Test System Design: A Systematic Approach

by ; ;
Edition: 1st
Format: Hardcover
Pub. Date: 2000-09-01
Publisher(s): Prentice Hall PTR
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Summary

More and more engineers now face the challenges of electronic testing -- and those challenges are becoming more complex each year. Test System Design: A Systematic Approach offers start-to-finish best practices for designing, developing, and implementing custom test systems. Ideal for both engineers who are creating test systems and those contracting the responsibility to third parties, this book covers the entire system lifecycle, from planning to upgrades, and beyond. Discover how to design and build more effective test systems up front -- and how to increase the useful lifespan of your systems through planned upgrades and the use of open standards. Learn proven best practices for simplifying development, minimizing risk, maximizing accuracy and reliability, and building systems that fit the skills of your operators. Evaluate your testing requirements, eliminate redundant tests, and determine which equipment you really need; decide how to source your test equipment; and walk through every key implementation issue, from interfaces to cabling, switch panels to electrical safety, racks to temperature control. The book also includes chapters on documentation, operator training, upgrades, and much more.

Table of Contents

Preface xiii
Acknowledgments xv
Part One Planning and Initial Design 1(60)
Initial Planning
3(24)
Getting the Most from Your Investment
4(13)
An Overview of the System Design Process
5(2)
Minimizing Risks and Costs through Good Design Techniques and/or Management of Third Parties
7(1)
Technical and System Aspects
8(5)
Information and Planning Aspects
13(2)
Organizational and Project Aspects
15(2)
Results
17(1)
Make vs. Buy Decisions
17(5)
Factors Affecting Make vs. Buy Decisions
18(1)
Cost
19(1)
Performance
19(1)
Time
19(1)
Experience
19(1)
Support
19(1)
Training/Documentation
19(1)
Life of System
20(1)
An Example
20(2)
Architecture, Obsolescence Protection, and Upgradability
22(3)
Planning for Future Upgrades
23(1)
Design Philosophies: Hardware First or Software First?
23(1)
Choosing a Control Method
24(1)
Choosing a Computer Operating System and Programming Language
24(1)
Writing Test Specifications and Documentation
25(1)
In-house Resources and Competencies Relevant to Test System Design, Test Suite Programming, and System Build
25(2)
Access to Organizations and Information
25(1)
Team
26(1)
Using COTS and Open Standards to Maximize Flexibility and Control Costs
27(12)
Understanding COTS and Open Standards
27(3)
Hardware
28(1)
Software
29(1)
How COTS and Open Standards Maximize Flexibility and Control Costs
30(3)
The Benefits of Multiple Suppliers
30(1)
The Benefits of COTS Production Volumes
31(1)
Availability
31(1)
Warranty and Support
31(1)
Documentation
32(1)
Potential Upgrade Paths
32(1)
COTS and NRE Costs
33(1)
COTS and Open Standards
34(2)
Disadvantages of COTS and Open Standards
36(3)
How Control Decisions Affect Hardware Architecture
39(22)
Choosing How to Control Your System
39(16)
Manual Control
42(6)
Semi-Automated Control
48(5)
Fully-Automated Control
53(1)
Go/No-go testing
54(1)
Parametric recording
54(1)
Increased complexity of the upgrade process
54(1)
Test equipment spares
55(1)
The ability to reconfigure by software
55(1)
Software development as one of the major cost drivers
55(1)
Standard Operating Procedures (SOPs)
55(1)
The Test Executive and Test Program Sets
56(1)
Using Results
57(1)
Making Future Control Upgrades Easier
57(4)
Reasons for Upgrading a Test System
59(2)
