TEST STRATEGIES STRATEGIE DI TEST

Transcript

1

2 TEST STRATEGIES STRATEGIE DI TEST The ideal test strategy must be defined during the development phase of every new product. Defining the testing strategy since the early stages of electronic design, can help optimising costs and increasing product quality while reducing risk of failures. The Test Solutions team within DeltaV is able to support any electronic and mechatronic designers in this analysis using his vast and comprehensive experience and specific testing tools. The test chain at production pahse. is typically optimized between Structural Tests and Functional Tests, often including direct In-circuit testing, Boundary scan testing, and firmware programming. La strategia di collaudo deve essere progettata contamporaneamente allo sviluppo di ogni nuovo prodotto. Disegnando il collaudo già nelle fasi di progettazione elettronica, è possibile ottimizzare i costi ed aumentare la qualità riducendo i guasti. Il team Test Solution di DeltaV è in grado di supportare i progettisti in questa analisi utilizzando alcuni software specifici e la grande esperienza maturata. La catena di collaudo viene così ottimizzata tra i Test Strutturali ed i Test Funzionali valutando anche le necessità di programmazioni firmware, In-circuit testing e Boundary Scan testing. p2

3 DESIGN FOR TESTABILITY PROGETTAZIONE ORIENTATA AL COLLAUDO The Design for Testability, DFT, allows designers to check the testability of the product, providing suggestions and modifications to the project for optimal chain efficiency test. With respect to electronic products it is essentially divided into two phases: - The Electric DFT, which verifies the logical connections in the wiring diagram, using the models of each component. - The Physical DFT, which verifies the accessibility to the card in order to perform structural tests (In-Circuit and Boundary Scan). La Design for Testability, DFT, permette di verificare la testabilità del prodotto, fornendo suggerimenti e modifiche al progetto per ottenere un ottimale efficienza della catena di test. Si divide essenzialmente in due fasi: - La DFT Elettrica, che verifica le connessioni logiche dello schema elettrico, sfruttando i modelli di ciascun componente. - La DFT Fisica, che verifica l accessibilità alla scheda per poter effettuare test strutturali (In Circuit e Boundary Scan). p3

4 BOUNDARY SCAN TESTING BOUNDARY SCAN TESTING The Boundary Scan testing is governed by the IEEE standards and runs on a bus at 4/5 wires, commonly known as JTAG. The vast majority of electronic devices available on the market are prepared for these tests, which is then often used simultaneously to the structural tests to significantly increase the diagnostics before functional testing. DeltaV can develop Test Sequences and Component Programming which may be used on dedicated benches, on standard ICT platforms or directly inside the Functional test benches. Il collaudo Boundary Scan è regolamentato dalle norme IEEE e viene eseguito su un bus a 4/5 fili, comunemente chiamato JTAG. La gran parte dei dispositivi elettronici disponibili sul mercato sono predisposti per questi test, che quindi viene spesso utilizzato contemporaneamente ai test strutturali per aumentarne notevolmente la diagnostica prima del collaudo funzionale. DeltaV è in grado di sviluppare sequenze di collaudo e programmazione componenti, che possono essere utilizzate su banchi dedicati, su piattaforme ICT o all interno dei banchi di collaudo funzionale. p4

5 IN-CIRCUIT TESTING IN-CIRCUIT TESTING Capability to handle varying complexity and extreme variability of projects, from double-sided contacting (Top & Bottom) to the two-level fixture (Dual level) to the direct connection to the connectors (Through connector) or vectorless technology. Possibility of programming components with variable data (MAC, IMIEI, etc.) and to perform digital test, including the Boundary Scan. DeltaV offers the full development of the fixture, the complete control of the entire building and debugging done on our machines, optimizing costs and reducing the ICT tester downtime to the end customer to which we release the solution. - AGILENT PLATFORM / PIATTAFORMA AGILENT Availability of HP 3070 series 3 with 5176 channels (2x) and HP 3070 series 1 with 2184 channels, with latest SW generation both for Unix and Win based machines. Disponibilità di HP 3070 serie 3 con 5176 canali (2x) e HP 3070 serie 1 con 2184 canali, con SW di ultima generazione sia per Unix che Win based. Capacità di gestire diversa complessità ed estrema variabilità dei progetti: dal doppio lato di contattazione (Top & Bottom) al doppio livello di fixture (Dual level) alla connessione diretta ai connettori (Through connector) o tecniche vectorless. Possibilità di programmazione componenti, dati variabili (MAC, IMIEI, ecc) e test digitali, inclusi i Boundary Scan. DeltaV offre l intero sviluppo della fixture, il completo controllo della costruzione e l intero debug dell applicazione svolto su proprie macchine, ottimizzando i costi e riducendo il tempo di fermo macchina dal cliente finale presso il quale rilasciamo la soluzione. - TERADYNE PLATFORM / PIATTAFORMA TERADYNE Availability of TS124 (including LX version with more than nodes), GR228x, Z18xx and Stinger. Disponibilità di macchine TS124 (anche in versione LX con nodi), GR228x, Z18xx e Stinger. p5

