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TS-5020 Automotive Electronics Functional Test System

Technical Overviews

Introduction

Test Engineering Challenges

On-time test deployment within budget requires a test system that provides adequate test coverage and low test times while ensuring the manufacture of quality products. In developing a test platform, you must balance three competing challenges: time (test development, execution and system deployment); cost (capital and integration); and scope (throughput, accuracy and flexibility). In today’s automotive electronics manufacturing environment, a reusable, scalable test platform helps meet evolving test requirements and lets you stay competitive.

There are three approaches for you to choose from when creating a test system: use your in-house test depart­ment to develop and build your own, outsource the development of an entire system, or use a commercial off-the-shelf platform as the basis for the test system to be deployed.

The Keysight Technologies, Inc. TS-5020 is a new, off-the-shelf test platform tuned specifically for automotive electronics functional test. With the look and feel of the higher-end Keysight TS-5400 Series II, the TS-5020 addresses the requirement for a lower cost measurement system, catered to a medium pin count range with light duty switching.

Manufacturing Goals

Producing quality electronic control units (ECMs) faster and at a lower cost without compromising test coverage can be a challenge in the fast-paced automotive electronics industry. In exploring the three competing goals of test engineering it becomes increasingly clear for the need to focus on each challenge individually, while simultaneously studying how they relate to one another. To meet the pressure in getting manufacturing test lines set up on time requires test engineering to perform faster test development, execution and line integration. In turn, increasing throughput to decrease the test cost per ECM requires faster test system to accommodate the rapid introduction of new convenience, security, safety and body electronic modules.

Achieving the proper balance among all the three goals is difficult yet necessary for manufacturers to better meet original equipment manufacturer (OEM) timelines. In an effort to find this balance, where time is the ultimate constraint, manufacturers are forced to make decisions on trading test coverage and for maintaining a lean time to market.

Either this, or manufacturers are forced to make decisions on trading wide ranging, flexible ECM test capability for module-dedicated test systems – a poor use of assets in the long term. Keysight’s new TS-5020 ensures that you do not have to trade off quality for test systems capability. The Keysight TS-5020 is a platform that allows for flexibility in scope, and maintains a low cost while simultaneously providing you a faster time to market.

The Keysight Solution

The TS-5020 automotive electronics functional test system helps manufac­turers get products to market faster by accelerating test system deployment. Engineered with the three critical manufacturing goals in mind, this system caters for flexibility, speed and quality to automotive electronics production.

When it comes to flexibility, a universal test system core of both hardware and software can easily be modified to suit your particular test strategy and range of ECMs. As for speed and quality, the test executive accelerates both the development and execution of tests with over 400 test routines tuned towards automotive applications.

The Keysight TS-5020 is designed to provide performance at a lower cost for applications from simple ECMs such as climate control, immobilizers and remote-keyless entry (RKE), to safety ECMs such as airbag and anti-lock brake system (ABS) or traction control (TC).

The TS-5020 system comes equipped with measurement hardware, switch­ing, a test executive and automotive-tuned library routines. Racking, cabling and optional fixturing are included, as well as standard software development tools that enable test engineers to deploy test systems at a much faster rate than building test systems from individual test systems from individual components.

Keysight TS-5020 Automo­tive Electronics Functional Test System

At the heart of Keysight TS-5020 is the award winning Keysight 34980A Switch/ Measure­ment Unit with a built-in 6.5 digit multimeter. The system interface uses the Express-Connect method. General Purpose Interface Bus (GPIB) instru­ments can be optionally added to enhance the measurement capabilities of the system together with a range of power supplies.

Key Features

Measurement switching

The 34980A provides the switching platform for the TS-5020. To achieve a low cost, low pin count switching, the module supplied with the 34980A is configured up to 32 x 4 x 96 (32 instrument x 4 ABUS x 96 pin) switch matrix. Additional modules can be added and configure every pin matrix card up to 4 x 128 to increase the pin channel support up to 480 pins total.

Measurement

Keeping the TS-5020 a low cost system, the 34980A also offers a built-in digital multimeter (DMM) complete with independently configurable channels for the measurements you choose. This is a 61/2 digits DMM with a .004% of accuracy in DC voltage measurements, complete with channel alarms and math functions.

Load switching

With its eight-slot mainframe, the 34980A can be added with a 20-channel “form A” switch to provide light duty load switching enabling it to support 3 A continuous current with a 5 A peak.

Mass interconnect

The switching interconnects to the unit under test (UUT) via the Express Connect interface. This interconnect consists of an interface connect assembly (ICA) and an interface test adapter (ITA), each having its own connector blocks and matching pins. The ICA is mounted to the system rack and feature a hinged insert that when released, allows the panel to fold down 90o away from the system. This design allows convenient access to the wiring. The ITA inserts into the ICA and locks in place.

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