Flash Device Programming Station for Low Volume High Mix

Many manufacturers who specialize in high volume continuous production choose to use a dedicated Flash programming station to meet their needs.  This can make a lot of sense whether it is implemented as an automated in-line system or as a manually handled station.  Often the extra time at ICT or EOL FCT is too costly, so a separate station works well. 

But for the CEM who deals with a high mix of relatively low volume production, it would seem that a separate station makes no sense at all.  But in reality, the “high-mix” feature can have significant impact. 

For most of the controls being produced, flashing as part of the production process is a requirement.  Often, the flashing solution is provided by the customer.  It may be a spin-off of the unit used in software development.  It is likely relatively unique and typically requires rather cumbersome operations. 

When the CEM is “blessed” with several different versions of these solutions, they can become a drag on productivity.  Set up and take down is time consuming or keeping the station installed uses valuable shop space.  Since each setup has a unique operation, either skilled operators or ongoing training are required. Then because the station was not likely designed to be production line robust, maintenance can be a serious problem. 

It should be no surprise that the high-mix CEM is faced with these problems.  They are part of what he is paid to solve.  But there is an alternative that is not terribly expensive and solves these problems.  It is a programming station designed for the High Mix environment.  Intrinsic Quality LLC in Elk Grove Village, IL manufactures just such a machine. 

The IQ Programming Station is based on the SMH Technologies FlashRunner.  Like the FlashRunner programmers, the stations are highly configurable.  First, they have the capability of programming any microcontroller or memory device.  Next the production setup for any particular control is quick and easy.  It could be as easy as selecting the product name from a list and using the designated cable harness.  Or if volumes justify or board design requires, a change of the bed of nails fixture can easily be made.  The system guides the operator throughout the process and records all transactions.  If serializing is needed, a printer can be easily attached to print labels. 

Even if the customer provides the flash programming setup, converting this to use the IQ Programming Station is straightforward and worthwhile. 

Yes, there is the question of capital cost.  But this can easily be recovered by the reduction in operational costs. 

Our solutions include Functional and ICT Test Systems and Fixture development as well as Microcontroller Flash Fixture Programming.   

For additional information, please Contact Intrinsic Quality  or call IQ at 847-258-5598. 

There’s still time to join SMH Technologies and IQ for an informative seminar on Universal In-System Programming on April 5, 2024 in Novi, MI. We’re featuring a morning and afternoon in-depth presentation by Mr. Ivan Rinaldi and Mr. Moreno Ortolan of SMH. Learn more about programming Flash Devices, Ingun Bed of Nails Fixtures and Feasa LED analytics. RSVP: larry.raymond@intrinsicquality.com

Theme: Keeping up with current Electronics Industry themes.

Last month I had the opportunity to attend APEX in San Diego.  Normally, I average about one show per year, so I have a sense that I won’t be seeing much new.  At Apex, I decided to be a little more aggressive in introducing myself and pursuing the needs of my company.  As it turns out this was a good plan.

It all started the moment I entered the show.  Walking down the aisle I almost literally ran into John Meyer.  John had recently retired from Methode Automotive and I was surprised to see him.  He proudly displayed his badge that indicated his company in all caps,  “RETIRED”.  He introduced me to his replacement at Methode.  We chatted and reopened our long relationship.  A real pleasure.

I had planned to meet the team from iBtest.  iBtest is sort of a mirror image of IQ.  They operate out of Guadalajara and Monterrey Mexico offering test engineering services, but focus mainly on Keysight ICT.  We, of course focus on Teradyne ICT.  Perhaps we could complement one another.  We met at the Ingun booth.  Both iBtest and IQ routinely use Ingun fixtures and accessories.  We migrated to a quiet area where we could discuss a relationship.  iBtest reinforced what we already knew.  In Mexico a local presence is critically important. We end up with an invitation to Monterrey in March.

