Test System with Test Trays and Automated Test Tray Handling

Abstract

A test system may be provided in which devices under test are loaded into test trays. Each test tray may include clamps for retaining a device under test within the test tray. The test tray may be configured to transmit test tray identification information to facilitate tracking of the device under test associated with the test tray. The test tray may include engagement features configured to receive corresponding engagement features on a computer-controlled loading arm. The loading arm may be used to move the test tray and associated device under test to a test fixture for testing. A contact extending structure may be retained in the test tray and may be configured to mate with the device under test. Contact pads on the contact extending structure may be mated with corresponding contacts on the test fixture to form an electrical connection between the device under test and the test fixture.

Description

This application claims the benefit of provisional patent application No. 61/595,572, filed Feb. 6, 2012, which is hereby incorporated by reference herein in its entirety.

BACKGROUND

This relates generally to automation, and more particularly, to automated equipment for use in manufacturing operations such as testing.

Electronic devices are often tested following assembly to ensure that device performance meets design specifications. For example, a device may be tested at a series of test stations to ensure that components and software in the device are operating satisfactorily. At each test station, an operator may couple a device to test equipment using a cable. Following successful testing at all test stations, a device may be shipped to an end user.

The process of attaching and detaching test cable connectors can reduce the lifetime of the test cable connectors and can be cumbersome and burdensome to test system operators. If care is not taken, tests may be less accurate and more time consuming than desired. Additionally, excessive contact between a test system operator and a device under test may increase the risk of cosmetic damage to the device under test.

It would therefore be desirable to be able to provide improved ways of performing manufacturing operations such as testing operations on electronic devices.

SUMMARY

A test system may be provided in which devices under test are loaded into test trays. Each test tray may include one or more spring-loaded members for retaining a device under test within the test tray.

A test tray may include a base portion having an opening and one or more side walls having an opening. Openings may be configured to align with input-output devices in the device under test when the device under test is installed in the test tray.

A test tray may be provided with engagement holes configured to receive corresponding engagement pins on a computer-controlled loading arm. The loading arm may engage with the test tray by inserting the engagement pins into the engagement holes. Once engaged, the loading arm may be used to pick up, hold, and transport the device under test to a desired location in the test system.

The test system may be a conveyor belt system in which test stations are located along a moving conveyor belt. The test trays and associated devices under test may be fed into the conveyor belt system for testing at the test stations. Each test station may be provided with one or more loading mechanisms. A sensor may be used to detect when a test tray and associated device under test has reached a predetermined location in the conveyor belt system. In response to detecting a test tray at a predetermined location, a computer-controlled loading arm may be actuated to pick up the test tray from the conveyor belt and to bring the test tray and associated device under test to a test station for testing.

A contact extending structure may be used to form an electrical connection between a device under test in a test tray and a test fixture at a test station. A slot may be formed in the test tray and may be used to retain the contact extending structure within the test tray. The contact extending structure may have a first end configured to mate with the electronic device and a second end having contact pads. The contact pads may be configured to mate with corresponding test fixture contacts at a test station.

A computer-controlled loading arm may install a test tray and associated device under test in a test fixture for testing by mating the contacts on the contact extending structure with the test fixture contacts at the test station. The contact extending structure may be used to convey test signals between the test fixture and the device under test.

Each test tray may be provided with a radio-frequency identification tag for transmitting test tray identification information. One or more sensors in the test system may be configured to receive the test tray identification information and to identify the test tray based on the received test tray identification information. The test tray identification information may be used to determine information about the device under test associated with each test tray.

Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an illustrative electronic device such as a handheld device of the type that may be manufactured using automated equipment in accordance with an embodiment of the present invention.

FIG. 2 is a perspective view of an illustrative electronic device such as a tablet computer of the type that may be manufactured using automated equipment in accordance with an embodiment of the present invention.

FIG. 3 is a schematic diagram of an illustrative electronic device with input/output devices and wireless communications circuitry in accordance with an embodiment of the present invention.

FIG. 4 is a diagram of manufacturing equipment of the type that may be used in manufacturing an electronic device in accordance with an embodiment of the present invention.

FIG. 5 is an exploded perspective view of an illustrative device under test, pad extender, and test tray in accordance with an embodiment of the present invention.

FIG. 6 is a perspective view of an illustrative device under test, pad extender, and test tray in accordance with an embodiment of the present invention.

FIG. 7 is a top perspective view of an illustrative test tray in accordance with an embodiment of the present invention.

FIG. 8 is a bottom perspective view of an illustrative test tray in accordance with an embodiment of the present invention.

FIG. 9 is a bottom perspective view of an illustrative test tray with an opening to accommodate tests in accordance with an embodiment of the present invention.

FIG. 10 is a rear perspective view of an illustrative pad extender for extending contacts in a device under test mounted in a test tray in accordance with an embodiment of the present invention.

FIG. 11 is a front perspective view of an illustrative pad extender for extending contacts in a device under test mounted in a test tray in accordance with an embodiment of the present invention.

