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Semiconductor

Automated PCBA Testing for Semiconductor Manufacturing

Summary

In the world of Semiconductor Manufacturing, wafer cleaning processes are getting increasingly complicated due to the complex nature of wafer structures required for high-performance semiconductors. To achieve residue-free cleanliness, one common approach is to use highly reactive Ozone gas to break down organic components and contaminants. The Ozone quickly reverts back to Oxygen once the cleaning process is complete, so there is little environmental concern required like with other compounds. Generating Ozone relies on a principle patented by Nikola Tesla to discharge electricity in an Oxygen-containing gas, but to do this effectively, the discharge needs to be at a high frequency and voltage. To fit the needs of the customer, DMC created an automated HIL tester built on National Instruments TestStand and LabVIEW that can automatically perform and grade tests for these Ozone Generating PCBAs. The PCBAs attach to the tester with custom cable harnesses that can withstand the high electrical loads necessary for simulating Ozone creation. DMC’s solution also includes a robust dual-channel safety system that both disconnects power physically from the device under test and disables power inputs in the test software, preventing any possible operator exposure to dangerous loads. To further increase the utility of the tester, DMC developed a solution that can test an entire stack of PCBAs, allowing the customer to perform environmental reliability testing with an assembly representative of the full Ozone Generator solution.

Solution

DMC’s Ozone Generator PCBA functional test solution integrates a custom TestStand sequence and grading with a cable-based connector to perform functional testing for EOL validation. The solution includes a custom-designed fixture that isolates devices under test to prevent operator electrical contact. The functional tester mates to the customer’s existing PXI hardware through an Everett Charles Technologies VG Mass Interconnect interface, allowing quick swapping between this test fixture and other EOL test fixtures. The TestStand sequences automatically load test parameters and allow the customer to quickly make changes to the sequence without needing to open the TestStand development environment. In two minutes, the tester is able to run and grade 63 tests for a PCBA and track the results to the PCBA serial number. This allows operators to quickly pass and fail components and keep production moving along steadily.

Oscillator Fixture

Due to the high electrical demands of the devices under test, DMC took special care for how signals were routed to mitigate EMI between connections. The safety system also quickly and effectively discharges both the device under test and internal capacitors when the safety interlock is broken, preventing operator contact with potentially dangerous electrical signals.

PCBA function test systems are becoming prevalent in modern production environments, especially for devices necessary to the rapidly expanding semiconductor industry. Today, more and more demand is placed on PCBAs to perform complex tasks quickly and accurately, so achieving complete test coverage fast enough for EOL validation can be challenging. By utilizing existing software frameworks and hardware expertise, DMC is helping manufacturers ensure a highly productive and effective path to delivering high-quality solutions.

Learn more about DMC’s Test & Measurement PCBA Test expertise and contact us for your next project.

Customer Benefits

  • Automated Tester that runs 63 automated graded tests in 2 minutes, reducing manual test step operations and decreasing individual EOL test cycle time by 50%.
  • Integrated device safety shields and safety interlock to ensure operator safety throughout the entire process.
  • Enables customer to identify quality concerns with environmental testing without disassembling products, decreasing product warranty costs.
  • Customizable test sequences and grading limits allow future-proofing of new PCBAs with different test requirements.

Technologies