CHAPTER-3

ELECTRONIC PRODUCT TESTING & DOCUMENTATION

3.1 IMPORTANCE OF PRODUCT TESTING AND ENVIRONMENTTAL TESTING

Testing is an essential part of developing a quality product it helps manufacturers create products that are reliable
within certain technical standards.

3.1.1 IMPORTANCE OF PRODUCT TESTING

• help to solve problems with current product.

• help identify potential cost saving in products.
• Types of damage to products found.
• provide standard data for other scientific, engineering, and quality assurance functions.
• decide if a new product development programme is on track.
• validate suitability for end-use.
• provides a basis for technical communication.

3.1.2 IMPORTANCE OF ENVIRONMENTAL TESTING

Environmental testing is used to test the products in their defined operating environments. The test consists of
simulating the environment in terms of a climate conditions and the mechanical conditions encountered during
actual operation and transportation. These tests provide a conference to design as that the product will work
reliably in its intended environment.

Various environmental test methods:

• dry heat test

• solar radiation test
• vibration test
• high temperature test
• temperature cycling
• bump test
• humidity test
• attitude test

3.2 DRY HEAT TESTING, VIBRATION TESTING, RANDOM TESTING, AND BUMP TESTING

3.2.1 DRY HEAT TESTING

• This test is carried out in a dry heat chamber with mono-block construction. These chambers are created with multi
layered insulation with double vapour barrier, high density and non-hygroscopic in nature.
• The air circulation within the chamber is of forced type.
• The dry heat test is divided as per the heat dissipating and non-heat dissipating product components.
• The main objective of the dry heat test is limited to determine the ability of components, equipments or products
to be used, transported, or stored at high temperatures.

3.2.2 VIBRATION TESTING

• Hey vibration is one of the more common mechanical stress environments. It is used extensively in the
development of aerospace, automotive, industrial, and portable products.
• It is commonly created using an electrodynamic shaker.
 • Vibration testing is the shaking of a product package to determine its ability to survive in real world conditions.

3.2.3 RANDOM TESTING (RANDOM VIBRATION TESTING)

• Random testing is the vibration testing that is experienced by a package in transit.

• Random vibration testing is one comprised of vibration energy at all frequencies over a specified range.
• A measurement of the acceleration spectral density (ASD) is the usual way to specify random vibration.

3.2.4 BUMP TESTING

• Bump testing is a method of simulating the physical environment during the product transportation bump is the
name given to the forces experienced by the product as it is bounced on a hard surface.
• The typical range of peak bump is 40 mm about 10 milliseconds. A practical bump test may consist of subjecting
period to 4000 bumps of a given amplitude.
• A bum is characterised by its amplitude duration and shape.

3.3 TEMPERATURE EXTREME TESTING FOR LINERA AND STEP STRESS PROFILES

• It examines at what temperature i.e., it cold or hot will a device cease to function properly.
3.3.1 LINEAR STRESS PROFILE
In linear profile time is on X axis and temperature on Y axis as shown in figure. It shows,
• rapid ramp to region of interest.
• stabilization soak.
• slow ramp or rapid ramp through expected failure point.
3.3.2 STEP STRESS PROFILE
Stress profile is shown in figure. It shows,
• increases temperature instantaneously.
• hellos for a soak at each temperature of interest to fully confirm operation at each temperature.

3.4 VIBRATION & TEMPERATURE CYCLING

3.4.1 VIBRATION CYCLING
The simplest procedure for vibration testing involves placing the product or package on vibration testing table that
performing vibration testing on a package or product to simulate one of the following environmental conditions.
1. Transportation environment: package and products experiencing vibration during transportation via truck, air or
rail.
2. Operating environment: many circuits or products experiencing vibration in their daily working life like
electronic circuits in vehicles and aircrafts.
3. Storage environment for sensitive products: some products sensitive to vibration due to nearby machines,
passing vehicles etc.
3.4.2 TEMPERATURE CYCLING
Temperature cycling is the process of cycling through two temperature extremes at relatively high rates of change. it
is used to screen products to catch early term, latent defects. This is known as ENVIRONMENTAL STRESS
SCREENING (ESS), but it is also referred to as burn in testing. The figure shows time on X axis and temperature on y
axis with the following profile exists in each interval of one cycle.

