How a test flow can be build for a car electronic sunroof control

A

adytzul_ac

#1
Hello dear colleagues!
I'm new in reliability testing but I do research on this topic very often. Could you tell me something about how a test flow could be build for a car electronic? Are there any limitation for creating a test flow?
 
Elsmar Forum Sponsor

Marc

Fully vaccinated are you?
Leader
Admin
#2
Hello dear colleagues!
I'm new in reliability testing but I do research on this topic very often. Could you tell me something about how a test flow could be build for a car electronic? Are there any limitation for creating a test flow?
I assume you are asking about a functional test. A test flow would be specific to the electronic assembly and dependent upon the assembly function(s). I wouldn't think there would be any specific limitations, and functions tested would typically include aspects such as voltage overload protection (i.e.: Not confined to specific functions the assembly is designed to do).

What is/are the function(s) of the electronic assembly?
 
Last edited:
A

adytzul_ac

#3
Hello! I wish you all a happy new year + health 100% :).
I'm talking about an automotive electronic board, placed inside the car, which controls the sunroof.
 

Marc

Fully vaccinated are you?
Leader
Admin
#4
Well, your assembly/controller has a specific number of functions dictated by the design. E.g.:
  • Open, a switch input function
  • Close, a switch input function
  • Stop, a switch input function
  • Auto-Open, a switch input function, and
  • Close Stop If Blocked (to stop it if resistance indicates something such as an arm or body is encountered when closing) - A safety function
  • NOTE: I haven't seen one, but I assume Auto-Close could be a function.
Much like a door window. Those are the primary design functional aspects. They are function design inputs.

I'll start with a couple disclaimers:
I am not an electrical engineer. In fact, I am electronic design stupid. I worked on a lot of high reliability electronics projects over the years, always from a functional quality position and from a physics aspect such as circuit board component layout, weights and resonant frequency of the board - E.g.: Finite Element Analysis of circuit boards. I did learn a fair amount of basic things such as circuit protections and such listening to the designers, but actually designing a circuit board, programming any chips is an Electrical Engineer function - WAY beyond my expertise.

OK - So, in addition to your functional tests (listed above) you will have to find out what electrical functional tests, such as voltage overload protection, there are to test. That is information the project electrical engineer/board designer will have to provide.

In my experience I always worked with a cross-functional team. When designing functional tests, we would get together and determine what to test and where in the manufacturing process any functional tests would be performed.

I don't remember there ever being any limitations on test flow (sequence), but I'm not sure what you mean by 'limitations'.
 
A

adytzul_ac

#5
I was thinking more on the environmental stress tests e.g. temperature steps, vibrations, shocks, humidity tests... and the way these tests should arranged in a test flow.
 

Marc

Fully vaccinated are you?
Leader
Admin
#6
OK - If you are referring to environmental testing, I wrote some test plans back in the 1980's mainly for DoD aerospace projects. I took the assembly or board or component requirements and listed them. Typically they were contract requirements based upon what environment the item would be used in. At the time the test plans I wrote were called Environmental Design Criteria test plans and they could be quite broad. For example:
  • Vibration - Transportation of the item
  • Vibration - Use environment
  • Thermal Cycling - Profiles defined by use and transportation and storage
  • Thermal Shock - Mainly for stressing electronic assemblies and their components (also see Environmental Stress Screening)
  • Shock - Mostly done on assemblies used in extreme environments
  • Humidity - Storage and use
  • Explosive Atmosphere - Use environment
  • Salt Spray - Storage and use
When I wrote those test plans I started by profiling the item starting from storage as stock to transportation to the customer. Then stock/storage at the customer's facility.
Questions I then had to answer, such as Where will it be used, such as in what environments. Aerospace or military communications equipment? Typically Explosive Atmosphere testing was one of the tests. Will the item be stored and/or used in tropical environments? Think Fungus testing and Salt Spray.

Most of the test parameters were taken from Mil-Std-810 and/or predicted use.

You get into some predictive stuff. For example the design of a vibration test profile or a temperature cycling profile. This contains some very old stuff from some EDCTPs I wrote in the 1980's:

Misc-Profiles.gif

However - In all of this, I had to justify, for example, vibration profiles and temperature cycling profiles. These are things I learned how to do from people and various conferences back then.

To move on - You make a list of all the tests you believe are necessary and any required by the contract, as many often were.

From there testing was scheduled. There was never a specific sequence. Any sequence typically depended upon whether the test houses were booked up or not. For example, testing at Wyle was usually a schedule breaker because they typically had a backup. Even in-house testing depended on how much the lab had scheduled.

BTW - Also see: Environmental Stress Screening (ESS) - Difference between MIL-HDBK-344 & 2164A - Short but you mention ESS.

Bottom line: You decide on what testing to do and when to do it. Technically there is not really a limit on what tests you decide to do, but costs will definitely keep them to the realistic minimum.

FWIW - I always had a timeline - These days I'd probably use project software, back then there wasn't really much in the way of tracking software. Always a lot of pressure from upper management - "When will this be finished?" for example. So, you'd send something to be tested at Wyle and... They schedule the test but end up actually doing the testing 3 weeks late.

So - If you have 10 test devices and 15 tests to do, you just have to decide which to do when. Sometimes it makes sense if you have limited test units, or simlyhave a mind for a sequence, you might take a device and do vibration first, then humidity with the prediction that vibration damage where technically if the test device passes, the vibration may open it up in a way humidity testing will reveal the damage.