Part Two Test System Design-Building a Completely New System 61(160)
Choosing Test Equipment
63(16)
Designing an Effective and Efficient Test Solution
64(1)
Drawing up the Test Parameters Matrix
64(2)
Eliminating Redundant Tests
66(4)
Using the Test Parameters Matrix to Choose Test Equipment
70(1)
Getting the Most from Your Equipment
71(1)
Evaluating the Cost-Effectiveness of Tests
72(4)
Cost of Test vs. Benefit of Test
72(1)
Omitting the Test
73(1)
Doing the Test Another Way
74(1)
Deriving Results from Other Data
75(1)
Coverage vs. Development Time
75(1)
Equipment Lists
76(1)
Effective Use of the Equipment
77(2)
Sourcing Test Equipment
79(18)
Deciding Whether to Outsource Equipment Selection
80(1)
Collecting Information on Available Equipment
81(5)
Functional Type of Equipment; Narrowing the Equipment List
82(1)
Equipment Fitness and Price
82(4)
Finding the Right Vendors
86(3)
Evaluating an Equipment Supplier
86(2)
``Measurement Consultants''
88(1)
Using Vendor Options for Effective Solutions
89(1)
Standard Options
89(1)
Special Options
89(1)
Custom Options
90(1)
What to Do if You Cannot Match Your Needs to a Commercial Item
90(4)
Design and Build Custom Test Equipment
91(1)
Contract Out the Design and Build of Custom Test Equipment
92(1)
Derive the Result from Other Parameters
92(1)
Redesign the DUT (``Design for Testability'')
93(1)
Eliminate a Test from Your Test Plan
94(1)
Placing Orders
94(3)
Interfacing to the DUT
97(16)
Connection to the DUT
98(2)
Edge Connection
98(1)
Custom Fixtures
99(1)
Cable Harnesses and Looms
100(4)
Shaping Cables
100(1)
Using Different Types of Cable in the Same System
101(3)
Using a Consistent Labeling System
104(1)
Switching
104(2)
Reliability Issues
106(1)
Accuracy Considerations at RF, HF, and Microwave Frequencies
107(2)
Controlling the Interface to the DUT
109(4)
Manual Control Following Documented Procedures
110(1)
Full Software Automation through a Fixture
111(2)
Cabling the Rack
113(20)
Cabling through the Racks
113(7)
Cabling and Racked Equipment
114(4)
Using Cables
118(1)
Cabling Multiple Racks
119(1)
Design to Minimize Cable Stress
120(1)
DC Considerations
121(4)
RF and Microwave Considerations
125(5)
Connectors
129(1)
Labeling and Documentation
130(3)
Using Switch Panels and Interface Panels
133(12)
Patch Panels
136(2)
Buying Standard Panels/Rows of Connectors
138(1)
Virginia® Type Interconnect
139(1)
Auto-interconnect to Your Fixtures
140(2)
Building Your Own Fixturing
142(1)
Specifying Your Own Fixturing for Someone Else to Build
143(2)
Electrical Safety of the System
145(18)
Key Safety Considerations for the Test Engineer
146(1)
Safety and Cutout Switches
147(10)
Using 110V and 240V in the Same Rack
148(2)
Isolating High Voltages and Currents from the Operator
150(3)
Cutoffs during Operator Intervention
153(2)
Barring Power during Hookup
155(1)
Master Power Cutout
156(1)
Earthing Considerations
157(2)
The Importance of True Earth
157(1)
Checking your Building for Earthing
158(1)
Effects of Multiple Earths
158(1)
Common Earthing for the System and DUT
158(1)
Other Safety Considerations
159(1)
Safety and Portable Test Systems
160(1)
Consulting the Experts
160(3)
Selecting Racks and Racking Furniture
163(20)
Racks and Rack Furniture
163(2)
Working Out What Size Rack(s) You Will Need
165(2)
Matching Equipment Outputs and Connector Locations
167(1)
Selecting connector Panels
167(2)
Racking Accessories
169(10)
Racking COTS Equipment
170(1)
Front- vs. Rear-Rack Mounting and Cabling
171(2)
Side-by-Side Racking for Half-Width Units
173(1)
Racking Special to Type and Custom Devices
174(1)
Using Sliding Rails
175(2)
Racking Smaller Items and Items Not Designed for Racking
177(1)
Shelf-Mounting Smaller Items
