Introducing the unified test system that revolutionised automated test in a global technology company.

In summary;

1 › the problem

The client did not have commonality across test solutions requiring high-cost maintenance of multiple test systems to cover their portfolio of products and an inability to test multiple units simultaneously on a single test system.

2 › the solution

Collaborating from initial concept through global rollout, Amfax worked with the client to produce a universal test solution that would enable up to 16 units to be tested simultaneously through a generic test rack, an interface test adapter, replaceable port modules, generic harnesses, and replaceable cassettes.

3 › the outcome

The solution was accepted as the global test station for the client and they now require that all new products must be designed for testing on it. Eight racks and ITAs, with 64 port modules, have now been distributed globally. The system was so successful that NI requested to demonstrate a case study on the solution.

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Why a global leader sought a new solution;

With expertise in more than 120 countries, our client designs and maintains products globally, often requiring numerous bespoke test solutions throughout their portfolio. They sought to:

• decrease cost of ownership,
• maximise the use of common resources to test different units, and
• reduce downtime through easier replaceability and maintenance.

​The key requirements of the project;

The major requirements were as follows:

• ability to test multiple units and different types of units at the same time with one test solution,
• enabling parallel testing of both identical and eventually different types of units and
• be modular in design to quickly enable replacement when required.

​The collaborative process that drove project success;

Collaboration from the first phone call;

​The team at Amfax worked with the client during the early concept ideas, exploring existing solutions and understanding the long-term needs of the client.

An overview of the final test solution;

A high functionality common test rack with mass interconnect;

The common test rack involves an NI core rack, expanded with additional resources and switching functionality. A mass interconnect system is installed, using direct access kits for connectivity to PXI cards and a custom hybrid module for all other rack resources. The system contains:

• four low voltage power supplies,
• one high voltage DC power supply,
• one high voltage 3-phase AC power supply,
• a precision DC source / calibrator,
• five DC loads,
• PXI chassis and controller, with

• 160 internal relays,
• drivers for 64 external relays,
• 16×32 matrix,
• 16 channels of RS485/232 serial communications,
• multifunctional inputs and outputs,
• one DMM, and
• four scopes multiplexed.

Image modified from © MAC Panel

A minimal wiring generic interface test adapter;

An interface test adapter rests on a shelf attached to the common rack as it connects through the mass interconnect. This accepts eight port modules. In-case of failure, this is a modular attachment with replaceable PCBs, etc.

The first variant of replaceable port modules;

Within each port module is an identifying code that the common rack can interpret to indicate the variant of port module installed. Internal port module current sensors enabled individual supplies to be monitored in real time and internal relays provided 2nd layer switching allowing sophisticated signal routing to be performed.

Good quality documentation that supported the programme;

The value of a well-executed block diagram;

​Amfax designed a detailed top-level block diagram early in the project that formed the basis of collaborative design discussions with the client. Later, the initial commissioning of the test system used this block diagram as the primary source of information to identify signal path connectivity during software development.

Using the clients preferred drawing and document packages;

​To make it easy for the client to take ownership of all drawings after project closures, Amfax used the clients preferred drawing and document packages such that the client could port these into their own documentation management system to provide the flexibility for them to maintain the design in the future. This includes using Altium Designer for electrical schematics, step files and DWG files for mechanical drawings, and Microsoft Office programmes for other supporting documents, test procedures, and manufacturing build documents.

The resulting impact and on-going success of the test solution;

Why modularity simplifies maintenance and support;

If there are any issues in-service, the extended modularity reduces downtime by enabling operators to swap out a failed module (i.e. the port module), and replace with a spare and/or send the module off for repair.

Proof of concept and rollout;

After successful commissioning at a clients’ contract manufacturer, over a 2 year period, a further 8 systems were produced as “Build to Print” and deployed at all the clients contract manufacturers globally.

All new DUTS are now tested on these systems with a program in place to convert the testing of all DUTs to the new system. This requires only DUT cassettes to be designed and manufactured along with new software.

The overall impact is that the client now sees a significant reduction in the cost of test. In their own words:

“This new test system has, and continues to be, a game changer for the company. Typical lead times for supporting new DUT’s has been reduced by approximately 50%”.

For our client, it’s now accepted as the global test station; all new product must be designed to be tested on it.