Mass InterConnect Solutions …creating order out of wiring chaos Introduction to Mass Interconnects David Rocker Director of Engineering

The contract was signed on June 5, 1943 Product History ENIAC was designed and built to calculate artillery firing tables for the U.S. Army's Ballistics Research Laboratory. The first problems run on the ENIAC however, were related to the design of the hydrogen bomb. The contract was signed on June 5, 1943 The computer was programmed by inserting patchcords into patch panels in different configurations to accomplish different tasks.

VPC - Patchpanel Founded in 1959 as a licensee of International Business Machines (IBM) to manufacture and distribute programmable patch panels for computers On display at: The New York Museum of Modern Art

What is Mass Interconnect? …creating order out of wiring chaos A mass interconnect system is a mechanical fixture designed to easily facilitate the connection of a large number of signals either coming from or going to a DUT. Problem Solution

What is Mass Interconnect? Frequent DUT/UUT Changeover Rapid connection to multiple UUTs Simplified System Wiring Flexible, Configurable, Expandable Intense Mating Cycle Requirements Reliability to over 20,000 mating cycles Standard interface platform – Easy to configure, maintain and support Extremely cost effective ~ built in expandability Flexibility - Pre-designed PCB/cabling solutions (off the shelf) Allows quick fixture (UUT) changeover Reliability - Supports thousands of connections and connector mating cycles Extends the life of your expensive test instruments Mass interconnect systems are most often required in the following circumstances: Frequent DUT changeover: If a test system has been designed to handle the requirements of multiple DUTs (each having different connection requirements), there is no quicker way to change out the signal connections than with a mass interconnect system. Whether the DUT requires a small or large number of connections, a mass interconnect system can usually make all of those connections from one ITA to another in a matter of seconds with a simple lever. Many manufacturing test platforms are designed using a standard set of instruments and full-crosspoint matrix switching so that any instrument can be connected to any testpoint, allowing just about any DUT to be connected to the equipment set. All of the custom wiring is done in the ITA enclosure to accommodate the specific requirements of the DUT, and many different DUTs could be used with the same instrument set. Intense mating cycle requirements: All interface connectors (small or large density) have a recommended maximum mating lifetime. For Dsub connectors, this might be 500 to 1000 cycles before signal integrity can no longer be guaranteed. For RF connectors like SMAs or SMBs, the number is much smaller, and the effect of a damaged connector can be crippling to a high-frequency instrument. In this way, a mass interconnect can preserve the life of test equipment by providing an interface with many thousands (often >20,000) of rated connections. The connection on the instrument side is only made once – from the instrument to the receiver module – while the DUT can be frequently connected or disconnected through the ITA-receiver mate. Even if the receiver modules experience pin failure or compromised signal integrity, this is still far less expensive to replace in most cases than the instrument itself. Simplified system wiring: At its most basic level of function, a mass interconnect system can force some cleanliness in the wiring connections made in a test system. By routing all connections through a common interface, wires are better maintained and less likely to get caught in hinges, pulled out of screw terminals, or stripped. Designing a mass interconnect into a system can often greatly reduce the amount of debug time needed based on these factors alone. DUT = Device Under Test UUT = Unit Under Test

Mass InterConnect Components ITA Patchcords Enclosure ITA Module ITA Cable Assembly Receiver Module Receiver Receiver Patchcords Vertical Hinged Mounting Frame For automated test systems, this usually entails some mechanical enclosure through which all signals are routed from instruments (typically in a rack) to the DUT, making it easy to quickly change out DUTs or to protect the cable connections on the front of the instruments from repeated connect/disconnect cycles. There are several major components of a mass interconnect system: Receiver The receiver is the “instrument side” of the mass interconnect, housing pin modules or bulkheads that expose each of the instrument, switch, power, or vacuum connections. Mounting Hardware Mounting hardware holds the receiver on the front of the rack. It is typically mounted on the front side of the rack with easy access to the test operator. Oftentimes, the mounting hardware will have a hinge on it to allow easy access to the instruments or cables behind the receiver. Receiver Modules The receiver modules expose the instrument, power, or vacuum connections through appropriate pins or other connectors inside the receiver. These are typically specified according to the density, bandwidth, current, or special-purpose requirement of the signals being passed through them. Cable Assemblies/Interface Boards The cable assemblies/interface boards offer a means of connecting the front of the test instruments to the receiver modules. With cable assemblies, standard cables are connected from the instruments either directly to pins in the receiver modules or to interface boards connected to the receiver modules. There are also interface boards available that connect directly from mass connectors (DIN, Dsub, SCSI, etc.) on the front of the instruments to the receiver modules. These offer the advantage of minimizing the signal length between the receiver module and the instrument but are rigid and therefore require precise, inflexible mounting locations. Interchangeable Test Adapter (ITA) The ITA is the main mechanical mate to the receiver. It is the “DUT side” interface that houses the modules/cables that will interface to the connections on the DUT. In many test systems, one receiver system can be connected to several different ITAs, each ITA having a different enclosure, cables, and DUT attached to it for rapid changeover of a test system requirements. ITA Cables/Modules ITA Cables/Modules The ITA modules are mounted inside the ITA in much the same way the receiver modules are mounted inside the receiver. They provide the main interconnect with the different signals coming through the receiver and expose those connections through cables, PCBs, or other connections inside the enclosure. Enclosure The enclosure is the mechanical housing around the ITA and the corresponding ITA cables/modules. It is often a physical platform on which to set the DUT, as in a bed-of-nails application. When all these components are fitted together, the test operator should have a simple way of connecting all the test points in the system to a device under test in a quick, orderly manner. ITA, Individual Test Adapter, “Adapts” tester to be capable of testing multiple UUTs From the instrument to the UUT — and everything between!

