Case Studies
Microsoft Uses NI LabVIEW and PXI Modular Instruments to Develop
Production Test System for Xbox 360 Controllers
Author(s): D.J. Mathias, Microsoft
Product Used: LabVIEW, Modular Instruments, Oscilloscopes/Digitizers, PXI/CompactPCI
The Challenge: Developing a comprehensive, low-cost production test system for the
Microsoft Xbox 360 wired and wireless controllers.
The Solution: Using a flexible, automated test system based on Microsoft Windows XP,
Microsoft SQL Server, National Instruments LabVIEW, and NI PXI modular instruments to test
the functional performance of the Xbox 360 controller, both wired and wireless versions.
Designing Powerful Controllers for a New Generation of Gaming
In 2001, Microsoft deployed a PXI-based end-of-line functional test system for the original Xbox
controller using NI LabVIEW and PXI modular instruments. The system tested device
communication and monitored data packets at the bit level to verify that all controller-functional
messages were within specification. The system also monitored signals at the chip level to
analyze the electrical signals for parameters such as rise/fall times, minimum/maximum voltage
levels, and current draw.
In May 2005, Microsoft announced its latest innovation for digital entertainment and gaming, the
Xbox 360, along with a new line of Xbox 360 wired and wireless controllers. The Xbox 360 wired
controllers use a versatile, low-cost USB interface to communicate to the main game console.
With the USB interface, the system easily accepts additional peripherals such as dance pads
and steering wheels. The Xbox 360 controller-functional test system needed to perform similar
tests to those of the original Xbox controller test system, but demanded higher-performance
signal capture to qualify the signal integrity of the new controller and ensure a high-quality user
experience. With the latest NI modular instruments, including the NI PXI-5124 12-bit, 200 MS/s
digitizer, we met the increased functional test requirements for the Xbox 360 controller. Using
the LabVIEW graphical development environment, we created more than 100 tests,
implemented Ethernet communication, and incorporated a data storage interface to our
Microsoft SQL Server database.
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Microsoft uses PXI and LabVIEW to ensure a quality gaming experience with the Xbox 360.
PXI Modular Instruments for Design Validation and Production Test
Using PXI instrumentation and LabVIEW, we built the test system in our Xbox 360 controller
design validation lab and recently deployed it to our production line. During the validation and
production cycle, the following NI PXI-based modular instruments provided us with a broad
range of measurement functionality:
PXI-5124 high-resolution digitizer for USB communication interface analysis
PXI-4472 dynamic signal acquisition module for vibration feedback motor analysis
PXI data acquisition modules for general-purpose analog I/O measurements
PXI-6509 digital I/O module for general-purpose I/O control
We rapidly adapted the test system capabilities to meet our requirements for both the validation
lab and production test by taking advantage of the broad range of PXI functionality, PXI
modularity, and the PXI software-centric measurement approach.
The PXI-5124 high-resolution digitizer is a key component in the Xbox 360 controller end-of-line
functional test system. The 200 MS/s real-time sampling rate and 12 bits of resolution on the
PXI-5124 digitizer helped us verify the signal integrity of the USB communication between the
controller and the Xbox 360 console with confidence. The high-resolution input and high-speed
sampling rate are important features that make the digitizer a low-cost, quality solution – and a
better option compared with higher-cost and lower-resolution oscilloscopes – to capture,
monitor, and analyze the Xbox 360 controller USB signals, audio signals, and serial data
signaling.
NI LabVIEW Interfacing with Microsoft SQL Server, TCP/IP, and ActiveX
Controls
Functional test is a key component to any production line. The challenge in developing a
production line functional tester is to package as many parallel test scenarios as possible within
the given production cycle time. With the new functional test system for the Xbox 360 controller,
we implemented a test strategy that resulted in a 100 percent increase in our test throughput
per test station.
We used LabVIEW to run multiple tests in parallel to maximize test coverage during the given
production cycle time, and we used the LabVIEW Database Connectivity Toolkit to connect to
our Microsoft SQL Server database to store every unit under test (UUT) parameter. As each
Xbox 360 controller rolls off the production line, each completed test sends more than 110 data
parameters to the dedicated Microsoft SQL Server for post-test analysis to implement future
production line and device enhancements. Using the integrated TCP/IP and support for
embedded ActiveX controls in LabVIEW, we communicated to the USB and wireless controllers
through our custom interfaces. Overall, LabVIEW helped us develop an optimized end-of-line
production test system for the Xbox 360 controller with data storage to our Microsoft SQL
Server, communication through TCP/IP, and programmatic interaction with ActiveX controls.
