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How to Effectively run a Functional Test on a PCB?

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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Is robust Supply chain important to an EMS provider?

The manufacturing industry partners with several companies when working on producing a product. It becomes tedious, and expensive and requires the management of too many resources for a manufacturing company to have all the departments in-house. Therefore to avoid managing a massive inventory and manpower, certain aspects of manufacturing are outsourced or as we like to say involving “partners” for manufacturing. These partners can be OEMs, CEMs, ECMs, ODMs, CMs and EMS. Here’s  How do you choose your service provider? Before we move to understand the relevance of EMS in manufacturing let’s take a look at other commonly used acronyms. Some terms used related to manufacturing are OEM, CEM, ECM, ODM, CM and EMS, each of which provide different services which at times are used interchangeably. However, at times, a combination of their services may also be used by manufacturers. In manufacturing, knowing which manufacturer to turn to depending on their speciality and your product is important. These providers can produce, manufacture, contract or source and procure specific components providing service and solutions for you to deliver your product. (i) Original Equipment Manufacturers(OEM) Original Equipment Manufacturers(OEM) produce certain or all components required for other companies to build their product and sell their finished items/goods to their customers. In other words, an OEM sells its parts/components to manufacturers who assemble them with several other parts/components to roll out a finished product. OEMs may focus on investing their time and resources on R&D and regularly work on innovating their products/components. OEM majorly focusses on B2B sales, although there has been a recent increase in customers building their own products(DIY  projects) and purchasing OEMs from distributors. The manufacturers also find it beneficial as the OEM usually provides warranty for the product and service is provided for a limited period of time. An OEM refers to components/parts made specifically for the original product (designed and developed for). On the other hand, the ‘aftermarket’ refers to the equipment made by some other company that a consumer may use as a replacement. (ii) CEM or Contract Electronics Manufacturer CEMs or Contract Electronics Manufacturers are companies that are outsourced by companies to make electronic products for them. The CEMs usually serve sectors like communication, medicine, defence, computer industries and transportation. They specialise in PCBA (printed circuit board assembly) and electro-mechanical services. They also provide design services to create electrical parts (they design, test and develop these parts)  used by OEMs and usually rebranded with the buyer’s logo. A CEM provides customers with the expertise in industry-standard, certifications required and regulations to be followed and uses advanced technologies. Thus, they would have an excellent and reliable supply chain to ensure a smooth flow in manufacturing. They are also known by another acronym which is ECM (Electronics Contract Manufacturing). (Iii)Contract Manufacturing(CM)​ CEMs or Contract Electronics Manufacturers are companies that are outsourced by companies to make electronic products for them. The CEMs usually serve sectors like communication, medicine, defence, computer industries and transportation. They specialise in PCBA (printed circuit board assembly) and electro-mechanical services. They also provide design services to create electrical parts (they design, test and develop these parts)  used by OEMs and usually rebranded with the buyer’s logo. A CEM provides customers with the expertise in industry-standard, certifications required and regulations to be followed and uses advanced technologies. Thus, they would have an excellent and reliable supply chain to ensure a smooth flow in manufacturing. They are also known by another acronym which is ECM (Electronics Contract Manufacturing). (iii)Original Design manufacturer(ODM) The manufacturer designs and produces products which are a part of a product or are rebranded and sold under another company’s name. Original Design Manufacturer (ODM) as the name suggests in actuality design, develop and own the IP (intellectual property) for the product which they can put out in the market, sell to a buyer(s) or as a white label product (a product sold under names of several buyers). Thus, the buyer usually chooses an ODM when they are looking for a finished product which is generic and not usually completely customised. The buyer looks for ‘private labelling’ where he chooses an existing product, might make a few changes and sell it under their brand name. (iii)Electronics manufacturing Service(EMS) OEMs or manufacturers often outsource a section or the entire process of procuring and/or manufacturing components (electronic components) required for the end product. Instead, they utilise their time and resources to focus on their core competencies such as research and developing their product and plan strategies for selling the product.  An EMS (Electronics Manufacturing Service) provider has a network of suppliers and vendors (or as we at Ark Circuitry call them as ‘partners’) who they have a longstanding relationship and thus are capable to procuring a wide range of products and since the partners understand the business, they would be able to cope with the peaks and troughs in demands. When this is possible it means that the EMS provider has an efficient and excellent supply chain. Why do OEMs choose EMS providers to procure all the necessary material on their behalf? Simple because it makes financial sense, i.e. the OEM doesn’t have to manage a procurement team as the EMS provider can carry out the operation at a much lesser cost. The Chartered Institute of Logistics & Transport UK (2019) defines ‘supply chain’ as: “Getting the Right product, in the Right quantity, in the Right condition, at the Right place, at the Right time, to the Right customer, at the Right price.” This definition is quite fitting for EMS providers. A good EMS provider will have the capability to provide manufacturers with a wide range of customised services that will deliver end-user solutions. Their services may include and not limited to (i) Electronic design & engineering (ii) Electronic assembly (iii) Electric manufacturing (iv) Electro-mechanical services, etc.  In order to be able to do so, the EMS provider must have excellent supply chain management, a network of suppliers and a well-experienced procurement team/member to be able to deliver

