Corelis ScanExpress Tools Decrease Test Development Time and Increase Test Coverage for Saia-Burgess
Boundary-scan, a non-intrusive digital test technology, proved an ideal fit for Saia’s increased testing requirements. Saia-Burgess quickly found advantages and benefits to complementing existing test procedures with Corelis tools.
QSC Streamlines Production Test with ScanExpress JET
QSC has been using Corelis ScanExpress boundary-scan test systems to ensure that all manufactured products are free from defects, primarily because it is an ideal solution for QSC’s digital products: boundary-scan provides non-intrusive test coverage without requiring external probe access. “Boundary-scan is our main board-level test platform,” explains QSC Digital Test Engineer, Sean Summers. “Bed of nails simply isn’t viable for the type of products that we build.”
Indyme Precisely Identifies Circuit Board Defects Using Corelis Boundary-Scan Advanced Diagnostics
During a recent production run, a significant number of unexpected failures were coming off the line. Investigation into the problem showed that not all boards were defective, but enough to indicate a deeper, intermittent problem was evident.
"Corelis boundary-scan with ScanExpress ADO really saved the day by identifying these early stage production problems. It quickly identified the issue so that we could take corrective action".
"With just this one fault identification, the Corelis boundary-scan tools provided a return on our investment far beyond expectations. If you have BGA parts in your product, boundary-scan is a requirement. It isn’t really an option if you’re serious about testing."
SLAC National Accelerator Laboratory Saves Time and Money Using Corelis Boundary-Scan Tools
O’Grady explained, “Two days of troubleshooting per board is excessive,
especially when highly skilled personnel need to be involved. When five boards
are bad, two weeks of my time is tied up causing major delays on other projects.
It simply got to a point where we needed to either reduce the debug time or
assign the task to someone else.”
“The Corelis tools have allowed me to recover lost time. When five boards have
problems, not only do Corelis tools save me two weeks worth of work, but I can
deliver five boards that much faster!”
Fujitsu Switches from ICT to Easy-to-Use Boundary-Scan Test and Programming System Resulting in Savings Exceeding $500,000 in Little More Than a Year
It was the high cost and long lead times for building In-Circuit Test (ICT) equipment that sent Mark Cooper, senior test engineer at Fujitsu, looking for circuit board testing alternatives. Production volumes of the company’s FLASHWAVE 4100 high-speed optical communications access device were substantial, but not enough to justify the $25,000 to $40,000 cost of an ICT test fixture and program for each type of board that required testing. The FLASHWAVE 4100 hardware configuration is a multi-slot “shelf” that accommodates up to 15 circuit boards, all interconnected through a common backplane. The boards perform a variety of functions from network control to multiplexing to interfacing for traditional SONET or multiple Ethernet LAN services, so there are 12 different card types, presenting Cooper with a complex manufacturing test operation combining fairly low volumes, but many different configurations. In addition, the cards themselves are complex - some double-sided - with a variety of programmable flash and CPLDs that need custom programming.
Boundary-Scan Parallel Test and Programming Cuts Costs and Simplifies Production of High-Volume Telephony Products
With demand growing so fast, IP telephony products like those from Zultys are
characterized by an all new cost model that requires maximum yield in
manufacturing. In addition, the products call for more complex and powerful
components that must be packed into ever smaller circuit boards. One of the ways
these companies can deliver on these promises is through the use of the latest
manufacturing and test technologies. Zultys sees these technologies as a
competitive edge in manufacturing its VoIP telephones for the enterprise market.
A key requirement for Zultys was to reduce test time to keep up with a "push-line" assembly process. The push-line uses a conveyor belt to move product down the assembly line through a series of stations. Once all the components are added and wired, the product moves to JTAG stations near the end of the line. The company chose the ScanExpress system from Corelis Inc. Zultys has two JTAG programming and test stations, each with four phones in parallel. In addition to the boot flash which is common to every unit, each phone has unique information programmed into its flash.
Corelis Scan Library and CodeRunner Enable Easy Development of Custom JTAG Tools to Simplify Programming and Debug of RAD750 Computer
The RAD750®, developed by BAE Systems, is a licensed,
radiation-hardened version of the PowerPC 750®. The RAD750
design objectives were focused on cutting power consumption,
weight and cost; key attributes in designing products for
space flight. Those objectives were accomplished through an
architecture that increases processing speeds to an
industry-leading 240 million instructions per second (MIPS)
and operates at speeds of 133 MHz and greater, reducing the
number of processors required. The RAD750 advanced
architecture and processing throughput – ten times the
performance of current space processors, according to BAE
Systems – will allow a new generation of high-performance
satellite payloads to solve more intensive computing
problems, such as deep space navigation, precise trajectory
adjustments to position spacecraft for flybys, altitude
control, landing, and exploration operations.