FIG. 12 is a perspective view of an illustrative test tray in which a device under test has been mounted in accordance with an embodiment of the present invention.

FIG. 13 is a perspective view of a portion of a test tray having clamps that hold a device under test in accordance with an embodiment of the present invention.

FIG. 14 is a top view of an illustrative test tray having spring-loaded clamps for retaining devices under test in accordance with an embodiment of the present invention.

FIG. 15 is a top view of an illustrative test system in which computer-controlled loading arms are used to transfer test trays between test stations and a conveyor belt in accordance with an embodiment of the present invention.

FIG. 16 is an exploded perspective view of an illustrative test fixture having test fixture contacts that mate with corresponding contacts on a pad extender in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

Electronic devices such as electronic device 10 of FIG. 1 may be manufactured using automated manufacturing equipment. The automated manufacturing equipment may include equipment for assembling device components together to form an electronic device. The automated manufacturing equipment may also include testing systems for evaluating whether devices have been properly assembled and are functioning properly.

Devices such as device 10 of FIG. 1 may be assembled and tested using an automated manufacturing system. The manufacturing system may include one or more stations such as one or more test stations for performing testing operations.

Devices that are being tested in a test system may sometimes be referred to as devices under test (DUTs). Devices under test may be provided to the test stations using a conveyor belt, using robotic arms, and/or using other loading equipment.

Test equipment at each test station may be used to perform an associated test on a device. For example, one test station may have equipment for testing a display in the device. Another test station may have equipment for testing an audio component in the device. Yet another test station may have equipment for testing light sensors in the device. Yet another test station may have equipment for testing wireless communications circuitry in the device. Automated equipment in the test system may be used in loading and unloading devices under test, in conveying devices under test between test stations, and in performing tests and maintaining a database of test results.

Any suitable device may be tested using test equipment. As an example, device 10 of FIG. 1 may be tested using test equipment. Device 10 may be a computer monitor with an integrated computer, a desktop computer, a television, a notebook computer, other portable electronic equipment such as a cellular telephone, a tablet computer, a media player, a wrist-watch device, a pendant device, an earpiece device, other compact portable devices, or other electronic equipment. In the configuration shown in FIG. 1, device 10 is a handheld electronic device such as a cellular telephone, media player, navigation system device, or gaming device.

As shown in FIG. 1, device 10 may include a housing such as housing 12. Housing 12, which may sometimes be referred to as a case, may be formed of plastic, glass, ceramics, fiber composites, metal (e.g., stainless steel, aluminum, etc.), other suitable materials, or a combination of these materials. In some situations, parts of housing 12 may be formed from dielectric or other low-conductivity material. In other situations, housing 12 or at least some of the structures that make up housing 12 may be formed from metal elements.

Device 10 may, if desired, have a display such as display 14. Display 14 may be a touch screen that incorporates capacitive touch electrodes or may be insensitive to touch. Display 14 may include image pixels formed from light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), plasma cells, electrophoretic display elements, electrowetting display elements, liquid crystal display (LCD) components, or other suitable image pixel structures. A cover glass layer may cover the surface of display 14. Openings for buttons such as button 20, openings for speaker ports such as speaker port 22, and other openings may be formed in the cover layer of display 14, if desired.

The central portion of display 14 (i.e., active region 16) may include active image pixel structures. The surrounding rectangular ring-shaped inactive region (region 18) may be devoid of active image pixel structures. If desired, the width of inactive region 18 may be minimized (e.g., to produce a borderless display).

Device 10 may include components such as front-facing camera 24. Camera 24 may be oriented to acquire images of a user during operation of device 10. Device 10 may also include a rear facing camera. A rear facing camera may be formed on a back side of device 10 (e.g., on an opposing side of display 14).

Device 10 may include sensors in portion 26 of inactive region 18. These sensors may include, for example, an infrared-light-based proximity sensor that includes an infrared-light emitter and a corresponding light detector to emit and detect reflected light from nearby objects. The sensors in portion 26 may also include an ambient light sensor for detecting the amount of light that is in the ambient environment for device 10. Other types of sensors may be used in device 10 if desired. The example of FIG. 1 is merely illustrative.

Device 10 may include input-output ports such as port 28. Ports such as port 28 may include audio input-output ports, analog input-output ports, digital data input-output ports, or other ports. Each port may have an associated connector. For example, an audio port may have an associated four-contact audio connector, a digital data port may have a connector with two or more pins (contacts), a connector with four or more pins, a connector with thirty pins, or other suitable data port connector.

Sensors such as the sensors associated with region 26 of FIG. 1, cameras such as camera 24, audio ports such as speaker port 22, buttons such as button 20, and ports such as port 28 may be located on any suitable portion of device housing 12 (e.g., a front housing face such as a display cover glass portion, a rear housing face such as a rear planar housing wall, sidewall structures, etc.).

