Burn-In Danny Ventura

Rafal Piersiak

June 8 – August 14, 2015

What is purpose of Burn-In?

• Burn-In is a reliability test in which a device is switched on and exercised at peak performance for a long time.

• Purpose of Thync Burn-In Board-• To test Thync module reliability

• Reduce testing cost/ unit

• Vastly increase production

Stages of Project

• Test/improve current waveform capture circuit on FT1 PCB

• Research system architecture

• Schematic capture

• Placement and layout

• Mechanical design and integration

Waveform Capture

• Input wave (yellow) and Output ADC (pink)

• With Diff Amplifier

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Burn-In State Diagram

Servo Reset

Pre Charge

Pucks ON

Pair with RN4020

Wave Analyze

LCD Results

Pass/Fail LEDs

Post Charge

Heart of the Board

• Peripherals• Switch

• Buzzer

• LEDs

• Servos

• FTDI

• ADCs

• BLE RN4020

• LCD

• USB Charging

BLE RN4020

• Simulates app• iPod is not needed to interact with

puck module

• Less human interaction is necessary

Waveform Capture Circuit

• Steps-down Puck’s 60V to 4V

• Probe A & B

• Diff amplifier smoothens output signal

USB Charging

• Circuit regulates 9V to 5V

• Monitors current

Board layout

STM32

Board layout

RN4020

Board layout

WaveformCapture

Board layout

USB Chargers

3d –Printing Fixtures

Current Set-up

• Current Flextronics set-up

• One oscilloscope is used to test one puck.

• 1 out of 4 channels in use

• $400 equipment only tests one puck

• Limited bandwidth

• Area used is 12 x 13 in.

Future Set-up

• LCD in front of stadium

• Puck and Servo fixtures

• Measures 10 x 12 in.

Current Vs. Future

4 Modules/Area 32 Modules/Area

Cost

Table includes equipment cost for testing 8 Thync modules

Current Setup Cost

Oscilloscope/Phantom $3240

Operator Time (11.68 minutes) $4.86

New Setup Cost

Test Fixture/PCB $665

Operator Time (1.10 minutes) $0.45

79% Cost Reduction for Equipment90% Cost Reduction for Operator Time

Benefits

• Cheaper per module to test and operate.

• Automates pre-charge, burn-in, and post-charge.

• Scalable

• Human operation is minimized to snapping module and push button.

• Reduces human handling.

• Smaller fixture uses less space.

• Tuned waveform capture, specific to custom designed burn-in waveform.

Team Effort

• Rafal guided

• Jay revised layout and schematic revisions

• Remi aided with circuit design of the WFC and differential amplifier

• Uma leads software that will be used with board

• Matt solved issues with RN4020

• Thanks to Hardware Team for individual input in project or guidance.

Conclusion

• Questions or comments?