After parting, I wandered to the IPTE booth.  Meeting the IPTE folks was on my agenda.  IPTE provides in-line board handling equipment.  They have recently been successful in Europe integrating the SMH FlashRunner to their handler to create an in-line programming station.  As the US distributors for SMH, IQ has been providing programming stations and SMH tech support for several years.  Like with any complex discipline there can be a steep learning curve with production programming.  IQ is mostly up the steep part.  We see a significant growth opportunity in automated programming stations, so I really wanted to introduce IQ to IPTE.  Introductions went well.  I met with the US General Manager and one of the Principals from Belgium.  They suggested they were looking for third party suppliers who could support programming and functional test.  I am thinking I should keep in touch.

Later I found myself at the Checksum booth.  There I met with John VanNewkirk, the company president.  We chatted first about hiking in the Cascades.  John was familiar with the places I had visited.  I shared my story about the old men on Aasgard Pass at night.  Turning to business, John quizzed me on my knowledge of Checksum.  I responded with the conventional knowledge that Checksum offered a competitive MDA system with an integral press down unit.  John shared that my knowledge was correct, but dated.  Today, Checksum is focused on adding parallel functional test.  Really? I thought.  And I responded that would mean multiple voltmeters, current meters, signal sources and lots of DIO.  Yes, John said and that is what Checksum is doing.  Not muxing, but multiple parallel instrumentation.  The target is small controls in large panels.  Providing parallel functional test for large panels clearly addresses a large and untapped market.  John implied that given our background perhaps IQ and Checksum could work together.

As I roamed around the show I realized there was a theme here.  In line, high volume, large panels.  Then I remembered I had an appointment with Keysight.  I scooted over to the hotel where Keysight had a conference room. On entry I was greeted by a dozen or so Keysight sales folks.  They had requested a presentation of FlashRunner High Speed (FR-HS) technology.  In preparation I had received from SMH their preliminary demo unit.  But before I addressed the -HS, I wanted to be sure everybody was up to speed on FR2.0 and FRTools.  So I brought out my demo pieces and explained each item before passing them around for touch and feel.  This was a good move as indicated by the questions that followed.

Then I did the FR-HS presentation and shared the demo units around.  We talked a lot about the 32 channel capability with the remote USB-C driver PODs providing great high speed signal integrity.  Finally I shared that they could expect a March product release.

Before parting I directed our dialog to the desire on the part of IQ to work closely with Keysight.  Keysight has introduced the i1000 Flexicore system.  The Flexicore can provide inline ICT, Functional and Flashing.  Keysight has selected the FlashRunner as the programming engine and was showing an in-line programming station on the APEX floor.  We talked some about IQ’s capabilities and I had a sense that what we could offer was appreciated.  I was encouraged to spend an adequate period inspecting the Flexicore at their booth.

Later I did visit the booth.  I had already studied the Flexicore literature.  But seeing and touching the system was still worthwhile.  While at the booth we talked about using FR-HS to make the machine sing.

There were multiple other visits.  The folks from Ingun were most generous.  My meeting with Signify provide both sides good info.

Overall my take has to be we need to pay attention to the theme.

High volume, in-line, parallel operations, a local presence.  I am certainly glad I went. 

Join Intrinsic Quality at the Test and Automotive Expo in Novi, Michigan on October 22-24, 2019

Please join Intrinsic Quality at the Automotive Testing Expo in Novi, Michigan on October 22 through 24, 2019.  IQ will be showcasing our Flash Device Production Programming Station and the new line of SMH FlashRunner Products at Booth #15038.  IQ’s Programming Stations are designed to provide a comprehensive solution for loading firmware for powertrain and ADAS applications.

Intrinsic Quality Flash Production Programming

Loading production firmware onto ECUs has become an increasingly complex task. Large files, multiple sections, security features make takt-times difficult to achieve. We focus on programming stations designed for automotive manufacturing. With SMH FlashRunner, NI software and instrumentation, and Ingun fixturing our systems are advanced, robust and flexible. IQ test systems are based on 35 years of experience. Our systems are built on time tested architecture that enables strong, fast and accurate test that is easy to use and maintain.

“Intrinsic Quality delivers Programming and Functional Test Stations for High Volume & High Complexity Production.”

