Validation Kit for Fluid Valve Electrical (DAIT) & Mechanical Parameters


The case study examines the deployment of a customized validation kit for fluid valve electrical (DAIT) and mechanical parameter collection to improve product quality assurance and longevity.

Client Background

An industry leader with over 80 years of industry expertise, specializing in a wide array of high-quality pneumatic and fluid control products. They were seeking a comprehensive solution to measure and validate both electrical and mechanical parameters of their large fluid valves for quality assurance and performance optimization.

Key Challenges

  • Complex Parameter Measurement: Accurate measurement and validation of complex electrical and mechanical parameters such as inductance, resistance, flap opening/closing time, max current consumption, holding current & peak current consumption which required specialized equipment and precise methodologies.
  • Integration with Existing Systems: Ensuring seamless integration of the validation kit with existing automotive testing systems and processes posed a significant challenge, requiring compatibility and adaptability to diverse setups.
  • Data Management and Analysis: Managing and analyzing the extensive data generated during validation necessitated the development of a system to organize, process, and extract meaningful insights.
  • Hardware Reliability and Compatibility: Designing robust hardware components that could withstand rigorous testing conditions and maintain compatibility with a variety of valve types and models was crucial.
  • Standardization and Calibration: Achieving standardization in validation procedures and calibration across different units and facilities was a challenge to maintain uniformity in validation outcomes.
  • Regulatory Compliance and Standards: Adhering to stringent industry regulations and compliance standards, including safety and environmental requirements, while maintaining optimal performance and efficiency was crucial.
  • Real-World Simulation and Testing: Simulating real-world conditions accurately during validation, including varying fluid pressures, temperatures, and usage scenarios, presented a challenge to replicate diverse operational environments.

Our Solutions

We designed a validation kit equipped with several key features to meet our objectives:

  • Comprehensive Data Recording and Export: An application was designed to record data with valve serial numbers and parameter statuses, exportable to Excel sheets for in-depth analysis.
  • Seamless PC Integration: The validation kit featured a PC application and USB connectivity for effortless communication with the measurement unit, ensuring easy data transfer and management.
  • Robust Hardware: The kit was housed in a sturdy aluminum enclosure with a built-in power supply tailored for efficient valve testing, ensuring durability and reliable performance.
  • Streamlined Reporting: The validation kit generated Excel-based reports, providing a convenient review of test results and efficient record-keeping essential for quality control processes.
  • Versatile PCB Design: The validation unit featured a well-designed printed circuit board (PCB) with user-serviceable parts, ensuring adaptability and flexibility for future enhancements.

Implementation Process

  • Research and Analysis: Conducted a thorough analysis of existing validation methods and available validation equipment, identifying areas for improvement.
  • Development of a Standardized Validation Procedure: Collaborated with domain experts to develop a comprehensive, step-by-step validation procedure encompassing electrical and mechanical parameter collection methods.
  • Design and Development of an Automated Data Collection System: Engaged a skilled development team to design and develop an automated data collection system that interfaces with the fluid valve and collects electrical and mechanical data accurately.
  • Engineering the Validation Kit: Collaborated with engineering teams to design a cost-effective validation kit incorporating the necessary sensors, connectors, and data processing components required for efficient validation.
  • Prototype Testing and Refinement: Constructed prototypes of the validation kit and automated data collection system. Conducted thorough testing to identify and rectify design or functionality issues.
  • Full-Scale Production and Distribution: Upon successful testing and refinement, initiated full-scale production of the validation kits. Developed distribution channels to ensure easy kit accessibility to stakeholders.

Results and Benefits


Data Accuracy and Integrity

Accurate measurement and recording of parameters ensured the integrity of collected data, enhancing subsequent analyses' reliability.


Flexibility and Serviceability

The complete PCB design with user-serviceable parts added flexibility, allowing for convenient maintenance and adaptability to evolving validation needs.


User-Friendly Interface

The implementation of a simple one-touch application activation feature ensured a user-friendly interface, simplifying users' operational experience.


Cost-Effective Solution

The comprehensive yet cost-effective hardware and software solution provided the necessary functionalities without exceeding budgets.


Integrated Hardware for Testing

Aluminum-enclosed hardware, with an inbuilt power supply, made valve testing efficient and accurate, contributing to a thorough validation.


Efficient Data Recording

The application seamlessly recorded data associated with valve serial numbers and parameter status, creating a comprehensive and well-organized dataset.


Simplified Reporting and Analysis

Exporting data to an Excel sheet allowed for simplified reporting and analysis, aiding in quick decision-making and troubleshooting.