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Automation in the automotive industry remains at a high level, while requirements are increasing due to digitalization and connected manufacturing processes. This also increases the challenges for measurement and test technology: complex test scenarios, short cycle times, and secure data integration and standards compliance are moving into focus. This article examines the interfaces between robotics and measurement technology - from installation testing to EMC measurements.
Increasing automation requires an adapted understanding of testing and quality assurance. Technicians and commissioning engineers must plan test sequences earlier and integrate them more deeply into industrial processes. Quality managers are required to design test processes so that they are data-based, reproducible and audit-proof. Automation experts need scalable, networked test and measurement systems that can be adapted quickly and flexibly to product changes, new vehicle concepts and test requirements. Last but not least, the skill set in production is also changing: data analysis and communication, EMC fundamentals, safety standards and software for test development are now basic knowledge in the Industry 4.0 test environment.
The wide variety of measurement and analysis systems requires cross-vendor interface standards for secure and efficient data exchange. Standardized interfaces enable seamless integration of new sensors, software tools and evaluation methods into existing test and automation systems. This creates the basis for a continuous test infrastructure that flexibly integrates both current and new technologies. In addition, AI-supported evaluation of large volumes of data is gaining in importance. Artificial intelligence supports real-time visualization of measurement results and enables forecasts of system condition. Intelligent dashboards provide QA managers with a comprehensive basis for decision-making and increase efficiency in process monitoring. At the same time, cybersecurity aspects are coming into focus. Protecting measurement data and networked systems against unauthorized access is mandatory. Compliance testing with regard to IT security and standards requirements is becoming an integral part of quality assurance, particularly against the background of increasing cloud applications.
Finally, sustainability and energy efficiency tests are expanding the requirements placed on modern test strategies. Evaluating the energy consumption of robotics systems and production facilities is now also part of quality assurance.
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Every newly installed robot means complex electronics for drives, controllers, sensors or actuators and therefore potential sources of danger for people and machines. The focus is on standards-compliant electrical safety testing of the corresponding installations, control cabinets, systems and devices. Modern test systems can be used to measure and document insulation resistance, protective conductor current, leakage current and other parameters precisely and safely. Systems should be optimally grounded and fault currents avoided. Today's device and operating concepts support error-free, fast use and meet both current test regulations and future changes to standards, for example through updatable firmware.
For interference-free automation processes, communication between controllers and devices (sensors, actuators, etc.) within the system must be secured. This includes testing cabling, bus physics and communication functions in Industrial Ethernet and PROFIBUS networks. Diagnostic devices for industrial communication networks are used for system installation, commissioning, acceptance, certification, network optimization and preventive maintenance. Compact designs now enable easy integration into existing systems. Software-supported data analyses make it possible to determine the topology or generate test reports on the current system condition.
Automatisierungsprozesse basieren auf der Ein- und Ausgabe von Prozesssignalen. Die Signale leiten sich von physikalischen Größen ab, zum Beispiel Füllstände, Druck- oder Temperaturwerte. Diese werden von entsprechenden Sensoren erfasst und in elektrische Parameter umgewandelt. Die Prozesstechnik nutzt solche Signale unter anderem in Form von Spannungszuständen und Leistungsänderungen. Die Steuerung von Prozesseinrichtungen, beispielsweise Aktoren, erfordert in der Regel eine Kombination aus Prozessdaten/-signalen und speziellen Sicherheitsdaten. Mit moderner Messtechnik lassen sich reale Sensordaten und industrielle Kommunikationssignale für Feldbusse nachbilden, um damit elektronische Komponenten zu validieren, die System- und Taktsynchronisierung zu überprüfen oder Signalfehler zu identifizieren.
Control technology coordinates the mechanical drive systems (actuators) of robots in production lines, for example during welding, painting or assembly. Wear-related changes can cause the function of mechanical systems to deteriorate over the course of operation. Recording important process data makes changes visible at an early stage. System operators benefit from the documented measured values by being able to perform sound evaluation and take this into account during maintenance measures.
