Universal In-System Programming Seminar

You’re welcome 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. 

Live programming station on display featuring:
– FlashRunner 2.0 with 8 or 16 independent channels;
– INGUN MA series bed of nails fixturing;
– Feasa LED analyzers performing functional test.

FlashRunner 2.0 is a New Scenario for ISP. 

RSVP: larry.raymond@intrinsicquality.com

 #Ingun #SMH #Flashprogramming #Feasa

FlashRunner 2.0 Advanced Cyber Security

In partnership with SMH Technologies, Intrinsic Quality is pleased to announce advanced cyber security features for all of the FlashRunner 2.0 Technology products, such as FlashRunner High Speed, FlashRunner 2.0 and FlashRunner LAN 2.0 NXG.  The new security features are inserted into the latest versions of OS and Workbench which can be downloaded at the SMH Technologies’ website.

This exciting new encryption method has been developed using asymmetric encryption to ensure the highest level of security.  The encryption inscribes a pair of  keys which are randomly generated by the FlashRunner ~ a private and a public key.

The public key is transmitted to Workbench and is used to encrypt the data, while the private key is securely stored within the FlashRunner, and is then used to decrypt the Workbench encrypted data.

Customers will now be able to encrypt their firmware using Workbench and the data can only be decrypted by their specific FlashRunner.  No other system will be able to decrypt those files without the specificFlashRunner, this includes SMH – no other entity can retrieve the actual data from the encrypted files.

An additional exciting component is the potential to encrypt dynamic data,  such as passwords, keys, serial numbers, etc.  Customers can now encrypt both static data and dynamic data utilizing the same encryption method.

New methods have been added to the DLL (both C and C#) to integrate dynamic encryption in the flashing sequence, and it is possible to now encrypt dynamic data directly from the DLL .

Intrinsic Quality is proud to be the leading U.S. Support Center for SMH FlashRunner 2.0, and the new FlashRunner HS.  We provide Sales, Technical Support and skilled Integration for your FlashRunner.  IQ also implements FlashRunner technology in microcontroller programming stations, Functional Test, and ICT.

For more information about FlashRunner and In-System Programmers, please contact Intrinsic Quality, or call IQ at 847-258-5598 

Anatomy of a Functional Test Fixture

Our current project answers  the need for a versatile pc based programmable Functional Test System with interchangeable fixture cartridges, with data logging capability, housed within a sturdy cabinet with space for instrumentation and other controls.  This project actually included a dual application set of systems: One for the CEM manufacturing floor to test their pneumatic controls, and another at the OEM for the finished control box testing before installation.

When meeting a Functional Test Challenge, IQ intuitively designs and develops systems that can grow with the future needs of the company.   Those characteristics are:

Customizable – Versatile – Innovative

Customizable:  Readily Inter-Changeable Fixtures to transform to your changing needs.

Easy Fixture Exchange

Versatility – The IQ Framework Cabinet:  Our IQ testers are built on a sturdy wheeled cart for easy transport to various manufacturing floor locations.  The Framework cabinet has 2 drawers with front or rear sliders for computers, power conditioners, pneumatic controls, or other instrumentation through four locking access door panels.  If you require new boards, devices or firmware, this addition is easily accomplished, as your manufacturing floor adapts to your future requirements.

Framework Cabinet for Instruments and Other Controls

Innovative:  Fixture Drawer Shield – exclusive interior dust cover to protect fixture wiring from dust and falling objects.

Fixture Drawer Shield – Dust Cover

Bed of Nails | Expert Test Fixture Design | Adaptive Harnesses

IQ’s Functional Test Fixtures:

Hardware:

• USB Instrumentation
• XJTAG boundary scan
• Data Acquisition
• PC Workstations
• Test Fixtures

Applications:

• Circuit Boards
• Assemblies
• Cabinet Harnesses

 

 

 

 

 

 

Software:

• LabVIEW
• LabWindows/CVI
• Visual Basic
• .Net

Services:

• Testability assessment (DFT)
• TRD/Test plan development
• Flash, FPGA, CPLD programming

Three Elements to a Successful Circuit Board Test Fixture

Over the years I have seen hundreds of different custom circuit board testers. Here at IQ alone we have completed over 2500 projects. But I am also constantly checking out my competitor’s work. I have seen really nice systems where the builders knew what they were doing and accomplished their goals well. Some of these almost rise to the level of commercial ATE.

