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PCB Testing Jigs & Automation

CAPUF provides comprehensive PCB Testing Jig and Automation service for companies manufacturing electronics products.

Our PCB Testing jigs can help you with the following:

  1. Test various electrical parameters to quickly identify faults in the PCB
  2. Automatic, secure, and fast MCU/MPU flashing
  3. Configuration & calibration in production
  4. Local server or cloud integration (Amazon AWS/Microsoft Azure/Google Cloud)
    • Send test reports to the cloud or local server.
    • Dashboard to visualize production progress on a real-time basis in a user-friendly manner.
    • Trending graphs for showing production progress, pass/fail status visualization.
    • Real-time analytics for testing – factory-wise, PCB variant-wise, testpoint-wise.

We have experience providing PCB testing jig for the following products in the past:

  • LED Lamp Drivers
  • Lithium Battery BMS, Battery BANK
  • Inverter Control Cards
  • UPS Control Cards
  • 800VA to 5KVA Transformers
  • Industrial IOT Controllers
  • Dataloggers
  • LORAWAN Gateways
  • Battery powered BLE sensors, etc.
  • MCB up to 120A

CAPUF PCB Testing Jigs

Below are some of the PCB testing jigs CAPUF has developed.

Modular PCB Testing JIG

CAPUF has developed a unique testing JIG structure which supports 5-20 different PCB variant testing on same jig. We just need to change the test pin plate for the PCB variant and rest of the structure, instrumentation hardware, software remains same.

Modular PCB Testing Jig helps reduce:

  • the space to store many jigs
  • need to maintain different jigs
  • to have a team who has knowledge and manages different jigs

PCB Testing Jig – Test Procedure

An example test procedure is shown below as a reference

PCB Testing JIG – Software

CAPUF has developed a modular PCB testing Jig software which can be configured for custom PCB Testing JIG requirements.

Want to develop a PCB Testing JIG?

Custom Battery Bank Testing JIG

Custom Transformer Testing JIG

CAPUF Smart Factory Cloud Platform

CAPUF provides a Pay-Per-Use Smart Factory Cloud Platform which can be used to monitor the production on real time basis on a subscription model.

CAPUF’s PCB Testing jig helps with the following:

  1. Test various electrical parameters to quickly identify faults in the PCB
  2. Automatic, secure, and fast MCU/MPU flashing
  3. Configuration & calibration in production
  4. Local server or cloud integration (Amazon AWS/Microsoft Azure/Google Cloud)
    • Send test reports to the cloud or local server.
    • Dashboard to visualize production progress on a real-time basis in a user-friendly manner.
    • Trending graphs for showing production progress, pass/fail status visualization.
    • Real-time analytics for testing – factory-wise, PCB variant-wise, test point-wise.

1. Test Electrical Parameter & Quickly identify Faults in the PCB

CAPUF can help you develop PCB testing automation solution for your custom requirement. Our Testing Jigs can measure the following parameters to ensure the PCB under test passes the most stringent testing parameters to verify the manufacturing quality:

  • AC/DC Voltage
  • AC/DC Current
  • Frequency
  • Digital Pulse
  • Waveform comparison
  • Continuity
  • Impedance Measurement
  • Any other indirect measurement, etc.

2. Automatic, Secure and fast MCU/MPU flashing

Over the years, we have developed the hardware and software solutions to automatically Flash MCU/MPU/SoM with the production program during PCB testing.

  • We can securely download the encrypted program from Local or cloud server.
  • Decrypt on the fly
  • Flash the program to the MCU on the PCB

We have successfully implemented MCU Flashing automation for various controller like STM32, Texas Instruments MSP430, Espressif ESP32, Holtek MCUs, Microchip, WCH Electronics, Nordic Semiconductor, Nuvoton, NXP, many SoM from Toradex, Phytec, Varascite, Compulab, etc.

3. Automatic Configuration & Calibration

Our PCB testing Jigs can automatically configure the PCB after testing is completed successfully.

This configuration could be done via interfaces like Modbus, UART, RS232, Ethernet, USB, Wi-Fi, BLE, etc.

We can also do the calibration of the PCBs for various references.

Like in the past we have done calibration for Modbus Input Cards for 0-10V, 0-20mA measurement calibration.

We have done calibration for PH sensor, Temperature, Humidity sensors, Inclinometer sensor.

4. Cloud Intergration (Amazon AWS/Microsoft Azure/Google Cloud)

Our PCB testing jigs provides easy interface to connect to your cloud or local server. We can push the testing data with meta data like product serial number, model number, PCB serial number, etc. Our Jig software is capable of sending data via secured HTTPS/MQTTS using JSON, XML, etc. payload.

During development phase, our team will work with your engineers to finalize the format so as to implement seamless integration.

PCB testing Jig Development Process

There are many step involved from start to production deployment as listed below:

  • Requirements Specification: CAPUF will engage with customer’s team to understand the requirements in detail, what all to test, range, accuracy, acceptance criteria, how long jigs should work without maintenance, etc.
  • Architecture: we will come up with an architecture how we are going to build the JIG structure and software to make the PCB testing jig for the requirement.
  • Software, Hardware Concept: We will share how the software will look like, what all features will be there, what are critical hardware we are selecting for the testing. Review with the customer’s team is required.
  • Jig Test Points: We will need PCB Gerber files with test points position clearly marked with parameter to be tested and its min, max pass range, also if any additional test, configuration, calibration is required for the PCB, what will be the interface to do so.
  • Jig Structure and instrumentation: based on the above inputs, our JIG development team will start working on JIG design, electrical team will start working on the selecting the right instruments, etc.
  • Wiring Diagram: Once above is done, our team will create a wiring diagram for our JIG assembly team.
  • Jig Assembly and wiring: At this stage JIG parts, equipment’s will arrive, and team will start assembling the JIG and complete the wiring.
  • Testing, fine tuning: Our team will test the jig, point by point and do the test run in manual mode first, once all the points are tested and we have done at least 10-20 full test runs, we will hand over the JIG to be used for production. At this stage, there might be some fine tuning required in the JIG structure, wiring, software, settings.
  • Soft deployment: At this stage our team along with customer will do testing of the production PCB. This is hand holding phase so that customer is well aligned with JIG and learn the SOP. Generally, for 100 units this step is followed. At this stage if any feedback is there, our team will work on those as well.
  • Production release: At this stage, JIGs are deployed in production and our team will monitor remotely or via customer’s team.
  • Monitor and maintain: Our engineer will be available 100% on standby so that in case any issue comes, our engineer can help the production team fix the issue or be on ground along with customer’s team to enable 100% production testing up time. This involves a monthly support contract with the customer.

Please feel free to contact us for your PCB testing needs. Our team will be happy to support you.

Want to develop a PCB Testing JIG?