In an era where embedded systems are becoming increasingly complex, the demand for high-fidelity, high-density test equipment has never been more critical. Pickering Interfaces, a global leader in modular signal switching and simulation solutions, has officially announced the launch of three new PXI/PXIe analog output modules. These additions to their extensive portfolio are specifically engineered to address the rigorous requirements of functional test and hardware-in-the-loop (HIL) applications, providing engineers with a streamlined approach to simulating real-world signal conditions.
The new product lines—comprising precision DAC outputs, multi-channel waveform generators, and high-density thermocouple simulators—are designed to consolidate test racks, reduce system complexity, and mitigate the long-term risks associated with obsolescence. By offering superior channel density within a single 3U PXI/PXIe slot, Pickering is positioning these modules as the backbone for next-generation automated test systems.
1. Main Facts: Bridging the Gap Between Simulation and Reality
The release marks a strategic expansion of Pickering’s instrumentation capabilities. Rather than relying on repurposed general-purpose equipment, the company has developed these modules with specific simulation tasks in mind.
- The 41-770/43-770 DAC Modules: These units offer up to four fully isolated analog output channels. They are capable of voltage outputs up to ±40 V and current outputs up to ±20 mA. A standout feature is the inclusion of fault-injection capabilities, allowing engineers to simulate open-circuit conditions—a vital requirement for verifying the resilience of embedded controllers against wiring faults or sensor degradation.
- The 41-625/43-625 Waveform Generators: Catering to applications requiring complex stimulus, these modules provide up to 32 independent output channels in a single slot. Supporting frequencies from DC to 300 kHz and utilizing Direct Digital Synthesis (DDS), these generators are optimized for replicating accelerometer signals and other multi-channel sensor inputs.
- The 41-761A Thermocouple Simulator: This module sets a new benchmark for density, offering up to 32 fully isolated, two-wire low-voltage outputs in a single PXI slot. Designed specifically for temperature simulation, it provides microvolt-level resolution and handles common-mode voltages to ensure highly accurate sensor-level emulation without the need for external signal conditioning.
2. Chronology: The Evolution of Pickering’s Modular Strategy
Pickering Interfaces has maintained a consistent trajectory of growth within the PXI (PCI eXtensions for Instrumentation) ecosystem. For decades, the company has focused on modularity, beginning with basic switching matrices and evolving into sophisticated simulation.
- The Foundation: Pickering established its reputation by addressing the "bottleneck" of test systems—the interconnect and signal routing. Their early dominance in LXI and PXI switching set the stage for integrated simulation.
- The Shift to HIL: Recognizing the rapid growth of the automotive and aerospace sectors, Pickering shifted focus toward HIL test environments, where "approximation" is no longer acceptable.
- Recent Developments: Over the past three years, the company has focused on increasing channel density. The release of the 41-770, 41-625, and 41-761A series is the culmination of this multi-year development cycle, reflecting a push toward "true signal simulation." By integrating the simulation hardware directly into the PXI/PXIe backplane, Pickering has effectively removed the latency and space penalties associated with hybrid or legacy rack-mount solutions.
3. Supporting Data: Technical Precision and Operational Efficiency
The technical specifications of the new modules underscore a commitment to performance that transcends traditional general-purpose instrumentation.
Channel Density and Isolation
One of the primary challenges in HIL testing is the physical footprint of the test system. In large-scale automotive ECU (Electronic Control Unit) testing, space in the test rack is at a premium. Pickering’s ability to pack 32 isolated channels into a single 3U slot represents a significant advancement. Isolation is not merely a feature; it is a necessity to prevent ground loops and common-mode noise from corrupting low-level sensor signals, such as those produced by thermocouples.
Programmability and Flexibility
The use of Direct Digital Synthesis (DDS) in the 41-625 waveform generator allows for instantaneous frequency adjustments via software. This is a critical requirement for testing dynamic systems, such as vibration controllers or engine management systems, where frequency response must be tested across a wide spectrum. Furthermore, the ability to store independent waveforms in memory blocks for each channel ensures that the stimulus remains synchronized even in high-channel-count configurations.