But I have also seen some real dogs. I can even think of a few projects where we missed the boat and shipped something less than elegant. I have been able to identify three things that enable the successful build of a test system. “Successful” as measured by its ability to satisfy the needs of the user, and be built on time and on budget.

1. The skill set of the building organization.

2. A realistic budget.

3. An appropriate identification of the major requirements.

1. The first one is surprisingly overlooked. To be successful designing and building a test system requires a knowledge of designing and building test systems. Designing printed circuit boards doesn’t educate an engineer on how to design a tester. Today’s testers require knowledge and experience in a diverse set of disciplines.

Many of the dog testers I have seen were hastily thrown together by product designers who had no idea of test system state of the art or the requirements for use on a factory floor. Others were built by techs or even interns on their first project. No surprise when the tester is deficient.

When we hire a fresh-out we look for top notch graduates. Then we assume (correctly) they have no idea what we are doing. We figure it takes over a year and several projects with close guidance before a young engineer begins to understand.

2. Of course a realist budget is necessary. When an unrealistic budget is ordained prematurely, it is a set up for a failure that can be several times more costly than a properly budgeted tester. Poorly built testers on a shoestring budget will underperform. Production goals will be stymied. Engineering resources will be poured into attempting to resolve a mess. Often the end result is a walk away with a half-solved problem. It is amazing how many test systems are running poorly and robbing their owners of potential profits.

3. But the intent of this note is to shine a light on the third enabling requirement. Test requirements are usually mentioned for sure, but often without adequate emphasis. People often assume that a tester is a known entity. “Just test it and tell me if its good or bad.” Unfortunately, there is so much more. Getting the necessary tech data is sometimes hard, but most folks recognize the need for data. The CAD data, BOM and drawings are usually available. But it is rare that the tech data includes test requirements. The test system designers need to know what are the characteristics and properties of the device that you would require be tested. The designers will need to know levels and accuracies so they can select and quote appropriate instrumentation.

A good design will have an awareness of the intended use. Is this going to be used for a single product? Or are there several similar products that might use the same basic design? What is the production volume? The design of a tester for 100 boards a month will be significantly different from a design for 10,000 boards a month.

Good test system designers know what is available on the market. Not only for standard measurement instrumentation but also for unusual test requirements. Measuring LED intensity and color, actuating switches automatically, communicating with NFC devices or loading flash firmware are examples of tester features that might be overlooked. There are dozens more that a competent test engineer might recommend.

Too often I have seen requirements written for the operator to read and verify some aspect of product performance. Generally this is asking for trouble. Operators will miss or misinterpret errors. Faults will get passed. The cost of single passed fault can easily exceed the cost of good test automation.

There are so many aspects like handling, safety, locking the fixture closed, data collection. So many others that could easily be overlooked and yet could be a big contributor to success or failure. The test requirements far exceed just a detailed description of the product. To determine the test system design requires a thorough understanding of the product, the use of the test system and how test systems are built with today’s technology to meet the needs of both the owners of the product and also the performers of the test.

Intrinsic Quality, LLC has over 35 years of experience in engineering and developing Automated Test Systems. We are experts in electronics manufacturing and test engineering. IQ is dedicated to the development of superior engineering and comprehensive ATE solutions for the electronics manufacturing, automotive, aerospace, military and medical industries. 

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. 

SMH In-System Programmer Award

Intrinsic Quality is pleased to share in the announcement that SMH Technologies has been awarded the achievement of “Best Silicon Device In-System Programmer Technology Company” for 2020.by  Corporate Vision.

For over 10 years, SMH Technologies has been a global leader in Silicon Device In-System Programming and related services for the electronic manufacturing industry. SMH is the developer of FlashRunner, a universal microcontroller programmer. To read more about the award view the complete article.

