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Hole diameter and placement relative to the pin diameter and pin deflection must be optimized. A nearly vertical pin might be assigned a hole diameter just slightly greater than its shaft diameter. This clearance balances avoidance of friction against pointing accuracy during testing. Other pins of the FIGURE 37.12 Test point staggering. same diameter that are highly tilted will require a slightly larger hole to avoid binding. The fixture adjusts drill sizes for each hole, depending on the amount the pin is deflected. This maintains pointing accuracy while eliminating pin binding. Hole locations may also be shifted slightly to compensate for the fact that the pin is pointed at an angle and that the point of contact will not be at the center of the hole. The result is a more reliable test fixture. Test program output With all pins fully mapped to grid locations, the test program file can now be constructed and saved. Tooling The last step in data preparation requires the marrying of the job being processed with the tooling. The tooling includes tooling to the test system and tooling for the specific fixture design utilized. Fixture file outputs The completed CNC files for fixture drilling and fabrication can now be created and the test fixture prepared.

Data Formats Modern circuit boards are designed using CAD systems These systems output data files used by the board shop to generate phototools, drill files, routing patterns, and other tools used to fabricate the boards While several standards have been developed for data outputs from this process that can provide useful data input to the final test process, adoption has not been universal As a result, test engineers and software providers have developed means of hijacking and converting the photoplot data stream, and can use this to drive the test process with certain compromises and a degree of inconvenience Both approaches are discussed in the following text 37531 Gerber Format Data Extraction The primary example of hijacked photoplot data arrives in Gerber photoplotter format Even here a standard was eventually developed RS-274X is a standard that affords a degree of consistency to the photoplotter files.

This data stream is a series of drawing commands that direct the photoplotter in drawing the copper patterns for each layer of the board The drawing is made with a selection of apertures that define different pen tip shapes and dimensions Thus a fine line is drawn by choosing a small aperture, issuing a light-on command, and directing a moveThese data are contained in a very large set of files, containing a picture of each layer of the board Combined with a drill file and aperture definitions, the appropriate information for generation of fixture and test program files is present, but a considerable amount of processing is necessary to develop understanding of layer-to-layer connectivity and finally identify test targets Although the standardization of Gerber data has been improved with efforts such as RS274X, it remains a data format originally optimized for the purpose of photoplotting and not for testing.

CAD system developers and board designers have a great degree of freedom in how they design board features and in how these features are represented in Gerber As a child will readily demonstrate, many different sequences can be used to draw even simple shapes A rectangle might be created by flashing a square pattern, or might be created by an elaborate spiral using a much finer aperture, a zigzag pattern, or a sequence of overlapping flashes This variety leads to occasional errors, because it is difficult for any Gerber extraction routine to be capable of handling all possible permutations The software system must successfully interpret any of these examples (and many others) as defining the same intact square area of copper conductor pattern on the final product Some methods result in huge file sizes..

Read the signal pulse length from the radio receiver (500 to 2,500 ms). Convert it to a number going from -127 to 0 to +127. Multiply by two to get full-scale operation. Set the direction of the motor from the value sign. Run or position the motor. Loop, and do it again.

Despite these problems, this method is far superior to self-learning, digitizing, or drill file extraction, and remains in common use in a variety of software packages. The data requirements to start from this format include:

Photoplot files for each layer, solder mask layers, etc. Photoplot files for silk screen legend(s) (required for computer-aided repair) Aperture file Drill file Board outline

37.5.3.2 CAD/CAM Data Extraction Method. Recognizing the problems inherent in photoplot extraction, system vendors have agreed to add support for test-oriented output formats, in particular IPC-D-356 and 356A. These formats provide data in a much more readily digested format, and eliminate most ambiguities in processing the data. These formats include the following data:

Signal ID, network name, and/or network number Reference designator or PIN number (e.g., U14, 12, R11) for the related component on board X-y coordinate of pad center (minimum data set requirement if grouped as connected) Pad dimensions relative to the center, and size of the hole (if any) Resistor or other component values (if appropriate and not usual) Board side (top or bottom) Mid-network flag suggesting that test point placement may not be required.