Automatic In-Line Test System

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For a complete automated production test of various electronic assemblies and PCBs, an In-Line test system with automatic component handling was developed. The system is designed to test different products with a simple fixture kit refitting in the test cell. Typical DUTs include circuit boards for power supplies and several other electronic PCBs.

Highlights

  • Fully automated test cell with multi-stage contacting (ICT, Boundary Scan, FCT)
  • Both single boards and panels can be tested on this system.
  • Unloading station with pass/fail parts sorting
  • Flexible system, can be reconfigured for various products
  • Standard Hardware, available worldwide
  • Standard, expandable Software
  • PXI-based instrumentation, standard technology available worldwide
  • Analog bus extension "ABex" for efficient signal routing and wireless test integration
  • Loading station for PCB-magazines
  • width adjustable PCB conveyor belt with Data-Matrix-Code scanner

Features

  • A multi-level software model is used to control the entire system. The actual test application is based on standard software modules and is installed on the main test computer. This application includes an intuitive Operator Interface, which can be used to execute DUT-specific test sequences. These test sequences are implemented in NI TestStand by using the Konrad TestStep Library.
  • The Konrad PLC Communication-Server serves as an interface to the PLC in the test cell; its functions are integrated into the actual test sequence. The mechanical components communicate with each other over SMEMA interfaces.
  • All parameters and limits in the test application can be modified easily.
  • All test data is stored and transferred to the installed traceability system - this was accompanied by the connection of the test system to the customer's information management system.

Instrumentation

The test system's instrumentation has been built using standard instruments on the PXI standard. Instruments include:

  • NI PXI-4110: Power Supply 0-6V, 0-20V, -20-0V, 46W
  • NI PXI-4130: SMU and 4Q Power Supply /Load (10W)
  • Konrad ICT System: PXI based guarding Amplifier + 172x4 channel switching matrix, 16 Bit ADC board
  • NI PXI-6528: isolated Digital I/O board
  • NI PXI-2569: 100x 60V/1A SPST Relay board
  • NI PXI-5402: 20 MHz function generator
  • NI PXI-4072: 6,5 digit DMM and LCR Meter
  • NI PXI-5114: 250 MHz Oscilloscope
  • NI PXI-2593: 500 MHz 16x1 Multiplexer
  • NI PXI-7813R: 160 channel DIO board with FPGA

Test Cell KT-3500 "FlexCell"

An essential component of the entire system is the Konrad Test Cell "FlexCell", which facilitates testing of various products. By implementing the FlexCell, a base system was created, both modular and space saving and with an open architecture. To decrease the boot and reset time, parallel operation for all components was implemented (4-way or 8-way, alternatively). Successfully tested PCBs or panels are marked accordingly by a marking system. Contacting is carried out in multiple stages over product specific fixture kits and a servo drive. For this reason, an In-Circuit test, Boundary Scan Test as well as a Functional Test can all be carried out successively in one single test cell. The instrumentation was designed as a PXI system extended by the analog bus "ABex". This offers the following advantages:

  • Wireless connection at the upper fixture kit
  • rugged Virginia-Panel interface
  • Terminal-Module concept for fast test integration
  • Analog bus for flexible signal routing and easy maintenance

Application

  • ICT
  • FCT
  • Boundary Scan