Intrinsic Quality is proud to be the leading U.S. Support Center for FlashRunner, and the new FlashRunner HS, providing Sales, Technical Support and skilled Integration. Intrinsic Quality has been chosen to provide development of algorithms for FlashRunner Series 1 and drivers for FlashRunner 2.0. IQ also implements FlashRunner technology in programming stations, Functional Test, and ICT. For more information about FlashRunner and In-System Programmers, please contact Intrinsic Quality, or call IQ at
847-258-5598 

Unexpected pleasures of Functional Testing

One of the great joys of engineering is to see objects that started as a concept in your brain being put to work in the real world.  

There is a sturdy looking bridge in Germany that a relative from an earlier generation designed. My mother took great pride in telling me that her great uncle had designed it. 

 I know that I felt the same pride when I saw some ductwork sticking out of the roof of a car factory and recognized it as one of the first things I had designed.  

At Intrinsic Quality, we as test engineers take similar pride when we see something in everyday use that we know was tested in one of our test systems. When I turn the knob on the controls of my (relatively) new car, I sometimes tell myself, “IQ designed and built the tester and helped to program the MCU’s on the board behind the knob.”  

Larry Raymond, President of Intrinsic Quality, enjoys telling stories as he is driving, and often talks about the various applications for the test systems that IQ has designed over the years:  drink machines, driver assistance technology, ventilators, mining trucks – and the list goes on. Not everything that we design a test for makes it to market, but we do take pride in each and every tester that starts as a point on our CAD, and makes its way to a factory floor – somewhere. 

With over 35 years of experience Intrinsic Quality, LLC. Provides expert electronics manufacturing and test engineering. IQ is dedicated to the development of superior engineering and comprehensive ATE solutions for the electronics manufacturing, automotive, aerospace, military and medical industries. 

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

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

Maintaining Signal Integrity in Test Fixtures

One of the recurring issues we deal with at IQ is Signal Integrity. This may sound a bit obscure, but a little explanation might help.

My wife was hollering at me. I couldn’t understand a thing she was saying. We were indoors and there was no particular competing source of noise. No blaring music, TV or even fans blowing. So why the problem?

Sure I don’t hear as well as I used to, but the real problem was she was three rooms away and the bedroom door was only open a few inches. As the sound traveled through each room it generated a variety of echoes off each wall. Each collision with a wall reduced the volume a little, too. The further the sound travelled, the more distorted it became. Sharp Ts and Ds became more slurred as they merged with their echoes. By the time her voice squeezed through the door opening, it was hardly intelligible and badly garbled. To me at least.

A similar affect occurs with electronic signals. An electrical pulse (a brief change from one voltage level to another and back) travelling down a wire gradually spreads out. After travelling some distance what started out like a sharp “T” evolves into a weak “TH”. Then each time it squeezes through a connection there are reflections, and the pulse loses more amplitude. The connection may even be of the highest quality, but there will still be reflections.

Digital electronics communications consist of sending a series of these pulses in an agreed to code. If the pulses deteriorate too far, the message becomes garbled.

If we are not paying attention to these practices, there will be an increase in reflections and noise. If the increase becomes bad enough, signals will be lost and the whole thing won’t work. And fixing it may be a real pain because everything appears to be properly connected.  When IQ designs our systems and fixtures and during the build process, we keep these occurrences in mind. We apply best practices that minimize signal degradation. We focus on using appropriate wire types, minimizing length and using the most suitable connectors – all properly terminated.  

ICT Engineering Quiz

Think you can pass the ICT Test? Intrinsic Quality faces many challenges when developing an ICT system. In our last quiz, we probed your knowledge of Functional Test. We thought it would be fun to investigate your In-Circuit expertise and see if you’re worth your salt.

Find out if you’re worthy.

Expand your know-how of:

• Contact Test
• Unused Multiplexed Pins
• Op Amp Debug

Can You Pass The IQ Test Engineering Quiz 1?

