CLIENT

Intellisense Systems, Inc. is a technology innovator and advanced systems integrator specializing in cutting edge sensors, wearable technologies, augmented intelligence, and visualization/display systems. Their business is committed to providing Department of Defense and commercial customers with innovative and cost-effective solutions to enable complete battlespace dominance. They are best known for their 3-lb, unattended Micro Weather Sensor (MWS) that can be hand emplaced or air dropped anywhere in the world to support military operations or used by Firefighters and first responders in contingency operations. These highly complex sensor suites require detailed quality inspections to ensure they are fully functional before delivery.  

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CHALLENGE

Time is money. Labor-intensive quality inspections impact both cost and lead time of these advanced technology systems. As order quantities increase, these effects become amplified and thus finding a way to automate this process is important to ensure efficiency. The complexity of the MWS makes automated testing that much more difficult. There are also multiple variants of the MWS which contain different sensor combinations that need to be accounted for.

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MOTIVO’S SOLUTION

Motivo worked closely with Intellisense throughout the duration of the project to determine what features would provide the best results and user experience. The final solution was a desktop unit with place-and-play functionality for minimal operator instructions: the technician can load a MWS and simply walk away. The automated test equipment contains a precision machined base plate which self-locates the unit under test before a 3D printed hat containing weather simulators actuates into place. The test equipment is able to excite and record the responses to a multitude of simulated weather related events and phenomena.

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OUTCOME

Motivo developed fully automated end-of-line testers ready for the manufacturing floor. The project went from initial ideation to a working first article unit in eight weeks and delivered multiple final production units eight weeks after that.

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