Dunkermotoren: Software Modernization for a Future-Proof Testing and Validation Platform

The existing testing and validation software at Dunkermotoren was increasingly reaching its limits due to new motor generations, additional testing procedures, and a growing number of test stations. Heavy reliance on a proprietary solution, limited scalability, long lead times and high licence and maintenance costs made it difficult to implement new requirements. 

Together with Dunkermotoren, we decided on a strategic restart and replaced the existing software with a modular testing and validation platform. The new solution reduces dependencies, supports a wide range of testing procedures, integrates new devices flexibly, and can be scaled across additional test benches and testing centers.
 

At the beginning of the project, we analyzed Dunkermotoren's existing system landscape and designed the target architecture for a new testing platform. To minimize risks to ongoing production operations, the modernization was carried out step by step. Functions and components were gradually migrated to the new platform and continuously enhanced. This approach allowed us to incorporate lessons learned from live operations while ensuring uninterrupted production at all times.

In the meantime, we developed a modular software architecture to integrate various test equipment, measurement systems and plant. We also took into account the calibration of measurement systems, as well as the evaluation and verification of measurement results, right from the start. Throughout the entire project, we supported Dunkermotoren with architectural expertise, agile development methods and the gradual empowerment of the team.

Within just two years, it became clear that the decision to invest in a new testing software solution delivered significant economic value. In addition to reducing licensing and maintenance costs, Dunkermotoren now benefits from shorter implementation times and greater flexibility in further development.

Thanks to continuous knowledge transfer, Dunkermotoren can independently expand the platform in the future and implement new functions without external support. This has significantly reduced the company's dependence on a third-party software provider.

New testing procedures, devices, and equipment can now be integrated with ease. Additional hardware such as power supplies, oscilloscopes, noise measurement systems, and high-voltage testing devices can be connected seamlessly. The modern user interface also simplifies the operation and configuration of test benches.

The modular architecture enables the platform to be deployed across additional test benches and testing centers. By leveraging our expertise in software modernization, we worked together with Dunkermotoren to create a flexible testing platform that provides a solid foundation for future requirements, technologies, and motor generations.

» Strategy: Architecture consulting, design of a modular software architecture, agile transformation and scrum coaching
» Develop: Software modernization and system replacement, development of a modular testing and validation platform, integration of testing devices and interfaces, agile software development based on Scrum
» Services: knowledge transfer and handover, maintenance and change management, continuous platform enhancement

Technologies:

• C#
• ASP.NET
• WPF
• WCF
• Angular

Interfaces:

• OPC-UA
• Ethernet/IP