The value and prominence of complex test equipment is growing rapidly across a number global industries. Custom test equipment systems play a critical role in quality control and throughput for precision product manufacturing, as seen in the testing of functionality and performance of electronic devices. Production capacity is bolstered considerably by automating these complex test processes. Automated and Semi-automated test equipment typically include various sensors, control mechanisms, and active subsystems used to accomplish testing within a wide range of applications.
When designing test equipment with complex functions or multiple active subassemblies, the delivery and control of power is of vital importance. This is often best handled by a custom power distribution unit (PDU), which takes input power signals and distributes them to the various downstream equipment. But how do you go about building a test system, and how are PDUs integrated into test equipment? We'll discuss these issues and more to help you understand the role of PDUs in test equipment.
Automated test equipment (ATE) includes any control hardware, sensors or software that collect and analyze test results. The whole system can vary widely in complexity, ranging from a single computer-controlled multimeter to a system of dozens of test instruments, both real and simulated. The devices that undergo testing are known by many names, including equipment under test (EUT), unit under test (UUT) or device under test (DUT).
High value test equipment can conduct precision testing with minimal human intervention, collecting and analyzing the results to deliver meaningful data without extensive labor. For these reasons, ATE reduces testing costs, especially in high-volume testing applications. This quality makes ATE desirable for numerous applications, including the following:
Because of automated test equipment's utility in such a range of markets, the global automated test equipment market is expected to increase drastically over the next several years. The market reached $4.36 billion in 2018, up from $3.54 billion in 2011, according to one research firm.
Allotting time for testing is a struggle for engineers and designers in all industries. Between steadily decreasing part sizes and shrinking deadlines, engineers have found less time to set up increasingly complex tests. Nearly 15% of wireless engineers and 45% of contract manufacturing engineers outsource their final testing because of these challenges.
Even though automated test equipment poses a unique advantage to many industries, test engineers and directors in those fields still face numerous challenges in procuring and designing automated testing systems.
Some of the unique challenges encountered in automated testing systems include the following:
Many of these procurement challenges can be solved by working with specialists in system customization like Astrodyne TDI. By producing custom products that intelligently integrate multiple modules, Astrodyne TDI can shorten verification timelines, assembly time, and safety certification processes so your engineers can focus on building for functionality.
One big consideration with test equipment is power. Automated test system power infrastructure is very different from typical power setups. Because test systems consist of many internal components, they require more complex power systems to ensure each part gets the energy it needs and avoids critical problems. Some automated test system requirements and components include the following elements.
Nearly every product, regardless of application or market, is required to comply to standardized EMC limitations. This limits the amount of electromagnetic noise the product can inject onto the local power line. Just as the components and functionalist of a complex test system vary widely, so too does the EMC noise generated. To ensure compliance to these regulations and to protect the ATE from any noise on the line, EMI Filters are included in the standard test equipment system architecture. EMI Filters should be located near the power input/output to the system. They are easily integrated into custom PDUs for streamlined system design.
Each piece of equipment in a test system requires a certain amount of current at the right voltage level and may require various safety- or functionality-based controls. A test system needs to include a power distribution unit to ensure downstream equipment receive appropriate power. Power distribution units for test systems ensure sufficient energy flows to each component while also protecting equipment from surges, sequencing power provision, and more. A PDU's internal power outlets possess a current and a rated voltage, and they are compatible with both direct and alternating currents.
PDUs are integral parts of a testing system due to their ability, and custom solutions may include fully integrated primary and secondary power sources. When using a PDU — or any of the other elements listed here — it's essential to create a power layout. This arrangement ensures each part receives the electricity it needs. Bottlenecks created by a lack of power can stall an entire operation if the affected component is integral to the system. Working with an experienced custom PDU supplier such as Astrodyne TDI reduces risks like this as they partner with your engineers to provide a comprehensive design.
Testing can also be affected by power losses, brownouts and malfunctions during normal operations. The uninterruptible power supply protects against this. UPSs ensure critical components in the system get continuous energy when the power supply encounters a problem. For example, cooling, control and monitoring systems are crucial to maintaining function during brownouts, as failure can prevent quick recovery or damage equipment.
PDUs and UPSs work together to ensure a testing device receives the energy it requires without the risk of failure. When necessary, UPSs combined with power converters enable you to condition standard electricity to meet the system's needs. Ultimately, however, it may be easier to use ATE with a global input voltage to bypass the need for a power converter. Be sure to install and apply a UPS to such vital test equipment to keep your systems running as effectively and efficiently as they should.
As the role of automated test equipment grows, safety control feature implementations take on new dimension as well. One ubiquitous feature, shared by nearly all modern test equipment is Emergency Power Off (EPO) functionality. EPO features simplify reactions to local emergency situations by directly inhibiting power switching and triggering shut down procedures.
Grounding is another crucial aspect of automated test equipment requirements, both for safety and measurement quality. Grounding secures the safety of operators and equipment by ensuring that all system equipment has a proper path for current to flow to the ground. Quality grounding also includes assurances that electrical connections to the ground are direct, which minimizes the production of radio frequency emissions that can interfere with measurement equipment.
There are hundreds of ways to configure and arrange these test equipment parts and features, but they form a basis for any test system power infrastructure.
All parts of a test system power infrastructure are necessary to ensure full functionality and long-term reliability. However, one of the most critical and most customizable modules of a test system is the power distribution unit. What is a power distribution unit, and how does it hold such importance?
A PDU's primary function is to take input power signals and distribute them to components in the system to ensure each gets sufficient power to function properly. While this basic ability serves most power distribution unit applications, there are additional functions of power distributions for test equipment that can benefit ATE. Many of these are seen in components of custom PDUs.
Some of the features of PDUs for test systems include the following:
When paired with a UPS to power critical components and an EMI filter to protect from noise in the power supply, PDUs provide excellent power infrastructure for test equipment, especially when customized to your device's specific needs.
There are many methods and configurations available for complex test equipment design. With so many options available, it can be challenging to determine the most effective approach. Along with the design itself, you also need to consider long-term factors, such as updating systems over time, maintaining custom solutions, and repairing or replacing damaged equipment.
One way to achieve quality results is to work closely with a vendor capable of integrating multiple subassemblies. By working with a single vendor with extensive experience in the field, your company can gain insights into options for test equipment design and leverage the company's expertise to design more streamlined and successful test setups. You can also make certain you're working with the best people to repair or replace damaged equipment, ensuring your test systems run for as long as possible.
If you're looking for a company that supports engineers and operators by offering quality power supply, EMI and PDU options for test equipment, Astrodyne TDI is here to help.
Astrodyne TDI designs and manufactures power supplies and EMI filters for a wide range of clients and markets. With more than 50 years of experience in the field, Astrodyne TDI can offer unique solutions for EMI filters and PDUs for automated test systems. We also specialize in custom solutions, enabling your company to experience all the benefits of custom PDUs.
If you're interested in a custom power distribution unit for test equipment or want to learn more about the applications of PDUs, contact Astrodyne TDI today.