Project Overview

SM Controls designed and manufactured a bespoke desktop test system to support a customer’s product service and repair process. The unit provides a common test platform for three product variants, allowing service engineers to recreate operating conditions and investigate returned products in a controlled environment.

Engineering Approach

The operator manually selects the required test voltage and uses an adjustable control to reproduce different normal operating conditions. Live voltage and current measurements remain visible throughout the test, giving the engineer the information needed to assess how the product is behaving rather than receiving only an automatic pass or fail result.

The control system was deliberately kept simple. A PLC offered no functional advantage for the application, so hard-wired controls and analogue instrumentation were used to provide a direct and intuitive operator interface without unnecessary complexity.

As the products under test may already be faulty, the unit incorporates protected outputs, an emergency-stop circuit and an interlocked enclosure that prevents access during operation. The completed system was functionally tested with all three product variants before handover.

The result is a consistent diagnostic platform that supports a quicker and more repeatable service process while retaining the engineer’s judgement when interpreting different fault conditions.

Services Delivered

– Electrical design
– Control-panel design and manufacture
– Bespoke test-equipment manufacture
– Instrumentation and safety integration
– Functional testing and commissioning
– Operating instructions and CE documentation