AUTOMATED

The objective of automated testing is

to simplify as much of the testing
effort as possible with a minimum set
of scripts. If unit testing consumes a
large percentage of a quality
assurance (QA) team's resources, for
example, then this process might be a
good candidate for automation.
AUTOMATED
Automated testing tools are capable
of executing tests, reporting
outcomes and comparing results with
earlier test runs. Tests carried out
with these tools can be run
repeatedly, at any time of day.
AUTOMATED
The method or process being used to
implement automation is called a test
automation framework.
Test Procedures for new Designs
The counterpoint to a specification is
a test procedure. With a specification
and an incoming test procedure, a
client can have assurance that he gets
what he orders.
There are actually three types of test
procedures we are concerned with here
Debug Test procedure-
developed by the engineer
todebug the design
There are actually three types of test
procedures we are concerned with here
Incoming Test
procedure- developed by
Client to check delivery of
the design work
There are actually three types of test
procedures we are concerned with here
Manufacturing Test
procedure- developed by
the Manufacturer to test
units as they are produced
Debug Test procedure
The debug test procedure will
be developed by the design
engineer as the design
proceeds. If he does not do
this, he is either
overconfident, unaware, or
very pushed for time.
Debug Test procedure
The aim of the debug test procedure
is todividethetestingof the design
intosmall, autonomous units.In this
respect the debug test is providing a
tool for the detection of faults in the
design in a way that most
conveniently allows them to be fixed
- by finding them in isolation.
Debug Test procedure
The debug test procedure will pay
particularattention to suspected trouble
spotsin a design. For instance, if an
analog input is known to be operating at a
particularly low input signal level, a
debug test procedure might include noise
measurement, thermal drift testing, and
evaluation of potential cross talk sources.
Incoming Test procedure
The clients incoming test procedure will
normally start with the specification of
the product and test that the specified
features are actually delivered. This
testing may be a repeat of part of the
overall functional test procedure carried
out byDesign engineer.
Incoming Test procedure
Handover should be used as an
opportunity for the designer to
demonstrate the prototype to the
client, ticking off as many of the
Incoming test procedure items as
possible, and covering the
remainder verbally.
Incoming Test procedure
The incoming test procedure has
different objectives from the debug
test procedure - its aim is to prove
that the design meets the
specification. Overall tests are usually
good for this objective. The debug
test procedure is attempting to
isolate any faults in the design
Incoming Test procedure
Specification "bugs".Sometimes the designer
and client have different interpretations of
the design requirements. The designer may
build a prototype which misses a feature
required by the client. The most efficient way
around this is communication during the
design process - but in lieu of this, at least the
problem is discovered at the prototype stage,
not manufacture.
Manufacturing Test procedure
The manufacturing test procedure is used to
test product as it is being manufactured. The
procedure is quite dependent on the
manufacturer, his production techniques, and
his testing equipment. At a minimum the
manufacturer will need a production sample
from the client. The manufacturing test
procedure is aneconomics driventest. The
procedure is designed to save money for the
manufacturer.
There are four basic types of "testing", in
order of capital expenditure:
Visual InspectionIts simple, its cheap, and
everyone should do it. Having a skilled person
inspect the PCBs will find most of the faults.
For one or two units in the manufacturing run
the visual should be pretty exhaustive,
checking every component against the
equivalent on the production sample and BOM,
and questioning even if the logo on an IC looks
different.
There are four basic types of "testing", in
order of capital expenditure:
Visual inspection for the bulk of the
manufacturing run is a quick process looking
fororientation, solder defectsand ensuring
thecorrect partsare in the correct place. A
visual also weeds out badly produced but
operational boards - for instance where thru-
hole parts are improperly seated before
soldering
There are four basic types of "testing", in
order of capital expenditure:
Operational Test(Sometimes called
Go/Nogo) With appropriate firmware,
powering up a board will test a fair
amount of circuitry even without a
test jig. The response can be
compared to the production sample.
There are four basic types of "testing", in
order of capital expenditure:
Automated Test Equipment (ATE)This is the best test
method. ATE will have pin drivers that can exercise
inputs and load outputs to do parametric testing in
addition to functional testing. ATE will also be made to
probe connections inside the circuit under test using a
bed of nails. ATE is not cheap, and jigs and the
programming for the equipment are an ongoing cost,
but it is superior to a plain functional test.
Test strategy considerations

