Gear Lever Testing system is automated solution developed to test the Gear Lever and Cable Assembly. The software controls the series of test to be conducted on Gear Lever and cable assembly. Communicates with GE Versa motion drives to control the servo motors to move the Gear Lever in the selected direction in precise speed. In this data acquires from USB and COM ports. Plots the online graph from the data acquired through different communication ports. The application measures LOAD, TORQUE, ANGLE, LVDT and DISPLACEMENT and stores data to the excel files for further analysis and generates reports in pdf format.




To develop an application software to control and automate the test sequence of the gear lever and cable assembly. Acquire data and plot online graph for a particular test sequence, capture the displacement value for the given different set points (force).

Hardware: GE Fanuc Micro PLC, High-speed DAQ PCI-6221, Multi port RS 232
Software: LabVIEW

GE Fanuc micro PLC is used to program all the test sequences to control the servo drives for x and y axis individually. Servo motors will drive the gear lever and cable assembly at different speeds. The application software communicates to GE Fanuc PLC through TCP/IP Ethernet port. Acquires LOAD, TORQUE, ANGLE, LVDT and DISPLACEMENT data from signal conditioners through multi port RS 232. Software has an option to set parameters like Test ID, Set Points, Speed, Direction and Operator name. Issues a start command to start the test and monitors the sequence, plots the online graph and stores the acquired data to an excel file. Test report can be generated in PDF format.