Testing method and system
First Claim
Patent Images
1. A method for functionally testing an electronic controller board for a spa system, the electronic controller board configured for electrical connection at respective terminal connectors to a source of AC line voltage, to one or more controlled line voltage load devices and to a spa panel control for inputting user commands in normal use, the electronic controller board having a microcomputer for overall control of the electronic device and at least one switch or relay, the method comprising:
- electrically connecting the electronic controller board at the respective terminal connectors to corresponding test station terminal connections on a test station;
with the test station in an interface check mode prior to application of AC line voltage to the electronic controller board, automatically measuring impedances at said test station terminal connections with the test station to determine whether the electronic controller board is properly connected to the test station by comparing the measured impedances to expected impedance values;
the test station aborting the test prior to application of AC line voltage to the electronic controller board if any test station terminal connections are determined not to be properly connected to corresponding board terminal connectors, and providing an indication to an operator of failed connections between the test station and the electronic controller board causing the test abort;
preventing application of AC line voltage through the test station to the controller board unless the electronic controller board terminal connectors are properly connected to the corresponding test station terminal connections;
with the test station in a test sequence mode, conducting an automated test in which line voltage is applied to the electronic controller board, said test sequence mode including exchanging data and commands between the test station and the electronic device microcomputer,wherein the test includes;
applying AC line voltage to the electronic controller board;
controlling the microcomputer to sequentially exercise controller board functions, including controlling the microcomputer to activate the at least one switch or relay to cause AC line voltage to be applied to at least one terminal connector and to a corresponding AC line voltage load connected to a corresponding test station terminal connection; and
measuring voltage and current parameters of the controller board, including a current drawn by the controller board at a time in which the at least one switch or relay is activated to apply AC line voltage to the corresponding line voltage load, to determine whether the measured parameters are within a predetermined range for proper functionality.
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Accused Products
Abstract
A method and system for functionally testing units under test, such as electronic controller boards for a spa system.
19 Citations
17 Claims
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1. A method for functionally testing an electronic controller board for a spa system, the electronic controller board configured for electrical connection at respective terminal connectors to a source of AC line voltage, to one or more controlled line voltage load devices and to a spa panel control for inputting user commands in normal use, the electronic controller board having a microcomputer for overall control of the electronic device and at least one switch or relay, the method comprising:
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electrically connecting the electronic controller board at the respective terminal connectors to corresponding test station terminal connections on a test station; with the test station in an interface check mode prior to application of AC line voltage to the electronic controller board, automatically measuring impedances at said test station terminal connections with the test station to determine whether the electronic controller board is properly connected to the test station by comparing the measured impedances to expected impedance values; the test station aborting the test prior to application of AC line voltage to the electronic controller board if any test station terminal connections are determined not to be properly connected to corresponding board terminal connectors, and providing an indication to an operator of failed connections between the test station and the electronic controller board causing the test abort; preventing application of AC line voltage through the test station to the controller board unless the electronic controller board terminal connectors are properly connected to the corresponding test station terminal connections; with the test station in a test sequence mode, conducting an automated test in which line voltage is applied to the electronic controller board, said test sequence mode including exchanging data and commands between the test station and the electronic device microcomputer, wherein the test includes; applying AC line voltage to the electronic controller board; controlling the microcomputer to sequentially exercise controller board functions, including controlling the microcomputer to activate the at least one switch or relay to cause AC line voltage to be applied to at least one terminal connector and to a corresponding AC line voltage load connected to a corresponding test station terminal connection; and measuring voltage and current parameters of the controller board, including a current drawn by the controller board at a time in which the at least one switch or relay is activated to apply AC line voltage to the corresponding line voltage load, to determine whether the measured parameters are within a predetermined range for proper functionality. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A test station for functionally testing spa controller systems for a spa system, the spa controller system having a microcomputer for overall control of the electronic device and at least one switch or relay, the controller systems configured for electrical connection at respective terminal connectors to a source of AC line voltage, to one or more controlled AC line voltage load devices and to a spa panel control for inputting user commands, the test station comprising:
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a test station controller including a display; test station terminal connections adapted for electrically connection to a spa controller system at the plurality of terminal connectors of a spa controller system to be tested, the test station terminal connections including an AC line voltage connection set configured for connection to a corresponding AC line voltage connector set comprising the terminal connectors of the spa controller system; an AC power module configured for connection to AC line voltage, and including a switching circuit controlled by the test station controller for selectively applying AC line voltage to the AC line voltage connection set; a measurement instrument for measuring electrical parameters including voltage, current, resistance and capacitance; a multiplexer system for selectively connecting the measurement instrument to selected ones of the test station terminal connections under control of the test station controller; an emulation module for emulating signals and electrical loads to be connected to the terminal connectors in normal use, the electrical loads including at least one AC line voltage load; and wherein the test station controller is adapted, with the test station in an interface check mode prior to application of line voltage to the spa controller, to measure impedances at said test station terminal connections with the measurement instrument to determine whether the controller system is properly connected to the test station by comparing the measured impedances to expected impedance values, and to prevent application of AC line voltage through the test station to the controller system unless the controller system terminal connectors are properly connected to the corresponding test station terminal connections; the test station controller configured to abort the test prior to application of line voltage to the spa controller if any test station terminal connections are determined not to be properly connected to corresponding spa controller terminal connectors, and providing an indication to an operator of failed connections between the test station and the spa controller causing the test abort; and wherein the test station controller is further adapted to carry out a test sequence mode comprising a test in which AC line voltage is applied to the controller system to provide electrical power to the microcomputer and the at least one switch or relay, said test sequence mode including exchanging data and commands between the test station and the electronic device microcomputer to functionally test the controller system, wherein the test sequence mode carried out by the test station controller includes; controlling the microcomputer to sequentially exercise spa controller functions, including controlling the microcomputer to activate the at least one switch or relay to cause AC line voltage to be applied to at least one terminal connector and to a corresponding AC line voltage load connected to a corresponding test station terminal connection by the emulation module; and measuring voltage and current parameters of the controller board, including a current drawn by the controller board at a time in which the at least one switch or relay is activated to apply AC line voltage to the corresponding line voltage load, to determine whether the measured parameters are within a predetermined range for proper functionality. - View Dependent Claims (12, 13, 14, 15, 16, 17)
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Specification