Software Integration
Pickering’s approach to the software layer is equally robust. By providing an API that supports C, Python, C#, MATLAB, Simulink, and LabVIEW, they ensure that the hardware integrates seamlessly into existing test benches. The inclusion of a Soft Front Panel allows engineers to conduct initial debugging and signal verification before committing to full-scale automation scripts, reducing development time by an estimated 20-30% compared to systems requiring custom driver development.
4. Official Responses: The Philosophy of "True Simulation"
Stephen Jenkins, Simulation Product Manager at Pickering, emphasizes that the core value proposition of these modules lies in their "purpose-built" nature.
"Building on Pickering’s industry-leading position in modular signal switching and sensor simulation, our expanding portfolio of PXI/PXIe analog output instrumentation modules spans a broad spectrum of electronics test applications," Jenkins stated. He noted that the primary goal was to move away from "repurposed general-purpose instruments" toward hardware that understands the specific electrical characteristics of the sensors it mimics.
"These new analog output modules deliver true signal simulation, not approximation," Jenkins added. "Each module is designed to accurately replicate real-world sensor or signal behavior for a specific simulation task—thermocouple, DAC, or arbitrary waveform—enabling more realistic and reliable automated testing than general-purpose voltage sources or arbitrary waveform generators."
This perspective highlights a fundamental shift in the test and measurement industry: as DUTs (Devices Under Test) become smarter, the tools used to test them must mimic the physical environment with higher degrees of accuracy to catch edge-case failures that general-purpose tools might overlook.
5. Implications: Shaping the Future of Automated Testing
The introduction of these modules has several far-reaching implications for the test and verification landscape.
Reducing Rack-Space Inflation
In the aerospace and defense sectors, where test systems often reside in remote or space-constrained facilities, the consolidation provided by these high-density modules is a significant cost-saver. By replacing multiple pieces of rack-mount equipment with a single PXI chassis, manufacturers can reduce power consumption, cooling requirements, and footprint, while simultaneously improving signal integrity by shortening cable runs.
Mitigating Obsolescence Risk
A perennial challenge for long-lifecycle programs—such as those in the automotive and energy industries—is the obsolescence of test hardware. Because Pickering adheres to the open PXI/PXIe standard, these modules provide a degree of future-proofing. If a controller needs to be upgraded in five years, the PXI backplane remains, allowing the test system to evolve incrementally rather than requiring a complete, costly "rip-and-replace" cycle.
Enhancing Fault Injection Capability
The modern push toward functional safety (as seen in ISO 26262 for automotive) requires rigorous fault injection testing. The ability to simulate "open-circuit" conditions and other failure modes via software, as enabled by the 41-770/43-770 series, transforms fault injection from a manual, time-consuming process into an automated, repeatable sequence. This is essential for achieving the high levels of diagnostic coverage required by modern safety standards.
Global Reach and Reliability
With operations spanning the US, UK, Germany, and beyond, Pickering Interfaces ensures that these modules are supported by a global infrastructure. This is critical for multinational OEMs who require consistent test platforms across their global manufacturing facilities. The ability to deploy the same PXI-based HIL system in a plant in China as in a lab in Germany provides for a level of consistency that ensures "golden unit" correlation across the entire production lifecycle.
Final Assessment
Pickering Interfaces has successfully aligned its product roadmap with the core challenges facing modern test engineers. By focusing on density, isolation, and specialized simulation accuracy, the 41-770, 41-625, and 41-761A series modules represent a maturation of modular test architecture. As the electronics industry continues to push the boundaries of what is possible in embedded control, tools like these will remain essential for ensuring that the systems we rely on—from autonomous vehicles to industrial energy grids—are safe, reliable, and rigorously tested.
