Basic electrical testing

Conventional cable and component properties are tested reliably and reproducibly. Continuity tests Short-circuit tests Testing passive components Testing resistors, capacitors and diodes

USB and signal integrity testing

For high-speed applications, digital transmission and signal quality are analyzed specifically. Complex USB tests Signal integrity analysis using an eye diagram Testing high-frequency-critical signal parameters Validation of actual transmission quality

Integrated electronics and audio

Communication cables with integrated electronic components can also be read, parameterized and programmed within the test process. Audio tests Reading integrated cable electronics Parameterizing integrated electronics Programming active components and EEPROMs

Modularity and variant flexibility

Test specimen-specific modules and the scalable platform enable rapid adaptation to different connection and cable types. Up to twelve slots on the MCD backplane Automatic detection of the test modules used Support for standardized and customer-specific connectors Flexible adaptation to new cable generations and customer requirements

Modern communication cables have long been more than simple connections

Modern communication cables transmit high-speed data, perform additional functions and sometimes contain integrated electronics. MCD Elektronik’s EOL test systems enable precise end-of-line testing – from electrical connections and signal quality to standards-compliant high-speed analysis and functional testing.

Challenges and concept

In addition to conventional electrical properties, modern communication cables must reliably support high-frequency data transmission, complex signal characteristics and integrated electronic assemblies. Particularly for USB-C connections with high data rates, signal quality determines subsequent system functionality.

Blinker, Kamera, Heizung und Assistenzsysteme.

EOLT Systems

Außenspiegel

Testing intelligent connections

Modular EOL test system for modern communication cables

MCD Elektronik developed a special end-of-line test system for this purpose, combining electrical, functional and signal-related tests in one solution. An MCD-developed backplane with up to twelve slots accommodates different test specimen-specific modules and supports application-specific combinations of connector types, interfaces and test scopes.

Low modules cover simple test tasks, while powerful high modules are used for complex applications. This allows the platform to be flexibly adapted to different cable types, new cable generations and customer-specific requirements.

System architecture

Up to 12 slots

Module concept

Low & high modules

Application range

Up to USB-C high-speed

Ein flexibler End-of-Line-Prüfstand

MCD entwickelte hierfür einen flexiblen End-of-Line-Prüfstand, der sämtliche Varianten innerhalb von weniger als 30 Sekunden prüft. Das System kombiniert optische, mechanische und elektrische Prüfverfahren zu einem durchgängigen Prüfkonzept.

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Scope of testing and functions

The EOL test system checks conventional electrical properties as well as complex data, signal and electronics functions of modern communication cables:

EOL test system for communication cables

Front view of the test system

Measuring devices, controller and module drawers

MCD backplane with module slots

Detailed view of the module fixture

Slots for test specimen-specific modules

High module for communication cables

Detailed view of the test module

Connections and status display

Conventional cable and component properties are tested reliably and reproducibly.

Continuity tests
Short-circuit tests
Testing passive components
Testing resistors, capacitors and diodes

For high-speed applications, digital transmission and signal quality are analyzed specifically.

Complex USB tests
Signal integrity analysis using an eye diagram
Testing high-frequency-critical signal parameters
Validation of actual transmission quality

Communication cables with integrated electronic components can also be read, parameterized and programmed within the test process.

Audio tests
Reading integrated cable electronics
Parameterizing integrated electronics
Programming active components and EEPROMs

Test specimen-specific modules and the scalable platform enable rapid adaptation to different connection and cable types.

Up to twelve slots on the MCD backplane
Automatic detection of the test modules used
Support for standardized and customer-specific connectors
Flexible adaptation to new cable generations and customer requirements

Bauteilaufnahme im EOL-Prüfstand

Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

Spiegeleinstellungen

Kamerasysteme kontrollieren Lichtfunktionen und Spiegelstellungen, während Antriebe, Klappmechanismen und elektrische Funktionen automatisiert getestet werden.

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Lichtfunktionen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

Kamerafunktion

Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Kamerafunktion

Länderspezifische Varianten

Auch das Nichtvorhandene zählt.

Die Negativprüfung stellt sicher, dass sich nicht verbaute Ausstattungsmerkmale nicht aktivieren lassen. Geprüft wird auch, was fehlen muss.

Scalable from standard connections to high-speed applications

The modular test platform covers conventional communication connections as well as USB-C applications with high data rates and integrated electronics. Different test scopes can therefore be implemented within a scalable system.

Test methods used and results

The EOL test system combines electrical cable and component tests with signal analyses and functional tests of integrated electronics to validate both the electrical function and actual transmission quality of modern communication cables.

Electrical cable and component testing

Continuity test

Short-circuit test

Testing resistors and capacitors

Testing diodes and other passive components

Signal and high-speed testing

Complex USB tests

Signal analysis using an eye diagram

Evaluation of high-frequency data transmission

Validation of signal quality and data integrity

Electronics and functional testing

Reading integrated electronic components

Parameterizing the cable electronics

Programming active components and EEPROMs

Audio tests within the test sequence

Flexibility and test result

Testing standardized and customer-specific connectors

Automatic integration of test specimen-specific modules

Fast adaptation to different cable types and generations

Complete validation of electrical function and transmission quality

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

Optische Prüfungen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Kamerabasierte Erkennung von Lichtfunktionen

Analyse von Spiegelstellungen

Kontrolle des Spiegelglases

Mechanische und elektrische Prüfungen

Antriebe und Klappmechanismen werden mechanisch geprüft, während Winkelpositionen bestimmt sowie Spannung und Stromaufnahme gemessen werden.

Bewegungsprüfung der Antriebe

Winkelmessung der Klappfunktion

Stromaufnahme der Motoren

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

FREQUENTLY ASKED QUESTIONS

FAQS

Modern communication cables are often no longer passive cables but contain active components, microcontrollers or programmable electronics. Intelligent communication cables with complex connectors must therefore be tested functionally and non-destructively. In addition to interruptions and contact problems, protocol behavior, logic-based functions, high-frequency signal components and interface communication are tested.

The test system enables audio analyses, oscilloscope measurements of signal quality, EEPROM programming and real-time diagnostics via integrated embedded systems, among other functions. FFT analyses, frequency and level measurements, I²C communication and USB or LAN analyses can also be combined within one test sequence. This allows the electrical, digital and signal-related properties of a cable to be evaluated in a coherent functional test.

The EOL test system reliably detects different fault patterns, including data flow interruptions and short circuits as well as incorrectly assigned individual pins or improperly contacted interfaces. For high-speed transmissions, the system also checks for possible signal interference, shielding anomalies and signal integrity problems to ensure stable operation in accordance with specifications.

The modular cassette-system architecture enables adaptation to different cable types and connectors. Nine low-module slots and one high-module slot allow flexible configuration using interchangeable cassette modules. The system can therefore be specifically converted and expanded for new cable generations or changing customer-specific requirements.

Each cassette module has integrated logic and a counter for recording mating cycles. This makes it possible to track how often a plug-in module has already been contacted. The recorded contacts support wear-dependent predictive maintenance and thus contribute to the process stability of the test system.

KEY FACTS

Key facts at a glance

Test system

EOL test system / Special test system

Handling

Manual

Concept

Single test bench / modular cassette test system based on a VTS 2030 rack.

Test methods & scope

Electrical: voltage and signal parameters
RF / frequency: RF and frequency signals, signal quality
Audio: audio signals
Communication: communication signals
Programming: programming and parameterization functions

Components

VTS 2030 rack, MCD TestMate, Toolmonitors, AudioAnalyzer, multimeter, oscilloscope / PicoScope 6404E, RF backplane, cassette modules