• During interval I: high temperature stabilization soak

• during interval 2: transition to low temperature
• during interval 3: lower temperature stabilization soak
• During interval 4: transition to high temperature
3.5 EMI AND EMC COMPLIANCE TESTING STANDARDISATION
3.5.1 EMI COMPLIANCE TESTING
• Electromagnetic interference (EMI) is a process by which disruptive electromagnetic energy is transmitted
from one electronic device to another via radiated or conducted paths or both.
• The radiated path of EMI involves radio wave coupling and conducted path involves hard wire.
• EMI has become major problem for electronic circuit designers and it is likely to become more sever in the
future.
SOURCES:
➢ Power lines
➢ Electric motors
➢ Microwave oven
➢ High current equipment
➢ Electrostatic discharge
➢ RF heaters
➢ Automotive ignition
➢ Fluorescent lamps
➢ Communication transmitters
EFFECTS:
➢ Interference to television and radio reception
➢ Loss of data in digital systems or in transmission of data
➢ Production delay of equipment
➢ Malfunction of medical electronic equipment
➢ Malfunction of microprocessor control systems

3.5.2 ELECTROMAGNETIC COMPATIBILITY EMC

➢ It is defined as the ability of an equipment or system to work satisfactory in an electromagnetic
environment without introducing intolerable electromagnetic disturbances in the environment.
➢ The goal of electromagnetic compatibility testing is the correct operation, in the same electromagnetic
environment, of different equipment that employs electromagnetic phenomena and the avoidance of any
interference effects.
➢ Special design techniques or solutions adopted to minimize field interference and subsequent reduction in
the noise due to EMC.
➢ In the defense application areas of various equipment or circuit get a crowded in a small space and have to
be electromagnetically compatible such as radar, radio transmitters, computer controlled weapon systems,
power generating stations and telephones.
➢ The interference caused to any of them will lead to disaster. So, some standards for EMI or EMC must be
followed in defense equipment.

3.6 UL AND CE CERTIFICATION OF INDUSTRIAL ELECTRONIC PRODUCTS

A UL mark is used in Canada and USA with CE marking below UL certification.

