PCBA Testing Systems
Our PCBA EOL functional test machines combine firmware flashing and validation in one automated platform. Using bed-of-nails fixtures with dedicated JTAG, they program ECU microcontrollers directly, then run full functional tests without repositioning.
Overview
At Trinitas we have developed PCBA End-of-Line (EOL) Functional Test System— an advanced automated platform designed for automotive ECU validation.
This system combines firmware flashing and functional testing in a single streamlined process, eliminating the need for multiple setups and reducing handling time. Built on NI LabVIEW and National Instruments cDAQ chassis, the system integrates signal generation, measurement, and power control to deliver high accuracy and scalability for both manufacturing and R&D environments.
Using a custom bed-of-nails fixture tailored to each PCB design, the system programs ECU microcontrollers via dedicated JTAG interfaces, then executes comprehensive functional tests without repositioning. This includes power sequencing, communication protocol checks (CAN, LIN, Ethernet), signal stimulation and measurement, and complete end-of-line validation. By merging programming and testing, our solution ensures consistent quality, higher throughput, and lower operational costs.
Mechanical Subsystems
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Custom Bed-of-Nails Fixture
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Precision-engineered to match the PCBA layout and test points for reliable electrical contact.
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Quick-Swap Fixture Design
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Enables fast changeover for different PCBA variants, reducing downtime in production lines.
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Robust Clamping & Alignment
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Ensures stable positioning of the PCBA during automated flashing and functional tests, minimizing contact errors
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Scalable & Modular Setup
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Supports integration with robotic handlers and additional test modules for future expansion.
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Durable Industrial Construction
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Built for high-cycle operation in manufacturing environments, ensuring long-term reliability
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Test Automation & Management
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LabVIEW-Based Unified Control Software
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Automates flashing, power sequencing, and functional test execution.
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Integrated Firmware Flashing
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Programs PCB microcontrollers before functional tests using dedicated interfaces.
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Automated Protocol Validation
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Executes CAN, LIN, and Ethernet communication checks without manual intervention.
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Customizable Test Sequences
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Adaptable for different PCBA functions and industry applications.
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High Throughput Design
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Reduces handling time and accelerates production cycles.
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Safety & Interlocks
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Emergency Stop & Safety Relays
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Protect operators and equipment during high-voltage or high-current tests.
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Fixture Presence Detection
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Prevents test execution if the fixture or PCBA is not properly seated.
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Overcurrent & Overvoltage Protection
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Ensures safe operation during power cycling and load simulation.
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Isolation for Communication Lines
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Protects sensitive ECU circuits during signal stimulation.
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Compliance with different Industry Safety Standards
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Designed to meet industry safety norms for testing & manufacturing environments.
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Mesaurement & Loading circuit
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Signal Measurement Modules
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Captures sensor feedback and monitors voltage levels across PCBA circuits.
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Supports high-resolution waveform analysis for complex automotive signals.
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Signal Generation Modules
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Simulates sensor signals for PCBA input validation.
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Generate PWM Control signals for actuators, motors during functional tests
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Communication Interfaces
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Validates network communication protocols (CAN, LIN, Ethernet).
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Supports diagnostics, flashing, and high-speed data exchange.
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Programmable Power Supply
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Simulates variable power conditions.
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Integrated Load Simulation
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Replicates real-world loads for accurate PCBA performance testing.
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Data Logging & Reporting
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Centralized SQL Database Storage
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Automatically logs all test data and events in secure SQL database for long-term traceability.
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Individual ECU Traceability
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Tracks each PCBA by serial number or barcode for compliance and quality control.
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Automated Report Generation
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Generates detailed test reports in CSV and PDF formats for easy sharing and documentation.
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Trend Analysis & Reliability Charts
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Provides performance insights over time, enabling predictive maintenance and quality improvement.
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MES & QA System Integration (Optional)
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Connects with customer systems for centralized data management and real-time monitoring.
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