6 FUNCTIONAL TESTING TEST FUNZIONALE DeltaV is able to propose and implement solutions for Functional Testers with high quality, speed and flexibility in responding to change requests from the customer. Test benches for High Power products (700V 150A) The completeness of the solution comes from the close collaboration between the team members, including software engineers, design engineers, system designers and mechanical engineers. DeltaV è in grado di proporre e realizzare soluzioni di Collaudo Funzionale di altissima qualità, rispondendo con velocità e flessibilità alle richieste di modifica da parte del cliente. La completezza della soluzione deriva dalla stretta collaborazione tra i componenti del gruppo, che includono progettisti software, progettisti elettronici e di sistema e progettisti meccanici. General Purpose test bench to manage Product Families with the possibility to modify only the bed of nail between different products within the same family p6

7 DeltaV - Test Solutions FUNCTIONAL TESTING TEST FUNZIONALE In addition to the activities described above, the Test Solutions team offers: Mechanical design, both for the fixture of adaptation into the test bench and for any tool related to the production activities Software Design for Windows and Linux OS, using Labview and C programs led by proprietary sequencers or standard NI Test Stand Electronic design of interface cards for test benches and / or for emulation functions necessary to the testing of the product under test A complemento delle attività descritte, il gruppo di Test Development offre: Progettazione meccanica, sia per le fixture di adattamento ai banchi di collaudo che per i tool legati alle attività produttive; Progettazione software, in ambiente Windows e Linux, utilizzando programmi C e Labview guidati da sequenziatori proprietari o Test Stand; Progettazione elettronica di schede di interfaccia per i banchi di collaudo e/o per emulazione di funzioni necessarie al collaudo del prodotto sotto test. p7

8 FUNCTIONAL TESTING [EXAMPLES] TEST FUNZIONALE [ESEMPI] ENERGY METER FUNCTIONAL TESTER This tester performs the functional test of energy meters with all operations executed automatically by the tester without operator interventions. Asyncronous parallel mode to execute tests. Instrumentation and the pneumatic circuits controlled by PC. A Voltage generator and a Current generator provide the calibrated voltage and current needed during the tests. The measure instruments are National Instruments adapters. ENERGY METER FUNCTIONAL TESTER This tester performs the functional test of energy meters with all operations executed automatically by the tester without operator interventions. Asyncronous parallel mode to execute tests. Instrumentation and the pneumatic circuits controlled by PC. A Voltage generator and a Current generator provide the calibrated voltage and current needed during the tests. The measure instruments are National Instruments adapters. p8

9 FUNCTIONAL TESTING [EXAMPLES] TEST FUNZIONALE [ESEMPI] ENERGY METER SAFETY TESTER The equipment perform the electric rigidity verification of energy meters All operations are executed automatically by the tester without operator interventions. Automatic data saving of each measurement. ENERGY METER TESTER DI SICUREZZA L apparecchiatura esegue la verifica della rigidità elettrica dei contatori di energia Tutte le operazioni vengono eseguite automaticamente dal tester, senza interventi dell operatore Salvataggio automatico dei dati di ogni misurazione. p9

10 AUTOMATIC VISION SYSTEMS SISTEMI DI VISIONE AUTOMATICA The automatic vision systems are a part of the Mechatronic solutions aiming at controlling the quality of products while significantly reducing the time required for inspection. DeltaV has developed several solutions for Automatic Inspection Stations both for the verification of cards and electronic modules and for mechanical parts. I sistemi di visione automatica sono una forma meccatronica di controllo della qualità, che riduce notevolmente il tempo di ispezione richiesto. DeltaV ha sviluppato diverse soluzioni per Stazioni di Ispezione Automatica sia per la verifica di schede e moduli elettronici, che per parti meccaniche. p10

11 AUTOMATIC VISION SYSTEMS SISTEMI AUTOMATICI DI VISIONE DeltaV tipycal applications of the vision systems are: Functional tests including Display and LED verification. Check the electronic assembly of electro-mechanical products. Surface inspection to verify color, porosity, dents, scratches. Shapes and mechanical control measures. Verification of colors, positions, patterns and OCR labels. Tipiche applicazioni della visione sviluppate da DeltaV sono: Test funzionali con inclusione di verifica display, LED, indicatori per gli utenti. Verifica assemblaggio di componenti elettronici di scheda o assiemi elettro-meccanici. Ispezione delle superfici per verifica colori, porosità, ammaccature, graffi. Controllo forme e misure meccaniche. Verifica di colori, posizioni, modelli e OCR nelle etichette. p11

