AC-DC Charger IC Test Automation

Power adapter converts AC to DC. The scope of this project is to build an automated functional tester for the IC manufacturer. The DUT will be tested for Steady State & Transient State Conditions spanning across different Line voltages, frequencies, DUT voltage & load.

Problem Statement

  • Customer is manually testing the product & the process was time consuming
  • They have multiple test cases and each test cases have multiple variations of the inputs.
  • Customer needs to tabulate all the results
  • Customer wanted an automated way to test and generate the test reports.

Challenge

  • Automating the entire test process including standardized custom reports to meet the USB Adapter test specs.
  • GUI to allow configuration of all input parameters.
  • Upgrading the drivers for old instruments.
  • Provide manual, automatic and semi-automatic testing options.
  • Post processing for report generation which includes graph plots for different test cases.
  • Capturing the waveform from Oscilloscope for Steady state & Transient state condition
  • Setting the input parameters and Capturing the Oscilloscope waveforms for Transient State-CC (Chroma E.load doesn’t have Dynamic CR mode)
  • Designing & connections for Break out box which is used for connecting Power analyser with AC Source.

Solution

  • Development of ATE to validate the product (USB Adapter)
  • Using:
  • NI USB TC for thermocouple
  • Chroma E Load box
  • Keysight DMM (2)
  • Yokogawa power analyser
  • Chroma AC Source
  • Tektronix Oscilloscope
  • LabVIEW Application to validate the products(DUT)
  • Modular software design approach so that it can be reused across different products.
Steady state manual checking GUI
Steady State Efficiency reports
Transient State GUI
Report – Efficiency graph
Report – Steady state Ripple

Impact to Customer

  • Testing time reduced from days to an hour
  • Accurate readings from DMM & Power Analyser are logged in the table
  • Generates a test report as per customer requirement including graphs and oscilloscope waveforms
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