<![CDATA[S5 Solutions | LabVIEW, ATE, Test Engineering Services - Blog]]>Mon, 27 Apr 2026 15:23:18 -0700Weebly<![CDATA[Boost Your Manufacturing Automation and Intelligence]]>Tue, 20 Jun 2023 22:14:19 GMThttps://www.s5solutions.com/blog/boost-your-manufacturing-automation-and-intelligence
Manufacturing Automation & Intelligence refers to the application of technology and data-driven solutions in the manufacturing industry to improve efficiency, quality, and profitability. It involves the integration of advanced technologies to automate manufacturing processes and make them more intelligent.
Manufacturing automation aims to minimize human intervention in the manufacturing process, reduce manual errors, and optimize productivity. It involves the use of automated machinery and software systems to perform tasks such as assembly, inspection, packaging, and quality control. Automation helps manufacturers to streamline their operations, reduce costs, and increase production speed and output.
Intelligence in manufacturing refers to the ability to collect, analyze and apply data to make informed decisions that improve the manufacturing process. Manufacturing intelligence is achieved through the use of algorithms that process large amounts of data in real-time to optimize production. By leveraging data from instruments, hardware, sensors, cameras, and other sources, manufacturers can gain insights into the performance of their equipment, identify potential issues, and make decisions that improve production efficiency.

Automation provides the foundation for intelligence by automating repetitive tasks and allowing for data collection. Intelligence, in turn, uses the data collected by automation to optimize production and improve decision-making.
Manufacturing automation and intelligence have several benefits for manufacturers, including increased efficiency, reduced costs, improved quality, and increased flexibility. By automating production processes, validation, and verification testing, manufacturers can reduce their reliance on manual labor and improve their output. By leveraging data to make informed decisions, they can reduce waste, optimize their supply chain, and improve product quality.

Overall, manufacturing automation and intelligence are essential for companies looking to remain competitive in today's fast-paced business environment. S5 Solutions can help. Tell us about your engineering project and let's get started!
]]><![CDATA[Enhancing Product Reliability with Bed of Nails Testers]]>Wed, 24 May 2023 22:48:45 GMThttps://www.s5solutions.com/blog/enhancing-product-reliability-with-bed-of-nails-testers
Bed of Nails Tester Basics
In the world of test engineering, specifically for electronics manufacturing and testing, certain tools, software, hardware, and test systems have become indispensable due to their versatility and effectiveness. One such tool is the "Bed of Nails Tester." This device, despite its intimidating name, plays a crucial role in ensuring that electronic components and circuits function as intended. As a test engineer or manager, you'll need to know the basics of the bed of nails tester, its function, how it works, its components, and why it's such a critical part of electronics testing.
How Does a Bed of Nails Tester Work?
A bed of nails tester operates based on a simple yet effective principle. The tester is equipped with numerous small, spring-loaded pins (the "nails") inserted into holes in an epoxy phenolic glass cloth laminated sheet. These pins are meticulously aligned using tooling pins to make contact with specific test points on a printed circuit board (PCB).

When a PCB is placed on the bed of nails tester, the spring-loaded pins make contact with the test points on the board, creating an electrical connection. This connection allows the tester to run electrical signals through the PCB and monitor the outputs, thus enabling it to check for faults or defects in the board's circuitry.

Function of a Bed of Nails Tester
One function of a bed of nails tester is to conduct in-circuit testing (ICT) - a method used to test individual components on a PCB for shorts, opens, resistance, capacitance, and other basic quantities.

Functional testing is another common use of a bed of nails tester. This type of testing stimulates the PCB as if it was in operation, then monitors all of its capabilities functionally, making sure it works correctly.

In other words, the bed of nails tester allows for an in-depth, component-by-component analysis of a PCB's performance as well as validating proper overall operation. It enables engineers and technicians to identify faulty components or connection issues on the board. In doing so, it plays a key role in quality assurance during the PCB manufacturing process.
Components of a Bed of Nails Tester
A bed of nails tester consists of several key components, including:
  • The Base: The base, or the "bed," is typically made from an epoxy phenolic glass cloth laminated sheet, known as a G-10 sheet. This base houses the pins and provides the structural integrity for the tester.
  • Pins: The pins, or "nails," are spring-loaded pogo pins inserted into holes in the base. These pins make contact with the test points on a PCB. They are available in many varieties capable of probing different PCB features.
  • Tooling Pins: Tooling pins are used to align the test pins accurately with the test points on a PCB.
  • Connections and Measuring: The pins are connected to a data acquisition (DAQ) device for measurement. The pins are wired or connected by by a "wireless" PCB that routes the signals. The DAQ measures the signals to test and analysize the PCB's performance.
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Example pogo pin used to probe a PCB
Understanding Bed of Nails Testing
Understanding bed of nails testing requires an appreciation for its role in the broader process of electronic manufacturing and quality assurance.

