Designing An Automated PCB Test System | Voltlog

High quality PCB Services pcbway.com/g/01s7lR In this first part of a two-part video series, I’ll take you through the design and build process of the VoltHub7, a project aimed at creating a semi-automated test and programming system for my custom-designed VoltLink boards.
Tired of repetitive manual testing? This video delves into the challenges and inefficiencies of manually testing and flashing multiple PCBs. You'll see how the VoltHub7 utilizes a custom-designed USB hub and a Raspberry Pi Zero 2W to automate this process, saving time and ensuring consistency.
→VoltHub7 Kicad Project on Github voltlog.com/y/volthub7
→Shop VoltLink on Tindie voltlog.com/y/voltlink
→Microchip USB2517 Datasheet PDF voltlog.com/y/fogua
→Microchip MIC2026 Datasheet PDF voltlog.com/y/3s4tl
→Shop Raspberry Pi Zero 2W voltlog.com/y/uh7y4
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→Timeline
00:05 Introduction
04:23 Selecting USB Hub Controller IC
06:08 Schematic & PCB
10:19 PCB Assembly
12:44 Testing
→Key points covered:
Problem: Repetitive and time-consuming manual testing of VoltLink boards.
Solution: Building a semi-automated system using a custom USB hub and Raspberry Pi.
Components: Microchip USB2517 hub controller, Raspberry Pi Zero 2W, pogo pins, and custom PCB design.
Step-by-step breakdown: Learn about component selection, design considerations, PCB layout, and assembly process.
Demonstration: Witness the initial functionality test of the USB hub and Raspberry Pi integration.
Stay tuned for Part 2! We'll explore the design and implementation of the automated test jig, the crucial element that eliminates the need for individual USB cable connections during testing.
Like this project? Leave a comment below and share your thoughts on automated testing solutions.
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[@DustinWatts]

I think I spent about a much time designing a test jig a as I spent designing the ESP32 TouhDown. Just so I can be sure that all board function perfectly. This test jig really looks nice! Congrats!

[@Gengh13]

Nice idea with the pogo pins for the usb.

[@2000jago]

Yay! A project video (as opposed to another "review" sponsored video). More like this please!

[@MakenModify]

In my previous job I designed Test Jigs on a daily base. Bigger and more complex, based on National Instruments TestStand and Labview. That made it pretty universal and easy to adapt to new designs. This one is a very purpose made design, specialized for your application. I really like it, I'm looking forward to seeing your final setup 👍

[@makertronika]

Excellent implementation and inspiring to do automated test jigs like this for my projects too.

[@akhurash]

I have designed a bunch of automated testers and built test setups. You did a really great job! Excited to see the fixture.

[@voltlog]

Awesome! Thank you!

[@rahulkushwaha9500]

put out more content line this, even if it is unfinished, it gives some path to follow when one is designing something. thanks

[@CraigBurden1]

Im working on something quite similar, although my board is a fair bit more complicated because the products it tests are also more complicated. I love seeing this kind of thing, especially when we have independently made similar decisions, it makes me feel like I made the right ones! I have a motherboard with all the base functionality and as much common functionality as I could squeeze on, then there is a shield that takes all the IO the base board exposes, conditions signals, level shifts, adds additional functions and ultimately exposes ribbon cables that go to the bed of nails. That way th sheild and bed of nails can easily be updated independently to the motherboard making it more extensible and able to support more products/revisions. One thing I really found helpful for mine was the RPi config EEPROM. Basically you add an EEPROM to your board that holds a DTS fragment, then when the pi boots it can load kernel drivers etc. It means you can more easily swap the pi if needed as well as more easily support I2C and SPI devices on the pi directly, both of which i am using extensively I am really looking forward to the rest of this series!

[@WAEviltechie]

Raspberry Pi actually does have documentation for the test point locations for the Zero 2 W. That combined with the mechanical drawing should give you what you need.

[@voltlog]

Please share the location of those.

[@riccardoiacob4560]

Instead of using 0 ohm links, why not just use cuttable jumper pads? It's supposed to be a test board run anyway, why bother placing loads of smd components increasing BOM cost and manufacturing time?

[@voltlog]

I guess it's a matter of personal preference. I very much prefer working with 0R jumpers and having a clean board.

[@jaro6985]

No one cares about BOM cost on a one off test jig.

[@AdmiralMaggieMD]

Nice work! PCB looks amazing! Interestingly I've been working on an automated test tool for a recent product as well. Mine requires interfacing with 16x 24v 4-20ma current loop inputs for initial calibration. I ended up using bunch of high voltage multiplexers. Your board looks a lot nicer though!

[@voltlog]

Thanks! Good luck with your project!

[@UnexpectedMaker]

Nicely done :) You have exposed IO from the onboard chip going to headers of your VoltLink boards. How do you plan to test those - to ensure they have continuity to the IC as well as no shorts from reflow? Or is that something you're not overly concerned about testing?

[@voltlog]

I do not plan to test those because the particular chip package that I'm using on the VoltLink together with the expertise of the SMT assembly house means that there is very little chance of soldering issues happening. I've had zero issues so far. If I would want to test those, that's still doable because it should be possible to toggle most of that IO from the silabs tool, I would just need to add some IO expansion to the PiZero to handle more GPIO.

[@susanford9741]

*promo sm*