Electrical and functional testing

Electronic assemblies are tested under defined conditions, and relevant electrical and functional parameters are evaluated automatically. Functional and end-of-line tests Current and voltage measurements Signal and communication testing Pin checks

Extended testing and process tasks

Depending on the application, additional test methods and production-related process steps can be integrated into the automated test system. RF testing Optical inspections Leak and load testing Flash programming and configuration Label printing

Handling, sorting and documentation

In addition to testing, automated workflows can also handle part handling, sorting and digital test result documentation. Automated handling Pass/fail sorting Digital test result documentation Data integration and traceability

Automated Systems

AUTOMATED TEST SYSTEMS

Automated test systems from MCD Elektronik handle test sequences, handling, contacting, measurement, evaluation, and documentation—either fully or partially automated. From semi-automated test stations to rotary indexing tables and robot-assisted test cells, MCD develops custom solutions for reproducible quality, stable processes, and efficient mass production testing.

AUTOMATED TESTING

Automated test systems execute test sequences according to defined specifications, thereby reducing manual influences in the testing process. Depending on the application, individual process steps or the entire test sequence can be automated.

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Blinker, Kamera, Heizung und Assistenzsysteme.

Automated Systems

Außenspiegel

AUTOMATED TEST SYSTEMS

Automated testing solutions for repeatable processes

The device under test is loaded, positioned, connected, stimulated, measured and evaluated. Depending on the system, automation also handles clamping, handling, measurement data acquisition, result evaluation and documentation.

MCD Elektronik develops automated test systems tailored to the device under test, the process, the degree of automation and quality requirements—from test concept to on-site commissioning.

Automation level

Individual steps to a fully automated test sequence

Process quality

High repeatability and consistent cycle times

Documentation

Traceable test results and comprehensive data traceability

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 %

TYPICAL TESTING METHODS AND CONCEPTS

Automated test systems combine testing and process steps into defined workflows. Depending on the application, functional tests, electrical measurements, communication tests, RF tests, optical inspections, as well as programming and documentation processes can be integrated.

Test station with result evaluation

Front view of test station

Display showing test overview

Robot-assisted VTS 2030 test station

Overall view of the test setup

Robot, test adapter and sensors

Operator area of a test system

View of the operator area

USER and ADMIN labeling

The test process can range from individual automated work steps to a fully automated sequence.

Loading and positioning the device under test
Contacting and locking
Stimulation and measurement data acquisition
Automatic result evaluation

Electronic assemblies are tested under defined conditions, and relevant electrical and functional parameters are evaluated automatically.

Functional and end-of-line tests
Current and voltage measurements
Signal and communication testing
Pin checks

Depending on the application, additional test methods and production-related process steps can be integrated into the automated test system.

RF testing
Optical inspections
Leak and load testing
Flash programming and configuration
Label printing

In addition to testing, automated workflows can also handle part handling, sorting and digital test result documentation.

Automated handling
Pass/fail sorting
Digital test result documentation
Data integration and traceability

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.

Flexible system concepts for different processes

Automated test systems can be configured in many ways: as a semi-automated test station, automated adapter station, rotary indexing table system, robot cell, validation station or combined assembly and test system.

Test methods and concepts used

The focus of automated test systems is on automating the test process itself. Mechanics, adaptation, measurement technology, software, safety, the operating concept and data integration are combined into a stable, scalable and maintainable overall system.

Functional and electrical testing

Functional and end-of-line testing of electronic assemblies

Current and voltage measurements

Signal and communication testing

Pin checks

Advanced test methods

RF testing

Optical inspection

Leak testing

Load testing

Automated process integration

Flash and programming processes

Label printing

Pass/fail sorting

Digital test result documentation

Flexible automation concepts

Semi-automated test stations

Automated adapter stations

Rotary indexing table systems

Robot cells

Validation stations

Flexible automation concepts

Combined assembly and test systems

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

AUTOMATED TESTING

Automated test systems execute test sequences according to defined specifications, thereby reducing manual intervention in the testing process. The test object is loaded, positioned, connected, stimulated, measured, and evaluated. Depending on the system, the automation handles individual steps or the entire test sequence, including clamping, handling, measurement data acquisition, result evaluation, and documentation.

