Company Profile

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Nexus Engiconsults

ABOUT US:

Nexus Engiconsults is committed to developing open architecture based, reliable

systems on established standards such as PXI, cPCI, PCI, FPGA and Real-time. We

take pride in providing systems that are modular and upgradable, yet easy to use.

Nexus has the technical competence and operational power to proactively create

and effectively implement original solutions in the fields of Functional Testing,

High Accuracy Measurement and Control.

Nexus Engiconsults’ primary objective is to positively affect the profitability of its

customers to ensure optimal value and benefit is achieved for them. To date

Nexus’s success has been due to adherence to this governing principle.

Nexus is an ATE manufacturer based out of New Delhi. We provide customized

solutions in Test, Measurement and Control applications. In the line of work, we

deal extensively with measurement devices, sensors and signal conditioners. Over

the last three years, we have given turnkey solutions involving High Precision Data

Acquisition, High Speed Data Acquisition, Real-time Control, Image processing,

Process Automation, Radio-frequency Signal Processing and Distributed Signal

Acquisition and Control.

OUR COMPETENCE LIES IN:

1) Developing effective software based Digital Signal Processing tools.

2) Using our insight into the use of Data Acquisition devices such as Digitizers,

HSDIOs, Switches, Power Supplies, Function Generators and Spectrum

Analyzers and platforms such as Real-time controllers, PCI, PXI and FPGA.

3) Our knowledge of sensors, actuators and other electromechanical

equipment used in the fabrication of automated test equipment.

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OUR TEAM:

Nexus Engiconsults was founded in 2008 by graduates from IIT Roorkee with

majors in Electronics & Communication and Electrical Engineering. We

currently have a team of 20 engineers working on the design, development,

implementation and integration of solutions. These engineers were selected

from the most prestigious institutes of India and trained extensively in the field

of acquisition and processing.

FIELDS OF OPERATION:

1. Customized solutions for R&D applications involving high speed or high

accuracy data acquisition.

2. Mechanical and thermodynamic control applications.

3. Vision inspection applications involving color inspection, optical character

recognition or non-contact measurement.

4. Supervisory control applications on industrial production lines.

5. Advanced test and measurement systems in RF communication and

wireless technology systems.

6. Electrical Automated Test Equipment for PCB testing.

7. Automation of assembly lines or fabrication units.

Type of Measurements:

1. Strain measurements

2. NVH analysis

3. Temperature measurements

4. Position measurements

5. Pressure measurements

6. Flow measurements

7. Sound measurements

8. Force and Torque measurements

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OUR CUSTOMERS:

Nexus Engiconsults has provided more than a hundred system solutions to the

R&D, Manufacturing, Consumer Electronics, Automotive and Locomotive

industries, the Defense and Government Educational and Research

Institutions. Some of the illustrious names we have associated with are:

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PROJECTS HANDLED:

1. Automatic Shock Testing machine

This system ascertains the health of a test object by giving it mechanical

shocks and analyzing the response given by accelerometers mounted on it.

The shocks were produced using a digitally controlled hydraulic system and

the accelerometer signals were analyzed for mechanical cracks and failures.

2. Hydraulic Shocker Testing system

The shockers mounted on to this system are stroked in a sinusoidal pattern

using a hydraulic actuator system and the load and position responses are

measured using sensors to get a mechanical characteristic that tells us if

the shocker is good. The hydraulic actuator was run using a power pack and

controlled with the help of a servo valve and an LVDT. We used PID control

algorithms to great effect.

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3. Data Acquisition and Logging system

The Client’s R&D division uses this system to sense body temperature, wind

speed and coolant flow rates during tests conducted on its vehicles in its

Endurance Test Chambers. The Datalogger given by us has at its heart an NI

Real-time controller with very high signal intake and processing capabilities.

The system measures just one foot in length and 8 inches in width and

depth and is capable of performing in the harshest of conditions.

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4. Automated Brake Assembly Line

The brake system assembly involves a complex sequence of operations and

interlocking between routines. We handled the operation, monitoring and

preliminary testing using a distributed network comprising of Touch Panels

deployed on individual test benches for user interface and an NI compact

Field Point for data acquisition and control.

5. Smart Minigrid

This is typically a SCADA system that acquires physical parameters (temp.

humidity, Flow) and electrical parameters (3 phase voltage, current,

frequency, power factor) from different subdivision (photo voltaic division,

Biomass gasifier room, Retreat division, Load room) in the plant and brings

all data together in a control room through serial communication.

All physical and electrical data continuously monitor on control room

screen and logged into a specified memory location for forecasting the load

and resources.

6. Photo voltaic solar panel profiling system

The R&D unit performs various tests on the PV solar panels for optimizing

the performance. To perform various tests on the panels and profiling the

output with variation in Sunlight, wind speed and orientation an automatic

system is developed which automatically

speed and orientation and collects data from 8 solar panels to produce the

profiles for each panel on completion of the test.

