Universal functional test system developed

The Peak Group has developed a new universal functional test system based on a series of modules that can be configured to meet the manufacturing test requirements of a variety of industries.

The Peak Group has developed a new universal functional test system based on a series of modules that can be configured to meet the manufacturing test requirements of a variety of industries.

Known as Apex, the new system is an evolution of Peak's earlier bespoke functional test systems, augmenting the company's many years of experience in this field with a high degree of modularity and standardisation made possible by the use of standard connector interfaces manufactured by Virginia Panel Corporation, for which Peak is the exclusive UK distributor.

In addition to carrying out functional testing on the electronics of the DUT (device under test), the system can be configured to carry out stimulus and response testing on electromechanical, optical, hydraulic and pneumatic components and their associated systems.

The system platform is based on an active backplane arrangement (supporting hot-swap functionality) utilising the Virginia Panel Corporation 18-way connector interface, into which a maximum of 16 expansion cards can be accommodated according to the user's requirements.

Most customer requirements can be met by a series of standard I/O and fixture control card solutions, with only aspects such as client-specific electronics interfacing and precision analogue measurements - for example, small air- pressure leakage detection - involving any significant degree of customisation.

The heart of the Apex system is the Commander (rack controller) card, which not only includes the basic rack control functions but is also equipped with digital input, digital output, analogue-to-digital and digital-to-analogue convertors, operator console interface, plus USB, RS232 host ports and thermocouple (K or J type) interfaces.

Although compatible with Peak's well-established TestMaster software suite, the Commander card resident P-clip (Peak Command Line Interpreter Programme) command syntax structure supports open Windows( applications, running on any PC via USB or RS232 interface, and so can be used with third-party software packages such as LabView.

Standard rack expansion cards include a 96-channel output card with 200 mA opto-isolated digital outputs for controlling pneumatic solenoids for operating functional test fixtures, a 96-channel opto-isolated digital input card with inputs accepting from 3 to 30 V per channel for reading back the outputs from the fixture's various pneumatic activators, and a 64-channel single-pole/changeover volt-free contact relay card.

A 96-node switching matrix card can connect 96 nodes from the device under test via up to seven 'lanes', creating a matrix structure which can route different nodes back to an on-board digital multimeter for measuring electrical parameters.

A 19-inch rack-mount power supply and measurement controller module supporting both system (+5 V and +24 V at 7.5 A) requirements with dual (0 - 30 V at 3 A) programmable outputs for DUT utilisation is also included, along with a range of supporting functions, including voltage or current measurement from each of the four independent supplies, fan cooling status telemetry and additional external system mains power distribution control.

A typical system would include standard expansion cards to provide the basic fixture control and test sequence control functions, plus one or more custom cards which might include functions such as solenoid load simulation, specialised signal conditioning for the measurement of physical parameters, ATMEL MCU flash programming and stepper-motor control for operating rotary switches or trimmers.

The modularity of the system plus the provision of self-diagnostic capabilities means that it is easy to maintain and upgrade.

In addition, the inclusion of on-board EEPROM means that the Commander card firmware can be modified or upgraded at any time - remotely via the host PC Internet connection, if appropriate access is allowed.

For customers using Peak's TestMaster software, Peak maintains a web server that stores users' test programme configurations and results, and loads software upgrades into the customer's system automatically (subject to a subscription fee).

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