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Department of Electrical Engineering Development of Test Equipment Department of Electrical Engineering Institutionen för systemteknik Bachelor of Science Thesis Development of Test Equipment Based On Boundary Scan to Analyze Camera Systems for the Car Industry Bachelor of Science Thesis in Electrical Engineering At Linköping Institute of Technology at Linköping University By Linus Jansson and Simon Jonsson LiTH-ISY-EX-ET--16/0453--SE Linköping, 2016 Department of Electrical Engineering Linköpings tekniska högskola Linköping University Institutionen för systemteknik SE-581 83 Linköping, Sweden 581 83 Linköping Bachelor of Science Thesis in Electrical Engineering Development of Test Equipment Based On Boundary Scan to Analyze Camera Systems for the Car Industry Authors: Linus Jansson and Simon Jonsson LiTH-ISY-EX-ET--16/0453--SE Supervisors: Maria Christensen Autoliv Electronics AB Håkan Prytz Autoliv Electronics AB Arta Alvandpour ISY, Linköping University Examiner: Dr. J Jacob Wikner ISY, Linköping University Division of Integrated Circuits and Systems Department of Electrical Engineering Linköping University SE-581 83 Linköping, Sweden Copyright 2016 Linus Jansson and Simon Jonsson Abstract Testing a PCB assembly can be very time consuming due to its complexity and compactness. Tests are desired to be consistent and test coverage should be as high as possible, which is perfect for automated testing software. This thesis intends to develop computer controlled tests of faulty PCB assemblies using boundary scan, which is meant to quickly locate the error so that an analysis engineer can evaluate it and prevent it from happening in future versions of the product. Boundary scan is even able to test the inner circuitry. Testing with boundary scan has been around for quite some time, but in recent years it has shown to be truly valuable and time saving, due to the increasing complexity of PCB assemblies. The conclusions reached in this study are promising for future tests and development of PCBs using boundary scan, which has shown to be quite the powerful tool. v vi Sammanfattning Att testa kretskort kan ta lång tid då de kan vara väldigt komplexa och kompakta. Det krävs att testningen är konsekvent och att testtäckningen är så hög som möjligt, något som är bra lämpat för automatiserad testningsmjukvara. Denna kandidatrapport handlar om hur man utvecklar ett datorstyrt system för att testa kretskort med hjälp av boundary scan, vilket används för att snabbt hitta ett fel, så att en expert kan ta hand om felet och förhindra det i framtiden. Boundary scan kan till och med användas för att testa inre kretsar. Boundary scan har funnits under en längre tid, men det är under de senare åren, när kretsar blir mer och mer avancerade, som det har visat sig vara väldigt värdefullt. Resultaten från den här studien är lovande för framtida studier inom testning och utveckling av kretskort med hjälp av boundary scan, vilket har visat sig vara ett väldigt kraftfullt verktyg. vii viii Acknowledgments We want to thank the quality and hardware department at Autoliv Electronics AB in Linköping. Special thanks to Maria Christensen and Håkan Prytz for being our supervisors at Autoliv during this project, and technology specialist Sten D. Iversen at EP-TeQ for helping us preparing and setting up the software tools. We also want to thank Jacob Wikner at ISY, Linköping University, for being our examiner. ix x Table of contents List of figures ................................................................................................................ xiii List of tables .................................................................................................................... xv Notations ....................................................................................................................... xvii 1 Introduction ............................................................................................................... 2 1.1 Motivation ........................................................................................................... 2 1.2 Purpose ................................................................................................................ 3 1.3 Problem statements ............................................................................................ 3 1.4 Research limitations ........................................................................................... 4 1.5 Thesis outline ...................................................................................................... 5 2 Background ................................................................................................................ 6 2.1 Features ................................................................................................................ 6 3 Theory ....................................................................................................................... 12 3.1 Boundary scan .................................................................................................. 12 3.1.1 Architecture ................................................................................................. 13 3.1.2 Boundary scan testing ................................................................................. 15 3.1.3 Boundary scan chains .................................................................................. 15 3.1.4 The on-board test access port controller ...................................................... 16 3.1.5 Instruction register ...................................................................................... 20 3.1.6 Data registers ............................................................................................... 21 3.2 Software ............................................................................................................. 22 3.2.1 Boundary scan description language ........................................................... 23 3.3 Hardware ........................................................................................................... 23 3.3.1 Multi-purpose camera unit .......................................................................... 24 3.3.2 In circuit test fixture .................................................................................... 24 3.3.3 Motherboard ................................................................................................. 29 3.3.4 CION measurement card ............................................................................. 30 3.3.5 The external test access port controller ........................................................ 31 3.4 Summary ........................................................................................................... 32 4 Method ...................................................................................................................... 34 4.1 Implementation ................................................................................................ 34 4.1.1 Start up ........................................................................................................ 34 4.1.2 Defining components ................................................................................... 35 4.1.3 Merging boards ............................................................................................ 36 4.2 Virtual tests ........................................................................................................ 38 4.2.1 Different testing methods ............................................................................ 39 xi 4.3 Preparations for the physical test ................................................................... 40 4.3.1 FPGA settings ............................................................................................. 40 4.3.2 Watchdog ..................................................................................................... 41 4.4 Summary ........................................................................................................... 42 5 Results ....................................................................................................................... 44 5.1 Virtual tests ........................................................................................................ 44 5.2 Preparations for physical tests ....................................................................... 48 5.3 Summary ........................................................................................................... 49 6 Discussion ................................................................................................................ 50 6.1 Results ................................................................................................................ 50 6.2 Method ............................................................................................................... 52 6.2.1 Source criticism ........................................................................................... 53 6.3 How to improve test coverage ........................................................................ 54 6.4 The work in a wider perspective .................................................................... 55 6.4.1 Ethical perspective ....................................................................................... 55 6.4.2 Societal perspective ...................................................................................... 56 6.5 Summary ..........................................................................................................
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