Test System for the Collaboration and Inspection of Rotation Speed Control Sensors (RSS)

In today’s post, we’d like to give you insights into another highly exciting project for us:

Recently, we had the opportunity to design and manufacture a compact stand-alone end-of-line test system for an existing customer, which calibrates and inspects RSS. These sensors will soon be installed in motorcycles from a renowned manufacturer.

Test Process:
The test specimen, consisting of a dual-channel Hall sensor and a connector plug, is placed into the test environment with a plexiglass safety enclosure via a sliding door. During the test cycle, predefined inspection criteria are automatically checked on both the sensor and the connector.
At the same time, the rotation sensor is calibrated: A test magnet rotates in a predefined manner in front of the test specimen. The measurement data from both independent sensor channels are recorded simultaneously. After (re-)programming the channels, the test process is repeated to ensure that the calibration has been successfully completed.

Advantages of Our Solution:
✅ Thoughtfully designed semi-automated construction enables the simultaneous/sequential execution of inspection and calibration, reducing cycle times.
✅ Stable and secure testing conditions: Thanks to the protective enclosure, the quality of inspection and calibration processes remains free from external influences or manipulation.
✅ Highest quality standards: The test conditions ensure top-tier quality assurance for a safety-critical component and significantly reduce the false-positive rate—true to our motto: zero ppm.
✅ Intuitive operator guidance: Simple visual instructions and multilingual support allow safe operation—even for untrained or non-native-speaking staff. This saves valuable training time and enables flexible capacity planning.
✅ Ergonomic design: All work steps can also be carried out while seated.
✅ Shopfloor flexibility: The compact design, based on our compact.UNI standard, facilitates transport and allows flexible use.

Additional Added Value:
Test results are documented in a database to ensure compliance with legal and contractual traceability requirements.

You can find more reference projects on our website.
Inquiries to sales@brainware-solutions.de.