FIG. 2 is a perspective view of device 10 in an illustrative configuration in which device 10 has been implemented in the form of a tablet computer. As shown in FIG. 2, device 10 may include a housing such as housing 12. Housing 12 may be formed from metal, plastic, fiber-based composite material, glass, ceramic, other materials, or combinations of these materials. Device 10 may have an upper (front) surface that is covered with display 14. Active portion 16 of display 14 may have a rectangular shape (as an example). Inactive portion 18 of display 14 may have an opening to accommodate button 20, a window region for camera 24, and a portion such as portion 26 that is associated with one or more optical sensors such as an infrared-based proximity sensor and/or an ambient light sensor.

A schematic diagram of an electronic device such as electronic device 10 is shown in FIG. 3. As shown in FIG. 3, electronic device 10 may include storage and processing circuitry 27. Storage and processing circuitry 27 may include storage such as hard disk drive storage, nonvolatile memory (e.g., flash memory or other electrically-programmable-read-only memory configured to form a solid state drive), volatile memory (e.g., static or dynamic random-access-memory), etc. Processing circuitry may be based on one or more microprocessors, microcontrollers, digital signal processors, baseband processors, power management units, audio codec chips, application specific integrated circuits, etc.

Storage and processing circuitry 27 may be used to run software on device 10, such as internet browsing applications, voice-over-internet-protocol (VoIP) telephone call applications, email applications, media playback applications, operating system functions, etc. To support interactions with external equipment, storage and processing circuitry 27 may be used in implementing communications protocols. Communications protocols that may be implemented using storage and processing circuitry 27 include internet protocols, wireless local area network (WLAN) protocols (e.g., IEEE 802.11 protocols—sometimes referred to as WiFi®), protocols for other short-range wireless communications links such as the Bluetooth® protocol, cellular telephone protocols, etc.

Circuitry 27 may be configured to implement control algorithms that control the use of antennas in device 10. For example, to support antenna diversity schemes and MIMO schemes or beam forming or other multi-antenna schemes, circuitry 27 may perform signal quality monitoring operations, sensor monitoring operations, and other data gathering operations and may, in response to the gathered data, control which antenna structures within device 10 are being used to receive and process data. As an example, circuitry 27 may control which of two or more antennas is being used to receive incoming radio-frequency signals, may control which of two or more antennas is being used to transmit radio-frequency signals, may control the process of routing incoming data streams over two or more antennas in device 10 in parallel, etc.

Input/output circuitry 29 may be used to allow data to be supplied to device 10 and to allow data to be provided from device 10 to external devices. Input/output circuitry 29 may include input/output devices 31. Input/output devices 31 may include touch screens, displays without touch sensor capabilities, buttons, joysticks, click wheels, scrolling wheels, touch pads, key pads, keyboards, microphones, speakers, tone generators, vibrators, cameras, sensors, light-emitting diodes and other status indicators, light sources, audio jacks and other audio port components, data ports, light sensors, motion sensors (accelerometers), capacitance sensors, proximity sensors, etc. A user can control the operation of device 10 by supplying commands through input/output devices 31 and may receive status information and other output from device 10 using the output resources of input/output devices 31.

Wireless communications circuitry 33 may include radio-frequency (RF) transceiver circuitry formed from one or more integrated circuits, power amplifier circuitry, low-noise input amplifiers, passive RF components, one or more antennas, transmission lines, and other circuitry for handling RF wireless signals. Wireless signals can also be sent using light (e.g., using infrared communications).

Wireless communications circuitry 33 may include satellite navigation system receiver circuitry 35, transceiver circuitry such as transceiver circuitry 37 and 39, and antenna circuitry such as antenna circuitry 41. Satellite navigation system receiver circuitry 35 may be used to support satellite navigation services such as United States' Global Positioning System (GPS) (e.g., for receiving satellite positioning signals at 1575 MHz) and/or other satellite navigation systems.

Transceiver circuitry 37 may handle 2.4 GHz and 5 GHz bands for WiFi® (IEEE 802.11) communications and may handle the 2.4 Bluetooth® communications band. Circuitry 37 may sometimes be referred to as wireless local area network (WLAN) transceiver circuitry (to support WiFi® communications) and Bluetooth® transceiver circuitry. Circuitry 33 may use cellular telephone transceiver circuitry (sometimes referred to as cellular radio) 39 for handling wireless communications in cellular telephone bands such as bands at 850 MHz, 900 MHz, 1800 MHz, 1900 MHz, 2100 MHz, and/or other cellular telephone bands of interest.

Examples of cellular telephone standards that may be supported by wireless circuitry 33 and device 10 include: the Global System for Mobile Communications (GSM) “2G” cellular telephone standard, the Evolution-Data Optimized (EVDO) cellular telephone standard, the “3G” Universal Mobile Telecommunications System (UMTS) cellular telephone standard, the “3G” Code Division Multiple Access 2000 (CDMA 2000) cellular telephone standard, and the “4G” Long Term Evolution (LTE) cellular telephone standard. Other cellular telephone standards may be used if desired. These cellular telephone standards are merely illustrative.