177(1)
Trays, Custom Rails, and Support Shelves
178(1)
Isolation Transformers
179(4)
Weight Considerations and Equipment Placement
183(22)
Checking Overall Weight and Weight Distribution
183(1)
Positioning Equipment in the Rack
184(9)
Using Accessories for Rack Stability
193(6)
Ballast
194(1)
Anti-Tilt Feet
195(2)
Risk Factors
197(2)
System Portability and Ruggedness
199(6)
Designing the Rack Layout for a Transportable Test System
199(4)
Moving Racks Not Designed for Transport in One Piece
203(2)
Temperature Control and Power Considerations
205(16)
The Importance of Power and Heat Budgets
205(1)
Calculating Power Budgets
206(1)
What to Do if You Need More Three-phase Power
207(1)
Calculating Heat Budgets
207(7)
Calculating Cooling Requirements for Each Device
212(1)
Checking If Your Rack Can Deliver Required Airflow
213(1)
Placement of Equipment to Aid Cooling
214(4)
Examples of Poor Equipment Placement
214(2)
Avoiding Hot Spots
216(2)
Using Fan Extractors in the Rack
218(1)
Cooling with Water or Other Liquids
218(3)
Part Three Racking Up 221(48)
Racking the System
223(24)
Positioning User Interface Components
223(5)
Positioning Switch Panels and Patch Panels
228(2)
Positioning Test Equipment in the Rack
230(3)
Safety Features
233(1)
Cabling for Ease of Use
234(2)
Using the Correct Cables
234(1)
Using the Correct Connectors
234(1)
Avoiding Damage to Cables
234(2)
Labeling the Cables
236(1)
Testing Weight Distribution
236(2)
Mounting Heavy Equipment Safely
238(1)
Connector Care
238(1)
Adapters
239(1)
Cover Panels
239(1)
Putting Everything Together
240(1)
Documentation of Physical Design and Cabling
241(1)
Tips for Racking an Existing Benchtop System
242(1)
Special Procedures for a Transportable System
243(4)
Documentation
247(8)
Documentation Standards
248(2)
Outsourcing the Development of Your Test System Documentation
249(1)
Documentation and System Lifetime Costs
250(1)
Documentation and Intellectual Property
251(1)
Version Tracking
251(1)
Configuration Control
252(1)
Documentation and System Support
252(3)
Operator Training
255(6)
Training Staff in Equipment Use
255(2)
Training Staff in Test Procedures
257(1)
Training Development and Documentation
258(1)
Maintaining Knowledge and Skills In-house
259(2)
Support
261(8)
Software vs. Hardware Support
261(1)
Configuration Control and Multiple Test Systems
262(1)
In-house Support vs. Third-Party Support
263(6)
Software Support
264(1)
Hardware Support
264(1)
In-house Support
265(2)
Third-Party Support
267(2)
Part Four Upgrading a Test System 269(32)
Using Standard Software and Open Standards for Obsolescence Protection
271(10)
Longer System Lifetime and ROI
271(4)
Outline of the Development of Open Software Standards
272(1)
Structure
272(3)
Planning for Future Requirements
275(3)
Open Standards and Obsolescence Protection
278(3)
Dealing with Obsolete Items
281(10)
Selecting Replacement Equipment
281(2)
Procedural Changes
282(1)
Software Changes
283(1)
Revising the Test Parameters Matrix
283(2)
Upgrading the Test Parameters Matrix
274(11)
Evaluating Your Long-term Support Requirements
285(1)
Upgrading the Computer and Control System
286(1)
Evaluating the Current Software
287(1)
Old Software and New Equipment
288(1)
Calibration and Certification
289(1)
When to Consider a Complete Rebuild
290(1)
Interface, Rack Layout, and Software Revision for an Upgraded Test System
291(10)
Replacing Equipment
291(3)
Evaluating the Existing Switch Interface
294(1)
Redesigning the Rack Layout
295(2)
Adding New Software Drivers
297(1)
Updating Software Modules
298(1)
Updating Documentation
299(2)
Bibliography 301(2)
Index 303

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