Caterpillar Machine Controls Electronic Testing Device

Caterpillar tests electrical systems by simulating system failure using breakout boxes that communicate with various equipment subsystems via an electronic control module. The sponsor charged the team with designing an automated breakout box with a laptop-based graphical user interface to report results to the user. The designed system consists of an interface box in the cab, and a main box by the electronic control module being tested. The laptop connects to the interface box, where system power is provided by equipment being tested, and houses a microcontroller, LED indicators, and a memory card. The main box houses 18 printed circuit boards, each consisting of 14 relay boards, a power board, a signal control unit, and a fault rail. Relay boards control signals from the electronic control module, sending them through by default or sending signals to the fault rail, which performs tests and records results. The signal control unit facilitates testing and the power board distributes power from the truck to the test system. The entire automated breakout system is controlled by a custom user interface that allows tests to be performed at the click of a button. Tests can also be put in a queue and run without an operator.