Multi-Probe Board Station for Concurrent PCB Signal Validation
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Solution Overview
Problem
Existing probe stations face limitations in the number of probe points that can be probed simultaneously, leading to inconsistencies in measurement due to varying pressure application and additional inaccuracies from soldering, which are time-consuming and cumbersome, especially when probing hundreds of points on circuit boards.
Innovation Solution
A probing station with multiple probe tips and motorized connectors on probe arms, allowing independent movement and concurrent probing of multiple points, calibrated for consistent pressure application using a robot or gantry system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual probing is used to access multiple probe points, then flexibility and adaptability are maintained, but measurement precision and reliability deteriorate due to manual pressure variations and human error
Solution Approach 1:
The system uses self-aligning probe tips with compliant mechanisms that automatically adjust to probe point locations and apply consistent force without human intervention. The probe tips are designed to self-correct positioning errors and maintain optimal contact pressure through elastic deformation, enabling the system to service itself during the probing process.
Solution Approach 2:
Manual mechanical probing operations are replaced with an automated robotic system that uses motorized connectors and multi-axial movement capabilities to position and operate probe tips. The system substitutes human manual control with automated mechanical systems that provide repeatable, precise, and consistent probing actions across all probe points.
2Reliability
If extensive wiring and soldering are used to connect probe points, then signal integrity is maintained, but device complexity and manufacturing time increase significantly
Solution Approach 1:
The system extracts and eliminates the need for extensive wiring and soldering by using direct probe contact to access signal points. Instead of creating permanent electrical connections through soldering, the system uses temporary probe contacts that can be rapidly positioned and removed, extracting the harmful complexity of wiring while maintaining signal integrity through direct measurement.
Solution Approach 2:
The system changes the fundamental parameter of connection permanence from permanent (soldered) to temporary (probed). This parameter change allows the same signal integrity to be achieved without the complexity of extensive wiring, as probes can be quickly repositioned to access different points without requiring permanent electrical connections at each location.
3Productivity
If multiple probe points are probed sequentially, then measurement accuracy is maintained, but productivity and validation speed deteriorate
Solution Approach 1:
The system merges multiple probing operations into a single integrated automated process. Multiple probe tips are combined on a single robotic system, allowing simultaneous or rapid sequential access to multiple probe points. The controller integrates the coordination of multiple probes, combining what would otherwise be separate manual operations into one unified high-speed process that maintains measurement precision while dramatically improving productivity.
Solution Approach 2:
The system performs preliminary positioning and calibration actions before actual measurement. The robotic system pre-positions probe tips at optimal locations, pre-calibrates force application, and pre-configures measurement parameters. This preliminary action ensures that when measurements are taken, they are performed with optimal precision settings already in place, enabling rapid validation without sacrificing accuracy.
4Reliability
If consistent probe pressure is applied manually, then measurement repeatability improves, but ease of operation deteriorates due to the skill and training required
Solution Approach 1:
The probe tips are designed with self-regulating pressure characteristics through compliant mechanisms and elastic materials. The probe structure itself provides the force regulation function, automatically adjusting contact pressure to optimal levels without requiring external control or operator skill. This self-service capability embeds the pressure control function directly into the probe hardware, eliminating the need for trained operators to manually regulate force.
Solution Approach 2:
Manual force application and pressure control are replaced with automated mechanical systems that use motorized connectors and controlled movement to position probes with precise force. The system substitutes human manual pressure control with automated mechanical actuators that can consistently apply and regulate force through electronic control, eliminating the skill requirement while maintaining measurement repeatability.
Data Source
AI summary
Systems and methods herein are for an automatic board probing station in which a plurality of probe tips are associated with a plurality of probe arms and with a plurality of motorized connectors, where the plurality of motorized connectors is to cause individual ones of the plurality of probe tips and individual ones of the plurality of probe arms to be movable independently, and where the plurality of probe tips is to communicate probe signals with a circuit analysis system and is to concurrently probe a plurality of probe points of a circuit board.