Retrofitting Legacy Systems with Modern Automation Capabilities
Case Studies
Existing Fixture Design Development
Traffic Control Industry
A traffic control industry client sought to modernise their existing testing infrastructure by retrofitting their operational fixtures with automatic opening and closing capabilities.
This presented a unique engineering challenge: developing an upgrade kit that could be seamlessly integrated into fixtures already in active service, without disrupting their production schedule or requiring complete system replacement.
Challenges
Elite faced several complex technical considerations:
- Determining whether automatic operation could be successfully integrated into the existing fixture designs without compromising their structural integrity or testing accuracy
- Ensuring that any solution developed could be incorporated into future fixture designs, providing long-term value and consistency across the customer's testing infrastructure
- Developing the necessary hardware, electronics and software in collaboration with the customer's existing test system architecture
Elite's Solution
Our engineering team approached this retrofit challenge with both innovation and pragmatism, developing solutions that honoured the customer's investment in existing equipment whilst delivering meaningful operational improvements:
- Through detailed technical analysis and extensive consultation with the customer, we designed a modular automatic opening and closing kit specifically engineered for retrofitting their existing top hat assemblies
- We ensured that our design philosophy incorporated forward compatibility, allowing the automatic operation features to be seamlessly integrated into all future fixture designs - protecting the customer's investment and standardising their testing capabilities
- Our electronics team developed bespoke circuitry and connectivity solutions that interfaced perfectly with the customer's target test system, rigorously testing and validating each component to ensure reliable long-term operation
- Throughout the development process, we maintained close communication with the customer, refining the solution based on their practical experience and operational feedback
Result
The completed retrofit kit represents Elite's ability to breathe new life into existing systems, demonstrating that modernisation doesn't always require wholesale replacement—sometimes the most cost-effective and sustainable solution comes from intelligent enhancement of proven technology.
Flash Programming · in-Circuit Test · Functional test
No other company provides a wider range of test solutions for PCB manufacturers than Elite Interfaces.
Since 1986, high volume electronics manufacturers have come to us for expert analysis, design and build of turnkey test solutions for all major test platforms.
If you need a test solution for the end of your production line for panellised boards or microcontroller boards, Elite Interfaces is the one stop shop, with an unsurpassed reputation for commitment, quality and customer service. Contact us now to discuss your current test solution challenge.
