Custom automated connection and testing system developed to reduce cycle times, improve test reliability, and minimize operator involvement in high-pressure production testing
A manufacturing client relied on an existing production test stand that had originally been developed as a prototype system but was later forced into full-scale production use. Over time, the limitations of the prototype design created operational inefficiencies, excessive operator involvement, and increased opportunities for testing errors and production delays.
The existing process required operators to manually connect and position multiple part configurations with inconsistent connection locations and poor dimensional tolerancing. High-pressure flow testing further complicated the process, as even minor sealing inconsistencies or pressure losses within the test system could compromise test accuracy and result validity.
The client needed a fully automated solution capable of significantly reducing cycle times while improving reliability and repeatability. Target performance goals included reducing total stand time per part by 25–50%, minimizing downtime associated with failed connections and cleanup, and eliminating unnecessary operator interaction during automated test sequences.
To achieve these objectives, the client partnered with Re:Build Optimation to design and build a new automated connection and testing platform optimized for speed, repeatability, and high-pressure performance.
Re:Build Optimation began the project with a detailed assessment of the existing test stand, part handling requirements, connection challenges, and test sequence operations. The engineering team analyzed the full production workflow to identify sources of delay, operator dependency, connection failures, and pressure losses throughout the testing process.
A key challenge involved accommodating multiple part configurations with inconsistent connection locations while still ensuring reliable sealing under high-pressure conditions. To address this, the team evaluated a range of compliant sealing technologies, automated actuation strategies, and part verification methods capable of adapting to dimensional variation without sacrificing test integrity.
In parallel, Re:Build Optimation reviewed the hydraulic and pneumatic flow paths within the existing system to identify restrictions and inefficiencies contributing to pressure loss and extended cycle times. The controls strategy was also redesigned to automate test execution, streamline failure recovery, and reduce unnecessary retesting.
The resulting solution combined advanced automation, intelligent controls, precision sealing technology, and optimized fluid handling into a fully integrated automated test platform.
Re:Build Optimation designed and implemented a fully automated connection and testing system capable of handling multiple part configurations with improved speed, reliability, and accuracy.
Key system improvements included:
The upgraded system was engineered to support continuous production operation while improving repeatability, reducing manual intervention, and enhancing overall process reliability.
Re:Build Optimation successfully completed the automated test stand modernization within a 35-week timeline, delivering substantial improvements in production efficiency and testing reliability.
The upgraded system achieved the client’s targeted cycle time reduction goals while dramatically decreasing operator involvement during testing operations. Part load and unload times were reduced from approximately 4–6 minutes per part to less than 1 minute per part, significantly increasing throughput and reducing labor demands.
Automated connection verification and improved sealing reliability reduced downtime associated with failed connections, pressure leaks, and subsequent cleanup activities. In addition, the automated test sequencing and selective retesting functionality minimized unnecessary delays by allowing failed tests to be isolated and rerun independently.
By automating test execution and optimizing flow performance, the client gained a faster, more repeatable, and more reliable testing platform capable of supporting long-term production requirements.
The automated test stand included:
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