Wireless communications circuitry 33 may include circuitry for other short-range and long-range wireless links if desired. For example, wireless communications circuitry 33 may include wireless circuitry for receiving radio and television signals, paging circuits, etc. In WiFi® and Bluetooth® links and other short-range wireless links, wireless signals are typically used to convey data over tens of hundreds of feet. In cellular telephone links and other long-range links, wireless signals are typically used to convey data over thousands of feet or miles.

Wireless communications circuitry 33 may include one or more antennas 41. Antennas 41 may be formed using any suitable antenna type. For example, antennas 41 may include antennas with resonating elements that are formed from loop antenna structures, patch antenna structures, inverted-F antenna structures, slot antenna structures, planar inverted-F antenna structures, helical antenna structures, hybrids of these designs, etc. Different types of antennas may be used for different bands and combinations of bands. For example, one type of antenna may be used in forming a local wireless link antenna and another type of antenna may be used in forming a remote wireless link antenna.

FIG. 4 is a diagram of an illustrative system of the type that may be used for manufacturing operations such as device testing. As shown in FIG. 4, system 30 may include one or more stations such as test stations 36. In general, test system 30 may include automated equipment that is used in loading and unloading devices under test, in conveying devices under test between test stations, and in performing tests and maintaining a database of test results. Each test station 36 may, for example, include test equipment 44 for performing one or more tests on device under test 10 and may therefore sometimes be referred to as a device tester or DUT tester. For example, a first type of test station 36 may have equipment for testing a display in device 10. A second type of test station 36 may have equipment for testing an audio component in device 10. Yet another type of test station 36 may have equipment for testing light sensors in device 10. Yet another type of test station 36 may have equipment for testing wireless communications circuitry in device 10. If desired, test system 30 may include more than one test station of the same type arranged along conveyor belt 38 so that multiple devices under test 10 can be tested in parallel.

Device under test 10 may, if desired, be installed in a test tray such as tray 32. Tray 32 may be configured to receive one or more devices under test. For example, tray 32 may have multiple slots, each of which is configured to receive a corresponding device under test. If desired, tray 32 may be configured to receive only a single device under test.

Device 10 may be installed in test tray 32 manually or using automated equipment. To facilitate manual installation, test tray 32 may include features to facilitate human manipulation. For example, test tray 32 may include features that help an operator open and close clamps or other device holding features in test tray 32.

Device under test 10 that is mounted in test tray 32 may be conveyed between test stations 36 using a conveyor belt such as conveyor belt 38 (e.g., a belt that moves in direction 40). When using a conveyor system such as one or more conveyor belts 38, each test station 36 may be provided with loading mechanisms (e.g., one or more computer-controlled loaders) 46. With this type of arrangement, test tray 32 may serve as an interface between device under test 10 and loader 46. Test tray 32 may, for example, be more robust than device 10, may have engagement features that are configured to mate with loader 46, may have an identification number that facilitates tracking, and may have other features that facilitate testing of device 10 by test stations 36.

For example, loader 46 in each test station 36 may be provided with one or more computer-controlled positioning arms. The positioning arms in loader 46 may be used in picking up a test tray (i.e., a test tray that is loaded with device under test 10) from conveyor 38 (arrow 50), may be used to present test tray 32 to tester 44 at test station 36 to perform desired testing on device under test 10, and may be used to replace test tray 32 on conveyor 38 following testing (arrow 52).

Test stations 36 may provide test results to computing equipment such as test host 42 (e.g., one or more networked computers) for processing. Test host 42 may maintain a database of test results, may be used in sending test commands to test stations 36, may track individual trays and devices under test as the trays and devices pass through system 30, and may perform other control operations.

FIG. 5 is a diagram showing how device under test 10 may be received within test tray 32. As shown in FIG. 5, test tray 32 may have a base such as base 48 on which device under test 10 rests. Sidewalls such as sidewalls 100 may be formed on peripheral portions of base 48, thereby forming a recess such as recess 154 in test tray 32. Device under test 10 may be installed in test tray 32 by placing device under test 10 within recess 154. Sidewalls 100 may be formed on one, two, three, or all four sides of device under test 10. Sidewalls 100 may contain device locating features such as tangential surfaces or notches and may have device retention structures such as clamps, clips, or other structures.

Device under test 10 may have one or more connector ports such as port 28 (see, e.g., FIG. 1). A contact extending structure such as contact extending structure 144 may have a mating connector such as plug 146. Plug 146 may be configured to mate with a connector in port 28 when device under test 10 has been mounted in test tray 32 and when contact extending structure 144 (sometimes referred to as “pad extender” 144) has been moved towards device under test 10 in direction 148.

