E-Cigarette Function Testing Plan

Overview

　　Functional testing of circuit boards is an essential step in the production process of electronic products.

　　Traditional functional testing typically relies on manual methods, where operators manually connect various benchtop instruments—such as power supplies, signal generators, oscilloscopes, and multimeters—to the circuit board under test. They then painstakingly perform step-by-step manual operations with these instruments to systematically measure each electrical parameter of the board. Finally, human judgment is used to determine whether the test results are good or bad, with operators manually recording the measured parameters. However, this manual testing approach not only leads to slow testing speeds and low efficiency but also introduces significant risks of errors due to human mistakes, misinterpretations, and inconsistent procedures. As a result, the reliability and consistency of the testing process are compromised, making it difficult to ensure the ultimate quality of the final product.

　　With the rapid advancement of computer-based electronic testing technology, automated test equipment (ATE) has seen significant growth. At the core of ATE systems is a computer—typically an industrial PC or standard PC—that connects various benchtop instruments or instrument modules via buses such as GPIB, PCI, VXI, PXI, and USB. Using specialized software, the system automatically controls each instrument module, executing predefined test procedures and parameters to perform comprehensive functional tests on the circuit boards (or entire devices) under evaluation. The system then autonomously determines whether the test results are correct or incorrect, automatically saving all test outcomes to the hard drive for easy access, analysis, and statistical reporting. This capability not only streamlines production process management but also enhances control over manufacturing workflows.

　　The adoption of Automated Test Equipment (ATE) not only enhances testing efficiency but also ensures greater consistency and reliability in test results, thereby guaranteeing the quality of the electronic products being manufactured. At the same time, it significantly reduces the technical expertise required from test personnel, helping companies cut labor costs. Moreover, implementing automated ATE systems effectively boosts a company’s corporate image, making it easier to earn customer trust in today’s highly competitive market. As a result, Automated Test Equipment (ATE) is increasingly favored by electronics manufacturers and enterprises alike.

1. Design Objectives

　　This solution is designed for the customer's circuit board functional testing project. In this plan, we will build an SRC connection-based functional test system by carefully aligning with the customer's specific functional requirements and technical specifications. This approach ensures that the system meets the customer's expectations, enabling fast and accurate detection.

2. Design Basis

　　Based on the email provided by the customer, the following customer test project requirements and product-related technical details have been compiled as the basis for this solution design.

　　"FCT Technical Requirements" Document

3. System Overview

3.1 Hardware System Architecture

　　A. Block Diagram Explanation

　　1. The fully functional, general-purpose test system’s hardware boards are mounted onto a baseboard within a single chassis. Each board serves the following functions:

　　II. Base Plate: The base plate comes in two versions—one with five slots and the other with ten slots. In the five-slot version, each slot is spaced 20 mm apart. For the ten-slot version, every five slots form a group, with two such groups separated by 40 mm, while the remaining individual slots are spaced 20 mm apart. Multiple base plates can be connected in series for extended use. The primary function of the base plate is to link all functional board cards together, enabling control over test signals and managing test output signals (such as PASS and FAIL signals, as well as a buzzer). Additionally, the board features a communication bus, a power bus, a power interface, and a communication interface, among other components.

　　3. Acquisition Switchboard: Responsible for voltage and current acquisition.

　　4. IO Switch Panel: Responsible for simulating key presses and controlling other actions.

　　5. Power Switching Control Panel: Responsible for switching and controlling the programmable power supply and simulated battery output.

　　6. Programmable DC Power Supply: Provides programmable DC power output. It can supply power to the board under test, read back the supplied voltage and current, and also features overvoltage and overcurrent protection capabilities.

　　7. Simulation Battery: The simulation battery provides charge and discharge functions for the device under test, while monitoring current and voltage parameters during these processes.

　　 B. Hardware Configuration

　　　a. The test movement kit includes the following circuit boards:

　　　　① Data acquisition switchboards: 2 units

　　　　②IO Switch Panel: 1 unit

　　　　③ Power switchboard: 1 unit

　　　b. Programmable Power Supplies: One 0-15V, 80A power supply, and one 0-30V, 5A power supply

　　　c. Simulation battery: 1 set

　　　d. Computer: 1 set

　　　Note: The above configuration refers to one set of hardware; this project requires two sets of hardware.

 

3.2 Software Solution

　　This functional testing system software was developed based on the SRC universal functional testing platform, featuring a modular and platform-based software design for ease of operation.

　　The Universal Functional System Software is a software suite featuring a user-friendly Windows-based graphical interface, designed for easy operation and ideal for performing both dynamic and static functional testing. The software system primarily includes the following key functional modules: an editing module, a testing module, a statistical module, debugging tools, and a self-check module. Additionally, the software employs password-protected, two-level access permissions, enabling customers to manage users effectively according to their respective roles and responsibilities.

　　 3.2.1 Editing Module

　　　Programming software is a software module designed to describe the testing functionality of the circuit modules under test and generate test files. These test files serve as the data used by the testing software module. Specifically, it allows users to set input stimulus signal parameters and output test item parameters for any (digital or analog) functional module. Additionally, the software supports learning and pre-testing features, and it even offers the capability to create custom module libraries.

