prototype

How to Effectively run a Functional Test on a PCB?

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A functional test is a quickest and most effective way to check an assembly function as designed. This simulates the intended field of application and also analyses the electrical behaviour of the assembled board. Read more to find out our top 7 checks and how we fixed defects during a recent project. Firstly, the assembly process is chosen depending on the customer’s requirements and the electronic components. A mixed process of through-hole and SMT assemblies was used to build these boards. Next, once the PCBA is ready, it undergoes functional testing or FCT before being shipped. These tests aim to eliminate any defects or faults that might hinder reliability, replace incorrect or faulty components, check solder points and generate a detailed report to share with our customers. This module will be used in an EV charging station. Certain specific components were provided by the customer and others were sourced from our suppliers.  The 7 Checkpoints We Ran To Ensure The Proper Functioning Of A PCBA: At Ark Circuitry, we go the extra mile to ensure reliable boards are manufactured. For this specific project, after uploading the code, the engineer tests the boards to ensure the board will carry out the intended functions in the actual application. The checkpoints that they look at ticking off are: 1. Relay check: According to the functions and design, we have used 5 relays on the board.  When the engineer inputs the command, a soft clicking noise is the expected output.  Relay and buzzer test in progress 2. Buzzer test: The next is the buzzer test. The buzzer must go off when the command is run to confirm its functioning.  3. GSM module and Wifi test: A Sim card is inserted and the code is run. This test records the HSN code of the network and IP addresses generated.  GSM and WIFI test 4. CAN test: CAN test  The Controller Area Network or the CAN test. When the command is given, the output returns as a pass and that signifies its functioning.  5. RFID test “Access denied” is the prompt that returns (that was set by the customer ) when the tag is tapped. This ensures the component’s proper functioning. Testing the RFID function 6. LED check The customer provided us with the LED strip. The power supply to the LED is tested. The lights go off at first. It then turns on switching from red to blue and we know its a check.  Power supply to the LED is tested using this test 7. Voltage check: An input power of 12V is fed and an output of 5V is recorded to ensure its functioning. If a defect is detected, they check for open/shorts in nets or faults in solder connections. Lastly, once the tests are complete, the data is processed and the results generated. The stored data would aid in maintaining the PCBA quality effectively.  A detailed report on the status of functioning is shared with the customer for analysis or to refer to the test log.  Some points to look for when a fault persists: Check and recheck that all IC pins are soldered properly  Ensure that there is no solder paste residue  Reflow oven: When the outer layer of the solder paste would have dried and the inner layer might be still wet it leads to no contact. Check if it has been soldered well. Do not use solder paste that might be old or not stored at the right temperature. Temperature and environment are crucial, this results in no solder Manual solder any joints where there is no contact Use reliable and good-quality components Ensure your engineers are well-trained from time to time and quick to pick up issues/faults There are other inspection processes that a customer can request. Furthermore, read our previous blog to know more about inspection Get in touch with us to know more about the services we can provide. We are an EMS provider and specialise In providing tailor-made end-to-end services to meet your requirements. We have the capabilities and the experience to deliver low or high-volume orders.   Let’s talk for more information. Call us on +91 91764 18660 Mails us at: arkcircuitry@gmail.com Visit us at: https://arkcircuits.com/ Facebook Twitter Linkedin Instagram Recent Blogs How to Effectively run a Functional Test on a PCB? Suneyna February 17, 2023 A functional test is a quickest and most effective way to check an assembly function as designed. … Read More How prototypes help identify and formulate design and save time Regan February 9, 2023 Prototypes can help manufacturers save manpower, time and money. It simulates the actual product … Read More

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How prototypes help identify and formulate design and save time