Following insertion of device under test 10 into test tray 32 and following insertion of plug connector 146 of pad extender 144 into connector 28 of device under test 10, test tray 32 of FIG. 5 may appear as shown in FIG. 6. Pad extender 144 may contain signal paths that connect pins in connector 28 to corresponding contacts 62 on pad extender 144. Contacts 62 may be configured to mate with corresponding contacts coupled to tester 44 at test station 36 and/or test host 42 during testing in system 30. If desired, pad extender 144 may be configured such that contacts 62 are flush with end surface 23 of test tray 32 when pad extender is connected to device under test 10 as shown in FIG. 6.

Because device under test 10 is connected to test contacts 62 in test tray 32 using pad extender 144 associated with test tray 32, it is not necessary to repeatedly connect and disconnect device under test 10 from cabling at each test station 36. Rather, connections between device under test 10 and the test equipment at each test station 36 by may be formed by coupling contacts 62 in pad extender 144 to corresponding contacts at each test station 36. By minimizing the number of times that cables need to be connected and disconnected from each device under test, the life of tester cables and connectors may be extended.

The use of test tray 32 may allow device under test 10 to be placed accurately within test stations 36 (e.g., with an accuracy of +/−0.1 mm or better, as an example). Test tray 32 may shield device under test 10 from scratches and other damage during testing. In general, device under test 10 may be received within test tray 32 in either an upwards facing configuration in which display 14 faces outwards (e.g., in which display 14 faces away from test tray 32) or in which display 14 faced downwards (e.g., in which display 14 faces towards test tray 32).

FIG. 7 is a perspective view of one suitable embodiment of test tray 32. As shown in FIG. 7, tray 32 may be provided with engagement features such as holes 160. Engagement features such as holes 160 may be formed on one, two, three, or all four sides of test tray 32 and may be configured to mate with corresponding engagement features on automated loading equipment such as loaders 46 at test stations 36 (FIG. 4). For example, holes 160 may be formed on opposing ends of test tray 32 such as ends 32A and 32B of test tray 32. The example of FIG. 7 in which engagement features 160 have been implemented in the form of holes is merely illustrative. Engagement features 160 may be implemented in the form of slots, notches, dimples, openings, recesses, protrusions, or other features that allow test equipment such as computer-controlled loading equipment to engage with test tray 32.

Automated loading equipment such as loaders 46 may have engagement pins that are configured to engage simultaneously with ends 32A and 32B, allowing loader 46 to pick up, hold, and transport device 10 to a desired location (e.g., to a test station such as test station 36 of FIG. 4). In the example of FIG. 7, test tray 32 is shown with four engagement holes on each end. This is, however, merely illustrative. If desired, tray 32 may include less than four engagement holes, more than four engagement holes, more than six engagement holes, more than 10 engagement holes, etc.

Tray 32 may be formed using non-marring material such as acetyl plastic, Delrin® (a polyoxymethylene plastic), other plastics, or other suitable non-marring materials. The use of non-marring materials may help avoid scratches or other damage to device under test 10 when device under test 10 is placed within test tray 32. If desired, a layer of material 156 may be formed on portions of test tray 32 such base portion 48. As an example, material 156 may be formed using the same material that is used to form tray 32. As another example, material 156 may be formed using elastomeric material such as rubberized foam. Material 156 may, in general, be formed using any suitable non-marring material.

Test tray 32 may be provided with guide structures configured to accurately position device under test 10 in a desired location within recessed portion 154 of tray 32. As shown in FIG. 7, guide structures such as guide surfaces 150 may be used as reference points for determining the location of a device under test relative to test tray 32 and/or test station 36. For example, a device under test may be positioned in a known location relative to test tray 32 by registering the device under test against guide surfaces 150. A guide structure on the end of tray 32 may have an exposed end guide surface such as guide surface 150A. Guide structures on the side of tray 32 may have exposed side guide surfaces such as guide surfaces 150B. Guide surfaces such as guide surfaces 150A and 150B may sometimes be referred to as datums.

FIG. 8 is a bottom perspective view of one suitable embodiment of test tray 32. As shown in FIG. 8, holes, openings, or gaps such as gaps 80 may be formed in sidewalls 100 of test tray 32. Gaps 80 in sidewalls 100 may allow portions of device 10 to be untouched by test tray 32. For example, structures such as buttons, switches, ports (e.g., a subscriber identity module (SIM) card port to authorize cellular telephone service), and other input/output devices may be formed in a housing sidewall of device 10. If desired, gaps 80 may be formed in portions of sidewalls 100 that are adjacent to (e.g., aligned with) these structures. This type of configuration may ensure that structures such as buttons or switches in device 10 are not unintentionally actuated or otherwise unnecessarily touched by test tray 32. This is, however, merely illustrative. If desired, sidewalls 100 of test tray 32 may be free of gaps.

