Configurable Test Plug I/O Board for Automated PCB Verification
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Solution Overview
Problem
Current testing methods for production tools in the semiconductor industry are labor-intensive and require custom-made PCBs and manual jumper-based testing, leading to inefficiencies and potential errors, especially when dealing with safety-interlock devices and software-hardware communication.
Innovation Solution
A configurable 'test plug' form factor I/O control board with a wireless mesh network that allows for automated testing of PCBs and production tools, enabling quick system testing, diagnostics, and troubleshooting without the need for custom PCBs or extensive rewiring, using software to configure and monitor I/O connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual jumper-based testing is used on custom PCBs, then testing can be performed with basic equipment, but testing time increases significantly and error probability increases
Solution Approach 1:
The patent replaces manual mechanical jumper-based testing with an automated wireless electronic control system. The system uses wireless communication (Bluetooth, Wi-Fi) to automatically configure and control I/O controllers, eliminating the need for physical jumper manipulation. This automation significantly reduces testing time and human error while maintaining the ability to test custom PCBs.
Solution Approach 2:
The system enables self-service testing through automated configuration and execution of test sequences. The electronic control system automatically manages I/O controller settings, performs diagnostic routines, and generates test reports without requiring manual intervention for each testing step, thereby reducing both time and operational complexity.
2Adaptability or versatility
If custom PCBs are developed for each production tool, then specific tool requirements are met, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent implements a universal electronic control system that can interface with multiple types of production tools through software configuration rather than hardware customization. The system uses a standardized wireless communication interface and programmable I/O controllers that can be configured via software to match specific tool requirements, eliminating the need for custom PCBs for each tool type.
Solution Approach 2:
The system achieves tool-specific adaptation through software parameter changes rather than hardware modifications. The electronic control system allows configuration of I/O controller parameters, communication protocols, and test sequences through software, enabling the same physical hardware to adapt to different production tool requirements without requiring custom PCB designs.
3Reliability
If software testing is performed on actual hardware, then realistic problems are detected, but production tools must be taken out-of-production causing line shutdown
Solution Approach 1:
The patent introduces a wireless electronic control system as an intermediary between the production tool and the testing equipment. This intermediary system can interface with the production tool's I/O controllers without requiring the tool to be removed from production. The system uses wireless communication to establish test connections that do not interrupt normal production operations, allowing simultaneous production and testing.
4Measurement precision
If multiple custom PCBs and cables are constructed for test platforms, then comprehensive testing coverage is achieved, but testing setup complexity and costs increase
Solution Approach 1:
The patent creates a universal test platform using wireless electronic control that can test multiple types of PCBs and production tools through software configuration. The system uses standardized wireless interfaces and programmable I/O controllers that can be reconfigured via software to match different test requirements, eliminating the need for multiple custom-built test cables and adapters for different tool types.
Data Source
AI summary
Various embodiments include methods and apparatuses to test production tools and related electrical components therefor including individual printed-circuit boards (PCBs). In one example, a test-plug hardware-platform includes at least one input/output (I/O) connector, and a configurable control system to provide command and operational signals through the I/O connector and collect data through the I/O connector from at least one PCB under test. A wireless-mesh network within the test-plug hardware-platform can interface wirelessly with at least the PCB under test. The at least one PCB operating within a production tool or other piece of equipment. Other methods and systems are disclosed.