Testing PCBs in Manufacturing

Printed circuit boards (PCBs) are an integral part of many electronic devices, as they provide the physical support and electrical connections for components such as processors, memory, and sensors. In the manufacturing process, it is crucial to ensure that PCBs are properly tested to ensure they are functioning correctly and meet the required specifications. There are several methods that can be used to test PCBs in a manufacturing setting, each with its own benefits and limitations.

One common method of testing PCBs is called in-circuit testing (ICT). This involves connecting a specialized testing machine to the PCB and running a series of tests to verify the proper operation of each component and the overall functioning of the board. ICT is relatively fast and can be automated, making it suitable for testing large numbers of PCBs in a short period of time. However, it can be limited in its ability to detect certain types of defects, such as those related to the soldering quality of components.

ICT can be completed with basic Bed-of-nails fixtures for simple board level testing. Spring probes are specialized electrical connectors that are designed to make temporary contact with the pads or points on a PCB. They consist of a spring-loaded metal probe that is mounted on a carrier, which is in turn mounted on a probe head that is compatible with the ICT machine. When the probe head is placed over the PCB, the spring probes can be pressed down onto the pads or points on the PCB, establishing an electrical connection.

Spring probes are commonly used in ICT because they are relatively simple and inexpensive, and they can be easily reconfigured to test different PCBs.

Another method of testing PCBs is called functional testing, which involves testing the overall functionality of the board by simulating its intended use. This may involve connecting the PCB to a computer or other device and running a series of tests to ensure that it is able to perform its intended functions correctly. Functional testing can be more time-consuming than ICT, but it can provide a more comprehensive assessment of the PCB’s performance.

Functional testing involves testing the overall functionality of a printed circuit board (PCB) by simulating its intended use. This can be done in several ways, depending on the specific requirements and characteristics of the PCB. Some common steps that may be involved in functional testing include:

1. Setting up the test environment: This may involve connecting the PCB to a computer or other device and configuring any necessary test equipment or software.
2. Writing test cases: Test cases are specific scenarios or conditions that the PCB will be subjected to during testing. These may include tests to verify that the PCB can perform specific tasks or functions, or tests to ensure that it can withstand certain environmental conditions.
3. Running the tests: Once the test environment is set up and the test cases have been written, the tests can be run by executing the test cases and observing the results. This may involve manually operating the PCB or using automated testing software.
4. Analyzing the results: After the tests have been run, the results should be analyzed to determine whether the PCB has passed or failed. Any defects or issues that are identified should be documented and addressed as necessary.

Functional testing can be a time-consuming process, but it is an important step in ensuring that PCBs are functioning correctly and meeting the required specifications. It is also important to have a robust and well-defined testing process in place to ensure that all necessary tests are performed and that the results are properly analyzed and acted upon.

There are many different types of functionality that can be tested on a printed circuit board (PCB), depending on the specific requirements and characteristics of the PCB. Some examples of functionality that may be tested during functional testing of a PCB include:

1. Basic electrical functions: This may include tests to verify that the PCB is able to power on and off correctly, that it can communicate with other devices or components as intended, and that it can perform basic tasks such as sending and receiving data. For CTS created custom test fixtures this can be completed using spring probing or other connectors to complete continuity.
2. Component-level functions: Tests may be performed to ensure that individual components on the PCB are functioning correctly. This can include LEDs, buttons, sensors, screens, etc. Once the critical components are identified CTS engineers can work to determine testing methods that will work best on your custom test fixture.
3. System-level functions: Tests may be performed to verify that the PCB is able to perform more complex tasks or functions, such as running an operating system or controlling a system of devices. While CTS strives to provide a complete custom test fixture, we do not provide programming. Concentric Technology Solutions Test Fixtures will support customer spec’d I/Os for connection to your own system.
4. Environmental testing: The PCB may be subjected to various environmental conditions, such as temperature, humidity, and vibration, to ensure that it can withstand these conditions and continue to function correctly. CTS custom test fixtures can help with these environmental tests by providing integrated RF boxes, lights, motors, or other items your testing may require.
5. Reliability testing: The PCB may be subjected to a series of tests to verify its reliability, such as by running the same tests multiple times or using the PCB for an extended period of time. Our custom test fixtures are reliable for 100s of thousands or millions of cycles and designed with easily replaceable wear components.

Overall, the specific functionality that is tested on a PCB will depend on the intended use of the PCB and the requirements of the device or system in which it is used.

Regardless of the specific testing method used, it is important to have a robust and thorough testing process in place to ensure that PCBs are functioning correctly and meeting the required specifications. This can help to reduce the risk of defects and improve the reliability of electronic devices that use PCBs. At Concentric Technology Solutions we can help develop a custom mechanical test fixture for your ICT or functional testing needs.

Get in touch with our engineering team.