PSEU Build-to-Print Rack Systems for Aerospace

Ball Systems delivered three identical, production-ready automated test systems to a major aerospace manufacturer. Integrating NI PXIe, Keysight power instrumentation, and Virginia Panel interconnect, we created a fully rack-mounted system built to print and delivered on schedule. 

7556 Front View Cabinet PC for Crane Aero

 

7556 Side View Cabinet for Crane Aero

 

IMG_5039

 

7556 Close-Up PC for Crane Aero Cabinet

 

 

The Challenge

A major aerospace manufacturer needed three production-ready Power Supply Electronics Unit (PSEU) Automated Test Equipment systems built to their engineering drawings. The systems required precise integration of rack-mounted instrumentation, multi-channel power delivery, PXI-based data acquisition, and a structured interconnect system capable of supporting the customer's production line workflow.

The complexity stemmed not just from the hardware density, with each rack housing an NI PXIe chassis, multiple Keysight power supply mainframes and modules, and an extensive Virginia Panel receiver architecture, but from the requirement that all three systems be functionally identical and qualified for aerospace production environments.

7556 Close-Up Back of Cabinet for Crane Aero with NI Components

What We Built

Each of the three systems is built around a full-height equipment rack on casters, configured for both front and rear access. The front presents the operator interface, a structured Virginia Panel receiver cabinet accepting the device-under-test connector harnesses, alongside instrument panels housing the Keysight power mainframes and NI PXIe controller. A wall-mounted articulating arm integrates the operator monitor, keyboard, and mouse at ergonomic height.

The rear of each rack provides full visibility into a carefully managed cabling architecture. Ethernet switching, power distribution, and signal routing are all routed through managed wire duct, with the NI MXI-Express backbone connecting the embedded controller to the PXI chassis for high-bandwidth instrument control.

Technology Stack

The instrumentation backbone of each system is the NI PXIe-1085, an 18-slot 3U chassis that provides high-bandwidth backplane throughput for the measurement modules. An NI MXI-Express Gen 2 x8 cable links the chassis to an external controller, enabling full software control via the customer's NI-based test executive.

Power delivery is handled by Keysight N6702C 1200W mainframes loaded with N6752A 50V/100W source/measure modules, giving the system flexible, programmable power sourcing across all PSEU test points. The interface architecture is built on Virginia Panel Corporation receiver cabinets and 192-position connector modules, providing a robust and repeatable mechanical connection to the unit under test.

Supporting bus communication, the system includes Total Phase USB-CAN interfaces and I2C/SPI host adapters for protocol-level stimulus and monitoring. RS-232/422/485 multi-port converters from Advantech handle legacy serial I/O requirements, and a USB 3.0 PCIe expansion card ensures adequate host-side bandwidth for data-intensive test sequences.

Lessons Learned

The labor efficiency on this project was second-to-none. Clear build-to-print drawings and an experienced technician team meant fewer decision points and less rework, which showed up directly in the hour variances. That discipline, particularly in wiring, is worth carrying forward as a model for similar multi-unit builds.

Outcome


All three PSEU ATE systems shipped on time in March 2026 for the customer's production qualification schedule. On-site coordination and hands-on communication with the customer's production engineering team at key milestones strengthened the relationship throughout the engagement.

This project is a representative example of Ball Systems' ability to execute high-fidelity build-to-print programs for aerospace customers, delivering proven test equipment at production scale, on schedule, and with the documentation and quality controls the industry demands.
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