When a PCB is manufactured, it's critical to ensure that all the circuits and components on the board are functioning correctly. This can be done with a combination of automated visual inspection, flying probe testing, as well as the more in-depth functional testing that bed of nails tester is able to provide.

By providing a way to make reliable, repeatable contact with multiple test points on a PCB, the bed of nails tester becomes an invaluable tool for manufacturers and test engineers. The tester can quickly identify defective components or connection issues, allowing for rapid corrections and thus ensuring the overall quality and reliability of the final product.

In summary, the bed of nails tester is a powerful tool in the electronics manufacturing industry. By providing a reliable and efficient method for testing the functionality and integrity of PCBs, it plays an essential role in the production of high-quality complex electronic products and devices.
]]><![CDATA[Adapting Existing Test Systems To New Product Variations]]>Mon, 08 May 2023 15:57:42 GMThttps://www.s5solutions.com/blog/adapting-existing-test-systems-to-new-product-variationsAdapting an existing automated test system to fit a new hardware, firmware, or electronic product can be a complex process that requires careful planning and execution.

Here are some general steps to follow:
  1. Evaluate the new product variation: Begin by thoroughly evaluating the new product's specifications and requirements, including any differences or nuances from previous products that may impact the test system.
  2. Identify the necessary changes to the system: Based on the evaluation, identify the necessary changes to the test system hardware, software, and test procedures to accommodate the new product.
  3. Modify the hardware: Modify the test system hardware as needed to support the new product. This may involve adding or replacing components, such as fixtures, connectors, or adapters.
  4. Update the firmware: If the new product has different firmware than previous products, update the test system's firmware to support the new product.
  5. Update the software: Modify the test software to support the new product, including any necessary changes to the user interface, test sequences, and data analysis. This can often require a LabVIEW or TestStand expert.
  6. Validate the changes: Before implementing the changes in production, validate that the updated test system can accurately and consistently test the new product.
  7. Implement the changes: Once the changes have been validated, implement them in production and train any necessary personnel or test engineers on the new procedures.
  8. Test and optimize: Test the new system thoroughly and optimize as needed to ensure efficient and effective testing of the new product.
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Throughout the process, it's essential to communicate with all stakeholders involved, including design and engineering teams, to ensure the test system accurately reflects the new product's requirements and specifications.]]><![CDATA[A Bridge (of the Enterprise) Too Far]]>Wed, 09 Nov 2022 22:21:40 GMThttps://www.s5solutions.com/blog/a-bridge-of-the-enterprise-too-far
User interface design has to balance a number of competing goals, mainly:
  • Functionality
  • Responsiveness
  • Aesthetics

That was  the case with this project for an in-vehicle data collection system. The interface was a touch screen that requires input from the same person driving the vehicle. It was very important that the interface be simple and easy to understand and fast to work with, to keep the driver's eyes on the road.

We started with a typical LabVIEW interface. It worked, but it was a bit boring. It also suffered from being difficult to see. The gray background did not provide much contrast while day driving.
Partly as a search for contrast, and partially because of being huge Star Trek fans, we made a version with the LCARS interface. It has great contrast and it looks really cool. There were some problems, though. The font was hard to read, and some of the graphic elements are more decorative, which just wasted valuable screen real estate.

We took the best elements of LCARS and toned it down a bit to come up with a very functional high-contrast GUI that works great for the drivers.
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]]><![CDATA[The Leaving Edge of Technology]]>Thu, 03 Nov 2022 16:36:28 GMThttps://www.s5solutions.com/blog/november-03rd-2022
​You built a great ATE system, but it’s been a while…maybe a long while.

Is it running LabVIEW 6i?
Maybe still on Windows XP?
Are you scrounging for backup parts on eBay?
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​Don't be embarrassed, we've seen it all. Let's get you upgraded.
]]><![CDATA[Classic NI Software]]>Wed, 02 Nov 2022 01:25:42 GMThttps://www.s5solutions.com/blog/classic-ni-softwareAnother blast from the past. Cleaning the office can be such an adventure. Do you remember the days of the LabVIEW Test Executive? And the introduction of a new product called "TestStand"? Version 1. Compatible with all versions of Windows: NT, 95, and 98!