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Prototypes can help manufacturers save manpower, time and money. It simulates the actual product that you can present to your customer. Read this blog to find out how. Prototyping: A powder-coated aluminium box was the proposed enclosure. We 3D printed an enclosure to check how the board fit and the placement of the button and switch. We presented the fabricated powder-coated box to the client. At this point, we proposed a brushed stainless steel enclosure for sophistication. The client accepted the suggestion. Rapid prototyping: To execute several revisions in a short time, rapid prototyping is often used. Rapid prototyping can reduce material wastage, and expenses and quicken the processing time. This can confirm the functioning and aesthetics of a product. Reasons for prototyping: Prototypes help the designer and engineer to work out a solution for a final product. The designer finalises the material, structure, functions and appearance of the solution. A prototype allows the designer and engineer to make informed decisions. You can create prototypes with available materials or other techniques. This helps you create a solution keeping the cost minimal. Prototyping helps simulate the actual product. An operating version of prototypes can give the customer an idea of the product. Building the concept tests the possibility of whether the idea is operable. Prototyping determines unanticipated technical, financial and other hurdles that may occur during manufacturing. Provide you with an idea of how the end user will interact with the product. Illustrating our recent prototype for Clarico Air: We have been rolling out tailor-made box builds for an Indoor Air Quality Management system. Before manufacturing the products, prototypes helped us develop a functional and appealing product. PCB design lifecycle: First, we began with a conversation with the client to understand their requirements. Then, our designer created a PCB design and fit it into the enclosure. But, upon testing the usability, the designer included a few changes to the design. After testing the board it was fit into the box. This was the final design. A few design changes were made with inputs from the client and to fit the PCB perfectly into the enclosure Enclosure design changes: Then, a powder-coated aluminium box was the proposed enclosure. We 3D printed an enclosure to check how the board fit and the placement of the button and switch. We presented the fabricated powder-coated box to the client. At this point, we proposed a brushed stainless steel enclosure for sophistication. The client accepted the suggestion. Enclosure design changes (contd): Manufacturing the fully finished products: Finally, on approval, the electrical and mechanical designs are finalised. Using both SMT and through-hole technology we manufactured the PCBs. The mechanical team fabricated the enclosures to place the PCBs in them. All the necessary wires and harnesses are fit. Brushed Stainless Steel enclosure. The logo is lasercut with a black background. Our take on the benefits of prototyping: Ensure to communicate to your customer that prototypes are mockups only. The client and the manufacturer benefit by saving time, energy and financial burn. Moreover, prototypes can project costs, technical specifications and programming glitches. By testing the functionality, minimise design flaws and include modifications. Drop several edits and quicken the design development process through prototyping. Check out Clarico’s case studies to know more about the Indoor Air Quality systems deployed by them in Noida and Gurgaon. Check Out Clarico Air To Know More About Their Capabilities And Project. Get In Touch With Us To Know More About The Services We Can Provide. We Are An EMS Provider And Specialise In Providing Tailor-made End-To-End Services To Meet Your Requirements. We Have The Capabilities To Deliver Low Or High Volume Orders.   Let’s talk for more information.   Call us on: +91 91764 18660   Mails us at: arkcircuitry@gmail.com   Visit us at: https://arkcircuits.com/ Facebook Twitter Linkedin Instagram Recent Blogs How prototypes help identify and formulate design and save time Regan February 9, 2023 Prototypes can help manufacturers save manpower, time and money. It simulates the actual product … Read More Reverse Engineering-13 ways to constructively use it in R&D Regan February 2, 2023 What happens if a product or machinery used becomes outdated and you can’t find its components? Can … Read More

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Reverse Engineering-13 ways to constructively use it in R&D

