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Keysight Technologies
Testing Automotive Fuse
Boxes with i1000D SFP
In-Circuit Test System




                          Application Note
Introduction

   The fuse box inside the car is the only part that connects to every
   electric feature - the lights, the engine, the transmission, and the
   audio. This fuse box, comprising a board with a bunch of fuse
   seems to be simple, but it is definitely critical for the smooth
   running of all the cars on the street. The Keysight Technologies,
   Inc. i1000D small footprint (SFP) inline in-circuit tester is designed
   to test it with the best fit of features.

   Inside this little black box is an array of colorful fuse plugs
   inserted in terminals mounted on a printed circuit board. Each
   fuse is color-coded to represent its specifications. A fuse board
   is not a complicated circuit to comprehend. Basically, it's made
   up of a bunch of fuse terminals, each soldered and connected on
   the printed circuit board. There will be some passive components
   like resistors, capacitors and diodes mounted as well, but nothing
   complex.

   However, it is not as easy as it seems when it comes to testing
   this board. Being one of the critical components in a vehicle,
   a simple board like this does warrant some serious test
   requirement considerations. Let's begin with a look at a typical
   manufacturing line setup.
Typical fuse box manufacturing process


   Plastic Molding




       SMT               Board level Test        AOI testing              Assembly




                          Final assembly       Functional Test         Fuse placement




                                                                     Cover Laser marking




The process begins with surface mounting of the components and fuse
terminals onto the printed circuit board. The printed circuit board is usually built
in a panel of multiple boards to cater for lower manufacturing cost.

The assembled circuit boards then get to their first test station where they are
tested at Board level. At this stage, none of the fuse plugs are inserted yet. So
the board simply contains only some components and a lot of fuse terminals.
Testing at this stage basically ensures that the printed circuit board is in good
condition before the rest of the parts are installed.

After passing the Board level test, fuse plugs are then inserted along with
the rest of the components and plastic parts. The unit then move onto the
Functional test station to undergo a more detailed test for the inserted fuses
and parts.

Finally, when the unit passes the Functional Test, it is then boxed up and
marked.




                                                                 3
Inspection and Test Strategy

Fuse box manufacturing test requirements
 

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