automotive industry

Automotive

Custom Test Solutions and Build-to-Print Services for the Automotive Industry

Your partner for Automotive Industry-Focused Test Solutions

Ball Systems designs, develops, and delivers custom test systems and produces comprehensivealternator image-1.jpg build-to-print systems for automotive companies who create or manufacture critical electronic or electro-mechanical components, assemblies and subsystems.

Automotive Industry-Focused Capabilities

  • Engine Control Module (ECM) testing
  • Airbag controller and sensor test systems
  • Safety Deployment Module (SDM) testing
  • Transmission Control Module (TCM) testing
  • Transmission pump testing
  • Starter test systems
  • Alternator test systems
  • Stator test systems
  • Braking systems test systems
  • Active safety test systems
  • Hybrid control module testing
  • HIL (Hardware-in-the-Loop) ECU testing systems and software
  • Fuel injector waveform measurement
  • Automotive radio and entertainment testing
  • Suitcase and portable plant testers
  • Burn-in carts and fixtures
  • Test and manufacturing process automation
  • EEPROM programming platforms
  • National Instruments PXI test systems
  • CAN bus design, validation, and testing
  • Custom test fixturing
  • Custom test electronics design (controllers, FPGAs, firmware, loads, communications, etc.)

 

Contact us today to see how we can help you with your automotive projects.

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Project Gallery

Custom designed portable test box to emulate factory test in self-contained platform that includes custom firmware, FPGA, etc.

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SDM-C Assembly Plant Tester

Custom designed NI PXI test console, including custom backplane, card cage, and custom test cards.

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NI PXI Test Cabinet with Custom Card Cage

Custom wired Virginia Panel (VPC) Interchangable Test Adapter (ITA), this project is custom-designed and wired to provide test interconnect.

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Custom designed programming station to provide simultaneous EEPROM in-line programming in high-speed line.

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UPS Cabinet, Rear View, Open

Custom designed test circuitry and low-volume production of test cards.

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Rack of LBX Load Boards

Pneumatically actuated, custom-designed probe block for testing high-current engine control module for hybrid technology vehicle.

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Pneumatically Actuated Custom High-Current Probe Assembly

Custom designed, low profile NI PXI test console, including custom backplane, card cage, and custom test cards.

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NI PXI Test Platform with Custom Card Cage

Custom designed PXI Test Console, including NI Chassis and VPC Interconnect.

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NI PXI Tester with VPC Interface

Custom wired and designed Virginia Panel (VPC) Interchangable Test Adapter to provide test interconnect.

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Interchangeable Test Adapter (ITA)

Pneumatically actuated, custom designed probe block for testing high-current engine control module for hybrid technology vehicle.

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High-Current Custom Probe Block

EEPROM verification fixture, including custom mechanical and electrical design and automation.

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EEPROM Verification Fixture

Custom designed test equipment cable harness, including VPC iCon series quick disconnect and product connectors.

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Custom iCon Cable Harness

High density custom backplane design and fabrication.

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Custom Connector Backplane

Custom cable harness design and build.

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Custom Automotive Cable Harness

Test cabinet houses 32 “conditioning nests” in cell manufacturing environment.

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Test cabinet houses 32 “conditioning nests” in cell manufacturing environment

Custom probe blocks and interface circuitry for burn-in cart fixtures.

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Burn-in Cart Fixture

Automation system control panel and enclosure.

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APM Handler Control Panel

Custom test cable harness for portable automotive audio system tester.

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Automotive Audio Cable Harnesses for Suitcase Tester

Portable suitcase tester for automotive audio systems that is designed to emulate production functional test environment.

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Automotive Custom Suitcase Tester

256-pin custom test cable harness.

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256-pin Custom Test Cable Harness

8-bay universal programming platform for EEPROM programming and verification with custom PCAs and integrated custom software.

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Universal Programming Station

Custom test station for hybrid technology engine control modules that meets high voltage, high power, and automation requirements.

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Automated PLC Controlled APM Handler

Pneumatically controlled conditioning nest for engine control module that is custom mechanical, electrical, and firmware design.

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DC-MF39131 Conditioning Nest

19” rack-mountable programmable custom load box.

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Toyota Modular Load Unit

Custom designed engine module tester interface, including custom probe interface, and ergonomic mechanical actuation.

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Instrument Oriented design – BallTestTM Sequencer

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 Instrument Oriented design – BallTestTM Sequencer

Toroidal inductors designed to application, and manufactured in-house.

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Turnkey alternator tester.

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Desktop hardware-in-the-loop test system.

Desktop hardware-in-the-loop test system

HIL Fuel Injector Measurement System for ECU Tester

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HIL Fuel Injector Measurement System for ECU Tester