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A PRIMER FOR PRODUCT TESTING

by George Martin

Start ı FCC-Mandated Tests ı Meeting the UL Specification ı When Options Make Sense ı Sources and PDF

For the first time in a while, unemployment is low, stocks are chugging along, and embedded systems are popular. Life is good.

I hate to be the person who brings good times to an end, but I need to talk about product testing. Itıs not exciting, but if I cover some basics, youıll be pointed in the right direction and perhaps the good times will last longer.

Iım also hoping that some of you will post your testing issues in the Circuit Cellar newsgroups. That way, we all get a chance to learn, and the dialogue will go both ways.

SETTING THE STAGE

Much of my design work is contracted with smaller (leaner-and-meaner) start-up companies. The products are new, not just replacements for existing devices. As a result, often when I ask about testing requirements, I get answers like, "I donıt know, but we do want to build a good unit." And, because manufacturers have little or no established competition with similar products, they canıt ask, "Whatıs the competition doing?"

In contrast, larger, more established companies have defined testing plans, and the cost is included in management-approved budgets. These companies determine customer and government requirements and the testing needed to meet those standards. They understand the ultimate cost of not testing properly.

For example, remember Texas Instrumentsı home computer from the ı70s? It was recalled because the external transformers started fires. With no intention to slam TI, my guess is that the company probably overlooked some testing. It wasnıt long after the recall that TI pulled out of that market. Iım sure there were many reasons for TIıs exit, but the transformer issue couldnıt have helped.

Regardless of whether youıre working with big or small companies, remember that the level of performance and low failure rates in todayıs electronics are remarkable. The performance bar is set high and is constantly being raised.

Itıs foolish to think you can put a design together and get to market without thorough testing. If your design ships with a defect, your users will find it. Youıll waste money trying to recover and may permanently damage your productıs reputation. A good test plan ensures that your design will hold up in the customerıs hands.

Let me start by listing some of the tests that are required, then Iıll describe some of the tests that are easy to perform in-house, and finally, propose a newsgroup forum where you can add your two cents about other tests that might be valuable to other manufacturers.

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