Data Acquisition and Evaluation

The responses of the test specimen are recorded and compared with target values or defined tolerance limits. Measured values Communication signals States Output signals

Typical Test Specimens

Functional tests are used for various electronic assemblies and systems whose actual functionality needs to be verified under defined conditions. PCBs Control units Embedded systems Communication modules Infotainment components Industrial electronics

Functional test systems can be used across different phases of the product and manufacturing process. Development Prototyping Series production Final inspection

FCT Systems

FUNCTIONAL TEST SYSTEMS

In electronics manufacturing, functional testing ensures that printed circuit boards, assemblies, or devices reliably perform their electrical and software functions. MCD Elektronik develops custom functional test systems. These systems connect to and stimulate the device under test, record and analyze measurement data, and document the results. The range extends from manual test stations to automated test systems.

FUNCTIONAL TESTS

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Blinker, Kamera, Heizung und Assistenzsysteme.

FCT Systems

Außenspiegel

FUNCTIONAL TEST SYSTEMS

Beim Funktionstest wird der Prüfling mit Spannungen, Signalen, Befehlen oder Lastzuständen angesteuert. Die daraus resultierenden Messwerte, Kommunikationssignale, Zustände oder Ausgangssignale werden erfasst und mit Sollwerten oder definierten Grenzbereichen verglichen.
In der Elektronikfertigung dient der Funktionstest dazu, Fehler frühzeitig zu erkennen, bevor Baugruppen weiterverarbeitet, in Endprodukte eingebaut oder ausgeliefert werden. Funktionstests können sowohl in der Entwicklung und Bemusterung als auch in der Serienfertigung und Endkontrolle eingesetzt werden.

Test Principle

Actual vs. Target Comparison

Test Specimens

PCBs to Industrial Electronics

Applications

From Development to Final Inspection

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

Functional tests replicate defined operating conditions and evaluate the responses of the test specimen. Control signals, measurement acquisition, communication, and output signals are combined into a comprehensive functional test.

Detailed View of a Functional Test System

Insight into the MCD Functional Test Solution

Mechanical & Electrical

Interface Panel of the Test System

Detailed View of the Connections

LVDS, USB, Bluetooth, WLAN, Ethernet and GPS

Test Setup for Multiple Smart Home Assemblies

Top View of the Test Fixture

Multi-Position Fixture, Contacting and Control Monitor

RF Measurement Technology of a Test Station

Detailed View of the Measurement Technology

Spectrum Analyzer and System Control

The test specimen is deliberately subjected to the input parameters and operating conditions required for the respective function.

Voltages
Signals
Commands
Load conditions

The responses of the test specimen are recorded and compared with target values or defined tolerance limits.

Measured values
Communication signals
States
Output signals

Functional tests are used for various electronic assemblies and systems whose actual functionality needs to be verified under defined conditions.

PCBs
Control units
Embedded systems
Communication modules
Infotainment components
Industrial electronics

Functional test systems can be used across different phases of the product and manufacturing process.

Development
Prototyping
Series production
Final inspection

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.

Early Fault Detection Before Further Processing and Delivery

In electronics manufacturing, functional testing helps detect faults at an early stage before assemblies are further processed, integrated into finished products, or shipped.

Test Methods and Concepts Used

The functionality of an electronic product is tested by generating defined input parameters and operating conditions, recording the responses of the test specimen, and then comparing them with target values or defined tolerance limits.