Microsoft Sees Results Using NI LabVIEW and PXI Modular Instruments
At Microsoft Corporation, we developed a versatile validation and end-of-line production test
system for the Xbox and Xbox 360 controllers using Microsoft Windows XP, LabVIEW, and PXI.
With the PXI-based system, we can achieve reliable production line testing and store all
parameters to our Microsoft SQL Server. Using the high resolution input and high sampling rate
of the PXI-5124 digitizer, we acquire our test signals with 12 bits of resolution at data rates up to
200 MS/s, which provides a low-cost automated test system. Finally, using the power of the PC,
we continue to easily upgrade and maintain our system today and for future development.
For more information, contact:
D.J. Mathias
Microsoft
One Microsoft Way
Redmond, WA 98052
Tel: 1-800-MICROSOFT
U.S. Navy: Developing Digital Test Equipment for Navy Aircraft
Communications Using NI LabVIEW and the PXI Platform
Author(s): Lawrence M. David Jr - ALE System Integration, Terry Stratoudakis, P.E. - ALE
System Integration
Product Used: LabVIEW, PXI-8196 RT, PXI-4060, PXI-6542, High-Speed Digital I/O, PXI-8196,
Digital Waveform Editor, Digital Multimeters, NI-HSDIO
The Challenge: Developing a small, versatile test system that mimics the on-board
communications of a military aircraft and analyzes the communications for accuracy and
completeness.
The Solution: Using the NI LabVIEW graphical programming environment, NI Digital
Waveform Editor software, and PXI hardware to design and develop a flexible and
comprehensive test system.
Using the NI LabVIEW graphical programming environment, NI Digital Waveform Editor
software, and PXI hardware to design and develop a flexible and comprehensive test system.
"The analysis capabilities of LabVIEW were instrumental in filtering and cross-referencing
results from multiple categories of tests to pinpoint circuitry defects. "
When a local high-tech electronics firm was awarded the contract to supply a communications
interface hub for a Navy surveillance aircraft, it was also tasked with designing digital test
equipment (DTE) to verify the initial functionality of the interface and provide ongoing verification
for 20 years of field maintenance. Using a PXI platform from National Instruments, ALE System
Integration provided expertise in hardware integration and software development for the system.
Using the National Instruments PXI platform, ALE System Integration developed a system to
test communications equipment onboard naval aircrafts.
System Requirements
The interface unit (the end product being tested) was designed to coordinate all the aircraft’s
digital and analog signal routing, including the internal intercom, external radio, radar, and all
digital instrumentation. The interface needs to correctly process all appropriate signals while
ignoring corrupted signals and noise. To verify this functionality, the DTE needed to inject all
valid and invalid signals and interpret the interface’s responses.
In addition to verifying the aircraft’s functionality, the DTE needed the capability to perform a
self-test operation and the flexibility to perform a one-time design verification including all flight-
worthiness tests; additional electromagnetic interference tests; and a series of physical tests
such as the highly accelerated life test (HALT), explosive atmosphere, salt atmosphere, and
thermal cycling. The DTE also had to be able to inject and interpret the wide range of signals
onboard the aircraft including analog audio, serial (9600 baud), high-speed digital (5 MHz), and
MIL-STD 1553, a military standard serial data bus that features a dual redundant balanced line
physical layer, time division multiplexing, and a half-duplex command/response protocol.
Designing the DTE with PXI Hardware from National Instruments
The DTE was implemented using an NI PXI-8196 embedded controller containing the following
modules: NI PXI-6513, NI PXI-6542, NI PXI-2569, NI PXI-6511, and NI PXI-4060. The PXI-6542
module was used at a clock speed of 20 MHz allocating four bits per tick of the 5 MHz device-
under-test (DUT) clock, thus improving test accuracy. The NI-HSDIO software greatly reduced
development time. The system also included a Condor QPC-1553 from GE Fanuc Embedded
Systems that included LabVIEW drivers to further simplify software development.
We also used two programmable power supplies, a 3-phase AC supply (GPIB) at 400 Hz to
mimic the aircraft’s power, and a DC supply (USB) to mimic internal supply circuitry. Both
programmable power supplies were interfaced to the system via the USB and GPIB ports of the
PXI-8196 embedded controller.