IQ engineers resolve a lot of very diverse test engineering issues for electronics manufacturers.  Here are some typical problems they might face. At Intrinsic Quality, we know that the test engineers that we work with are a busy group, but we thought it would be fun to share some of the problems we face in the form of a quick quiz. 

Have fun, and keep us in mind for your next project!

Test Engineering Quiz #1

Question 1:

A test fixture requires three small (150W) closed frame power supplies to be mounted near one another. Because space is limited, should these supplies be mounted right side up and stacked one on top of the other? Or should the supplies be turned on their sides and mounted side by side? Why?

Get the Answer

Question 2:

Jeremy needed to measure voltage at a test point that should have a nominal value near 200VDC. However his low cost A/D instrument only had a 10V range. So Jeremy connected a series 20MΩ and 1MΩ resistors from the test point to ground to drop the voltage.
Jeremy set up his software so that it would display a value of 21 *  (A/D Value).
With his Keithley DMM Jeremy confirmed the value at 200V but his test setup across the 1MΩ kept returning 102.5V. What was Jeremy’s error?

See if You’re Right

Question 3:

At In-Circuit Test the system is capable of measuring the impedance of resistors, capacitors and inductors even though the devices are part of a complex circuit. What technique is used to perform these measurements that prevents the surrounding circuitry from dramatically influencing the measurement?

Check Your Answer

Thanks for participating in the Intrinsic Quality Test Engineering Quiz 1. Check your email for more challenging Quizzes from IQ coming soon!

Intrinsic Quality develops solutions to Test Engineering problems just like these on a regular basis. After you check your answers take a minute to see some of what we do.

Functional Test Systems

ICT Test Programs

Flash Programmers and Programming Stations

Functional and ICT fixtures

Panel Build

Robotic test stations

Test software development (LabVIEW, CVI, C++

SMH Flashrunner – Production InSystem Programmers

FEASA LED Analysers

Essential Functional Test for Ventilator Controller

The pandemic has caused a global electronic engineering and test manufacturing need for reliable and high quality ventilators.  First responders, doctors, and nurses are truly amazing superheroes making the world safer for us all.  While we are not heroes, Intrinsic Quality is proud to be part of the solution.  We have recently finished our participation in a program to test ventilators which have been in great demand in many hospitals.

When you are tasked with building something as important as ventilators, you need to make sure the test equipment is robust and capable enough to do the task.  This is the response IQ brings to all of our projects regardless of how newsworthy they may be.

 

Intrinsic Quality was proud to provide Essential Functional Test for Ventilator Controller board for a major CEM this month.  Complete operation of the ventilator control board was designed with the integration of a Fluke DMM and a Keysight Power Supply.  IQ provided additional design elements to the fixture as well as smooth interface wiring to the bed of nails fixture with the additional feature of wireless remote pins for testing.

The CEM’s software was also integrated to test inspratory time, pause and flow rates.  Tidal volume and pressures were also part of the function testing to analyze the full range of oxygen cycle for inspiratory and expiratory volumes. The controller board analysis also included various pressure and flow triggers for adult, paediatric, and neonatal patients.

The IQ Bed of Nails Fixture was designed for efficient controller board interchange. The autolock fixture lid provided a secure and seamless transition for changeover to the next controller board or DUT.  The CEM firmware automatically recognized each new board under test and signal levels were automatically verified and set up.  Normal changeover operation was automatic, as the system read both the fixture and DUT identifications.  The PC keyboard and monitor are readily accessible for programming and maintenance by the test engineer.

Each Intrinsic Quality tester is built on a sturdy wheeled cart for effortless transport to another manufacturing floor location.  The cart holds two cabinet drawers with front or rear sliders for computers, power conditioners, pneumatic controls, or other components through four access door panels.  The addition of new boards, devices or firmware is easily accomplished, as the manufacturing floor adapts to future needs.

Intrinsic Quality is ready to provide Functional and ICT Electronics Test Engineering for your manufacturing needs.  We also provide Flash Device Programming as well as Robotics Testing.  Please contact IQ today at 847-258-5598  or visit us at IntrinsicQuality.com