Test tray 32 may have one or more openings in base 48 to facilitate test measurements on device under test 10 during testing. For example, as shown in the bottom perspective view of FIG. 9, openings such as opening 82 may be formed in base 48 and may be configured to align with one or more input-output devices in device under test 10 when device 10 is installed in tray 32. Test equipment at a test station may communicate with a component in device 10 via opening 82. In the example of FIG. 9, opening 82 has an inverted cone shape to facilitate testing of a camera in device 10 (e.g., a light signal from a test light source may be transmitted through opening 82 to reach a camera in device 10, or a light-emitting diode flash from a camera in device 10 may emit light through opening 82 to reach a light sensor at a test station). Other examples of components in device 10 that may be tested using openings such as opening 82 in test tray 32 include ambient light sensors, light-based proximity sensors, capacitive sensors, light-emitting diodes (e.g., for status indicators), display components, magnetic sensors, or other electrical components.

When device 10 is installed in test tray 32, some components in device 10 may face away from test tray 32 (e.g., components formed on a front side of device 10) and some components in device 10 may face towards test tray 32 (e.g., components formed on a back side of device 10). If desired, openings such as openings 82 may only be formed in portions of base 48 that are aligned with components in device 10 that face towards test tray 32.

FIG. 10 is a perspective view of pad extender 144 showing how connector 146 may protrude from one end of pad extender 144. FIG. 11 is a perspective view of pad extender 144 showing how contacts 62 may be formed on an opposing end of pad extender 144.

FIG. 12 is a perspective view of test tray 32 after device under test 10 has been inserted into test tray 32. As shown in FIG. 12, test tray 32 may have clamps 164 for holding device under test 10 within test tray 32. The inner surfaces of clamps 164 may serve as guide surfaces 150 (FIG. 7) or, if desired, may be separate structures adjacent to guide surfaces 150.

Test tray 32 may have one or more notches or slots such as slot 170. Slot 170 may be configured to receive pad extender 144. If desired, pad extender 144 may be retained within slot 170 when device 10 is installed in test tray 32 (e.g., when connector 146 of pad extender 144 is connected to connector port 28 in device 10) and when device 10 is not installed in test tray 32 (e.g., when test tray 32 is empty).

FIG. 13 is a perspective view showing how clamps 164 may have portions that extend over a top surface of device under test 10. Clamps 164 may be spring-loaded to facilitate installation of device under test 10 in test tray 32. For example, springs or other biasing structures may be used to bias the upper portions of clamps 164 towards device 10. When it is desired to load device 10 into test tray 32, clamps 164 may be pulled in direction 102 and device 10 may be placed on base 48. Following placement of device 10 on base 48, clamps 164 may be released and clamps 164 may be forced towards device 10 (e.g., in direction 104) to secure device 10 to test tray 32.

In addition to securing a device under test to a test tray, some clamps may serve the additional purpose of accurately positioning a device under test within a test tray. FIG. 14 is a top view of an illustrative test tray in which spring-loaded members may be used to both secure and accurately position a device under test within a test tray. As shown in FIG. 14, spring-loaded members such as spring-loaded corner clamp 174 and spring-loaded side clamp 194 may be located at the periphery of recess 154 (e.g., may be mounted in sidewall portions 100 of FIG. 7).

Clamps such as corner clamp 174 may be located at one or more corners of test tray 32 and may be used to accurately position a device under test within the test tray. For example, clamp 174 may be used to press device 10 against alignment features in test tray 32 (e.g., may be used to press device 10 against two of three datums within test tray 32 such as guide surfaces 150). Corner clamp 174 may have a lip or protruding portion such as portion 201 that extends partially over a top surface of device 10 when device 10 is inserted in test tray 32. Clamp 174 may be configured to rotate about pivot point 172. A biasing structure such as spring 184 may be used to bias end portion 210 of clamp 174 in direction 178 (e.g., away from recess 154). Because clamp 174 rotates about point 172, the biasing force exerted on end portion 210 of clamp 174 may in turn provide a biasing force on opposing end portion 204 in direction 182. When portion 210 of clamp 174 is pressed in direction 176, clamp 174 will pivot about pivot point 172 and portion 204 of clamp 174 will move outwards in direction 180 to accommodate insertion of device under test 10 in recessed portion 154 of test tray 32. After inserting device under test 10 into test tray 32, end portion 210 of clamp 174 may be released and corner portion 204 may be forced towards device 10 in direction 182.

Clamps such as side clamp 194 may be located on one or more sides of test tray 32. If desired, clamp 194 may have a lip or protruding portion that extends partially over a top surface of device 10 when device 10 is inserted in test tray 32. Side clamp 194 may pivot about pivot point 188. A biasing structure such as spring 186 may be used to bias end portion 208 of clamp 194 in direction 196 (e.g., away from recess 154). Because clamp 194 rotates about pivot point 188, the biasing force exerted on end portion 208 of clamp 194 may in turn provide a biasing force on opposing end portion 206 of clamp 194 in direction 202. When portion 208 of clamp 194 is pressed in direction 192, clamp 194 will pivot about pivot point 188 and portion 206 of clamp 194 will move outwards in direction 198 to accommodate insertion of device under test 10 in recessed portion 154 of test tray 32. After inserting device under test 10 into test tray 32, portion 208 may be released and end portion 206 may be forced towards device 10 in direction 202.