"The JTAG connection to the Power PCI bridge chip on the product provided a path to the EEPROM, but no tools existed. We developed custom tools built on the Corelis Scan Function Library to get it done" said Craig Hatfield, systems engineer for BAE Systems. "We also developed additional debug utilities to provide visibility into the system without the need for any onboard software. These utilities are helpful when integrating new hardware on or attached to the computer."
Corelis’ Boundary-Scan Test Products Solve Difficult Prototype Problems at Vanguard Managed Solutions, Saving Countless Hours of Non-Productive Debug Work
Vanguard Managed Solutions (VanguardMS) has been designing,
developing, and deploying innovative and cost-effective
networking solutions for over 40 years. During that period
VanguardMS has established an enviable track record by
focusing on “time-to-market” as the most critical element in
successfully delivering complete managed-network solutions
to meet the needs of its hundreds of customers around the
world. In recent years VanguardMS has relied on Corelis’
ScanExpress Boundary-Scan test systems to shorten its
development cycles and bring new products to market sooner
by improving the productivity of its engineers in the
development and debugging of prototype units.
Scott Dextradeur is an MS Production Test Engineer at VanguardMS whose responsibilities include the testing of production-run assemblies. An exceptional case was recently presented to Scott when a group of R&D engineers came to him urgently requesting help to “bring-up” a CPU-based prototype board.
Corelis’ Boundary-Scan Technology Facilitates Applied Data Systems’ Customization of Embedded Systems and Streamlines ISO 9001 Certification
Applied Data Systems (www.applieddata.net)
is the leading supplier of “application-ready” RISC-based single board embedded
systems with flat panel displays for customers who need XScale or StrongARM-based
systems running Windows CE, Linux or the operating system of choice. Nearly half
of the company’s customer production designs are completely customized.
“We call ourselves a delicatessen,” jokes Bob Olsen, president of the company,
“because we try to accommodate every customer’s preferences.”
As the company’s product family grew over the past three years,
the configurations of board designs became so numerous that
tracking and programming those designs became inefficient, time
consuming, and very expensive. Looking into different
alternatives to solve their problems, ADS decided to apply
boundary-scan technology for testing and in-system programming.
Boundary-scan Tools from Corelis reduce development cost at Spectral Systems, Inc. (SSI) by testing prototype boards before the designs are even functional
Spectral Systems, Inc. (SSI) is a leading-edge aerospace engineering and product development company located in southwestern Ohio, the birthplace of manned flight. SSI was founded in 1995 and has grown very rapidly from an engineering service provider to a developer and integrator of advanced Intelligence, Surveillance and Reconnaissance (ISR) and Electronic Warfare (EW) systems, sensors and embedded processors.
Ben Steele is a program manager at Spectral Systems responsible for the design and development of state-of-the-art, multi-channel, multi-function digital receiver subsystems. Ben came to Corelis looking for a more effective method for bringing up complex prototype assemblies. The diminishing access of test points on these complex board assemblies, due to fine pitch components and restrictive packaging types such as BGA, often prevented the use of traditional probing methods and was making board bring-up a costly and time consuming process.
Design engineers are often faced with a confounding problem when bringing up new prototype assemblies. Detecting a manufacturing defect before a design has been verified as “functional” can be a frustrating task. When this problem is multiplied by the inability to access crucial test points then the initial debug process can become a huge bottleneck that slips the entire development schedule. Aware of these potential pitfalls, Ben was seeking for a more effective solution to help streamline this initial debug process.
Corelis Boundary-Scan Tools Help Streamline Production Throughput while Reducing Development Cost at Navman NZ Ltd.
Navman is a leading manufacturer of world-class marine electronics and Global Positioning System (GPS) technology. Established in 1988, the New Zealand based company provides a diverse range of navigation technologies across wide ranging industries.
Terry Dagnin is the lead test engineer at Navman and is responsible for Inspection, Test, and Test Engineering. Terry came to Corelis looking for test solutions that are capable of probing areas of printed circuit board assemblies that are difficult to access due to fine pitch components such as Ball Grid Array (BGA) devices.
