PCBA Functional Test and Device Verificational Test Scaled with Cyth PCBACheck
- Oct 15
- 5 min read
Scalable automated PXI testing solution enables comprehensive functional verification of Bluetooth earpiece devices.
Project Summary
Consumer electronics manufacturer accelerated time to market and drove high product quality through an automated PCBA and functional verification test (FVT) solution.
System Features & Components
Custom bed-of-nails fixture simultaneously tests eight printed circuit board assemblies (PCBAs)
Ultra-low power measurements to test consumption in device battery-saving modes
RF shielded enclosure for ensuring high-quality Bluetooth transmission quality measurement
PCBACheck reference architecture with test automation and sequencing built on Cyth's architecture built on NI LabVIEW and TestStand software
Outcomes
Comprehensive automated validation of circuit board functionality
High throughput testing capabilities with parallel testing
Automated data collection with pass/fail results and automated reports for regulatory compliance purposes
Technology at-a-glance
Cyth PCBACheck Reference Design
Hardware:
Software:
Bluetooth Audio Device Testing
The electronic devices we used on a daily basis, like smartwatches, wireless keyboards, heart rate monitors and many others are built on printed circuit board assemblies (PCBAs) that integrate capabilities like transmission, power management, and a seamless user experience into a package sometimes smaller than a postage stamp.
Circuit board manufacturers are pressured to deliver reliable products while simultaneously maintaining high throughput. Every board that is produced must function perfectly before final assembly to ensure high product quality, bolster customer satisfaction and support strong brand reputation.
A leading consumer electronics manufacturer was on the verge of scaling up the production of their new device, a premium Bluetooth earpiece, but they were limited by their manual testing processes.
Bringing their product to market was dependent on the implementation of circuit board functional verification test (FVT) pre-assembly and final production test of the final device post-assembly.
Scaling Production Capacity through Automation
The bluetooth earpiece manufacturer needed guidance on an overall testing methodology and technology stack to meet their high-throughput production metrics.
Bringing a high-end product to market required rigorous quality assurance to ensure seamless, reliable functionality across multiple complex functions:
Wireless integration with cellphones
Touch-sensitive controls
Automatic, intelligent power management
Each capability required unique, specialized testing and validation before final assembly into the consumer product. Throughput metrics required that they test eight boards simultaneously to meet production demands while ensuring comprehensive validation of every component.
An automated solution was critical to avoid production bottlenecks and ensure comprehensive validation coverage across every component. Accurate measurements necessitated an enclosed RF test environment; the process included:
Verifying firmware upload
Measuring power consumption across states
Confirming Bluetooth signal quality
To get their product to market sooner they couldn’t afford to take the time to learn best practices as they went; they decided to bring in a testing expert to help bring their PCBA and end-of-line testing needs to life. They decided to partner with Cyth Systems because of their custom bed-of-nails design experience and expertise in transforming complex test requirements into reliable, scallable end-of-line testers.
FCT through FVT
Cyth Systems delivered a turnkey solution with the capabilities to perform functional circuit testing (FCT) of eight audio device PCBAs and perform final verification (FVT) test once the PCBA was built into the final product.
The solution, built on cyth's PCBACheck reference architecture, integrated three core technology platform components into a single automated workflow:
1. NI PXI hardware for comprehensive I/O coverage
2. LabVIEW programming for custom signaling and control
3. TestStand for test sequencing and operator interface
Cyth customized a clamshell bed-of-nails fixture to the accommodate the board features and connectivity requirements. The primary hardware is detailed in Table 1.
Component | Model | Key Specifications | Function |
|---|---|---|---|
PXI Chassis | PXI-1082 | 8-slot capacity | Chassis for connectivity with measurement instruments and control hardware |
Source Measure Unit | PXI-4138 | 4-quadrant, ±60V, ±3A, 100fA resolution | Ultra-low power consumption measurement |
Digital Multimeter | PXI-4081 | 7.5-digit precision, ±1000V, 1.8MS/s | High-precision electrical characterization |
Programmer | JTAG | Firmware & audio file upload | Automated device programming |
Test Fixture | PCBACheck Bed-of-Nails | 8-board capacity | Simultaneous board contact and testing |
RF Testing | RF Enclosure | Signal generator & analyzer | Bluetooth signal quality validation in isolated environment |
Embedded PC | Embedded PC | Operator interface and system coordination |
Table 1. Critical hardware for system processing and measurements
The LabVIEW software provided seamless device communication and natively supported device drivers. TestStand orchestrated ted test sequences with intuitive guidance for test operators through the embedded PC’s HMI, shortening training times and ensuring consistent test execution.
The PCBA probing and testing was enabled through the integration of:
Custom clamshell bed-of-nails fixture that can accommodate the test of eight parallel units
RF testing environment including signal generator and analyzer for Bluetooth connectivity and performance validation
JTAG programmer for firmware and audio file upload
Power consumption testing during simulated device “sleep” and “wake” modes
Comprehensive device driver integration for seamless hardware communication
Left: Bluetooth earpiece device printed circuit board assemblies (PCBAs) before FCT. Right: Probes located on the test fixture’s hood. Bottom: single earpiece device PCBA.
The automated test process included an eight-step sequence:
Test operator loads eight PCBAs into clamshell bed-of-nails fixture
Clamshell and RF enclosure cover are shut by operator to enable electrical contact between the fixture’s probes and the circuit board and block out external electromegnetic interference (EMI)
Firmware and audio files automatically loaded onto boards
LabVIEW and NI TestStand software execute test sequences with pre-defined final verification test parameters
Power consumption test performed, simulating the device's “asleep” vs. “awake” modes
Bluetooth features and signal performance are validated using an RF signal generator & analyzer, to simulate transmission between the earpiece and a cellphone
Pass/fail results displayed for operator; next steps recommended if fail results displayed
Data is acquired by the PXI hardware and automatically saved in pre-defined storage locations
Test operator opens the enclosure cover, removes tested boards, and repeats.
Designed for Scalability
The PCBACheck reference architecture, based on LabVIEW, TestStand and NI PXI hardware, shortened test development timelines and delivered significant manufacturing and quality improvements for the bluetooth earpiece manufacturer.
Testing throughput increase: automation of previously manual processes and capability to simultaneously test eight units greatly mitigated quality issues and dramatically increased production throughput
Complete functional test coverage: Comprehensive validation of RF communication, power management, touch sensors, and firmware integration to ensure readiness for consumer use
Zero-defect launch: Validation of every manufactured unit ensures reliable field performance and increased customer satisfaction
Automated compliance documentation: Automated data capture, analysis, report generation and storage performed for every device under test (DUT) for regulatory compliance and traceability
Reduced manufacturing costs: Reduction of manual testing processes streamlined operator workflows and improved test consistency and reliability
Cyth’s proven PCBACheck reference design built on a critical technology stack enabled rapid production scaling. The turnkey and intuitive system helped operators ramp up quickly, with the LabVIEW and TestStand based architecture abstracting away complex test processes into an improved workflow that is adaptable to future product variations and testing requirements. The automated test solution also enhanced the device manufacturer’s ability to perform reliable, repeatable RF testing to ensure the support of advanced wireless protocols.
Test automation is a key differentiator for the device manufacturer, as the products they now ship to their clients are reliable, high-quality and delivered on-time. The scalable architecture of the automated testing solution will be adaptable to future product requirements and testing needs to continue high product quality and reliability. Autoamted functional validation for every single device helps to protect brand reputation and strengthen market position within the wireless audio market.
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