TESTING METHOD AND SYSTEM

• US 20070233509A1
• Filed: 01/22/2007
• Published: 10/04/2007
• Est. Priority Date: 01/23/2006
• Status: Active Grant

• Current Assignee: Balboa Water Group LLC (Helios Technologies, Inc.)
• Original Assignee: Balboa Water Group Incorporated
• Inventors: Buchman, Jeffrey, Tarpo, James
• Granted Patent: US 8,645,149 B2
• Time in Patent Office: Days
• US Class Current: 324/600
• CPC Class Codes: G01R 31/2836 Fault-finding or characterising G01R31/2822 - G01R31/2831 take precedence
• CPC Class Codes: G01R 31/50 Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections testing of sparking plugs H01T13/58
• CPC Class Codes: G01R 31/54 Testing for continuity

Abstract

A method and system for functionally testing units under test, such as electronic controller boards for a spa system.

Claims

1. A method for functionally testing an electronic device configured for electrical connection at respective terminal connectors to a source of line voltage, to one or more controlled line voltage load devices and to a panel control for inputting user commands in normal use, the method comprising:

electrically connecting the electronic device at the respective terminal connectors to corresponding test station terminal connections on a test station;

with the test station in an interface check mode, automatically measuring impedances at said test station terminal connections with the test station to determine whether the electronic device is properly connected to the test station by comparing the measured impedances to expected impedance values;

preventing application of line voltage through the test station to the electronic device unless the device terminal connectors are properly connected to the corresponding test station terminal connections;

entering a test sequence mode comprising a test in which electric power is applied to the electronic device to determine functional operation of the electronic device.

2. The method of claim 1, wherein the test sequence mode includes sequentially exercising electronic device functions and measuring voltage and current parameters to determine whether the measured parameters are within an predetermined range for proper functionality.

3. The method of claim 1, further comprising issuing a test report electronically which indicates results of the test sequence and a pass or fail function test status.

4. The method of claim 3, wherein the test report is transmitted electronically via an internet connection to a remote server maintained by a manufacturer of the electronic device.

5. A method for establishing warranty status of a previously fielded electronic device, comprising:

electronically capturing an identification information on the electronic device;

entering the captured identification information in a computer algorithm to perform a warranty check on the electronic device to determine whether the electronic device is within a predetermined warranty period;

if the electronic device is within the warranty period, issuing a manufacturer return material authorization (RMA) authorizing return of the electronic device to a repair depot or to a manufacturer.

6. The method of claim 5, wherein the identification information is encoded in a bar code pattern, and the algorithm includes decoding the bar code pattern to determine a warranty period expiration date for the electronic device, and determining that the electronic device is subject to a manufacturer warranty if the expiration date has not passed.

7. The method of claim 5, wherein the identification information includes a serial number and a date of manufacture of the electronic device.

8. 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 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 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, 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;

preventing application of 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;

entering a test sequence mode comprising a test in which line voltage is applied to the electronic controller board.

9. The method of claim 8, wherein the test sequence mode includes sequentially exercising the controller board functions and measuring voltage and current parameters to determine whether the measured parameters are within an predetermined range for proper functionality.

10. The method of claim 8, further comprising issuing a test report electronically which indicates results of the test sequence and a pass or fail board function test status.

11. The method of claim 10, wherein the test report is transmitted electronically via an internet connection to a remote server maintained by a circuit board vendor.

12. A method for establishing warranty status of a previously fielded spa controller board, comprising:

electronically capturing an encoded bar code pattern on the controller board;

entering the captured encoded bar code pattern in a computer algorithm to perform a warranty check on the spa controller board to determine whether the controller board is within a predetermined warranty period;

issuing a manufacturer return material authorization (RMA) for the controller board authorizing return of the controller board to the manufacturer.

13. The method of claim 12, wherein the algorithm includes decoding the bar code pattern to determine a warranty period expiration date for the controller board, and determining that the board is subject to a manufacturer warranty if the expiration date has not passed.

14. The method of claim 12, wherein the bar code pattern determines a serial number and a date of manufacture of the electronic device.

15. A test station for functionally testing spa controller boards for a spa system, the controller board configured for electrical connection at respective terminal connectors to a source of line voltage, to one or more controlled line voltage load devices and to a spa panel control for inputting user commands, the test station comprising:

a test station controller including a display;

test station terminal connections adapted for electrically connection to the controller board at the plurality of terminal connectors of a spa controller board;

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;

and wherein the test station controller is adapted, with the test station in an interface check mode, to automatically measuring impedances at said test station terminal connections with the measurement instrument to determine whether the controller board is properly connected to the test station by comparing the measured impedances to expected impedance values, and to prevent application of line voltage through the test station to the controller board unless the controller board terminal connectors are properly connected to the corresponding test station terminal connections.

16. The system of claim 15, wherein the test station controller is further adapted to carry out a test sequence mode comprising a test in which line voltage is applied to the controller board to functionally test the spa controller board.

17. The system of claim 16, wherein test station controller is further adapted when in said test sequence mode to sequentially exercise the controller board functions and measure voltage and current parameters to determine whether the measured parameters are within an predetermined range for proper functionality.

18. A test station for functionally testing electrical circuit board systems, wherein a circuit board system is configured for electrical connection at respective terminal connectors to a source of line voltage, to one or more controlled line voltage load devices and to a panel control for inputting user commands, the test station comprising:

a test station controller including a display;

test station terminal connections adapted for electrically connection to a circuit board system under test (UUT) at the terminal connectors of the UUT;

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 of the UUT in normal use;

and wherein the test station controller is adapted, with the test station in an interface check mode, to automatically measure impedances at said test station terminal connections with the measurement instrument to determine whether the UUT is properly connected to the test station by comparing the measured impedances to expected impedance values, and to prevent application of line voltage through the test station to the UUT unless the terminal connectors of the circuit board system are properly connected to the corresponding test station terminal connections.

19. The system of claim 18, wherein the test station controller is further adapted to carry out a test sequence mode comprising a test in which line voltage is applied to the UUT to functionally test the UUT.

20. The system of claim 19, wherein test station controller is further adapted when in said test sequence mode to sequentially exercise the UUT functions and to measure voltage and current parameters to determine whether the measured parameters are within an predetermined range for proper functionality.