AJOLLY Testing is supporting the industrialization of a new DOCSIS 3.1 modem design in Manaus - Brazil, focusing on cost reduction, WiFi and FEM optimization, and efficient production. Key actions include tester adaptation, test analysis, hardware diagnostics, and process improvement using TestStand and LitePoint tools. In the United States, AJOLLY is also developing, designing, manufacturing and installing a complete end-of-line test and calibration line for a 10G fiber access platform, including synchronization, secure personalization and firmware upgrade with IP isolation, optical calibration, smart jigs for automated testing of buttons and status LEDs, 10Gbps Ethernet throughput validation, full fiber throughput verification through OLT-based test flows, and final functional control using TestStand and National Instruments hardware. In Mexico, AJOLLY is also redeveloping a LabVIEW-based software for an automated fuse box press, implementing a DQMH architecture with optimized Ethernet/IP and database communication to boost performance and reliability.
In light of the continuous evolution of technology and the growing demands for competitiveness, AJOLLY Testing is assisting in the transition to a new DOCSIS 3.1 modem design. The main objective is to reduce production costs by redesigning the WiFi section and FEM modules, while maintaining high performance and an efficient industrialization process.
Another major project is the development, design, manufacturing and installation of a complete end-of-line test and calibration line for a 10G fiber access platform in the United States. The solution integrates TestStand-based automation, National Instruments I/O, thermocouple monitoring, optical oscilloscopes and optical power meters, together with a secure IP-isolated architecture for personalization and firmware upgrade operations. It also includes smart jigs for automated testing of buttons and status LEDs, as well as 10Gbps Ethernet throughput and full fiber throughput validation through OLT-based traffic testing, helping ensure robust calibration, traceability and production readiness.
Another project is the redevelopment of an automated fuse box assembly press machine for Yazaki, where AJOLLY Testing is reengineering the software to achieve better performance and reliability.
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The industrialization of this new DOCSIS 3.1 modem design brings several key technical challenges:
- 🛠️ Adaptation of testers and scripts: Analysis of the new specifications and updates to the test sequences to ensure optimized validation using TestStand and LitePoint IQfact.
- 📊 Support for the production pilot and test analysis: Data collection and processing to quickly detect anomalies and provide correction recommendations.
- 🧠 Hardware failure detection and collaboration with R&D: Identification of production defects and efficient communication for rapid adjustments.
- 📈 Process optimization and increased production: Improvements in test time and infrastructure to maximize production cadence without compromising quality.
- 📍 Location: Manaus, Brazil.
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Development, Design, Manufacturing and Installation of a Complete EOL Test and Calibration Line for a 10G Fiber Access Platform
- Complete industrial solution: from engineering and station design to manufacturing, installation and start-up.
- Personalization and firmware upgrade station: secure programming flow with IP-isolated network architecture.
- Optical calibration station: use of optical oscilloscopes, optical power meters, NI I/O and thermocouple monitoring to secure measurement conditions.
- Smart jig station: automated actuation and validation of buttons and status LEDs.
- Ethernet throughput validation station: automated 10Gbps Ethernet traffic verification.
- Full fiber throughput station: OLT-based traffic validation under production conditions.
- Final functional control station: complete end-of-line validation before release to production.
- Software and automation environment: TestStand-based architecture focused on robustness, repeatability and maintainability.
- 📍 Location: Portland, United States.
- Redevelopment of an Automated Fuse Box Assembly Press Machine
- Existing System: LabVIEW-based software integrating PLC and computer control.
- Issue: Machine is operational but fails to meet performance expectations; original supplier unable to deliver improvements.
- AJOLLY Testing’s Solution:
- ⚙️ Development of a new software using DQMH architecture.
- 🧩 Focus on modularity, maintainability, and robustness.
- 🔗 Optimization of Ethernet/IP communication.
- 🗄️ Improved database data handling.
- 🧪 Development of a Python-based PLC simulator for Ethernet/IP, replicating real use cases to closely match the production environment. This enables reliable validation, reduces on-site installation time, and increases deployment confidence.
- 🚨 Complete redesign of the error handling system, as the previous software reported no errors, which severely hindered diagnostics and maintenance.
- 📍 Location: Durango, Mexico.