12 DeltaV - Test Solutions DELTAV AREAS OF EXPERTISE AREE DI ESPERIENZA The Development capabilities within the Functional Test arena are based on years of experience in many different sectors: Le capacità di sviluppo nel mondo del Test Funzionale si basano su decenni di esperienza in molteplici settori, quali: Information Technology: server and storage systems (data storage) Communication: over wire, fiber and wireless RF: from wireless busses to Mobile and Wimax/LTE Consumer: analog and digital (POS, Flat screen and Set top box) Industrial: from Combustion Control to Power Management Power Supply: at card level and final product level (including Safety Tests and Meters) Stress test: including Temperature and Vibration Imaging: product inspection (including Thermocameras and Xray) Information Technology: sistemi server e di storage (banche dati) Communication: su filo, su fibra e wireless RF: dai bus wireless al Mobile al Wimax/LTE Consumer: analogici e digitali (POS, Flat screen e Set top box) Industriale: dal Combustion Control al Monitoring di Potenza Alimentatori: sia schede che prodotto finito (inclusi Safety Tests e Meters) Stress test: incluse le variabili Temperatura e Vibrazione Imaging: per ispezioni di prodotti (incluse Termocamere e Raggi X) p12

13 LT 10 LT 10 is a self contained AOI system for system integrators. Features: Integrated image acquisition and illumination system Integrated IO with 8 inputs and 8 outputs Complete software platform with all features of Novus 15 Solder, Presence and Measurement Capability* * depending on application p13

14 HARDWARE LT 10 is compact for easy integration in existing process units. These drawings show the Head installed on a foot for integration in a system, but this may not always be needed. LT 10 mechanical characteristics: Head unit dimensions 284 (w) x 426 (d) x 366 (h) mm Head contains all image acquisition and I/O hardware Rear panel connectivity to computer (2 x USB, 1 x Ethernet) Rear panel connectivity for I/O p14

15 ...HARDWARE The optical head includes structured algorithmic lighting for 3D imaging, and white light for photorealistic images: LT 10 Image Acquisition characteristics: 5 or 10 Megapixel Camera connected by Gigabit Ethernet or USB individually controlled high power, long life LED illuminators Variable working distance (resolution varies accordingly) Choice of lenses from 23mm to 70mm according to application. p15

16 ...HARDWARE Comprehensive I/O supports 8 inputs and 8 outputs (2 outputs used normally for status lights on Head) I/O Characteristics Inputs may be passive (closing a circuit) or active (24V, 0.5A) Outputs may be passive (closing a circuit) or active (providing 24V up to 1A) Inputs individually fused, with Optical Isolation Outputs individually fused, with push-fit relays p16

17 NOVUS 15 Novus 15 is at the core of the system, a modern and powerful software designed to supervise, manage, and program a group of BlackBoxes. Programming is graphically driven based on a high level object oriented paradigm, programming is independent of the final application, the programming exists only to define the object, Novus takes care of the How to.... Novus 15 comprises a full suite of tools for remote analysis, review and repair of defects, remote and central management of databases, built in, customizable statistical software and powerful production software, easily integrated in existing visualization workstations. Novus 15 is perfectly integrated in the DeltaV Cloud for seamless delivery of updates and support tools. For fast data free programming of the Automated Visual Inspection a Golden Board concept is used, however unlike traditional bitmap comparison Novus 15 learns statistically significant features and characteristics automatically in realtime. More complex testing is possible, but unlike other systems where the algorithms require significant debug by a skilled programmer with good knowledge of the system Novus 15 provides step by step assistance, allowing manipulation of inspection parameters in real time without the need to retest repeatedly to try to understand the effects of different settings. p17

18 NOVUS 15 SOFTWARE Windows 7, 64-Bit Novus has been built for a 64-Bit environment, although it will run in 32-bit installations this is only advisable for an offline situation. Novus 15 is the name of the application that runs on the PC. Software requirements for Novus 15 are not absolute, the following are listed in order of their importance to a good user experience with the software. Display capable of 1920x1080 ( Full HD ) Many screens in Novus 15 are based upon this size and aspect ratio, using a smaller screen will be detrimental to the user experience. There is no specification made about the Regional version of the OS. It should be noted that some areas of the software observe the OS regional settings and that using these with a non-regional language selected in Novus 15 can be confusing for the user. Minimum 4GB of RAM. Novus will use as much RAM as is available, testing has demonstrated a difference in performance between a system with 4GB and a system with 6GB. For an offline station running 32-Bit then 2GB is the maximum addressable by the OS. Intel Processor, Multi-core, Faster is better Novus is multi-threading, more cores will result in better performance, but processor speed alone is not enough. p18