VPC Maximizes the ROI for Test Assets By Preventing Damage to Valuable Test Instrumentation Test Instrument Card ($Valuable Test Instrumentation) Delicate Commercial Connector VPC Systems are designed for 20,000 cycles specifically for Test Applications Protect Valuable Test Instrumentation (Local Language)

Communication System ITA VPC Maximizes the ROI for Test Assets Quickly and Easily Adapting Tester to be Capable of Testing Multiple UUTs Navigation System ITA Communication System ITA Individual Test Adapter ITA “Adapts” tester to be capable of testing multiple UUTs Weapons System ITA Standardized Test Interface (Local Language)

Mass InterConnect Deployment Test and Measurement Applications Defense Aerospace Automotive Medical Contract Manufacturing High Volume Testing Environments Standard interface platform – Easy to configure, maintain and support Extremely cost effective ~ built in expandability Flexibility - Pre-designed PCB/cabling solutions (off the shelf) Allows quick fixture (UUT) changeover Reliability - Supports thousands of connections and connector mating cycles Extends the life of your expensive test instruments

Aerospace Symtx • 50 Module Solution Functional testing of satellite bus electronics circuit card assemblies, part of a command and control subsystem in commercial & military satellites Verify and troubleshoot any one of a dozen assembly types at the card level, prior to box level integration and further functional testing The test system uses VXI switching chassis and instrumentation and a high performance VPC 9050 - 50 module receiver interface panel to accommodate a variety of test adapters on a single test system www.symtx.com

Automotive Konrad Technologie GmbH • G12 Solution G12 Mass InterConnect acts as the interface between Open Test Platform (OTP) and the device-under-test (DUT). Using a variety of Agilent hardware and software, including the new 34980A Multifunction Switch/Measure unit as the system core, the OTP is flexible and scalable to allow expansion for new test requirements. With cable assemblies specific to each modular instrument used in the Agilent 34980A, as well as power and pneumatic connections, the G12 provides a reliable and repeatable interface designed to withstand over 20,000 mating and unmating cycles. Innovative QuadraPaddle modules enable consolidation of as many as 192 signal points in a single receiver slot and 480 signal points in 2 receiver slots. www.konrad-technology.com

FTS-200 from Cal-Bay Systems Medical Device Testing Functional Test System for Low-Volume High-Mix Production and Design Validation Test Computer-based instrumentation hardware with bandwidth up to 200 MHz Mass-interconnect test fixture interface from Virginia Panel Test execution software based on industry standard LabVIEW and TestStand application development environments www.calbay.com 

Instrumentation “loop back” Boeing Commercial Airplane – 787 Program Fixed Patch Panels Tester design was implemented in previous HUD test applications ~ modernized (PXI based) In this design, Honeywell designed QP/PCBs are implemented to reduce the “rats nest” of wiring in the previous design Fixed patch panels are used for fault induced simulation VPC ~ 90 Series (25/50 module) are used to direct the instrumentation and other assets Consoles shipped for use at Rockwell Collins (Cedar Rapids) and Boeing, Seattle. HUD Test Console VPC 9050 VPC 9025 Instrumentation “loop back”

I/O in Modules Analog Signal • Digital Signal Coax / RF • Fiber Optic Power • Thermocouple Pneumatic • Vacuum Variety of Input and Output connections are possible in the modules

About VPC Founded in 1959 as a licensee of International Business Machines (IBM) to manufacture and distribute programmable patch panels for computers Designs, manufactures and markets Interconnect products for Test and Measurement applications in both commercial and military markets. Standard interface system for the United States Air Force Modular Automated Test Equipment Program (MATE) United States Navy standard electrical interface for the CASS Program Standard for the Interface Connector Assembly (ICA) used in commercial air transport testing (ARINC 608A committee) First to offer the most comprehensive connector interface for VXI

Virginia Panel Corporation For over 47 years, VPC has Provided highest quality and most innovative Mass Interconnect Solutions on the market Aligned closely with Test & Measurement partners to develop and support standards Designed new interconnect products with lower profiles & higher densities to solve dynamic test requirements

Summary Simplified Cable Management (Local Language) Protect Valuable Test Instrumentation (Local Language) Standardized Test Interface (Local Language) VPC Mass Interconnects offer the lowest total cost of ownership over the life of your test system (Local Language)