FIG. 15 is a top view of an illustrative conveyor belt 38 showing how test trays 32 might be used in a test system such as conveyor belt system 30. Each test tray may contain a radio-frequency identification (RFID) tag such as tray ID tag 280 (e.g., a tag that wirelessly transmits tray identification information such as a tray serial number to RFID reading equipment). Conveyor belt system 30 may have one or more built in sensors such as RFID reader 313 that may be used to monitor incoming test trays 32 for RFIDs. If the RFID reader at a test station determines that the tray ID for a test tray matches previously received instructions, the test station may initiate loading mechanisms (e.g., loader 46) to load the test tray into the test station. The serial number or other identification information associated with test tray 32 may be used in determining whether or not a device requires testing at a given test station, may be used in determining whether or not a device under test has successfully passed a given test, and/or may be used in determining other information about a device that is installed in test tray 32.

One or more loaders 46 may be associated with each test station. As shown in FIG. 15, loader 46 may include loading arm 306 and loading arm positioner 310. Positioner 310 may be a computer-controlled actuator such as a motor-driven or air-driven actuator and may be configured to move loading arm 306 along three axes (e.g., along X, Y, and Z axes). Loading arm 306 may have engagement arm members 306′. Each engagement arm member 306′ may have loading arm engagement features such as engagement pins 360 that are configured to mate with corresponding engagement holes 160 in test tray 32. Engagement arm members may be controlled using air-driven or motor-drive actuators such as actuators 308. Actuators 308 may be configured to move engagement arm members 306′ in a direction that is parallel to axis Y.

Initially, device under test 10 and test tray 32 may be located on the left hand side of conveyor belt 38. As conveyor belt 38 moves in direction 290, test tray 32 may approach location 312. A sensor such as RFID reader 313 may be positioned along conveyor belt 38 and may be configured to identify a serial number with test tray 32 as it passes location 312. Based on the identified serial number, test host 42 (FIG. 4) may be used to determine whether or not the device under test associated with that test tray needs to be tested at a given test station. As test tray 32 approaches loader 46, a sensor such as sensor 315 may be used to detect the presence of test tray 32 at location 314. Sensor 315 may (as an example) be a laser-based distance sensor. If desired, a single sensor may be used to both detect and identify test trays 32. The example of FIG. 15 in which separate sensors are used for identification and detection of test tray 32 is merely illustrative.

In response to detection of test tray 32 by sensor 315, loading arm 306 may automatically be moved by loading arm actuator 310 into the position shown in FIG. 15. As conveyor belt 38 continues to move in direction 290, device under test 10 and test tray 32 may be received within loading arm 306. If desired, one or more sensors may be used to inform a controlling computer such as host 42 (FIG. 4) when a test tray is properly received within loading arm 306.

Engagement pins 360 (sometimes referred to as protrusions) may be used to engage with test tray 32 so that loader arm 306 may pick up test tray 32 from conveyor belt 38 and transfer test tray 32 to a desired location (e.g., test station 36). Initially, engagement pins 360 may be held in a retracted position by actuators 308. After conveyor belt 38 has moved tray 32 into a position within arm 306, actuators 308 may be used to extend pins 360 into holes 160. If desired, actuator 308 may be configured to move pins 360 towards test tray 32 by moving engagement arm members 306′ inward. The example in which actuator 308 moves only engagement pins 360 to engage with holes 160 is merely illustrative. Once loader arm 306 has engaged with test tray 32, loader arm 306 may deliver test tray 32 and device under test 10 to a test fixture at the test station associated with loader arm 306. In some configurations, loader arm 306 may unload test tray 32 at the test station by disengaging pins 360 from holes 160. In other configurations, loader 306 may remain engaged with test tray 32 while device under test 10 is tested at a test station.

Following testing at a given test station, loading arm 306 may return test tray 32 to conveyor belt 38. If desired, a first loading arm may be used in picking up test tray 32 from conveyor belt 38 and a second loading arm may be used to return test tray 32 to conveyor belt 38. Test tray 32 may have a first and second sets of engagement holes 160 so that first and second loading arms may simultaneously engage with test tray 32 (e.g., so that test tray 32 may be transferred between loading arms).

Each test station 36 (FIG. 4) at which device under test 10 is tested may have an associated test fixture configured to receive test tray 32 and associated device under test 10. FIG. 16 is an exploded perspective view of test system 30 showing how test tray 32 may be received by a test fixture such as test fixture 34. After loading arm has 306 engaged with test tray 32, loading arm 306 may present test tray 32 and device under test 10 to test fixture 34 at a test station for testing. Test fixture 34 may have contacts such as test fixture contacts 134. Contacts 134 (sometimes referred to as contact pads or contact pins) may be configured to mate with contacts 62 on pad extender 144. By bringing pad extender contacts 62 into contact with test fixture contacts 134, an electrical connection may be formed between device under test 10 and test fixture 34. Test signals may be conveyed between test fixture 34 and device under test 10 via pad extender 144.

