provides interactive visualization, monitoring, and configurable alarms.

InstrumentStudio

InstrumentStudio simplifies the setup and configuration of NI PXI hardware.

It provides customizable layouts for monitoring instruments and supports interactive debugging alongside code-based workflows.

G Web Development Software

G Web Development Software enables engineers to develop web-based user interfaces without traditional web development skills.

Applications of NI ATE Core Configurations

According to the NI product brochure, ATE Core Configurations support applications across multiple engineering and industrial sectors.

These include:

• Aerospace testing.
• Transportation production testing.
• Electronic device validation.
• Manufacturing test applications.
• Research and development.
• Automated validation and verification.

The configurable rack infrastructure and instrumentation integration capabilities provide flexibility for different testing environments.

Why Choose NI ATE Core Configurations?

NI ATE Core Configurations provide a structured approach to building rack-based automated test systems.

By integrating mechanical infrastructure, power distribution, safety features, system monitoring, and instrumentation support, the platform helps simplify the process of developing and deploying automated test equipment.

Key advantages include:

1. Standardized mechanical, power, and safety infrastructure.
2. Three rack size options: 15U, 38U, and 44U.
3. Power configurations up to 36 kW.
4. Integrated Rack Control Unit.
5. Emergency power-off and thermal shutdown capabilities.
6. Support for PXI, CompactDAQ, and CompactRIO hardware.
7. Configurable I/O and rack accessories.
8. NI hardware services, repair, and calibration support.

Conclusion

NI ATE Core Configurations provide a flexible infrastructure foundation for organizations developing automated test equipment and rack-based testing solutions.

With multiple rack sizes, configurable power distribution, integrated monitoring capabilities, and support for PXI instrumentation, the platform can accommodate a variety of engineering and industrial testing requirements.

For organizations looking to simplify test system procurement, reduce hardware assembly effort, and develop scalable automated testing infrastructure, NI ATE Core Configurations offer an integrated solution worth considering.