CTC
CTC modernizes its testing operations with a scalable, future-proof solution
With increasing demands for testing and certification, CTC needed to take the next step in its testing operations. They have developed a scalable solution in collaboration with Prevas - consolidating all data into a single platform and laying the foundation for faster and more reliable product development.
Test challenges that call for smarter solutions
“Today’s heat pumps are complex products,” says Alexander Lindberg, Head of Testing and Verification at CTC. “They need to adapt to temperature, weather forecasts, and user behavior. At the same time, they must be smart, quiet, and integrate seamlessly with both building and societal energy systems.”
CTC develops air-to-water and ground source heat pumps for the residential market. Production takes place in Ljungby, Sweden, where the company also houses purchasing, warehousing, engineering, lab facilities, and software development. Since 2017, CTC has been part of the NIBE Group.
Developing modern heat pumps requires extensive testing, and CTC faced challenges with legacy systems that had been built at different times and tailored to specific products. Knowledge and workflows couldn't easily be transferred between test rigs, and the systems were becoming outdated – all while new standards and market demands kept emerging.
“We had to use several different software tools just to get the data,” says Alexander Lindberg. “One program controlled the rig, another communicated with the product, and a third collected measurements. Getting them to work together was difficult, and we had to adjust the same parameters in multiple places to ensure reliable results.”
New platform consolidates all data and increases testing capacity
CTC turned to Prevas to develop a new, modern testing system. Prevas was responsible for all control and monitoring software, as well as sensors and other hardware for data collection. The system also included two climate chambers, a power control unit, and an extensive water circuit with tanks, valves, pumps, and heat exchangers. The goal was to build a platform that could be scaled to support parallel testing and certification processes – with full simulation of seasons, temperature, humidity, and other environmental parameters.
The major advantage is that we can manage all data collection within a single system.
Alexander Lindberg, Head of Testing and Verification at CTC
Operator-Friendly Test System with Full Overview
“The major advantage is that we can manage all data collection within a single system – both from the products and from external sensors,” says Alexander Lindberg. “The system is also designed to be further developed, allowing us to add new features and use the same foundation for testing future products.”
Prevas built the new control system using the DQMH framework in LabVIEW, giving CTC an open solution supported by a strong developer community for future development. Prevas also added a number of custom-developed modules, making the test system both flexible and powerful.
“We developed for example a sequence engine that makes it possible to set up different test scenarios,” says Linus Amoli, Consulting Manager at Prevas Test & Measurement. “Complex sequences can be built step by step, with support for loops, timers, and automated actions. This gives operators the ability to quickly create and run tests – without needing to write any new code.”
CTC also requested the ability to manually control and troubleshoot individual components and sections of the system. To meet this need, Prevas developed a schematic interface that visualizes all pipes, pumps, valves, and tanks.
“The operator can click directly on a component to adjust settings such as temperature or flow,” Linus Amoli explains. “It provides a clear overview and an intuitive way to locate and fix faults.”
Close collaboration led to a flexible and future-proof solution
Throughout the project, CTC and Prevas worked closely together to define requirements and desired features, develop a suitable software design, and create a simple and intuitive user interface. They set aside time to build mutual understanding and align around challenges and trade-offs during the development process.
“It was a complex assignment where close collaboration was key to making it all come together,” says Alexander Lindberg. “Prevas was attentive and quickly understood what matters most in our testing operations. We achieved excellent results – and stayed on track with both timeline and budget.”
Looking ahead, CTC sees a continued increase in testing needs – driven by a growing market, the development of new high-performance models, and evolving standards and certification requirements.
“We now have a very strong foundation, with full ownership of our test system and no vendor lock-in,” says Alexander Lindberg. “We’re able to adapt and fine-tune the system ourselves, and for larger development steps where we lack in-house expertise or capacity, we’ll continue working with Prevas as a strategic development partner.”