The Customer
SenseAir, now part of Asahi Kasei Microdevices, is a world-leading manufacturer of CO₂ and gas sensors with production in Delsbo, Hälsingland, Sweden. Their sensors are used globally in ventilation, indoor climate control, safety, and industrial measurement — applications where measurement accuracy and reliability are critical.
The SenseAir project is one of CargoBeacon's most significant customer engineering projects. Over several years, we developed a complete ecosystem of test and production systems that powers their manufacturing in Delsbo — from automated test stations on the production floor to advanced characterization systems for sensor development.
The Challenge
SenseAir needed to modernize their test infrastructure to meet growing production volumes and tightening quality requirements. Existing systems lacked parallel testing, real-time monitoring, and automated reporting. Beyond production tests, they also needed advanced characterization systems for developing new sensor models — temperature sweeps, humidity cross-sensitivity measurements, and aging tests.
Every sensor must be tested against electrical specifications, gas response, and calibration values. With multiple product variants and high volumes, a flexible system was required that could handle parallel DUTs, automated sequences, and complete data collection without compromising throughput.
Systems Delivered
Test Executive System
The core of the entire test infrastructure. A sequence-based automated test system managing the full lifecycle of each device under test (DUT). The system supports parallel testing of multiple DUTs simultaneously, with individual timeout handling and automatic retry logic for unstable measurement points.
Hardware Interface Layer
Custom drivers and abstraction layers for all measurement instruments and hardware components used in the test environment. The interface layer isolates the test sequence layer from hardware-specific details, making it possible to swap instruments without modifying test logic.
Measurement Instruments
Multimeters, source meters, gas analyzers
Environmental Control
Gas flow controllers, temperature/humidity chambers
DUT Communication
I²C, UART, SPI
Network Communication
TCP/IP-based instrument communication
Production Test Stations
Multiple test stations installed directly on the production floor, each configured for different product variants. The stations test electrical characteristics, gas response, calibration verification, and burn-in — all in an automated, operator-friendly environment.
Characterization System
Dedicated system for long-duration sensor tests that run around the clock. Used during development of new sensor models and to document sensor performance under varying conditions. Tests can run for days or weeks, producing large datasets that are analyzed automatically.
Data Collection & SPC
Every measurement point is logged in real-time to a SQL Server database. Statistical process control (SPC) calculates Cp/Cpk values continuously, monitors trends, and triggers automatic alerts when process drift is detected — before it affects final product quality.
Calibration Management
All instruments in the test environment require regular calibration. The system tracks calibration intervals, due dates, and certificates. Automatic reminders ensure no instrument is used outside its calibrated interval, and proactive scheduling reduced calibration-related downtime by 50%.
Report Generation
Automatic generation of all production reports. Test results, batch summaries, yield analyses, trend reports, and scrap statistics — all exportable to PDF and Excel. Eliminated manual reporting and ensured consistent documentation.
Technical Environment
Platform
Windows, LabVIEW
Communication
TCP/IP, I²C, UART, SPI
Database
SQL Server
Results
The systems delivered to SenseAir have had a direct and measurable impact on their production capacity and quality control. All systems are still running in production today.
Need test automation for your production?
We build custom test and production systems with full data collection and SPC. Contact us to discuss your requirements.