The overall debugging steps of an electronic solution should be clearly and meticulously specified in the debugging process document so that operators can easily understand and follow them. Because there are many types of electronic solutions and the circuits are complex, and the types, requirements, and technical specifications of internal unit circuits also differ, the debugging procedures are not all the same.
However, for a general electronic solution, the general process of debugging usually includes: overall appearance inspection, structural debugging, power supply debugging, overall power consumption testing, overall system alignment, and testing of overall technical specifications.
Table of Contents
1. Overall appearance inspection.
The inspection items vary depending on the product type and requirements, and the specific requirements can be carried out according to the process instruction card. For a general electronic solution, the main checks include the appearance of the enclosure, foreign objects inside the machine, function switches, fastening screws, keys or buttons, and other items.
2. Structural debugging.
An electronic solution is a mechatronic product. The purpose of structural adjustment is to check the firmness and reliability of the overall assembly. Specific contents include: whether the connections and wiring between each unit circuit board, component, and the overall machine are firm and reliable, and whether there is any loosening; whether the adjustment devices are flexible and properly positioned; whether the plugs and sockets are in good contact, etc.
3. Power supply debugging.
Check and confirm that the switch of the product’s power supply system (such as the power supply circuit) is in the off position, check whether the power conversion switch meets the requirements, whether the fuse is installed, and whether the input voltage is correct. Then plug in the power switch plug and close the power switch to energize.
After the power is turned on, the power indicator light should turn on. At this time, pay attention to whether the indicator light is lit, whether there is discharging, arcing, smoking, abnormal odor, and other phenomena. If any of these phenomena occur, cut off the power immediately and check. In addition, check whether various safety switches and control systems function and whether various heat dissipation systems work normally.
Power supply debugging is usually carried out under no-load conditions. Initial adjustment is performed after disconnecting all loads from the power supply. The purpose is to avoid damage to some electronic components caused by connecting the power supply circuit to a load before it has been debugged.
During debugging, energize the power supply circuit board, measure whether there is a stable DC voltage output and whether its value conforms to the design requirements, or adjust the sampling potentiometer to reach the rated value. Measure the DC operating point and voltage waveform at the test points, and check whether the working state is normal and whether there is self-excited oscillation, etc.
After no-load debugging is normal, add a load to the power supply for fine adjustment. Under the condition that the initial adjustment is normal, add the rated load, then measure various performance indicators and observe whether they meet the design requirements.
When the required optimal value is reached, lock the relevant adjustment components (such as potentiometers) so that the power supply circuit has the optimal functional state required when a load is added.
4. Overall power consumption testing.
Overall power consumption testing is an important technical indicator of an electronic solution. During testing, a voltage regulator is often used to supply the unit under test with the rated power supply voltage, and the AC current during normal operation is measured. The product of the two gives the overall power consumption. If the measured value deviates from the design requirements, it indicates that there are hidden faults inside the machine, and a comprehensive inspection of the overall machine should be carried out.
5. Overall system alignment.
After the debugged unit circuits are assembled into the overall machine, their performance parameters will be affected to varying degrees. Therefore, after the overall machine is assembled, the unit circuit boards should be further debugged as necessary to ensure that the functions of each unit circuit board meet the requirements of the overall machine’s performance indicators.
6. Testing of overall technical specifications.
The debugged overall machine should be tested for technical specifications to determine whether it reaches the technical level required by the design. Different types of overall machines have different technical specifications, and their testing methods are also different. When necessary, test data should be recorded, test results analyzed, and a debugging report written.
During the debugging process, various test instruments and power supplies are involved. These instruments and equipment, as well as the machine under test, often contain high-voltage circuits, high-voltage large-capacity capacitors, MOS circuits, etc. To protect the personal safety of debugging personnel and avoid damage to test instruments and components, safety operating procedures must be strictly followed.
Safety measures in debugging work mainly include the safety of the test environment, the safety of power supply equipment, the safety of test instruments, and operational safety. The experience and methods of electronic solution debugging can be summarized in four sentences: isolate circuit blocks, DC before AC, pay attention to human-machine safety, and use instruments correctly.