19 BASIC GUI ORIENTATION Upon starting the software and logging in the user will always see the Home face: The Home face gives access to the other three main faces: Production The operators interface to test product, review the results, and also have access to Novus Reports. Setup The engineers interface to create and debug programs. Maintenance The engineers interface for machine configuration, calibration and to manage the database. The interface has four main faces, which are always (dependent on user rights) available from the buttons in the top right: p19

20 PRODUCTION GUI Key Points of Novus Production GUI Choosing the Program to Inspect Loading the Board Running Inspection Verifying Defects Disposition of Defective Boards If the user clicked the large Production button (marked B) then the chooser is displayed: Choosing the Program to Inspect Before the user can inspect in Production they must first choose the Program. To be used in Production a program must have been certified in Setup. Double clicking the program will cause it to be loaded. p20

21 PRODUCTION GUI Disposition of Defective Boards At this stage the user has a number of possibilities for a bad board: Board has a (inspected) barcode Data will be recorded on the Novus Server under the read barcode, and can be recalled at a repair station later. The board may simply be removed and sent to the next station. Board has no barcode The user presses the button or key on the keypad, to print a repair ticket. The ticket may be attached to the board, and under this ID the data can be recovered at a repair station later. Board has no barcode The user presses may review the verified defects once the board has been unloaded. This sequence may be used to attach markers to components to be repaired. p21

22 ...NOVUS 15 PRODUCTION GUI Disposition of Defective Boards At this stage the user has a number of possibilities for a bad board: Board has a (inspected) barcode Data will be recorded on the Novus Server under the read barcode, and can be recalled at a repair station later. The board may simply be removed and sent to the next station. Board has no barcode (Option 1) The user presses the button or key on the keypad, to print a repair ticket. The ticket may be attached to the board, and under this ID the data can be recovered at a repair station later. p22

23 USE CASE LT 10 is best understood by studying a use case, this example is based on a real use case, but an DeltaV product has been substituted for the customer product. Product to be Inspected: Description of Product: Product is the LED illuminator as used in Insite systems. Prior to final assembly a flying lead is soldered to the three terminals. Required Control: The following characteristics must be controlled: Presence of the pin / tinned wire through the hole Correct soldering of the pin / tinned wire Possible error conditions are: No wire, no solder No wire, soldered Wire, no solder Wire (or no wire), excess solder Quality of soldering (traceability) p23

24 ...USE CASE Description of Process: The flying lead is mounted to the LED in a robotic station where it is then automatically hot iron soldered. The LED is held in a carrier for the duration of the operation. LED unit enters process Flying lead is inserted Terminals are robot soldered Completed part to inspect Good parts proceed further in the process, bad parts are rejected as scrap. There is no operator intervention in the decision to scrap. p24

25 ...USE CASE Timing Diagram Operation of the system is controlled by a PLC, using 4 I/O signals to interface with the LT 10: p25

26 ...USE CASE Inspection Description The small area to be inspected (3 terminals) is covered by a Field of View (FOV) of 12x9mm, obtained with a focal length of 70mm, and working distance of 35mm. This FOV with a 10 megapixel camera yields approximately 200 pixels / mm at the object level (or ca. 5μm pixel size). The object to be inspected is mechanically secured, and presented at a repeatable position, therefore no alignment inspection is necessary. The pins are defined as a component, with three terminals with corresponding lands: The solder joint is analyzed in 3D, using the algorithmic lighting: For each solder joint the system returns a probability, or Quality Index (QI). Solder joints with an insufficient QI will fail. This Quality Index can be tracked for process control purposes. p26

27 ...USE CASE Inspection Results The following images show the range of inspection coverage: No pin / tinned wire, no solder (3 pins): DEFECTIVE Pin / tinned wire present, no solder (3 pins): DEFECTIVE p27

28 ...USE CASE No pin / tinned wire, solder (1 pin): DEFECTIVE Pin / tinned wire, insufficient solder. DEFECTIVE Excessive solder DEFECTIVE Wire not tinned, no solder DEFECTIVE p28

29 ...USE CASE Inspection Confidence The following image shows good pins: Good (3 pins): GOOD Comparing the Quality Index for each of these examples: A required Quality Index of 0.75 will allow all defects to be found with no danger of false calls. p29