The SMH FlashRunner 2.0 provides 1 to 16 channels of high-speed Flash programming.  Channels are independent, asynchronous and can implement virtually any programming protocol.  As a stand-alone instrument, the FlashRunner can communicate with a separate PC or be triggered by DIO.  It provides both programmable power supplies and programmable clocking.  The software is both flexible and powerful allowing for versatile entry of variable data such as ECU IDs and security codes.  The FlashRunner 2.0 is the key instrument in an Intrinsic Quality programming station and can also be integrated in Functional or ICT stations.

Intrinsic Quality’s programming stations are highly adaptable with a standard GUI, all programming setup and detailed logging within a turn key operation. Easily manage configuration of ECU ID, with password and locking features.  Additional parameters including firmware revision, power, and signal levels are automatically verified and set up. Our stations are adaptable:  the addition of new boards, devices or firmware is easily accomplished, as your manufacturing floor adapts to future needs.

 

Intrinsic Quality Open House – A Rousing Success!

IQ welcomed Brent O’Connor of Novatronix, Stephen Baird of Ingun, USA and Al Bickner of Circuit Technologies Company.

Intrinsic Quality llc, held an Open House on Friday, June 14, 2019. IQ had a wonderful turn out! We celebrated our move to the new building, which affords us much more space for our engineering and manufacturing clients.

IQ was joined by Stephen Baird, Regional Sales Manager for Ingun, USA.  Stephen did a demo of Ingun’s Test Systems and provided an intriguing display of their capabilities.  IQ held a demonstration of several Test Equipment Projects including a Fanuc Robot installation for a major appliance manufacturer.  ICT and Flash Programming station projects were also demo-ed to local  manufacturers.

IQ was very pleased to welcome other corporate associates, as well as several family members.   Intrinsic Quality wants to send out a big thank you to all who were able to visit and offer their support.   And for those who couldn’t make it, we appreciate your interest in IQ as well.  It was a very good day to share thoughts, and develop our business friendships.

IQ Introduces the Prodigy Suite of Automatic In-System Microcontroller Device Programmers

Intrinsic Quality is pleased to announce several new options for the programming of flash devices for your manufacturing process: IQ’s Suite of highly flexible Prodigy Microcontroller Programming Stations, including IQ’s new entry level Prodigy In-System Programmer; and the complete line of PC-based Prodigy and Paragon models.

It’s time to reimagine your programming process. Are your techs randomly shuffling your random and obsolete computers and peripherals to create a variety of programming tools for a solitary task in your test process? IQ’s Prodigy Suite has affordable solutions to upgrade your flash programming for the long term. All our micocontroller device programmers feature IQ’s brilliant design integrated with SMH’s FlashRunner in-system programmers.

Our Prodigy 1011 is a stand-alone microcontroller based programmer (no well) that is set up for an external harness or fixture. The 1011 is our response to the need for an affordable production ready, high speed, entry level programming station. Based on the SMH FlashRunner FR01ENG, Prodigy 1011 is the perfect answer to low volume high mix manufacturers who previously could not justify a commercial programming station. The Prodigy 1011 is remarkably capabable of adapting to multiple devices, protocols and various vendors for long-term functionality. Adaptability: Auto selection of part number is based on a 5 bit ID provided by the fixture or ATE OR for higher volume applications, the 1011 connects readily to simple interchangeable bed of nail fixtures. In ATE applications, Prodigy easily connects to the ATE fixture with auto detect remote operation. Prodigy 1011’s  throughput is impressive, as production can move rapidly with minimized operator error and lightning fast programming times. View all of IQ’s Prodigy 1011 features here.

 IQ‘s Prodigy 2000 single or dual well programmer stations are desogmed fpr easo;u interchangeable fixtures and include Intrinsic Quality‘s expert device programming services. All programming parameters are included as firmware revision, power, and signal levels are automatically verified and set up. The Prodigy 2111 and further models are available in an amazing variety of configurations that include single or dual well and multiple channel capabilities. For more information, visit our Prodigy Models detail page.