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Choosing the right test/inspection for a printed circuit board.

Why do PCB manufacturers encourage customers to opt for inspection or to run tests on the PCB? Is it really necessary? How do you avoid the hassle of reworking your product? What are the different tests available? Read this post for information.  Why is an inspection/test required? Before the device or system leaves the manufacturing unit a thorough inspection of the PCB mitigates problems in a  manufactured product. This helps companies cut down expenses and valuable resources.  Sometimes even as simple as solder flux can interfere with the functionality of the PCB  and using a non-clean low-residue solder paste is suggested. What are the different tests available? There are 3 widely used tests to check the functionality, durability and accuracy of the system : automated optical inspection, X-ray Inspection and burn-in test.   Automated Optical Inspection (AOI) The AOI uses cameras to capture pictures of the PCB and then compares them with detailed schematics to check errors. when capturing pictures, light is focused from different angles on the board. The images are put together to create a full profile of the board. This system helps in the early detection of nodules, scratches on the board, incomplete or thinning solder, open circuits, missing components and short circuits.  Relying on cameras, the AOI is limited to what is visually detected and is unable to inspect hidden connections, especially in multi-layer boards. Moreover, as external light is used, there could be errors during inspection due to the emerging shadows. Hence, depending on the complexity of the board manufacturers use a combination of inspections to ascertain faults or errors in a board. X-ray Inspection (AXI) For boards that are tightly packed with several components (especially small ones) and for multi-layer boards, AOI inspection might not be a suitable test. AOI only detects errors visually from the surface in comparison to X-ray inspection which provides better clarity and inspects the PCB in detail.  Besides, X-ray passes directly through objects and does not need external light as required in AOI. Furthermore, it helps detect issues by examining the board thoroughly as it goes beyond just the surface.  However, this method also has its limitations. The process is extremely time-consuming and setting up an X-ray inspection system is expensive. AXI requires an experienced operator to use the machine which is also an added expense. This leads to exploring the third option, the burn-in test.  Burn-in Test A burn-in test can enable the early detection of potential problems and helps keep the cost of testing and replacing parts at the lowest. In electronic devices, a burn-in test can determine the maximum temperature it can sustain. A burn-in may also be a part of routine maintenance or repair. The malfunction might not be straightforward until the hardware is warmed/cooled to a certain temperature or checked for humidity as a factor. Tests under these various environmental parameters could aid in diagnosing the problem and fixing it. The burn-in test can be performed for an entire system or individual components. The system is operated for extended hours or extreme working conditions to check its functionality and reliability. Running a quick burn-in test to check the PCBs Identifying defects at an early stage of the manufacturing process is the most practical way of reducing costs and allows errors to be rectified.  At Ark Circuitry we use high-quality components to ensure the proper functioning of a PCB. We also encourage customers to opt for testing as it is not only important to check the functionality of the product but also to avoid danger when used in highly sensitive applications. Ark Circuitry Ventures Is An EMS Provider And Specialise In Providing End-To-End Services That Can Be Tailor-Made To Meet Your Requirements.  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 Choosing the right test/inspection for a printed circuit board. Suneyna S JoJo November 4, 2022 Why do PCB manufacturers encourage customers to opt for inspection or to run tests on the PCB? Is it … Read More The process of a small run SMT Production Suneyna S JoJo October 27, 2022 Ever wondered what makes it important for your electronics to work efficiently apart from its … Read More

Choosing the right test/inspection for a printed circuit board. Read More »