qdTest: test and programming fixtures for small batches and high-mix electronics manufacturing

Flexible, economical and independent circuit board testing with qdTest

For manufacturers of electronic devices produced in small and medium volumes, quality assurance in electronics manufacturing usually involves high costs and a complex infrastructure. The modular qdTest system family from querdenker engineering now offers a compact, low-cost stand-alone solution that needs no external infrastructure yet covers a wide range of functions. Individually 3D-printed board holders and standardised electronics modules make it possible to handle test and programming tasks flexibly, from simply flashing firmware to complex functional tests with integrated measurement. The new qdTest test system is particularly suited to high-mix manufacturing, medical technology and other regulated industries.

Quality assurance for small batches

In electronics manufacturing, programming and functional testing of assembled boards are essential quality assurance tasks. After PCB assembly, the boards have to be checked for correct function, and the firmware or configuration has to be loaded. Externally manufactured components also have to pass an incoming inspection to make sure they are free of faults.

However, the test systems available on the market are typically designed for high volumes. They require an elaborate infrastructure with extensive lab hardware, additional measurement and programming equipment, and workstations staffed by qualified specialists to carry out the necessary tests.

For device manufacturers with small and medium batches or high-mix manufacturing in particular, investing in elaborate test equipment hardly makes economic sense. Outsourcing test tasks to external service providers, on the other hand, means losing flexibility, control over quality and know-how, which is questionable from a strategic point of view.

qdTest: the modular test and programming fixture system

querdenker engineering developed the qdTest family specifically for small and medium volumes. The aim was to offer a modular, easily configurable system that is convincing both economically and functionally, closing a gap in the market.

To let interested parties check the economic benefit of qdTest quickly, anonymously and without going into detail, we provide an online price calculator that shows the approximate cost range.

A key feature of qdTest is its compact design, individually adapted to the design of the board under test. The system combines mechanics, measurement and software in a single device. As a genuine stand-alone solution, it needs no connection to an external PC. It can be operated either with integrated buttons or with a connected barcode scanner and monitor, which makes it easy to integrate into existing manufacturing processes. Test results can be saved to a USB stick or sent directly to the ERP system via a REST API. The test configuration and the microcontroller firmware to be flashed are stored on the USB stick and can be managed via cloud access if required.

The qdTest fixtures are individually 3D printed and adapted to each client's requirements. Standardised electronics modules allow the system to be configured flexibly. Applications range from simple programming adapters to complex functional test setups with current and voltage measurement, switching relays and multi-channel power supply.

Compared with conventional test systems, the investment is considerably lower. Savings in the five- to six-figure range are possible. Because the qdTest system is compact and works autonomously, no elaborate equipment infrastructure is needed. Software-controlled automation makes test processes reproducible and efficient. Remote maintenance is also possible via an optional cloud connection. With qdTest, the device manufacturer remains independent and, when using the cloud, retains full control over all test data.

Electronics boards combined individually for board-specific tests

The technical platform of qdTest is based on electronics we developed ourselves, consisting of a powerful Raspberry Pi 5 as the SOM, integrated voltage sources and various communication buses. Depending on the test requirements, different expansion modules can be used, for example for relay control, voltage and current measurement, and programmable power supplies.

The available modules include an eight-channel relay board that can switch voltages up to 30 volts and currents up to 1 ampere. A voltage measurement board measures voltages on 16 channels with an accuracy of ±0.2 %. Another module is the current measurement board, which measures currents on eight channels with an accuracy of ±0.3 %. In addition, a two-quadrant power supply can source or sink voltages from 2 to 20 volts at a current of ±5 amperes, with an accuracy of ±0.15 %.

The fixtures are designed for boards up to 250 x 170 mm and have room for up to ten electronics modules. The housings are available in four sizes. Depending on the application, variants with lever operation or with a cable outlet are available.

More about qdTest

Details of our qdTest fixture family and a link to our price calculator can be found on the product page.

The online configurator: configure your test fixture individually

The qdTest configurator from querdenker engineering GmbH is an online tool that lets developers configure the test system themselves to suit their needs. Both the mechanical specification and all electronic components can be selected as required.

The configurator guides the user intuitively through the entire process. Mechanical, electronic and test-specific parameters can be defined precisely. On this basis, a specific request for quotation can be submitted and a transparent price calculated.

For the mechanical configuration, there are four housing types to choose from, which determine the construction and size of the test system. You can also specify whether the system should have operating controls and automatic lid-closure detection.

Two buttons allow the system to be operated without a connected mouse or keyboard. This is particularly useful when manual input is needed during the test sequence or when a compact setup matters. Integrated LEDs indicate the test status, so simple programming or test tasks can be carried out without a connected monitor. Automatic lid-closure detection registers when the fixture is closed and starts the test or programming process on its own, without any further manual step.

In the configurator, you can also define the number of boards under test and their exact position in the test system. A particularly practical feature: a test point report from the CAD system is imported directly into the configurator, and the test points of the board under test are displayed immediately. Test points can also be added manually. The final layout can be exported as a DXF file for verification and for integration into your own CAD system.

In the electronics section of the configurator, you can specify the complete power supply, the communication interfaces, suitable microcontroller flashers and the relay, voltage measurement and current measurement functions. This lets you match the choice of electronics modules to the test task.

Once the mechanical and electronic configuration is complete, a full summary is generated. It allows a final check of all selected components before the price is calculated and the enquiry is submitted.

The qdTest configurator can also be used to define and manage test sequences. These set out the order and the conditions in which the individual test steps will later be carried out.

qdTest: more autonomy and price transparency in board testing

What makes qdTest special is that quality assurance and the development department can configure the test and programming system themselves. The online configurator considerably shortens the time-consuming and resource-intensive process of writing requirement and design specifications. Together with the online configurator, qdTest lets prospective customers define their requirements, select the electronic components they need, organise the test cases and calculate a transparent price. The querdenker engineering team is also available for individual advice. Tiered pricing applies from the second system onwards.

With qdTest, electronics test systems stay simple, and their price makes them economical even at small and medium volumes.