Device under test 10 may be tested at multiple test stations. If desired, each test station may have a test fixture with an associated set of test fixture contacts 134. Pad extender 144 may be configured to mate with corresponding test fixture contacts 134 at each test station.

The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. The foregoing embodiments may be implemented individually or in any combination.

Claims

1. Test apparatus for testing an electronic device, comprising:

a test tray configured to receive the electronic device, wherein the test tray includes a plurality of test tray engagement features configured to receive corresponding loader engagement features on a computer-controlled loader; and

a contact extending structure having first and second ends, wherein the first end comprises a connector configured to mate with the electronic device, and wherein the second end comprises a plurality of contact pads configured to mate with contacts at a test station.

2. The test apparatus defined in claim 1, wherein the test tray further includes at least one spring-loaded member configured to retain the electronic device within the test tray.

3. The test apparatus defined in claim 1, wherein the test tray comprises a base and at least one side wall, wherein the at least one side wall comprises at least one opening, and wherein the opening aligns with an input-output device in the electronic device when the electronic device is received within the test tray.

4. The test apparatus defined in claim 1, wherein the test tray comprises a base and at least one side wall, wherein the base comprises at least one opening, and wherein the opening aligns with an input-output device in the electronic device when the electronic device is received within the test tray.

5. The test apparatus defined in claim 1, wherein the test tray comprises a slot configured to receive the contact extending structure.

6. The test apparatus defined in claim 1, wherein the plurality of test tray engagement features comprises a plurality of recesses in the test tray.

7. The test apparatus defined in claim 1, wherein the test tray comprises a radio-frequency identification tag configured to transmit test tray identification information.

8. A test system for testing a device under test, comprising:

a test tray configured to receive the device under test, wherein the test tray comprises a radio-frequency identification tag configured to transmit test tray identification information;

a sensor configured to receive the test tray identification information;

a test fixture configured to receive the test tray; and

computer-controlled loading equipment configured to engage with the test tray and to move the test tray towards the text fixture for testing.

9. The test system defined in claim 8, wherein the test fixture comprises a plurality of test fixture contacts, the test system further comprising:

a contact extending structure having first and second ends, wherein the first end comprises a connector configured to mate with the device under test and wherein the second end comprises a plurality of contact pads configured to mate with the plurality of test fixture contacts.

10. The test system defined in claim 8, wherein the test tray comprises test tray engagement features, wherein the computer-controlled loading equipment comprises a loading arm having loading arm engagement features, and wherein the loading arm is configured to hold and move the test tray by engaging the loading arm engagement features with the test tray engagement features.

11. The test system defined in claim 8, wherein the test tray comprises a plurality of recesses, wherein the computer-controlled loading equipment comprises a loading arm having a plurality of protrusions, and wherein the loading arm is configured to hold and move the test tray by inserting each protrusion in the plurality of protrusions in an associated recess in the plurality of recesses.

12. The test system defined in claim 8, wherein the test tray comprises at least one spring-loaded member configured to retain the device under test within the test tray.

13. The test system defined in claim 8, wherein the computer-controlled loading equipment comprises a loading arm and an actuator and wherein the actuator is configured to actuate the loading arm to engage with the test tray in response to the sensor receiving the test tray identification information.

14. A method of testing a device under test, comprising:

installing the device under test into a test tray;

connecting a contact extending structure to a connector port in the device under test;

while the device under test is installed in the test tray and while the contact extending structure is connected to the connector port, feeding the test tray into a conveyor belt system; and

with a computer-controlled loading arm, installing the test tray in a test fixture for testing.

15. The method defined in claim 14, further comprising:

with the test tray, transmitting test tray identification information; and

with a sensor, receiving the test tray identification information.

16. The method defined in claim 14, further comprising:

with a sensor, detecting the test tray at a predetermined location in the conveyor belt system; and

in response to detecting the test tray at the predetermined location, automatically actuating the computer-controlled loading arm to pick up the test tray.

17. The method defined in claim 16, wherein the computer-controlled loading arm comprises a plurality of pins, wherein the test tray comprises a plurality of holes, and wherein automatically actuating the computer-controlled loading arm to pick up the test tray comprises inserting each pin in the plurality of pins into an associated hole in the plurality of holes.

18. The method defined in claim 14 wherein the contact extending structure comprises a plurality of contact pads, wherein the test fixture comprises a plurality of test fixture contacts, and wherein installing the test tray in the test fixture comprises electrically connecting the plurality of contact pads to the plurality of test fixture contacts.

19. The method defined in claim 14, further comprising:

after installing the test tray in the test fixture, performing testing on the device under test.

20. The method defined in claim 19, wherein performing testing on the device under test comprises:

with the contact extending structure, conveying test signals between the test fixture and the device under test.