3.6.1 UL CERTIFICATION:

• Underwriters laboratories incorporation (UL) is an independent Product Safety certification organization that test
products for compliance to specific safety standards.
• It is a well-known testing lab that develop standards and test procedures as well as it evaluates products,
components, materials, and systems for compliance to specific requirements, and permits acceptable products to
carry a UL certification mark.
 • If your product carries this mark underwriters laboratories found that samples of this product meet UL’s safety
requirements.
• These requirements are primarily based on the UL’s own published standards for safety.
• This type of mark is seen commonly on appliances and computer equipments, furnaces and heaters, fuses,
electrical panel boards, smoke and carbon monoxide detectors, fire extinguishers, and sprinkle systems, personal
floatation devices like life jackets, and life preservers, bullet resistant glass, and thousands of other products.
CATEGORIES OF UL CERTIFICATIONS:
UL listed: Products under listing service are set to be UL listed identified by the distinctive UL
mark.
UL Recognized: meaning UL has found acceptable for use in complete UL listed product.
UL Classified: It is for specific hazards or properties.
3.6.2 CE (CONFORMANCE EUROPEAN) CERTIFICATION:
• The European Commission describes the CE mark as a passport that allows manufacturers to circulate industrial
products freely within internal market of the European union.
• The CE mark certifies that the product have met EU health, safety, and environmental
requirements that ensures consumer and workplace safety.
• Once your product receives the CE mark, it can be marketed through the EU without
undergoing further product modification.
• The CE Mark should be at least 5 mm in height and affixing this mark indicates conformity not only with EMC
directive but also safety directives.
3.7 IMPORTANCE OF DOCUMENTATION
• Documentation is an integral part of any product development. It provides the information for understanding the
product, its capabilities, and utilities.
• Documentation is essential for operation, repair, maintenance, servicing, and upgradation of a product.
IMPORTANCE:
1. To specify procurement and scheduling
2. To build and inspect finished good to the original engineering specifications.
3. To ensure consistent quality.
4. To produce milestones for manufacturing.
PURPOSE:
1. Cost and schedule estimation
2. Building specification
3. Inspection detailing
3.8 LIST TYPES OF DOCUMENTATION
• A well-explained and well- presented technical documentation of a product is produced for every electronic
equipment or device.
TYPES OF DOCUMENTS:
• Proposal document
• Engineering notebook
• Documents regarding drawings and schematics
• Documents regarding software source listings
• Brochures
• Presentation document
• Manual
• Memos
• Electronic files
3.9 TYPES OF DOCUMENTS
1. PROPOSAL DOCUMENT:
• A proposal document is an initial document, which is to be prepared with respect to funding.
• The main intention of writing a proposal is to follow the rules for the Funding Agency.
• Many times, the proposal consists of a set of documents which begins with a cover letter, followed by an abstract,
brief introduction of the organization, Objective of the proposal, description of the project, schedule of the project,
estimate of the project, terms and conditions, future modifications if any etc.
2. ENGINEERING NOTEBOOK:
• An engineering notebook is a groundwork document for developing a good product.
• It contains the overall list to start the design, reasons for designs, expected test and experimentation list, record all
circumstances and equipments used for each test and experiment, the results of the experimentation and tests.
• It is a document the form of a logbook, which is written in sequence i.e., having entries movement to movement as
well as day to day.
3. DOCUMENTS REGARDING DRAWINGS AND SCHEMATICS:
• A project drawing and schematic documents is an important document that contains entire project development.
• It is one of the documents which is get updated continuously.
4. DOCUMENTS REGARDING SOFTWARE SOURCE LISTING:
• In the development of many products, software is one of the most essential and supporting item.
• Hence documentation and record of software development is equally important.
• There are different formats and methods for preparing, presenting, recording, and maintaining the development of
software.
5. BROCHURES:
• A brochure is a document used to introduce product or equipment to either customers or users.
• This document is in compact form, providing the entire details of the product, creating the first impression in the
customer’s mind.
• It is prepared from professionals who involved in the development of product.
6. PRESENTATION DOCUMENT:
• Presentation is basically a communication document that covers specific details of the product.
• Clarity as well as simplicity in information is very important in presentation documentation.
7. MANUAL:
• A manually is a most integral part of your product.
• This document contains tables of contents organisational details product details etc.
• It specifies the user or customer the overall information and utility of the product.
8. MEMOS:
• A memo is a document, typically used for communication within a company.
• Memos can be as formal as a business letter and used to present a report.
• Before writing a memo, outline the purpose for it, and decide, because the memo is the best communication
channel.
9. ELECTRONIC FILES:
• Because of revolutions in the IT, computer, communication and networking fields, business are fast becoming
paperless.
• Electronic files can be easily created, stored, and quickly accessed. Search files contain business correspondence,
records, software programs, diagrams, pictures, photographs, and illustrations.

