Tongxing FCT Solution Drastically Reduces PCBA Outgoing Defect Rate

During high-volume production of automotive controllers, each PCBA (Printed Circuit Board Assembly) must undergo FCT (Functional Circuit Test) before vehicle installation. This involves comprehensive functional validation under powered conditions, simulating real-world operating environments and electrical loads to detect electrical defects and prevent faulty units from entering the vehicle assembly line. Tongxing’s FCT solution leverages the TSMaster software platform and in-house developed high-performance hardware to create an end-to-end automated test system covering the entire workflow: “Flashing → Stimulation → Verification → Traceability.” At the software level, it supports automated test sequences, UDS Bootloader flashing, CAN/LIN/FlexRay bus monitoring, and seamless integration with MES systems. The hardware layer includes proprietary DI/DO/AI/AO/PWM signal boards, bus interface cards, programmable power supply modules, and customized fixture needle beds. This solution delivers six core testing capabilities: 1. **Multi-mode Program Flashing**: Fully automatic UDS Bootloader flashing for mainstream chip platforms, completing both Bootloader and Application program flashing in a single operation. 2. **Mixed-signal Simulation and I/O Testing**: High-precision boards simulate sensor signals such as voltage, frequency, and PWM, while verifying the PCBA’s output logic. 3. **Automated Bus Communication and Diagnostics**: Automatically executes DTC reading/clearing, DID reading, security access verification, and bus stability monitoring. 4. **Power Supply and Power Load Testing**: Simulates voltage fluctuations and transient surges under 12V/24V power conditions to test static/dynamic current consumption and thermal stability, identifying issues like cold solder joints or defective driver ICs. 5. **Fault Simulation Testing**: Emulates faults such as open circuits, short circuits, and sensor failures to validate accurate DTC reporting and protective mechanisms. 6. **End-to-end Data Traceability**: Test data is uploaded in real time to MES systems, linked to barcode identifiers for full-process traceability, meeting automotive-grade quality management requirements. The solution has already been successfully deployed in two representative scenarios: - **Rotating Center Console Display Controller FCT**, covering display interfaces, encoder signals, CAN communication, and power management; - **Swappable Seat Controller Testing**, integrating high-current load testing and LIN bus diagnostics to effectively identify driver circuit defects. Built on an architecture combining industrial PCs (IPCs), TSMaster software, and specialized hardware boards, this FCT system offers one-stop integration, high-precision signal acquisition, multi-bus protocol compatibility, seamless MES connectivity, and modular, rapid deployment.