Summary
DMC developed an automated End-of-Line (EOL) tester to perform a series of In-Circuit Tests (ICT) of a custom-designed Wireless Lockbox Controller. The lockbox targets the Electric Vehicle (EV) market; therefore, it is important to thoroughly test its electronics to validate each device and ensure functionality under a variety of conditions.
Using a bed-of-nails (BON) test fixture, the EOL test programs, and the Device Under Test (DUT), it verifies its operation, ensures all hardware and communication interfaces function correctly, and provisions the newly fabricated device into the management system.
Customer Benefits
Faster Deployment & Provisioning
Automatically provisions devices under test (DUTs) into the management system, reducing setup time, ensuring consistency, and minimizing human error.
Higher Production Throughput
Automates end-of-line testing to reduce manual effort, accelerate production, and increase manufacturing efficiency.
Improved Product Quality
Provides 100% functional test coverage, helping identify defects before shipment and reducing field failures, warranty claims, and customer returns.
Lower Manufacturing Costs
Detects issues early in the production process, minimizing rework, troubleshooting, and costly downstream repairs.
Scalable & Future-Ready Test Platform
Adapts to new hardware revisions, firmware updates, and product variations without requiring major test system redesigns.
Complete Traceability & Compliance
Captures detailed test results and device data, enabling quality tracking, audit readiness, and continuous process improvement.
Solution
The EOL tester verifies the integrity and functionality of the Wireless Lockbox Controller before it leaves the production line. The system consists of a bed-of-nails (BON) test fixture that makes electrical contact with key test points on the DUT. Once the DUT is placed into the fixture, the test sequence begins at the push of a button. The test sequence is fully configurable and could include a number of steps, for example:
- Initial Power Test – Ensures the DUT powers are on correctly before programming.
- Program MCU – Flashing firmware and updating security parameters.
- Full Power Test – Verifies power consumption under normal operation.
- External Peripherals Test – Emulates internal/external sensor signals and performs actuator tests to ensure PCB functionality.
- Provision DUT – Configures the DUT for deployment, applying final settings.
Key Technologies
Hardware: Custom bed-of-nails (BoN) test fixture.
Software: Python-based test automation scripts, logging and reporting tools, batch scripting for firmware flashing and security parameter updates.
Results
By implementing this automated EOL tester, our client significantly reduced the risk of shipping defective products while increasing production speed and efficiency. The system’s reliability and scalability ensure it remains a valuable asset as the company expands into a very competitive EV market.
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