Thereforethere are a number of elements that should

be included in the planning for the test strategy
example:
Test strategy considerations

Minimise number of test stages: As testing adds no

value to the product, the number of stages where
testing is undertaken within the overall process should
be minimised
 Test strategy considerations

Sufficienttest stages to catch faults early: While

testing should be minimised, this should be balanced
against the fact that fault finding and repair typically
multiplies by a factor of ten each time the item moves
to the next stage in the production process.
Test strategy considerations

Minimise test times: During the development phase

of the product testability and aggressive target test
times should be set for each test stage to ensure that
the most innovative test techniques are used while not
compromising test coverage.
Test strategy considerations

Collectmetrics and data: As part of the testing

regime, test results should not just be collected but
they should also be analysed, often an almost real
time to provide an up to date picture of any fault
patterns, etc
Test strategy considerations

Optimize production process: Using metrics and

data obtained from testing, the process should be
optimised. Often processes such as soldering can show
pattern faults which should be corrected as quickly as
possible. Any feedback can be used to reduce failure
rates, adjust the test regimes, etc to reduce the
overall production time. In some instances it may be
possible to remove some test stages if almost no
failures are detected there. Alternatively batch
sampling may be used.
Test Strategy Example

Optimise production process: Using metrics and

data obtained from testing, the process should be
optimised. Often processes such as soldering can show
pattern faults which should be corrected as quickly as
possible. Any feedback can be used to reduce failure
rates, adjust the test regimes, etc to reduce the
overall production time. In some instances it may be
possible to remove some test stages if almost no
failures are detected there. Alternatively batch
sampling may be used.
Test Strategy Example
Test strategy example options

Goods inwards testing: This form of testing us rarely

used these days. IT is time consuming and therefore
costly. It would only be done where tight specifications
for items such as RF filters, etc. may be involved -
normally figures for failure rates can be placed on
suppliers, and if high levels of failure are seen later in
the process, then further investigation can be
undertaken.
Test strategy example options

Goods inwards testing: This form of testing us rarely

used these days. IT is time consuming and therefore
costly. It would only be done where tight specifications
for items such as RF filters, etc. may be involved -
normally figures for failure rates can be placed on
suppliers, and if high levels of failure are seen later in
the process, then further investigation can be
undertaken.
Test strategy example options

PCB inspection: The PCB inspection stage typically

uses either automatic optical inspection, AOI, and / or
automatic X-ray inspection, AXI. Sometimes, an AOI
capability may be included in any pick-and-place
system, enabling issues with the pick-and-place
process to be detected almost immediately. Often, AOI
/ AXI is undertaken after any soldering process. In this
way, both pick-and-place and soldering defects can be
detected.
 Test strategy example options

In-circuittest: An in-circuit test stage has been

shown in the test strategy example. It purpose is
primarily to detect manufacturing defects. It is most
likely that it may be deemed not to be required if
AOI / AXI is used. The drawback of the ICT is that
growing board complexity reduces test access, and
therefore the coverage of any in-circuit testing.
Test strategy example options

Module functional test: Even when a board is

manufactured correctly, there is a chance that it may
still not operate to its specification. This may result
from component tolerances being outside their
specification, or even component tolerances all being
at a particular end of their allowed tolerance, and the
combined effect forming a failure. Again, if failure
rates are very low at this stage, deferring testing until
the next stage may be a possibility. This test could also
include techniques such as boundary scan.
Test strategy example options

Unittest: Again, this is typically a functional test.

Typically it will test the overall unit to its
specification, and in some processes could be the pre-
delivery test.
Test strategy example options