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What happens if a product or machinery used becomes outdated and you can’t find its components? Can you find out the working of a machine and incorporate design changes before launching a new product? How can you clone or replicate or revise an existing product? What is Reverse Engineering? When a product is developed, firstly, it begins with an idea, then moves to constructing the design and finally the product is built. However, with reverse engineering, the process begins with a final product. The engineer deconstructs the product going in layer by layer to understand and arrive at the product design specifications. Where is it used? Reverse engineering can be used in several industries including electronics, mechanical, consumer products, software, biomedical, chemical, electronics, automotive, design, manufacturing, healthcare and medicine among several others. Why is it used? Reverse engineering is used to either re-create a product, improve it or understand its design for manufacturing in the future. During this technical process, vital information is collected to be used to analyse and research a product. Data on design elements like specifications, core components, processing flow, functional performance, manufacturing process and critical dimensions is gathered. 13 common reasons for reverse engineering include: To retrofit parts or components: New or modified parts, equipment or components which are not available at the time of manufacture and might be necessary to the end customer can be installed using reverse engineering.  Unavailability of original documentation: This method is used  when there are missing files or legacy systems are involved OEM components unavailability: Reverse engineering can be used to factor out obsolescence. Many OEM parts or components may have a short commercial lifespan or are out of production, replacements can be constructed with available material. It may also be used when maintenance is discontinued by the original manufacturer for a product.  Migrating legacy systems: To modernise software or include functions to adapt to the technological advancements, reverse engineering helps tackle these challenges. Migrating legacy systems to new platforms is possible with this method.  Privacy protection: By understanding the product better, the engineer can develop stricter protocols to restrict the copying of systems.  Revise product faults: You can fix issues with a product if you reverse engineer it. Particularly those problems that are not supported by the original manufacturers can be solved by this method.  Sourcing alternatives: Understanding the components or parts that go into a product, readily available or cheaper alternatives can be sourced. This ensures uninterrupted production and can also reduce costs. 13 common reasons for reverse engineering include (CONTD) Accelerate R&D: By deducing the know-how of a product there is scope for innovation & rapid production.  Educational: To understand a well developed product or to mitigate faults in the future.  Competitor analysis: This may not be ethically sound, but several companies expose their competitors’ public statement using this method. When a competitor has falsely campaigned or marketed a certain product, sometimes they are brought to light using reverse engineering Restoring or repurposing: A product that is no longer in use can be redesigned and improved to be made useful.  Proactive maintenance: This helps manufacturers stock spares and reduce unexpected downtime for critical components before they fail.  Digitise data: As mentioned above, when original data is unavailable, reverse engineering can help re-create the data in the digital form and preserve it.  Engineer researching a board that was manufactured by us (ARK Circuitry) to mitigate possible faults so as to source critical components required and to be stocked In Conclusion: With great knowledge comes power, and with power comes great responsibility. Although reverse engineering is a useful design and development technique and can be widely used in several areas, it is to be used with caution. If output of reverse engineering is to be commercially available, it is always advisable to look into the legal aspects as well. There is no one process in following this technique, it is up to the engineer to analyse the product according to the requirement.   Follow us for the follow up post on reverse engineering.  We will take you through the step-by-step process of one of our techniques for your better understanding.  Ark Circuitry Is An EMS Provider And Specialise In Providing End-To-End Services That Can Be Tailor-Made To Meet Your Requirements. We have experienced engineers who are dedicated to research and develop products with superior functioning.  Let’s talk for more information.  Call us on: +91 88259 58660 Mails us at: arkcircuitry@gmail.com Visit us at: https://arkcircuits.com/ Recent Blogs Reverse Engineering-13 ways to constructively use it in R&D Regan February 2, 2023 What happens if a product or machinery used becomes outdated and you can’t find its components? Can … Read More Why is cleaning a PCBA an essential process in manufacturing? Regan January 5, 2023 The functioning of electronic devices relies heavily on circuit boards. Care needs to be taken when … Read More

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Why is cleaning a PCBA an essential process in manufacturing?

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The functioning of electronic devices relies heavily on circuit boards. Care needs to be taken when manufacturing the boards and more so after. Even a spec of dust or residue can affect the reliability and this articles explains more.