​Years of projects later, it is fun to look back and remember all the hours I spent using these tools.
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]]><![CDATA[I heard it on the VINE]]>Mon, 31 Oct 2022 20:02:52 GMThttps://www.s5solutions.com/blog/i-heard-it-on-the-vine
By Tony Kuiper

In many projects involving design, we find ourselves conflicted between simplicity and functionality. Machine control and communication between components is not immune to this.

As we were designing a somewhat complex hardware simulator we reviewed the generally available COTS solutions, finding a few that might work well enough, but didn’t quite meet all the requirements for how we wanted the software to be able to interact with the large number of offboard peripherals we needed, or were a bit heavy on the hardware side.
We saw this as a two-fold problem: hardware and software.

Simple hardware communications solutions like I2C and SPI were readily available but lacked the intelligence that smarter communications would provide. RS485 came close with its multi-drop capability, and CANbus fixed the issue of bus contention, however at the expense of additional interface components and cabling considerations, and a significantly heavier firmware load. RS232 was very simple to implement but was only point-to-point.  None of these off-the-shelf solutions really scratched the itch.
Slightly disappointed, we turned to pondering software. Whatever software was required, we knew we wanted to be very light-weight. Something you could run in Arduino Micro/Nano or equivalent.  Something that could self-identify, and could respond to both directed and broadcast traffic.

Then a flash of memory struck - we remembered the Token Ring network of old, now superseded by Ethernet, and soon we had merged the best concepts of hardware and software together to come up with the VINE.

The VINE is a combination of modified RS232 hardware and a Token-passing software method. In normal RS232, both RX and TX lines go between the same two components, but in the VINE, the TX line goes to the next Leaf. The Controller transmits to the first Leaf, who transmits to the second Leaf, etc, until the final Leaf transmits back to the Controller.

Therefore the main magic is in the Token passed around - the message itself. At the front of each message is an address, and when a Leaf on the VINE receives a message, it decrements that address and, when the address reaches a “1”, the Leaf handles that message and responds appropriately. That Token/Message then makes its way back through the rest of the Leaves, being ignored because the Address is now and forever will always be “0”.  

Identification of Leaves on the VINE is simple also, sending out an Address of “*” will cause all Leaves to both forward the broadcast and also respond with their name. Their addressing in the VINE becomes inherent due to the auto-incrementing of response messages by each Leaf.

Thus, with a bit of clever borrowing, we have a self-organizing, virtually unlimited multi-drop network of intelligent nodes, with a human-readable protocol running on an electrically simple interface.
]]><![CDATA[Blast from the Past]]>Wed, 04 May 2022 18:07:49 GMThttps://www.s5solutions.com/blog/blast-from-the-past
I got a blast from the past cleaning up at the office. "The only LabVIEW subscription with VI software included".

​The disks are still attached, but I can't find the opening for them on my laptop.
]]><![CDATA[It Takes Two Weeks to do Anything]]>Tue, 21 Dec 2021 18:32:10 GMThttps://www.s5solutions.com/blog/it-takes-two-weeks-to-do-anything
Estimating is hard. So hard that many engineers don't really try; everything they estimate will take two weeks. Change a button from red to blue: two weeks. Write a specification for a new software feature: two weeks. Build a rocket for human flight: okay, most engineers are smart enough to estimate at least 3 weeks, but you get the point. 
​
Of course, “two weeks” usually isn’t really an estimate at all. So, what do we mean when we say something will take two weeks?
  • “I am a good engineer. I can envision a solution, so I can probably implement it pretty quickly.” But seeing a path is not the same thing as walking that path, yet we fall for this trap easily.​​​
  • “It takes what it takes. Don’t try to pin me down.”
  • ​“My job is engineering. Let the project manager estimate things.”
  • “I have no idea how long it will take, but it won’t be done tomorrow, so go away.”

We’ve probably seen all of these excuses used. We’ve probably used some or all of these excuses.
Estimating is hard, but it is a skill that is very important to your success, your company’s success, and your customer’s success.

What techniques do you use to estimate more accurately?
]]><![CDATA[Simplify]]>Tue, 09 Nov 2021 16:54:34 GMThttps://www.s5solutions.com/blog/simplify
I love it when I’m working on a project and pieces fall into place that make it simpler. It is almost always a surprise. I am struggling through a problem, adding layer upon layer of complexity to try to handle issues, as engineers love to do. Then all of a sudden, something dials in. Sometimes it almost seems like the problem solved itself -- maybe it did, but my engineering ego still wants the credit. :) Let’s call it a team effort.
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