Postburn-in / pre-despatch: Some items of

equipment, especially rugged items may need to
undergo some form of burn-in. Often when this is
undertaken background monitoring is undertaken.
MULTIMETERS
Thereare two types:
DIGITAL and
ANALOGUE
ADigital Multimeterhas a set
of digits on the display and an
Analogue Multimeter has a
scale with a pointer (or
needle).
USING A MULTIMETER
Analogue and digital multimeters have
either a rotary selector switch or push
buttons to select the appropriate function
and range. Some Digital Multimeters (DMMs)
are auto ranging; they automatically select
the correct range of voltage, resistance, or
current when doing a test. However you
need to select the function.
 USING A MULTIMETER
Before making any measurement you need to know
what you are checking. If you are measuring voltage,
select the AC range (10v, 50v, 250v, or 1000v) or DC
range (0.5v, 2.5v, 10v, 50v, 250v, or 1000v). If you are
measuring resistance, select the Ohms range (x1,
x10, x100, x1k, x10k). If you are measuring current,
select the appropriate current range DCmA 0.5mA,
50mA, 500mA. Every multimeter is different
however the photo below shows a low cost meter
with the basic ranges.
USING A MULTIMETER
You must select a voltage or current range that
is bigger or HIGHER than the maximum
expected value, so the needle does not swing
across the scale and hit the "end stop."
If you are using a DMM (Digital Multi Meter),
the meter will indicate if the voltage or
current is higher than the selected scale, by
showing "OL" - this means "Overload."
 The Common (negative) lead ALWAYS fits into
the "COM" socket. The red lead fits into the
red socket for Voltage and Resistance.
Place the red lead (red banana plug)
into "A" (for HIGH CURRENT "Amps")
or mA,uA for LOW CURRENT.
MEASURING VOLTAGE
Mostof the readings taken with a
multimeter will be VOLTAGE readings.
Before taking a reading, you should select
the highest range and if the needle does not
move up scale (to the right), you can select
another range.
Always switch to the highest range before
probing a circuit and keep your fingers away
from the component being tested
MEASURING VOLTAGES IN A CIRCUIT
 MEASURING CURRENT
You will rarely need to take current
measurements, however most multimeters have
DC current ranges such as 0.5mA,50mA, 500mA
and 10Amp (via the extra banana socket) and
some meters have AC current ranges. Measuring
the current of a circuit will tell you a lot of
things. If you know the normal current, a high or
low current can let you know if the circuit is
overloaded or not fully operational.
 MEASURING CURRENT
Current is always measured when the circuit is
working (i.e: with power applied).
It is measured IN SERIES with the circuit or
component under test.
The easiest way to measure current is to
remove the fuse and take a reading across the
fuse-holder. Or remove one lead of the battery
or turn the project off, and measure across
the switch.
 MEASURING CURRENT
Ifthis is not possible, you will need to remove
one end of a component and measure with the
two probes in the "opening."
MEASURING CURRENT
MEASURING CURRENT
Do NOT measure the CURRENT of
a battery
(by placing the meter directly
across the terminals)
A battery will deliver a very HIGH
current
and damage the meter
MEASURING RESISTANCE
Turn a circuit off before measuring resistance.
If any voltage is present, the value of resistance
will be incorrect.
In most cases you cannot measure a component
while it is in-circuit. This is because the meter is
actually measuring a voltage across a component
and calling it a "resistance." The voltage comes
from the battery inside the meter. If any other
voltage is present, the meter will produce a false
reading.
MEASURING RESISTANCE
Ifyou are measuring the resistance of a
component while still "in circuit," (with the power
off) the reading will be lower than the true
MEASURING RESISTANCE
Ifyou are measuring the resistance of a
component while still "in circuit," (with the power
off) the reading will be lower than the true
MEASURING RESISTANCE
MEASURING RESISTANCE
Surface Mount Resistors
 3-digit Surface Mount resistors on a PC board
 4-digit Surface Mount resistors on a PC board
The photo above showssurface mount
resistors on a circuit board. The components
that are not marked are capacitors
(capacitors are NEVER marked).
All the SM resistors in the above photos
conform to a 3-digit or 4-digit code. But
there are a number of codes, and the 4-digit
code caters for high tolerance resistors, so
it's getting very complicated.
Here
is a basic 3-digit SM resistor:
A 330k SM resistor
 The first two digits represent the two digits
in the answer. The third digit represents
the number of zero's you must place after
the two digits. The answer will be OHMS.
For example: 334 is written 33 0 000. This
is written 330,000 ohms. The comma can be
replaced by the letter "k". The final answer
is: 330k.
222 = 22 00 = 2,200 = 2k2
 473 =
474=
105 =

There is one trick you have to

remember. Resistances less than 100
ohms are written: 100, 220, 470. These
are 10 and NO zero's = 10 ohms = 10R
or 22 and no zero's = 22R or 47 and no
zero's = 47R. Sometimes the resistor is
marked: 10,22 and 47 to prevent a
mistake.
A "BURNT" RESISTOR
normally and technically called a
"burnt-out" resistor.
The resistance of a "burnt" resistor can
sometimes be determined by scraping
away the outer coating - if the resistor
has a spiral of resistance-material. You
may be able to find a spot where the
spiral has been damaged.
 Note the spirals of conductive carbon.
The number of spirals has nothing to with the
resistance. It is the amount of carbon particles in
the "track" that determines the resistance. It is also
the thickness and width of the track that
determines the resistance. And then it is the
overall size of the resistor that determines the
wattage. And then the size of the leads, the
closeness to the PCB and the size of the lands that
eventually determines how hot the resistor
will get.
ESTINGPOTENTIOMETERS (variable
resistors)