Harnessing the power of flash programming with IQ‘s innovative FlashRunner based Universal Flash Programmer station is the right decision for your manufacturing process.  

IQ’s Paragon 3118: High Speed PC based Production Device Programmer

Paragon 3118 and additional models include the cutting edge technology of SMH’s FlashRunner 2.0 ISP programmer for blistering speed and renowned programming accuracy.

Like the Prodigy, these microcontroller programmers are flash based PC units with dual or single well configurations and a variety of multiple channel options.

Intrinsic Quality: USA Distributor for the FlashRunner In-System Programmer

Intrinsic Quality is pleased to be the Midwest’s leading distributor of SMH’s FlashRunner – A Revolutionary, Universal, Production In-System Flash Programmer.  FlashRunner answers the call for a Universal In-System Programmer that supports multiple microcontroller device manufacturers.  You’re looking for a fast and reliable way to program your devices that ensures data integrity and uninterrupted production.  With In-Circuit or In-System Programming, Flashrunner has answered that call and superceded traditional on-socket or pre-programmed programmable devices with several noteworthy advantages.

 

 

FlashRunner’s attributes:

• Seamless integration into your ATE and Fixtures
• On-board programming of microcontrollers, CPLDs, EEPROM and flash devices
• Economical – lowers manufacturing and testing costs
• Compatible with Agilent, Teradyne, SPEA, Genrad and other device manufacturers
• Effortless programming
• Allows for last minute reprogramming
• Flexible in-circuit testing
• Multiple device programming on single or multiple boards in a panel assembly
• Firmware updates are smoothly integrated without additional cost
• Priced starting from $1,900

There are several different FlashRunner Series from which to choose that are easily integrated into your production environment adapting to various ATE, ICT and other test fixtures.

For more information about FlashRunner, contact Intrinsic Quality today:

(847)258-5598      or     info@intrinsicquality.com

 

 

 

High Praise from a Major OEM

Intrinsic Quality recently delivered a custom engineered test fixture to a major OEM. During our quality control meeting, we asked the Vice President “What is Your Impression of IQ?”. His response wasn’t unexpected, after all, we know our standards for quality engineering are paramount, but we were happy to hear his high praise: “our perception of Intrinsic Quality is that you make darn good fixtures”.

Custom FlashRunner Fixture

While this test fixture project wasn’t unusual for IQ, our challenge was to facilitate the placement and firmware programming of a 4 pin connector consumer control within a conveyor assembly station. IQ engineered a quick mount fixture that takes the operator just a few seconds to click the consumer control module into place, lower the connector cover and load the firmware. The operator then places the loaded consumer control module into the System Control Panel on conveyor. Our IQ Test Fixture incorporated FlashRunner™ a high-performance, standalone In-System Programmer which instantly loaded the OEM’s firmware. Our achievement in this fixture was remarkable – we had created a fixture where in one smooth motion the operator could place the component into the System Control Panel. So successful that each operator is now able to operate two IQ test fixtures simultaneously and maintain the conveyor assembly’s speed. With IQ’s fixture this OEM was able to boost their manufacture to over 25000 units a day.

Every company is striving to improve its reputation with their customers.  Hearing acknowledgement of your reputation feels like you’ve just knocked one out of the park.  But we asked that question also to explore other ways we might serve this OEM  – Yes, we make darn good test fixtures but we also take pride in the quality of our test executive, reliable measurement software, and test data management.  Call IQ today at 847-258-5598  and let’s talk about your ATE needs.        

Intrinsic Quality’s Flash Programming Station – IQPS Revealed

Flexible Parallel Programming Fits High Volume Manufacturing

Intrinsic Quality’s Flash Programming Station can substantially reduce manufacturing costs.

Background

Medium to high volume manufactures are pressed to reduce manufacturing costs while retaining maximum flexibility.  One process step in manufacturing a microcontroller based printed circuit board assembly is getting correct firmware into the flash memory of the microcontroller.  There are several options for this so called flashing of the micro, each with advantages and disadvantages.