　　　The editing interface features a visual table format for managing test steps, making it easy to use and highly interactive. This interface allows you to edit all test-related information, including data that needs to be imported. Additionally, the interface supports multiple colors to clearly differentiate between various types of test steps, enhancing both visibility and ease of editing. Each circuit board generates its own unique test file; when switching to a different board type, simply load the corresponding test file. This module is designed specifically for engineers to use.

　　　The functional testing system provides a user-friendly, visually intuitive programming environment for functional tests, enabling users to perform a variety of operations directly within the interface—such as creating, opening, editing, and saving test files, as well as creating, opening, editing, and saving module library files—all with just a click of the mouse.

　　　The programming interface is a standard single-document Windows application. It is divided into five main sections: the module editing area, the module properties area, the test step editing area, the information area, and the module library area, along with various toolbars (including the common toolbar, the module editing toolbar, and the test step editing toolbar) and the menu bar.

　　　As shown in the figure below:

　　　On this interface, you can configure all test methods in a manner similar to an Excel spreadsheet—simply select the desired test method from a drop-down list and set the corresponding parameters, such as the excitation voltage level or the upper and lower limits for measured values.

　　　As for the oscilloscope method setup:

In the table, after selecting the corresponding test pin in the "Port" column for the relevant test step (a specific row), click the table cell in the "Settings" column next to that port—this will bring up the following dialog box:

　　　Select the TDS2014 oscilloscope from the equipment selection, then choose the test methods available for this oscilloscope under the "Methods" option. You can then enter the corresponding parameters in the parameter list, as shown in the figure below:

　　　After selecting the test method, use the oscilloscope's corresponding method during testing to perform the relevant measurements. Then, based on the error range set for positive and negative deviations, determine whether the test results are acceptable or not.

　　　Note: The device and method shown in this screenshot may differ from the equipment actually used. The equipment currently in use—and the one specified in the plan—shall take precedence.

　　　In this system software, all test methods follow the same selection and setup procedures as illustrated above—consistent, easy to configure, straightforward to use, and highly flexible for modification. You can freely arrange the test sequence based on the actual functionality of the board card.

　　 3.2.2 Testing Module

　　　The test software is a software module designed to perform functional tests on the component being evaluated, using test data customized based on the programming software. It analyzes and evaluates the test results according to the parameters defined in the test files, verifying whether each test item’s parameters are within normal ranges and confirming that the component’s functions operate correctly. Additionally, the software can print out the test results for reference and generate a test report file for documentation purposes.

　　　The test interface is a standard single-document Windows application. The user interface for testing is divided into six main sections: the module list area, file information area, test information area, console, statistics area, and message area, along with a frequently used toolbar and menu bar. As shown in the figure.

　　　The module list area displays all the modules in the current test file. (For clear and quick identification of issues, you can organize the boards under test into separate modules based on their distinct testing functions.) This makes it easy to monitor the status of each module during testing, and double-clicking a module icon will even open its schematic diagram.

　　　The file information section specifies the current test file's name, along with any annotations related to the file.

　　　The test information area dynamically displays the progress of the test process and, once testing is complete, the overall status of the entire test. It consists of a status indicator light, a global progress bar, module-specific progress bars, and module information. The top progress bar represents the overall progress across all modules, while the bottom progress bar shows the progress of the currently active test module. The test status indicator light provides feedback on the outcome of the entire test: a red light indicates an error, while a green light signifies that the test has passed successfully.

　　　The console is equipped with control buttons for starting and stopping tests, as well as options like printing and exiting.

　　　The statistics area displays current time information and the test pass/fail status for the day.

　　　The information area is used to display detailed information during the test.

　　　After the editors have finalized the test file, testers only need to securely mount the board card, then either click the test button or select automatic testing. The software will automatically initiate the test, evaluate the results, and promptly indicate whether the test passed ("PASS") or failed ("FAIL"). Based on the feedback, testers can take appropriate actions. Additionally, the test results will be saved into the corresponding test results database, making it easy for future statistical analysis.

　　 3.2.3 Statistics Module

　　　According to the test result documents, the test outcomes can be statistically analyzed. This module is intended for reference by production management. The statistical report types include detailed reports, daily production reports, and historical statistics reports. The detailed report provides a breakdown of the tests performed on a specific board, the daily production report summarizes the test data collected on that particular day, and the historical statistics report offers an overview of data trends over a specified period.

　　　The statistics include both clear board card statistics and historical data statistics. The main interface of the statistics panel is as follows:

　　　The main reports included are as follows:

　　　Detailed Report

　　　The detailed report lists the measurement details for a selected board after you choose it, as shown in the figure below:

　　　View Report

　　　Can query the test details of the board being tested based on the input barcode, and allows you to choose whether to display the correct or incorrect result—as shown in the image below:

　　　Pass Rate Pie Chart (Pie Chart for Boards Only):

　　　After selecting a specific board card, a pie chart showing the current board's pass rate will be displayed. Additionally, in the historical statistics, you can choose a specific time period to view the pass rate pie chart for the boards tested during that interval, as illustrated below:

　　　Pie chart for the day:

3.3 Functional Testing of Equipment Appearance

Adopting the structure (as shown in the figure below for reference only; the actual product shall prevail), custom-made needle bed

Schematic Diagram of E-cigarette FCT