Based on our customer requirement, we built a custom IO module tester machine. This machine will test all the requirements that our customer need to meet the specifications of the IO modules. The requirements for input modules are to test the ON/OFF state voltage, minimum/maximum ON state current, and OFF state current. The requirements for output modules are to test load operation, saturation voltage and OFF state current leak. Both input and output module will be tested its Fore Ground (FG) connection, to ensure all FG connection are connected to each other. This machine can test AC and DC current and voltage, has current measurement range from 1000 uA to 3A and has voltage measurement range from 100mV to 700V. This machine can test up to 20 different IO modules because it has exchangeable jigs.

The main controller for the machine is using PC with custom software to check all the required IO modules. This machine still using a PLC but only to make sure there is not fault when the IO module is connected and can communicate with PLC CPU or not before the test start. The PLC then communicate with the PC using RSLinx software through DDELink communication to tell the PC that there is no fault for the IO module then the machine can start the test. This machine will test all IO one by one to make sure all IO is OK and meet the required specification.

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