Predictive maintenance is also gaining importance in automotive production and is changing maintenance strategies in the long term. If changes in condition are detected early, downtime can be avoided, maintenance windows optimized and repairs planned in a targeted manner. For test and measurement technology, this means a paradigm shift: instead of point-in-time testing at defined intervals, continuous condition monitoring, software-based measurement and analysis processes and cloud-based documentation are required.
Integrated sensors, current and temperature monitoring at robot joints provide important indications of bearing problems or overheating before failure occurs. In this context, conventional test and monitoring tools are being expanded by software-supported diagnostic platforms. AI algorithms for anomaly detection, trend analysis or forecasting the service life of individual components are also playing an increasingly important role. Edge computing allows sensor data to be preprocessed directly in the system and transmitted to the cloud in filtered form.
Irregularities in the power supply can not only impair the service life of devices and machines, but also lead to IT problems and system failures. Careful analysis of power quality and stability in industrial systems is an important part of preventive maintenance. It helps optimize energy efficiency and reduce premature signs of wear. Power supply monitoring can be carried out either continuously or temporarily. This enables faults and energy losses to be detected and quantified at an early stage.
Where more electronics are used, the risk of electromagnetic interference that must be taken into account during design also increases. Robot communication via Industrial Ethernet or wireless interfaces also generates potential sources of interference, especially in confined production environments. EMC testing must be carried out comprehensively by manufacturers and suppliers alike. In addition to general standards compliance, the focus is also on testing under operating conditions: how does a robot arm behave in a real cycle when a neighboring system with a frequency inverter is running at the same time?
Many manufacturers are already shifting EMC pre-compliance tests into the development phase in order to detect potential problems early. Mobile or partially automated EMC test stations are increasingly being used to qualify subsystems, helping to shorten development time. The combination with permanently installed thermal imaging cameras and long-term data recording is also gaining in importance in order to make weak points visible under real conditions. EMC measurements are therefore becoming more dynamic, more data-intensive and smarter. Compact EMC test systems with automation interfaces can be integrated directly into the production process. In addition, simulating typical operating scenarios in shielded mini EMC chambers enables realistic, reproducible results.
Whether control unit, wiring harness or robot joint unit: at the end of the line, all components must be fully functional and compliant with standards - with increasing variant diversity, software-based functions and highly integrated electronics. Modern EoL test systems must not only cover electrical and functional tests within a few seconds, but also capture serial numbers, automatically recognize configurations, document measurement results and transmit them to the MES or ERP. Testing is often performed directly after pressing, screwdriving or calibration. Maximum accuracy with minimal cycle time is decisive here.
The trend is moving toward networked test cells with AI-supported fault detection, remote access and interfaces to digital twins. For QA managers, this means that conventional test reports are no longer sufficient; instead, continuous data flows are required. A modular test architecture with configurable software allows different variants to be recognized automatically and tested accordingly. In addition, connection to central databases ensures seamless traceability and documentation.
DThe robotics trend in industry brings with it a wide range of fundamental and specialized measurement tasks. These include installation and safety tests, power quality and power analyses, load tests of mechanical and electrical systems, monitoring tasks and EMC measurements. High test coverage is required in order to reproduce all operating states, application scenarios and fault cases. In addition, complete documentation of all measurements must be considered in order to demonstrate a safe and standards-compliant operating environment. At the same time, demand is increasing for modular test stations that can be adapted cost-effectively to changing test requirements - in a complex and, at the same time, increasingly pervasive world of automation.
Increasing automation is placing new demands on measurement technology, quality assurance, and data analysis. The experts at dataTec assist companies in selecting future-proof measurement and testing solutions for modern production environments—ranging from electrical safety testing to network analysis and EMC measurement technology, all the way to applications for predictive maintenance.
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