I don't know if I'm helping or not. I hope so. I was doing that stuff 30 years ago...

Also see: Reliabilty, maintainability and dependability standards list and The History and Rationale of the MIL-STD-810 testing standard
 
Thread starter Similar threads Forum Replies Date
R Microbiological test (USP61, USP62, USP71, ISO 11137.1, ISO11137.2) --- Testing flow chart Other Medical Device Related Standards 0
M Proper method to test flow of a regulator Inspection, Prints (Drawings), Testing, Sampling and Related Topics 1
A Test Method - DIN ISO 1133 for melt flow needed to verify supplier results Manufacturing and Related Processes 1
P Plastic Identification/Test - Melt Flow Index to Determine Correct Material? Manufacturing and Related Processes 16
C Raw Materials verification - Melt Flow Test - Resins: Customer not Satisfied ISO 13485:2016 - Medical Device Quality Management Systems 4
B Sample for Test R&R - Study on viscosity with a melt flow indexer Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 1
W Conducting an MSA Test on scales Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 3
T Lot Release Test and Certificate of Analysis 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 6
John Broomfield Construction Inspection and Test Plan Misc. Quality Assurance and Business Systems Related Topics 5
Z COVID-19 Antigen Test Kit (Self-test) Registration in Peru Other Medical Device Regulations World-Wide 0
R GearBox Test Bench Calibration General Measurement Device and Calibration Topics 2
N 60601-2-34 Electrosurgery interference Test IEC 60601 - Medical Electrical Equipment Safety Standards Series 0
M Gage R&R automated test equipment Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5
F Self-test minimum requirements IEC 60601 - Medical Electrical Equipment Safety Standards Series 5
H Regarding the validity of EMC & Safety test reports without NABL & ILAC-MRA mark. CE Marking (Conformité Européene) / CB Scheme 2
Z Implement methods of Round Robin test Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 5
D 62304 code review, unit test, integration test example IEC 62304 - Medical Device Software Life Cycle Processes 2
D DOD First Article Test Plan & Report Manufacturing and Related Processes 4
Stoic Details of Operational Qualification (OQ) test design for plastic extrusion processes, effect of material property noise, and GHTF/SG3/N99-10 US Medical Device Regulations 2
A Earth (ground) leakage current routine test IEC 60601 - Medical Electrical Equipment Safety Standards Series 1
G Audit & Agreements for "Test Laboratory" Supplier? US Medical Device Regulations 4
G Developing our custom test methods and test equipment US Medical Device Regulations 5
K Looking for a tape to perform cross hatch test on powder coating parts Reliability Analysis - Predictions, Testing and Standards 3
G Change Control for Test Samples Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
MaHoDie Summative Usability test Human Factors and Ergonomics in Engineering 2
A Calibration of spring loaded test fixture General Measurement Device and Calibration Topics 5
E Pressure vessels hydraulic test IEC 60601 - Medical Electrical Equipment Safety Standards Series 0
C Spinal implant predicate device test results 21 CFR Part 820 - US FDA Quality System Regulations (QSR) 0
S Statistical Test Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 0
Ed Panek Looking for Test Resource General Measurement Device and Calibration Topics 1
S Discussion on OBL and OEM test data for submission as per new EUMDR EU Medical Device Regulations 0
E Do I need test reports for all standards mentioned in my 510k application? Other Medical Device Related Standards 8
C DV/PV Test Part Storage IATF 16949 - Automotive Quality Systems Standard 9
R Statistical Methods for comparing test and reference product equivalence for quality attributes US Food and Drug Administration (FDA) 3
Vader22 5 Why RCA for failure to test Contingency Plan IATF 16949 - Automotive Quality Systems Standard 9
S Knee-Patella wear test CE Marking (Conformité Européene) / CB Scheme 4
L PFMEA for test procedures (ISO 14971) ISO 14971 - Medical Device Risk Management 5
A Direct vs. Post-License Investigational Test Authorization (ITA) Canada Medical Device Regulations 0
P Test Method Validation (TMV) for all Measurement Methods in Rec/Inspection Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 1
L AS9100 Section 8.4.2 - External provider test reports AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 10
E How to test 8.7.4.7 d) ? What "not protectively earthed accessible part" means? IEC 60601 - Medical Electrical Equipment Safety Standards Series 3
T ANOVA analysis to find F test. Using Minitab Software 3
P API Q1 - Monogram Product & API 4F - Proof Load Test Oil and Gas Industry Standards and Regulations 3
D Test Management Software Software Quality Assurance 1
B How to test operator to see if they can catch the defective parts? Manufacturing and Related Processes 8
G 60601-1 8.8.3. short circuit of both side during insulation test IEC 60601 - Medical Electrical Equipment Safety Standards Series 1
K Bacterial Endotoxin test for Purified water Manufacturing and Related Processes 2
shimonv Test Method Validation ISO 13485:2016 - Medical Device Quality Management Systems 10
C Test compulsory for Sutures? Manufacturing and Related Processes 6
dgrainger Informational DRAFT: The Medical Devices (Coronavirus Test Device Approvals) (Amendment) Regulations 2021 UK Medical Device Regulations 1

Similar threads

Top Bottom