Test Engineer Intern

This project was handed down to me from my manager. The concept was a self-contained, portable test system housed in a waterproof hard case that could be taken directly to customers to demonstrate motors or run quick validation tests in the field.

I started by mapping out the existing build as a wiring schematic, identified areas to improve, and rebuilt it cleaner and more compact. Once the hardware was solid, I used LabVIEW as the software to interact with the CompactDAQ giving the user control over the motor. Once the hardware and software worked, everything then got packed into the case. .I designed a front panel to fit the case perfectly. In the end, this gave the user full control by allowing them to adjust test parameters, monitoring motor status in real time, and log data from each run.

I was tasked with building out a durability test cart. This involved integrating a PWM generator, power supply, and a 12-channel motor panel I was given to finish wiring. Once everything was connected, the cart gave the test engineer full control over 12 eMotors simultaneously. It allowed them to adjust PWM signals, monitor motor speed, and log data while the motors were under durability testing. I also supported the engineer during maintenance and troubleshooting when issues came up during the test runs.

While supporting the durability test cart, I noticed the test engineer had to manually validate the RPM of each motor every time the test restarted. The engineer was checking diagnostics one by one. It was a recurring pain point, so I came up with a quick, low-cost solution.

Using an ESP32 and an LCD screen, I built a small display box that reads the diagnostic signal from each motor and shows the motor number and live RPM on screen. Instead of expensive industrial hardware, I used cheap components and BNC connectors to connect easily into the back of the cart, giving the engineer a fast way to cycle through all 12 motors and confirm they were spinning at the right speed before resuming a test.