Control and Simulation

Voltage Control

Signal Control

Transmission of Defined Commands

Testing Under Defined Load Conditions

Measurement and Signal Acquisition

Acquisition of Measurement Values

Acquisition of Communication Signals

State Detection

Output Signal Acquisition

Functional Evaluation

Comparison with Target Values

Evaluation Based on Defined Tolerance Limits

Detection of Functional Faults

Testing Under Defined Conditions

Flexible Applications

Development and Prototyping

Series Production

Final Inspection

Testing of Various Electronic Assemblies and 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

FUNCTIONAL TESTS

A functional test, or FKT for short, checks not only whether an electronic product is physically constructed correctly, but also whether it actually operates as intended under defined conditions. To do this, the device under test is subjected to voltages, signals, commands, or load conditions. The resulting responses—such as measured values, communication signals, states, or output signals—are recorded and compared with target values or specified limits. In electronics manufacturing, functional testing is primarily used to detect defects early on, before assemblies are further processed, integrated into final products, or shipped. Typical test objects include printed circuit boards, control units, embedded systems, communication modules, infotainment components, and industrial electronics. Functional tests can be used both in development and for sampling, as well as in mass production and for final inspection.

TYPICAL TESTING METHODS AND CONCEPTS

FKT systems can be configured in various ways depending on the test object, test depth, quantity, and degree of automation. Options include manual test stations, semi-automatic stations, systems with interchangeable adapters, multiple test stations, or automatable test systems for mass production.

Depending on the application, MCD Elektronik develops manual test stations, semi-automatic stations, systems with interchangeable adapters, multiple test stations, or automatable test systems for mass production.

Typical test tasks include current and voltage measurements, digital and analog signal testing, communication and interface tests, sensor and actuator simulations, flash and programming processes, as well as audio, video, or display tests. The focus is on reliably contacting defined test points via customer-specific needle bed adapters and contacts, as well as on the targeted stimulation of the assembly. To this end, digital and analog input signals, loads, sensor states, and voltage interruptions are simulated, and the resulting system responses are measured and evaluated.

MCD Elektronik views the functional tester as a complete system in which test adapters, measurement technology, software, mechanics, data connectivity, and the user interface are precisely coordinated.

Test Methods and Concepts Used

Procedure

FCT Systems

INSERT

The test specimen is placed in the adapter or test specimen holder. The system closes and locks, and the test sequence starts automatically.

CONTACT / SCREEN

A connection is established (e.g., via a needle adapter). Optionally, RF shielding can be used to ensure stable measurements, or a protective cover can be used to prevent accidental contact.

STIMULUS & MEASUREMENT

Specified voltages, signals, and loads are applied. Analog and digital input signals are stimulated, while output signals are measured and compared to the setpoints.

DIAGNOSE & LOGGING

The measured responses of the test specimens are compared with the expected results, signal waveforms, and defined tolerance limits. The resulting measurement data are recorded and documented.

RESULTS & TRACEABILITY

The system returns a definitive result (Pass/Fail) and generates digital documentation. Optional: Label printing with scannable codes for unique identification and traceability.

FREQUENTLY ASKED QUESTIONS

FAQS

A functional test is a testing procedure used to verify whether an electronic assembly, device, or system performs its intended functions correctly. To do this, defined signals, voltages, commands, or load conditions are applied, and the test subject’s responses are compared with these values.

FKT test systems are suitable for electronic, electromechanical, and mechatronic products. These include, for example, printed circuit boards, electronic assemblies, control units, embedded systems, communication modules, automotive components, and industrial electronics. The key requirement is that the product can be connected, stimulated, measured, and evaluated under defined operating conditions and has not yet been permanently installed.

A functional test specifically checks individual functions or assemblies of a product. An EOL test typically goes beyond this; it takes place at the end of the manufacturing process and combines several testing tasks into a single comprehensive process. This includes functional tests, as well as electrical measurements, mechanical testing, etc. Thus, the EOL test is, among other things, a final functional test performed at the end of the manufacturing process before shipment or.

An automated FKT is useful for recurring test procedures, higher production volumes, demanding quality requirements, or when measurement results must be documented in a reproducible manner. Automated systems reduce manual errors, shorten test times, and enable standardized quality assurance.

Test adapters serve as the mechanical and electrical interface between the test system and the device under test. They ensure reproducible contact, secure positioning, and stable measurement conditions. For printed circuit boards, special test points can be accessed using needle bed adapters; for wireless or RF applications, shielded adapters are also recommended.