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Photo voltaic solar panel profiling system

unit performs various tests on the PV solar panels for optimizing



system is developed which automatically changes light intensity, wind


profiles for each panel on completion of the test.

unit performs various tests on the PV solar panels for optimizing



changes light intensity, wind


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7. Photo Voltaic Cell testing System

The Photovoltaic Cell Testing System allows user to see the real time VI

characteristic graph of PV Modules. The system read the VI characteristic of

module and analysis different parameter of the module. In this system four

modules can be tested at a time and data will be saved in the txt file and

can also generate report for future analysis. User can configure different

parameters like Voltage range, temperature, analysis range, module details

etc which is useful for module testing.

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8. Core inductance testing system

The C-cores manufactured by Hitachi Metglas Gurgaon are used in Air

Conditioning and the power factor of the core determines the energy

consumed and hence the efficiency. To ensure reliability and uniformity in

the test of these cores, an automatic test system is developed which

controls the input frequency signal and determines the power factor. The

system consists of an Agilent Function generator , a wide band amplifier

and a Clarke Hess power meter. All the instruments are controlled by a PC

using GPIB communication.

9. Data Acquisition system

There is a requirement for a PC based system for acquiring and analyzing

the various electrical and speed parameters of the Mixer/Grinder motor

that helps the user to design a optimize power rating and cost effective

universal AC grinder/mixer motor for various loads in the different load

conditions. The system also include a dynamometer unit for simulate the

load on the test piece that is also controllable through PC system.

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10. Endurance and fatigue testing lab

There are about five to seven test rig that has to be automated for the

endurance and fatigue testing of the vehicle parts (like four wheeler

chassis, cabin, leaf spring, Fuel tank, drive line etc).

There is hydraulic based actuator system that has to be controlled on the

real road conditions data and generate the report for the test results.

The beauty of the software application is that a single software application

(Build in Lab VIEW and FPGA) is able to control the all test rigs whether it is

single or two or more than two actuator system with very high accuracy

and speed.

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11. EL-60 Load sensor testing

This is a functional testing of one of their component El-60. There are

several control valves and pressure transmitter. The challenge was to

operate the control valves in a defined sequence for different functional

tests, logged the data and generated the test report.

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12. Ball Joint Test Rig

There is a requirement of endurance and fatigue testing of Ball Joint used in

the automotive assembly. So there is a need to control the hydraulic

system that is loading the test piece and acquire the feedback data and

logged them.

Endurance Test: In this test the load is applied at a particular frequency for

a particular number of cycles. In this test there are two modes

o Synchronous Mode: In this both Load and Angle are applied

at same frequency

o Asynchronous Mode: In this mode either Load or Angle can

be applied as per the selection in parameters window.

Fatigue Test: In this the load is applied and increased gradually to check

the bending up to a particular limit.

13. Wire harness microsecond continuity level testing

The wire harnesses manufactured are to be tested up to a microsecond

level of discontinuity. The requirement is for better safety of the vehicles

manufactured by the customer of Motherson. Using a high speed digitizer

and LabVIEW software a system is being developed to detect the

discontinuity and the duration of each discontinuity.

14. Gear Test Rig

This is an endurance and fatigue test rig for testing the drive line assembly

of four wheelers.

The Drive line assembly was testing with simulated real time data. The

challenge was to simulate the torque and speed data in different road

conditions and run the endurance test for whole drive line including gears,

propeller shaft, differential gear box

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propeller shaft, differential gear box etc.





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15. Leakage Current testing

There is a 1000 volt supply connected to the solar PV cell. Challenge was to

measure the leakage current on four channels & supply voltage on one

channel (measure current as low as uA & voltage of 1KV together). If at any

point current value is above than the permissible value then raise alarm &

stop scanning that particular channel.

16. Brake Accelerator test rig

This is a functional test rig for brake accelerator test piece. In the test rig

there are several pneumatic control valves and pressure transducer that

has to be controlled in a defined test sequence and acquire the pressure

data, monitor continuously and logged that.

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17. Headlight Lamp Geometry Inspection System

The project involved snapping the bulb from three directions, processing the

image for measurement of filament dimensions and orientation, and

comparing them with the standard specifications for validation. This was done

using FireWire cameras on a Real-time controller. The vision system gave

reliable results for a resolution of 30 microns.

18. Fuse-box Inspection System

This is a PC-based system which is aided by a high-resolution USB Color

camera for image acquisition. Using Color matching and Optical Character

recognition, we successfully recognized individual fuses on a fuse-box and

compared them to a template for position validation.

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19. Online Battery Inspection System

The system inspects batteries coming out of a production line for visual

defects from two angles. For this, two cameras were used – one a CamLink

color camera and the other a Firewire monochromatic camera along with a

desktop PC for processing. The inspection involves color recognition,

pattern matching and optical measurement. The system validates the test

specimen in very good time and removes the element of human error.

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CONCLUSION:

Nexus Engiconsults provide custom solution in test, measurement and control system .We look

forward to hearing from you and discuss any application and need in the field of test,

measurement and control system.

Please feel free to contact us on below given contact details.

CONTACTS:

NEXUS ENGICONSULTS PVT. LTD

Head Office

A-115,2nd

floor Main Vikas Marg

Shakarpur New Delhi-110092

Work Office

E-112, 2nd

floor Sector -6

Noida-201301

Email ID: [email protected]

Website: www.nexusengiconsults.com

Tel: 0120-4541595

Mob: +91 9810769831/ 7838371805