Resistance Check in Fuel Sender Testing
Challenge
Design an automated test application for production units (Fuel Sender) that is both time-efficient and cost-effective.
Solution:
Utilize a Graphical Programming Method to shorten production time.
One of our customer’s requirements was the ability to test the resistance value of a Fuel Level Sensor (FLS) in an application. As an engineering solution provider, Haliatech was expected to develop an application in which the product testing process could be carried out efficiently, thereby optimizing production costs.
The operating principle of a Fuel Gauge lies in its two main components: the float and the potentiometer that connects to it. As shown in the diagram, the float rises as the fuel level increases. When the fuel level inside the tank changes, the resistance value of the potentiometer also changes.
To test this, it is necessary to simulate the position of the float and measure the resistance value. We designed the solution into several key components:
- Software Application
- Equipped with precise and efficient algorithms for data acquisition, analysis, and recording into a database.
- Includes a user-friendly interface for production operators.
- Digital Multimeter (DMM) Hardware
- Used as the communication instrument.
- Within the system, there are two resistance measurement methods:
- 2-Wire Method: The most common and simple method. Accurate measurements can be obtained for resistance values above 100 kΩ.
- 4-Wire Method: Provides higher accuracy for resistance values below 100 kΩ. This method requires four test probe leads and more extensive wiring.
2 -Wire Method
4 -Wire Method
Main Application Functions
- User Level Access
- Several user levels are available: Operator, Leader, and Engineering Administrator.
- Test Menu
- The main menu allowing users to perform UUT (Unit Under Test) testing after the unit is mounted on the jig and the test probe leads are connected.
- Settings Menu
- Enables users to modify software configurations and specify which UUT will be tested.
- Report Menu
- Displays test reports for previously tested UUTs
- Access Menu
- Used to view and manage user accounts.
Test Menu
Access Menu
Conclusion :
Haliatech successfully developed an automated testing application that is both time-efficient and cost-effective, enabling significant improvements in production optimization.
If you have any questions regarding this application or general solutions for NI product users, please contact us at: sales@haliatech.com
Author Information:
Mukhrizi
Haliatech
Bekasi – Indonesia
(+6221) 85508561