The design and test engineers at Navman were under a deadline to introduce their iCN 630 portable in-vehicle navigation product to market and announce it at the 2003 International Consumer Electronics Show. Navman’s first pilot production run was 1,000 units. Testing and very fast in-system programming were critical for on schedule delivery.
Corelis JTAG tools provided real benefits for Ixia in testing Double-Data Rate SDRAM memories through Xilinx VertexE FPGAs
Located in Calabasas, California,
Ixia is a leading developer of sophisticated optical and electrical network traffic performance analysis solutions. Mr. Xinchen Wang, Hardware Engineer at Ixia, is responsible for JTAG testing and verification for one of Ixia’s new interface load modules.
According to Xinchen Wang, to achieve increased net coverage through JTAG testing for Ixia’s new traffic generation and analysis tool, it is important to first verify that all the FPGA’s external Double Data Rate (DDR) SDRAM connections are properly placed and functioning correctly to aide in further design troubleshooting.
Corelis JTAG Tools Help Maintain Test Engineer's Sanity While Increasing Throughput and Reducing Cost at Imperial Technology Inc.
“A large, double sided, very complex PC board assembly was being tested in a “hot mock-up” and was consuming seven Test Engineer hours to test, troubleshoot, and repair. This required that a high level Test Engineer be dedicated to this testing function. The repetitious testing strained his sanity and added considerable cost to the process,” said Bruce C. Johnson.
Bruce is the Quality Assurance Manager at Imperial Technology and is responsible for Inspection, Test, and Test Engineering. Imperial Technology, located in El Segundo, California, designs and manufactures state of the art high speed, solid state disk drive memories.
In minimal time, Corelis provided a turn-key solution that included the
ScanExpress boundary-scan test system and a custom test procedure.
2Wire Corporation Significantly Reduces Time-to-Market Schedule by Pushing Corelis Boundary-Scan Technology to its Limits
2Wire, Inc. delivers a full suite of broadband products and services to the residential marketplace. The 2Wire HomePortal™ family of products are the first intelligent residential gateways to integrate the wealth of options available through the Internet and create a complete home data, voice, and entertainment network.
An enormous product development and testing challenge faced 2Wire, a Silicon Valley start-up specializing in producing broadband residential gateways for the consumer market. “We committed to an extremely aggressive time-to-market schedule,” says Bill Schimandle, senior test engineer for 2Wire,“ which required us to develop new strategies in software development, board prototyping, hardware bring up, and production testing”.
Smartbits Systems Dramatically Increases Production Yields with use of Corelis'
ScanExpress Boundary-Scan Tester
Smartbits Systems, a SPIRENT COMMUNICATIONS company, specializes in high-performance analysis and measurement systems for the networking industry, data service providers, and end-users worldwide.
“To achieve complex product functionality in small size packages, Smartbits Systems is developing and producing densely populated boards with many high-speed BGA parts,” said Surin Shaw, Test Engineering Manager at Smartbits Systems.
When previously testing Smartbits Systems’ densely populated boards, Mr. Shaw noticed an increasing failure rate and lower yields as the boards became more dense. In advance of new products and technologies where the migration of BGA components into the design was imminent, Smartbits Systems needed new tools to detect shorts and opens underneath the BGA components. X-ray was one option but is not fully effective at detecting opens. At that point, Mr. Shaw decided to look for test methods that will find interconnect and other manufacturing defects prior to running the functional test. Considering various alternatives, boundary-scan appeared to be the right solution for these types of problems.
Corelis' ScanExpress keeps Rapid2 on track Corelis' boundary scan test tool
ScanExpress finds manufacturing defects in complex high-speed data acquisition cards and enables scientific project to keep to schedule
Brackley, UK - 17th December 2001 - Engineers at
Daresbury Laboratory are using Corelis' boundary scan tool,
ScanExpress to validate the interconnect including memory interconnect between hundreds of ICs on a number of complex 19 inch (12U) data acquisition cards for the laboratory's Rapid2 project. The cards are 10- layer PCBs, populated both sides, and many of the components used are packaged in ball-grid-arrays (BGAs), making probe testing impossible.
By performing automated boundary scan tests ScanExpress can validate the PCB's interconnect (more than 32,000 nets connecting more than 1800 components) in a matter of seconds. This and
ScanExpress' ability to marry boundary scan description language (BSDL) models of the card's components with the design's netlist, means comprehensive tests and programming files are created automatically.
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