To check the value of a variable

resistor, it should be removed from
circuit or at least 2 legs should be
removed. A Rheostat is a variable
resistor using only one end and the
middle connected to a circuit.
TESTINGPOTENTIOMETERS (variable
resistors)

To check the value of a variable

resistor, it should be removed from
circuit or at least 2 legs should be
removed. A Rheostat is a variable
resistor using only one end and the
middle connected to a circuit.
TESTINGPOTENTIOMETERS (variable
resistors)
The resistance between the two outside pins
is the value marked on the component and
the centre leg will change from nearly zero to
the full resistance as the shaft is rotated.
"Pots" generally suffer from "crackle" when
turned and this can be fixed by spraying up
the shaft and into the pot via the shaft with a
tube fixed to a can of "spray-lubricant"
(contact cleaner).
"Pre-setpots" and "trim pots" are miniature
versions of a potentiometer and they are all
tested the same.The photo shows a pot, two
mini pots and 3 mini trim pots.
CONTINUITY
Some multimeters have a "buzzer" that detects
when the probes are touching each other or the
resistance between the probes is very LOW. This
is called a CONTINUITY TESTER.
You can use the resistance scale "x1" or "x10" to
detect low values of resistance.
Set the pointer to "0" (right end of the scale) by
touching the probes together and adjusting the
"zero ohms" control.
When taking a reading, you will have to decide if
a low value of resistance is a short-circuit or an
"operating value."
CONTINUITY
Turn off the equipment before making
any continuity tests. The presence of
even a small voltage (from an
electrolytic) can give a false reading.
You can determine the resistance of a
lead very accurately by taking the
example above and applying it to your
circuit.
CONTINUITY
If the battery is 12.6v and the
voltage across the circuit is 10v,
when the current is 2.6 amps, the
resistance of the "leads" is 12.6 - 10
= 2.6 R=V/I = 2.6/2.6 = 1ohm. By
making the lead shorter or using
thicker wire, the resistance will be
less and the voltage on the project
TESTING FUSES, LEADS AND WIRES
A BLOWN FUSE
The appearance of a fuse after it
has "blown" can tell you a lot about
the fault in the circuit.
If the inside of the glass tube (of
the fuse) is totally blackened, the
fuse has been damaged very quickly.
TESTING FUSES, LEADS AND WIRES
A BLOWN FUSE
This indicates a very high current
has passed through the fuse.
Depending on the rating of the fuse,
(current rating) you will be able to
look for components that can pass a
high current when damaged - such
as high power transistors, FETs,
TESTING FUSES, LEADS AND WIRES
A BLOWN FUSE
This indicates a very high current
has passed through the fuse.
Depending on the rating of the fuse,
(current rating) you will be able to
look for components that can pass a
high current when damaged - such
as high power transistors, FETs,
TESTING FUSES, LEADS AND WIRES
FAST AND SLOW BLOW FUSES
There are many different sizes, shapes and
ratings of a fuse. They are all current ratings
as a fuse does not have a voltage rating. Some
fuses are designed for cars as they fit into the
special fuse holders. A fuse can be designed
for 50mA, 100mA, 250mA, 315mA, 500mA,
1Amp, 1.5amp, 2amp, 3amp, 3.15amp 5amp,
10amp, 15amp, 20amp, 25amp, 30amp,
35amp, 50amp and higher.
TESTING FUSES, LEADS AND WIRES
FAST AND SLOW BLOW FUSES
There are many different sizes, shapes and
ratings of a fuse. They are all current ratings
as a fuse does not have a voltage rating. Some
fuses are designed for cars as they fit into the
special fuse holders. A fuse can be designed
for 50mA, 100mA, 250mA, 315mA, 500mA,
1Amp, 1.5amp, 2amp, 3amp, 3.15amp 5amp,
10amp, 15amp, 20amp, 25amp, 30amp,
35amp, 50amp and higher.