The MCD Elektronik FCT test system tests circuit boards in dental devices

It enables fast and reliable functional testing of up to four PCBs simultaneously, is used specifically for LED polymerization devices and meets the validation requirements of the medical technology sector.
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Challenges and concept

The test system was developed for functional testing of circuit boards used in LED curing lamps for dental technology. Up to four boards can be tested simultaneously in an adapter with a mobile ULC rack. Markings in the adapter and a semi-automatic test sequence support safe and unambiguous process control.

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Blinker, Kamera, Heizung und Assistenzsysteme.

FCT Systems

Außenspiegel

Dental PCBs

Compact FCT system for dental PCBs

MCD Elektronik implemented a test station that tests several LED driver and controller boards in parallel, enabling very short cycle times. The specially adapted fixture makes it easy to clearly identify the units under test within the adapter.

During the semi-automatic test sequence, the operator is guided through the test steps via touchscreen or barcode scanner. At the same time, test results are documented centrally and assigned unambiguously to each unit under test.

Parallel testing
Up to 4 PCBs
Cycle performance
Up to 2 PCB sets/min
Test sequence
Semi-automatic

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

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil
Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

Test and functional scope

The FCT system checks the electrical and functional characteristics of the dental PCBs and combines testing with validated process control and complete traceability:

Multiple test adapter for dental PCBs
Detailed view of the four test stations
Fixture, contacting and unit identification
FCT test system for dental PCBs
Overall view of the test station
Test adapter, measurement technology and operator monitor

Current and voltage values are measured automatically under different load conditions, and the LED current sources are tested specifically.

  • Fully automatic current measurements under various load conditions
  • Fully automatic voltage measurements under various load conditions
  • Testing of two 470 nm LED current sources
  • Testing of one 410 nm LED current source

The functions of the controller board and its controls are tested within the test sequence.

  • Testing of the controller board’s operating functions
  • Testing of the indicator LEDs
  • Testing of the buzzer and buttons
  • Semi-automatic confirmation of test steps via touchscreen or barcode scanner

Test results are recorded unambiguously, error data is protected and assigned to the respective units under test.

  • Individual documentation of failed test results
  • Protection of error data against overwriting
  • Complete traceability of test results
  • Complete traceability of the units under test

The system was validated for use in medical applications and supports reliable process control in series production.

  • Validation in accordance with medical technology guidelines
  • Qualification for use in medical applications
  • Markings in the adapter for unambiguous PCB assignment
  • Operator guidance via touchscreen or barcode scanner
Bauteilaufnahme im EOL-Prüfstand
Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

FCT-dentistry-device-pcbs_mcd-002-2048x1365-1024x683

Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

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

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

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.

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High throughput with compact multiple testing

Up to four PCBs can be tested simultaneously. This enables cycle times of up to two sets of boards per minute while combining high test speed with reliable process control.

Test methods used and challenges

The test solution combines automated electrical measurements with MIO1616 control, TestManager CE and centralized test documentation. Special requirements arise from validation for medical applications and the tamper-proof assignment and storage of test results.

Control and measurement technology
Control via the MIO1616 unit
Test sequence with TestManager CE
Multimeter module for electrical measurements
Operation and process control
Touchscreen monitor for user interaction
Confirmation of test steps via touchscreen or barcode scanner
Semi-automatic test sequence with clear unit assignment
Test data and traceability
Central recording and documentation of all test data
Tamper-proof evaluation of test results
Unambiguous assignment of errors to individual test points
Process and quality assurance
Validation in accordance with medical technology guidelines
Protection of failed test results against overwriting
Precise analysis of PCB quality
Increased process reliability in series production
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

The test system is designed for circuit boards in an LED polymerization device used in dental technology. The device uses LED light to permanently cure materials such as dental plastics, adhesives or coatings.
The FCT automatically tests three LED driver boards for current and voltage under different loads, while the controller board is tested in parallel for subsequent operating functions such as indicator LEDs, buzzer and buttons.
Loading and testing all four boards simultaneously significantly reduces handling time because the units under test do not have to be inserted and tested individually. This achieves a throughput of around two sets of boards per minute, significantly exceeding the customer’s requirement of ten boards per hour.
The PCBs are contacted via a bed-of-nails fixture in which the test probes extend only when the adapter is closed. Markings in the adapter and semi-automatic operator guidance, which requires queried functions to be confirmed manually, also reduce operating errors and ensure reproducible contacting.
Reliability, documentation and the ability to validate are particularly important for medical technology products. In this project, this is reflected in complete error assignment, protection of test data against modification and final validation in accordance with medical technology guidelines. The system also had to be qualified for international production use at high temperatures and extreme humidity, so the test station was tested in a climatic chamber in advance.

KEY FACTS

Key facts at a glance

Test system
Functional test system / FCT
Handling
Semi-automatic
Concept
Multiple test bench with multi-up panel – up to 4 PCBs simultaneously, with adapter and mobile ULC rack
Test methods & scope
Electrical: voltage, current, loads
Optical / visual: testing of indicator LEDs and LED functions
Haptic / operating function: testing of button, buzzer and controller functions
LED testing: LED wavelengths 410 nm and 470 nm
Components
TestManager CE, MIO1616, multimeter, touchscreen monitor, mobile ULC rack, bed-of-nails adapter, barcode scanner

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