Ball Systems used existing, off-the-shelf high current AC and DC loads from NH Research for this project. The load system developed by Ball Systems interfaced with an external DAQ system provided by the customer in their existing test cell. The DAQ system is comprised of current and voltage transducers, load cells for torque measurements, and speed sensors. The sensors connect to a National Instruments measurement system including analog input, counter, digital IO, and thermocouple. A power analyzing oscilloscope was also included to analyze the power waveforms. All of the load equipment was tightly integrated into a 19-rack mount dual-cabinet solution to simplify use and transport by the customer.

The test program and GUI were written using National Instruments LabVIEW. This system helps complete test simulations and test profiles and models to create usable data. Software paralleling of high-powered load devices was also effectively completed in the load system, and WAV forms were simulated as comparative models for actual DUT performance that would be measured during the test. Part of the integration involved developing a GUI and remote test system communication/control architecture for remote operation in order to ensure operator safety.

In this case, the Ball Systems solution was later integrated into an existing test cell at the customer facility.