Universal PCB Functional Tester

A functional PCB tester is a critical machine used in electronics manufacturing that ensures the quality and reliability of populated printed circuit boards.https://suvastika.com/ats-for-pcb-testing-a-revolutionary-software-by-su-vastika-to-check-tp-points-of-pcb/

It performs automated tests to verify the electrical connections, components, and features/functionally of the populated  PCB and helps manufacturers maintain consistent quality across different batches of products.

The PCB Functional testing machine consists of a hardware platform that includes test probes, switches, and other measurement instruments and a software system that controls the test sequence and records the test results.

The software is usually designed to be highly customizable, allowing manufacturers to define their tests and specifications and to add new tests as needed.

PCB functional testing machines are essential for ensuring the quality and reliability of electronic products because catching defects early in the manufacturing process can save manufacturers time and money by preventing costly rework in the field or product recalls which can impact reputation and future sales.

They are also essential for maintaining consistent quality across different batches of PCBs, ensuring that products meet the required standards and specifications even if some components change across clusters.

There are many functional testers available in the market. Some functional PCB testers are designed to test the PCB’s functionality and program the microcontroller on the PCB.

These testers are often equipped with programming tools, such as an ISP (in-system programming) or JTAG (Joint Test Action Group) interface, to program the microcontroller directly on the PCB. Suvastika’s PCB Functional Tester has this capability inbuilt.

However, not all functional PCB testers are designed to program microcontrollers. Some testers may only be capable of testing the functionality of the PCB and not programming the microcontroller. In this case, a separate programming tool would need to program the microcontroller, which is an additional step and hassle in production.

It’s essential to check the specifications of the specific functional PCB tester you are thinking of using to determine if it can program the microcontroller on the PCB.In-circuit testing – Wikipedia

Salient Features:

  • Fully Automatic PCB Functional Testing machine  with cloud  connectivity
  • Modular Jig fixture to handle different PCB variant
  • The standard jig can support up to 40 test points and can be expanded easily
  • Can check AC/DC voltage, Current, Resistance, etc., for each test point
  • Automated MCU firmware Programming and verification
  • Automated calibration of parameters
  • UART interface for protocol-level testing or board configuration
  • PC Interface: 2x USB 2.0
  • Operating voltage 230V, 50/60Hz
  • Weight: 12-15 Kg, depending on the instrumentation
  • Dimensions: 18 inches (L) x 18 inches (B) x 25 inches (H)
  • Operating Temperature: 0 – 45 Degrees C
  • PC Software
  • Operator Access Control
  • Testing Jig Configuration
  • Test Program Creation and modification
  • Thermal printer Interface for printing QR code stickers (PASS, FAIL)
  • Test data is stored in the local database as well as synched with the Cloud
  • Smart Factory Cloud Platform to monitor PCB Functional testing Remotely
  • Designed and manufactured in India
  • Customization is possible on request

Suvastika is also offering PCB Functional Testing on a Subscription basis which is the first time any company is offering it as an enterprise solution.

Application of PCB Functional Tester:

  • Automated Production testing of analogue/digital electronics assemblies (PCB tests). Functional testing for products like Inverter/UPS, BMS, sensors, Dataloggers, Controller cards, display cards, and any PCB needs functional testing.
  • Alternative to expensive high-end testers
  • Automation of manual tests in the R&D and Validation department.
  • The repair departments in the factory can use PCB functional tester to quickly find issues instead of debugging the board manually by spending hours.

Parts of PCB Functional Tester

There are three main parts in a PCB Functional Testing Setup

  1. Testing Jig
  2. PC Software
  3. Smart Factory Cloud Platform

For PCB Functional Testing, one needs PCB Function testing Jig, A PC, and software, and if remote monitoring is required, then a cloud-based intelligent factory app.

Windows PC software allows one to configure the PCB functional tester for any PCB with any number of test points, and you can set how many points to be tested, the maximum, and minimum voltage/current/resistance value, how many samples need to be used for averaging, etc.

Operator/Admin access control can be provided using ID/ password or QR code scanning.

One can save different test programs for each PCB or its variant and then can select to start using it for the test quickly.

While running, PC software shows the testing progress and status of each test. Each test point measurement is compared with its configured min and maximum value, and the result is displayed as PASS or FAIL, along with the actual measured value for that particular test point.

In the image above, the right-hand side panel is the terminal view, which allows an operator or floor supervisor to see the progress in more detail. This helps quickly find the issue in case PCB functional tester is not working or misbehaving.

PC software automatically generates the serial number based on Date, Time, Factory Code, Jig Code, and serial number, which helps one to identify the PCB in its complete lifetime.

QR code will be posted on the PCB once testing is completed.

Test result data is stored in the local database and pushed to Suvastika’s Smart Factory cloud platform, where Factory managers can easily monitor the testing progress and the result.

Suvastika’s Smart Factory Cloud App

Cloud Platform Login: This is the log page of Suvastika’s Smart Factory Cloud Platform. One can log in using an authorized email id and password.

List of different variants of PCBs tested (in the selected duration)

Once login is successful, you can see all other variants of PCBs getting tested and their pass-fail count with percentage. This gives a perfect overview to the factory manager.

One can change the period to see the status during that period, like if you want to see which PCBs got tested last month.


List of all Serial numbers of a particular PCB variant

If the Factory manager wants to see details on a specific variant of the PCB that is getting tested, the eye icon can be clicked, and the screen below will open where the list of PCB with their serial number and other information like test duration, who is the test engineer, pass/fail status are listed.

Detailed view showing each test point

Factory managers can go into further detail by clicking on any serial number, and then the screen, as shown, will be displayed. Here you see a list of all tests carried out on the PCB and its result.

This helps the factory manager see what’s going on in minute detail and gives complete control.

Production Trend with Pass, Fail

For quick analysis, Suvastika’s innovative factory platform provides a trend view where the factory manager can see how production progressed for a period, like in this month so far or last month, or during the selected period, which could be the last 6/12 months.

This view is critical to see if production is improving and if failures are getting controlled after specific changes made by the team. Etc.

The best part is no one needs to take manual reading to do this analysis. Everything is automated and manipulation-proof.

Suvastika’s team is constantly working on improving the features of its PCB Functional Tester, its associated PC software, and the Smart Factory Cloud Platform.