 

One of the process techniques often selected is In System Programming (ISP).  ISP refers to flashing the micro after it has been assembled onto its circuit board.  Using ISP has the advantage of last minute programming which provides desired flexibility.  ISP also eliminates the extra cost of buying preprogrammed parts.  ISP can be integrated into the production process either by adding the programming to a production tester or adding a separate process step.

 

When production volumes increase, the beat rate, takt of the production line becomes a critical issue.  Often production test (ICT or Functional) struggles to keep pace with a balanced line.  Flashing a sizeable file into the micro can be a time consuming process, so adding the programming time to already stressed production testers spells trouble.

 

Flash Programming Station Features:

Having a separate process step requires a dedicated programming station.  The features necessary at this station have a commonality with features at each of the manufacturing steps.

• Setup and change-over should be quickly and easily accomplished by factory personnel.
• The use of the equipment by line operators should be intuitive and require a minimum of training.
• The programming and handling operation must be less than the takt to keep pace with line beat rate.
• The equipment must be durable and easily maintained.
• Addition of new boards, devices or firmware must be easily accommodated
• The cost of the equipment should be modest
• The equipment should be able to program various devices from various manufacturers with a common programming API.

 

Intrinsic Quality’s IQPS Programming Station effortlessly meets all of these requirements:

Introducing the IQ Programming Station:

 

The architecture of the IQPS is specifically designed to meet the requirements for cost effective, high reliability and versatile manufacturing equipment.  The concept is simple.  Use a Windows PC, a high quality fixture receiver with interchangeable bed of nails fixtures, and couple this to a powerful universal ISP programmer.  The programmer, the station sensors and displays and the DUT will require proper power and control so the IQPS adds power supplies, switching, measurement and sourcing so that the final station has the resources necessary to do the job.

 

Call Intrinsic Quality today to discuss how our Engineering Team can respond to your needs: (847) 258-5598

 

 

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Making LED Test a Breeze

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Feasa Analyzer – Nearly Effortless LED Testing:

 

Recently Intrinsic Quality visited with a major manufacturer of electronic interface panels. They were looking to have a PCB assembly tested with 18 LEDs mounted. They were concerned about the ease of implementing LED test and were not interested in changing their current testers. Instead, they wanted an easy to set up secondary test station for the functional testing of the LEDs on assemblies.

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Setting up the test will be a breeze. The test parameters can be set using the Feasa analyser software utilities’ “Auto-Learn” feature. This will take the readings of a known good board and use those settings as the test specifications. Tolerences can be set either numerically or by percentage. The software has a friendly user interface and can be enabled for data logging.

Implementation of  functional LED test is expected to improve the manufacturer’s throughput while decreasing the number of defective units shipped – all easily accomplished with Feasa LED analyser hardware and software. Additional information about Feasa products is located at IntrinsicQuality.com/feasa

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Intrinsic Quality Poised to Work with ITAR Certified Companies

Intrinsic Quality is pleased to announce they have been registered with the DLA Defense Logistics Agency and the U.S. / Canada Joint Certification Office, enabling them to work with ITAR certified companies. This registration allows them to:

a. Request unclassified technical data controlled by the DOD or DND;

b. Respond to defense-related contracts whose specifications involve unclassified technical data releasable only to certified contractors;

c. Attend restricted gatherings where unclassified technical data are presented (i.e., symposia, program briefings, meetings designed to publicize advance requirements of the contracting agency, pre-solicitation, pre-bid, pre-proposal and pre-award conferences); and

d. Arrange unclassified visits directly with other certified U.S. or Canadian defense contractors or U.S. and Canadian military facilities.

Intrinsic Quality: ITAR registered for Defense and Military Electronics Testing Solutions

Any technology used for American space–commercial, NASA-related, or defense is typically ITAR controlled. Intrinsic Quality has developed electronics testing solutions in a variety of industries for over 25 years, and is looking forward to start working with ITAR certified companies to meet their electronics test needs.  Call IQ today at: 847-258-5598