Unlike a purely manual test station, an automated test system ensures high repeatability, consistent cycle times, and traceable test results. It is particularly well-suited for recurring test tasks, increasing production volumes, complex measurement sequences, or high requirements for quality and traceability.

MCD Elektronik does not develop such systems as off-the-shelf solutions, but rather tailors them to the test object, process, degree of automation, and quality requirements—from test design through on-site commissioning.

TYPICAL TESTING METHODS AND CONCEPTS

Automatisierte Testsysteme können sehr unterschiedlich ausgelegt sein: als halbautomatische Prüfstation, automatisierter Adapterplatz, Rundschalttischsystem, Roboterzelle, Validierungsstation oder kombinierte Montage- und Prüfanlage.

Entscheidend ist dabei nicht, ob das System in einer Fertigungslinie steht, sondern welche Prüf- und Prozessschritte automatisiert ablaufen. Während ein Inline-Testsystem per Fördertechnik oder Handlingsysteme direkt in den laufenden Produktionsfluss eingebunden ist, kann ein automatisiertes Testsystem dagegen auch als eigenständige Station, Roboterzelle, Rundschalttisch oder halbautomatischer Prüfplatz außerhalb einer Linie arbeiten. Der Schwerpunkt liegt hierbei auf der Automatisierung des Prüfprozesses selbst.

Typische Prüfaufgaben umfassen Funktions- und End-of-Line-Tests elektronischer Baugruppen. Dazu gehören Strom- und Spannungsmessungen, Signal- und Kommunikationsprüfungen, HF-Tests, optische Inspektionen, Pin-Checks, Dichtheits- und Belastungsprüfungen, Flash- und Programmierprozesse, Labeldruck, Pass/Fail-Sortierung sowie die digitale Ergebnisdokumentation.

Für MCD steht dabei das Gesamtsystem im Fokus: Mechanik, Adaption, Messtechnik, Software, Sicherheit, Bedienkonzept und Datenanbindung werden so kombiniert, dass ein stabiler, skalierbarer und wartbarer Prüfprozess entsteht.

Test methods and concepts used

Procedure

Automated Systems

INSERT

Test specimens are loaded manually, semi-automatically, or by robot and are uniquely identified.

POSITIONING

The system positions the DUT, locks it in place if necessary, and establishes electrical, mechanical, or signal-based connections in a reproducible manner.

STIMULUS & MEASUREMENT

Signals, voltages, loads, or control commands are automatically transmitted to the device under test. Responses, measured values, and process data are automatically recorded.

DIAGNOSIS & RESPONSE

Measurement results are compared with target values and tolerance limits; PASS parts are approved. FAIL parts are marked, separated, or set aside for rework.

RESULTS & TRACEABILITY

The system digitally stores test results, measured values, and process data. Optional: label printing or data transfer to MES, ERP, or customer systems.

FREQUENTLY ASKED QUESTIONS

FAQS

An automated test system is a testing solution in which one or more steps of the testing process are performed automatically. These include, for example, contacting, stimulation, measurement, evaluation, documentation of results, handling, or sorting. This varies between semi-automated and fully automated systems. With semi-automatic test systems, the operator usually still performs individual process steps, such as loading or unloading the test specimen, while the actual test sequence is controlled and evaluated automatically. Fully automatic test systems, on the other hand, also perform handling, positioning, contacting, testing, and post-processing without manual intervention—for example, using robots, rotary indexing tables, or integrated automation modules.

Automated testing refers to the automation of the testing process itself. The system can be configured as a single test station, a robotic cell, a rotary indexing table, or a test station. Inline testing is a specific form of this: The test system is directly integrated into a running production line and linked to the material flow, cycle time, and line control. In both cases, however, the testing process is automated.

Typical tasks include functional tests, end-of-line inspections, current and voltage measurements, signal and communication tests, optical inspections, leak tests, programming processes, label printing, pass/fail sorting, and database integration.

An automated test system is useful when recurring test procedures, high production volumes, complex measurement sequences, tight cycle time requirements, or high standards for repeatability and documentation are necessary. In addition, an automation solution reduces manual interference and ensures consistent test conditions.

Yes. Depending on their configuration, existing test stations can be expanded with automatic locking mechanisms, contact systems, handling systems, robots, gantries, software functions, or data interfaces. This allows the level of automation to be increased incrementally without necessarily having to build a completely new, automated test station.