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EMC test planning for customers

EMC test planning for customers. 2 April 2004 EMC Compo 04 Kimball Williams – IEEE President. Introduction. Objectives of the workshop Test objectives Test system description Test scheduling Hardware preparation Software considerations Pass / fail criteria Time frames for preparation

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EMC test planning for customers

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  1. EMC test planningfor customers 2 April 2004 EMC Compo 04 Kimball Williams – IEEE President

  2. Introduction • Objectives of the workshop • Test objectives • Test system description • Test scheduling • Hardware preparation • Software considerations • Pass / fail criteria • Time frames for preparation • Statistical considerations • Test variations • Records requirements • Running a test • Data reduction and analysis • Reporting the results

  3. Test Objectives • Givens: • Who / Where / When / How / What / Why

  4. Test Objectives • Givens: • Customer’s point of view • Find out what your customer wants • “Pass” a required test • Validate a design • Correct an EMC ‘problem’ • Gather data.

  5. Test Objectives • Givens: • Customer’s point of view • Laboratory’s point of view • Provide accurate test data • Mitigate the design when needed • Conclude the test on schedule

  6. Test Objectives • Givens: • Customer’s point of view • Laboratory’s point of view • Mutual agreement: • Understand the customer’s requirements • Plan to address his major needs • Enlist his help in the required preparation • The test plan can assist in this process

  7. Test System Description • EMC lab equipment used for test • Customers equipment • Combined “official test” and Customer’s equipment – diagram • Justification of ‘modifications’ • Verify EMC lab equipment function • Get customer’s agreement

  8. Test scheduling • Flexibility • Equipment (calibration / breakage / otherwise occupied / ….) • Test engineers & technicians (vacations / illnesses / Dr. appointments / etc. ad infinitum…. • Customer’s equipment (working prototypes that don’t work / critical components that do not get delivered / development engineers that go on vacation / ….

  9. Test scheduling • Flexibility • Communications: Contact between the customer and test lab is critical

  10. Hardware Preparation • EMC laboratory “first systems test” • Development engineers accompany unit to lab for ‘first’ test • Initial setup • Working modes • Power and grounding issues • Cables / connectors / adapters • Setup considerations if multiple units are to be tested • Support hardware • Equipment operation “cycle time”

  11. Software considerations • Operational vs test software • Test “cycle time” implications • Emissions test requirements (scan speed) • Effects on emissions signature • “Missing” time pulsed emissions • Immunity test implications • “Fail-safe” or “Limp-home” modes • Special ‘fast recovery’ test software • Concerns about the validity of tests with special software (hardware / shadowing) • Start this process EARLY!

  12. Pass / fail criteria • “Fail?” ! “My product fail?” • Emissions pass / fail – set? • Design engineers are focused on success (form/fit/function), not failure • Defining a failure mode is alien and they may need help • Again…ask this question EARLY

  13. Time frames for preparation • As early as possible • Life after a successful prototype demo • Documents to support testing • Schematics • parts lists • systems drawings • Software flow charts • ck-lists

  14. Time frames for preparation • First discussions – immediately after tests are scheduled • First “demo” the operation of equipment (In the EMC lab) – minimum of one week before tests • Full documentation supporting tests at a customer / lab staff meeting

  15. Statistical considerations • “I want 100% test certainty” • ISO 17025: “…data applies only to the device tested…” • Measurement uncertainty (A / B / Z)

  16. Test variations • Contingency planning • What to do when things go wrong • Recovery strategies • Back up plans • Brainstorming sessions • Standard brainstorming methods • Involve your customer • Follow up on ‘most likely’ ideas

  17. Records requirements • Normal records • Test plan • Test records (data sheets) / notebooks / etc • Test matrix (Link to all other records) • Transducer data • Statistical process control records • Abnormal records • Modified test setup diagrams • Verification tests of modified setups

  18. Running a test • Follow the plan! • Carefully put together the plan • Use its ‘tracking’ features • Deviate only with full knowledge of customer • Hand modifications as needed. • Changes required • Reference documents • Rational for changes • Customer ‘by-in’

  19. Data reduction and analysis • Dealing with the volume of data • Filing system described in the ‘plan’ • Pre-planned locations for everything • Representative data set aside for the ‘report’ • File everything else – ‘just in case’ • Customer has the ‘right’ to have it all if he wants it

  20. Reporting the results • ISO 17025 format • Company requirements • Certification agency requirements • Don’t make it dull! • However, if your management requires ‘dull’ reports – at least put your excitement into your presentation!

  21. Thank you! Questions?

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