3.10 LIST RULES FOR PREPARATION OF EFFECTIVE DOCUMENT

• It is important to first identify the purpose of document. Once the purpose is known, then important is an
appropriate style of writing.
 • All communications must be in a simple language. The overall format should be uniform, so that the document can
be understood easily.
• Use available resources, such as drawings, tables, charts, references etc., while preparing a document.
The following visual techniques are used in preparing an effective document.
1. LINE DRAWINGS:
• Drawings are used for instructional purpose that emphasise specific points. Line drawings widely used
in the manuals.
2. PHOTOGRAPHS:
• Provide easy understanding of product equipment because of realistic in nature.
3. CHARTS:
• What's may be either quantitative or directive to bar chart, while pie charts are qualitative and explain
the comparison between elements.
• Flow charts define the flow of sequence of operation and action.
4. TABLES:
• Tables are used for quantitative analysis and give comparative information in a compact form.
• Tables provide exact details like numbers, and they are more quantitative than charts.
5. VIEW GRAPHS:
• Text and visuals are used to strengthen the message of a technical details.
3.11 PCB DOCUMENTATION
• The main task in the PCB design process is the creation of accurate PCB manufacturing drawings.
• A solution to the product design varies from company to company. Though some problems exist, it is still
important to use PCB documentation.
A standard PCB documentation consists of the following information:
1. FRONT COVER: it consists of products title, version number, company details, etc.,
2. CONTENT: it is the list of all topics discussed in the document.
3. CIRCUIT DIAGRAM, SCHEMATIC DIAGRAM: Such diagrams are supported with soft copy in a CAD format. This
may be single page or multi page document. The schematic diagram should contain the requirements for the
layout design.
4. BILL OF MATERIALS: it includes parts list with quantity and cost.
5. FABRICATION DRAWING: this document shows dimensional specifications of PCB. That is board material,
board dimension, hole dimension, plating etc.,
6. ASSEMBLY DRAWING: this is also called a silk screen, indicating the assembled PCB drawing with electrical and
mechanical parts.
7. ARTWORK: it is exactly a scaled configuration of PCB. Showing PCB interconnects called tracks.
8. PCB LAYOUT: A PCB layout is supported with software copy in a CAD format.
9. ACTUAL SIZE OF PCB INFORMATION: it is a schematic diagram in actual size, showing all PCB components.
10. PART DETAILS: it has number abbreviations, package size and lead spacing.
11. DRILLING DIAGRAMS: it has positioning and size of hole in PCB.

3.12 ASSEMBLY AND FABRICATION RELATED DOCUMENTATION FOR LAMINATE GRADE

• Hey laminate is an insulating base prepared using a layer glass fabric impregnated with resin either with epoxy or
polyamide material and it is pressed under control of heat.
PROPERTIES OF LAMINATES:
• dielectric constant
• dielectric strength
• dissipation factor
• absorption of water
• tensile strength
 • compression
• environmental residents
• flammability characteristics
• heat resistance
• machinability

3.13 PREPARATION OF MANUAL DOCUMENT

• A user manual is a document provided to a user that helps in using a particular system, product or service
seamlessly. It is also known as an instruction manual or a user guide.
• Such documents cover detailed information around operations, standards & guidelines, troubleshooting guides,
functionalities & more.
• User manuals usually contain step-by-step instructions guiding users through how to use your product and potential
troubleshooting in case something goes wrong.
FOLLOWING ARE THE FEW STEPS TO CREATE MANUAL DOCUMENT:
1. Identify the users.
2. Focus on the problem.
3. Use sequential steps in order.
4. Map user journey.
5. Choose a Template.
6. Write simple and easy to follow content.
7. Treat all users as laymen.
8. Test instructions alongside the product using naive users.
9. Build content using a practical approach.
10. Explain symbols, icons, and codes early.

3.14 DETAILS OF SERVICE MANUAL

A service manual helps in debugging faults. Commonly occurring faults of corresponding and remedy are given in tabular
form. It is used by technicians.
• title of product and title of manual
• Information of product and its specifications
• table of contents
• service notes
• product part information
• detailed panel layouts
• clear product assembly description with help of diagrams
• disassembly steps
• servicing tests
• circuit block layouts
• expected test point results
• supporting diagrams
• input or output electrical drawings
• control drawings
• rack settings and input or output designations
• interconnection diagram
• hardware or software factory acceptance
3.15 TEST REPORT/ MANUALS
A test report should contain all the details of product like dimension, test carried out and its results, accuracy of
measurement. It consists of following information:
• title of manual
• table of content
• scope of the test
• background of the test
• definition of the test
• list of equipments required
• specific environment requirement and test setup
• well defined test procedure
• performance test reporting
• Final Test report
• test report review
3.16 BILL OF MATERIALS(BOM)
• The BOM produced by the engineering department and is used by the production and purchasing departments.
Therefore, any changes in BOM must be done with the consent of engineering.
• BOM defines all necessary components required for assembly of the product.
• Basically, the BOM is a collection of part numbers, quantity, and its price.
• These components can be electrical, electronic, and mechanical items.
• It is useful in maintaining the control of each phase the manufacturing process by providing bills of material for
designing as well as planning purpose.
• Also, it helps in providing timely part usage report and query of material cost. It is possible to keep track and
coordination with all departments involved in the manufacturing process.