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Technological Revolution and its impact on Electronics Manufacturing Services

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Electronics equipment, consumer electronics, and the growing demand for innovative technological advancements paves way for manufacturers to capitalise on the opportunities. With the sophistication in manufacturing technology, the growing complexity of electronic devices is both time-consuming and expensive.  This requires manufacturers to engage with experienced solution partners who offer industry expertise. The advent of digital computers Clearly, the digital computer era and its subsequent progress around the 1990s have increased the usage of electronics in mainstream industries. Electronics have become indispensable in the global industrial sector. The increase in demand for consumer electronics, healthcare equipment, aviation, automotive industries, industrial automation, defence, and network and communication equipment has provided business opportunities to several EMS providers (Electronics Manufacturing Service Providers).  These manufacturers provide a series of valued added services such as manufacturing, procurement, design & development and distribution for electronic product manufacturers. The Shift in modern technology Electronic devices have seen several cycles of change and the miniaturisation of devices associated with the development and technological advancement has been evident with time. The capabilities have become vast, more economical than the previous generations, easily available and diverse over the decades.  The printed board circuits have become small in size and more powerful in function. The role of EMS in manufacturing EMS providers have become important partners of manufacturers in accelerating the manufacturing process. EMS can include design, assembly, manufacturing, testing of electronic components, and procurement for manufacturers. They can be contracted during any step of the production process. Depending on individual requirements they can provide simple design solutions prior to the development, sourcing or procurement of components, assembly, testing of electronics components or products, manufacturing components, printed circuit boards and assembly of products or prototypes. Emerging Technologies have revolutionised the Manufacturing Processes The evolution of technology has shrunk the size of components and PCBs have become progressively small in size. Electronic processes have become more complex such as multiple layers, smaller boards, delicate components and parts, precise placements and other such concerns. Manufacturers are expected to speed up the process without cutting costs or jeopardising the quality of products while adapting to newer and unfamiliar technologies.  Furthermore, the production processes have become more streamlined with innovative and sophisticated technological solutions. The consistent and rapid development of IoT has enhanced the efficiency of the production process. Industrial automation or robotics in the manufacturing industries have revolutionised the production process both in terms of speed and precision. For example, the process of hand soldering components on PCBs is being replaced by Surface Mount Technology (SMT) that enables seamless assembly of SMD (surface mount devices) on boards. A fundamental revolution has also taken place in the machine learning space aka AI or artificial intelligence. It is a transformative technology in the way machines function and communicates.  Without a doubt, the surge in demand has also reflected in EMS companies transcending from just providing manufacturing services to now offering end-to-end services to customers to support them during manufacturing. These services may include guidance in the certification process, collaborating during ideation, maintenance systems, new product design and development, hardware and system architecture implementations, supplier management, etc. to name a few. Strategic transitions with growth in Electronics demands Particularly in the manufacturing space, there have been several collaborations, mergers, negotiations and other relevant agreements among OEMs, ODMs, EMS providers and customers to adapt to the changes that have been taking place. It is not just outsourcing a specific or all processes of manufacturing, companies have also begun to hire production lines for manufacturing. To boost production, several strategies like expanding software functionality, streamlining manufacturing processes through digitisation, automated assembly lines, etc are becoming prominent. Supply chain management- The Key to manufacturing The revolution in technology is to speed up the processes without hastening the system. Nevertheless, the challenges in the supply chain continue to cause limitations to the EMS which hampers the speed of innovation and technology adoption. This disrupts delivery schedules, costs, logistics and production planning. Thus an EMS provider building a network and supply chain relationships highly impact keeping deliveries on time. Ark Circuitry,  a leading player in SMT manufacturing, is designed and capable Of catering to a global customer base. Powerful, integrated software and hardware systems are essential to electronics manufacturing services. We ensure to facilitate better flexibility, productivity, and quality across applications. Let’s talk for more information.  Call us on: +91 91764 18660 Mails us at: arkcircuitry@gmail.com Visit us at: https://arkcircuits.com/ Facebook Twitter Linkedin Instagram Recent Blogs Technological Revolution and its impact on Electronics Manufacturing Services Suneyna S JoJo December 10, 2022 Electronics equipment, consumer electronics, and the growing demand for innovative technological … Read More Is robust Supply chain important to an EMS provider? Suneyna S JoJo November 24, 2022 The manufacturing industry partners with several companies when working on producing a product. It … Read More

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