Analyzing Digital Test Data with LabVIEW
With a graphical user interface (GUI) developed using LabVIEW software, the technician
experiences improved flexibility in configuring test runs of any of the 10 categories of tests in
addition to a DTE self-test. The analysis capabilities of LabVIEW were instrumental in filtering
and cross-referencing results from multiple categories of tests to pinpoint circuitry defects. One
constraint of this project was the simultaneous development of the test system and the interface
unit. However, two major advantages of using LabVIEW to develop this system were the
prototyping and debugging capabilities including custom probes and highlighted execution. The
code developed for the test system was reused to carry on the ongoing tests for the system.
We were able to develop the test system with ongoing changes to the specification and give
invaluable support to our client in their own development process. The key to this success was
the NI Digital Waveform Editor software. With this tool, our client created digital waveform files
using the editor, which we then fed into the test system. The resulting digital data file was easy
for our client to review. Overall, this was a great experience for our client. Using the LabVIEW
and PXI platform, we delivered software faster than our client expected, and we were able to
integrate seamlessly with their team.
For more information, contact:
Terry Stratoudakis,
P.E. ALE System Integration
United States
terry@aleconsultants.com
Sanmina-SCI Exceeds Throughput Goals with PXI Tester and
Multithreaded Software
Author(s): Mike Oehrlein, Sanmina-SCI Corporation
Product: Digital Multimeters, LabWindows/CVI, Modular Instruments, NI TestStand,
PXI/CompactPCI
The Challenge: Developing a compact and high-speed functional test station that performs
parallel calibration on eight medical devices.
The Solution: Using National Instruments LabWindows/CVI, NI TestStand, and high-
performance PXI modular instruments to develop an automated and modular production tester
with database and statistical process control capability for medical device calibration.
Test System Requirements
Sanmina-SCI, one of the world’s leading contract manufacturers, recently developed a test
application for a medical device that measures blood glucose levels by measuring the current
and impedance characteristics produced from an electrochemical reaction. We needed to build
a functional test and calibration system that complied with FDA regulations, calibrated the DC
amplifier circuits of the measurement engine, and verified the operation of other critical support
circuits contained within the device under test. Additionally, in real time, the system had to
switch a variety of input loads into the measurement engine to emulate the complex task of
simulating blood response. Lastly, the system had to reliably and repeatedly process up to
83,000 devices per week while maintaining a cycle time of effectively 30 seconds per device.
Because of these requirements, we chose a flexible software framework that facilitated
multithreaded parallel testing; efficient communication with commercial databases; and a
custom software interface with strict user management for administrators, supervisors,
engineers, and manufacturing operators.
Compact, High-Speed Test Solution
The Sanmina-SCI design team knew from previous experience that a design solution based on
traditional instrumentation alone could not meet test-throughput needs. For this application, the
design team needed to build a hybrid test system based on PXI and GPIB modular instruments
as well as a custom FPGA-controlled interface to the device under test that could test eight
devices in parallel. The completed test system included eight NI PXI-4070 6½-digit FlexDMM
devices, eight NI PXI-6533 high-speed digital I/O modules, an NI PXI-6508 general-purpose
digital I/O module, a GPIB-based power supply, and an LCR meter. The FlexDMM delivered the
throughput and accuracy the design team needed to acquire all of the voltage and current
measurements on the device under test. The design team used the PXI digital devices to
communicate with the DUT and write the calibration values to the onboard EEPROM.
We chose NI TestStand for test management software because it provided test sequencing of
LabWindows/CVI and C# .NET modules, native parallel testing support, and a comprehensive
user management framework. Its flexible and open source code operator interface also gave
our design team full control over the look and feel of the operator interface. Rather than worry
about thread management and synchronization, we could use NI TestStand to focus on the
details of the test management process. We used LabWindows/CVI for test module
development because of the built-in test and measurement functions and user interface
controls, in addition to the SQL database connectivity capabilities. With LabWindows/CVI, we
could create highly efficient ANSI C source code that integrated with modular instruments and
GPIB. By using commercially available software such as LabWindows/CVI and NI TestStand,
we kept software development time and costs to a minimum.
Exceeded Yield Expectations
The PXI-based tester provided a compact calibration system that met the high-speed
throughput requirements while exceeding the initial system yield requirements by achieving
yields greater than 95 percent in production. The customer was satisfied with the completed test
system and has plans to expand the system by building additional stations to satisfy product
demand and adapting fixtures and software for the next-generation devices.
For more information, contact:
Mike Oehrlein
Sanmina-SCI Corporation
13000 S. Memorial Pkwy
PO Box 1000
Huntsville, AL 35807
Tel: (256) 882-4800, ext. 8587
www.sanmina-sci.com
