Migrating Existing Test Systems
The test hardware works. The adapters are available. The test processes have proven themselves. But the software is increasingly becoming a problem.
Many test systems remain in operation for years or even decades. A migration therefore often becomes necessary not for optimization reasons, but only when the existing solution can no longer be continued reliably from a technical or organizational perspective.
Typical triggers include:
- the software in use is no longer supported
- operating systems or computer platforms are outdated
- the original supplier is no longer available
- necessary changes are becoming increasingly difficult
- knowledge of the existing software is being lost
- spare parts or compatible components are becoming problematic
- the existing solution can no longer be extended in a practical way
In such situations, the entire test system does not automatically need to be replaced.
Continue Using Existing Technology
Replace What Has Become a Problem
Measurement equipment, adapters, wiring, and mechanical components of an existing system can often continue to perform their tasks reliably.
We therefore begin by analyzing which components can reasonably remain in use and which parts actually need to be replaced or adapted.
The goal is not to rebuild a functioning system. The goal is to replace the software foundation that has become problematic with a current solution that can continue to evolve over the long term.
Tecap as the New Software Foundation
Tecap takes over the tasks of the previous test system software on the basis of a ready-made product.
The core functions for test execution, instrument control, variants, user management, production processes, and result data therefore do not have to be redeveloped specifically for the existing system.
The customer-specific work mainly remains in the interfaces to the existing technology.
This avoids creating a new custom solution that merely replaces the old custom solution.
Assess the Existing System Before Making Changes
Understand the Existing System
A migration begins with an analysis of the existing system.
Among other things, we examine:
- measurement instruments in use
- signal routing and switching matrices
- adapters and contacting
- communication interfaces
- existing test programs
- product variants
- production processes
- result data and databases
- connections to PLC, MES, or other systems
On this basis, it can be determined which components can continue to be used unchanged and where adaptations are required.
Preserve Proven Test Processes
Existing systems often contain many years of accumulated experience.
Limits, special cases, product variants, and test procedures do not have to be lost during a migration. Existing test programs can be analyzed and, depending on the original solution, transferred to Tecap step by step.
This does not mean blindly carrying over old program code. The important point is to reproduce the test strategy and process knowledge contained within it on a new software foundation.
Clear Separation Instead of New Software Complexity
The Product Remains the Product
During a migration, Tecap itself remains a clearly defined product platform.
Its core functions are not changed or reprogrammed for every system. Project-specific characteristics are integrated through extension points provided for that purpose.
This prevents more and more customer-specific functions from becoming deeply embedded within complex runtime software over the years.
Adaptations Where They Belong
If, for example, system handling needs to be changed, this logic is placed in the intended interface or the corresponding plugin.
This also makes future changes easier to understand and manage:
- instrument integration remains within the instrument interface
- system handling remains within the intended process interface
- customer-specific communication remains within the corresponding plugin
- the actual test program remains separate from these functions
- the Tecap platform remains clearly defined as a product
This creates manageable responsibilities instead of an organically grown software structure in which a change can affect many different areas.
Migration in an Ongoing Production Environment
Modernize Step by Step
A migration does not necessarily mean replacing all components at the same time.
Depending on the system and production environment, the transition can be carried out step by step:
- retain existing hardware
- integrate instruments gradually
- migrate existing test programs
- connect production interfaces
- operate new and existing components together during the transition where appropriate
- continue developing the system on the new platform afterwards
Preserve Existing Investments
High-quality measurement equipment, mechanical components, and adapters in particular can represent a substantial share of the original system value.
If these components remain technically suitable, there is no reason to replace them solely because the software solution has become outdated.
Tecap makes it possible to continue using existing investments while fundamentally renewing the software foundation of the system.
A New Foundation for the Years Ahead
A migration initially solves a specific problem: the existing software can no longer be operated or maintained effectively.
With Tecap, this can at the same time create a platform on which future changes become manageable again.
- Continue using existing test hardware.
- Preserve proven test processes.
- Replace software that can no longer be maintained.
- Keep individual functions clearly separated from the product platform.
- Implement future extensions at defined integration points.