Find the Root Cause of “No Fault” Found
In addition to continuity and shorts testing, the Voyager detects and isolates intermittent circuits on every test point simultaneously and continuously.
- Repeated returns of the same assembly for repair
- Excessive spare part stock to cover units out of service
- Downtime to replace units
- Scraping costs associated with unrepairable units
- Wasted test time using technology that cannot detect intermittent faults
Distance to Fault
The Voyager includes a spread spectrum TDR so that the fault can be located. Once an intermittent is detected, the TDR is immediately connected to the failed test point and used to determine the distance to the fault.
A low-level DC voltage stimulus is injected into each connected and programmed test point, while simultaneously monitoring all test points for any changes in current flow. No scanning or digital averaging or sampling is used.
Continuity and Shorts Testing
To find hard failures, a Digital Multi-Meter (DMM) reads the circuit resistance and compares them with a known “golden” reference.
A mapping utility which automatically finds the nodal configuration without the need of detailed analysis of either the UUT or schematics.
The scope graphically tracks small resistance changes measured across any two test points, or group of test points, in the UUT to aid in diagnosing which points in a node may be causing a lack of continuity, a shorting condition, or circuit intermittency.
The intermittent detection software displays the faults graphically so that you can easily observe the results.
The Voyager can easily be hand-carried to the field or transported in the available shipping case.
How It Works
The Voyager injects a low level DC voltage stimulus into each connected and programmed test point while simultaneously monitoring all test points for any changes or anomalies in the resulting current flow. No scanning or sampling is used to detect the faults. The system’s electronics detect the changes in state and latch the occurrences as it happens.
The Log Scope function allows the user to graphically track small resistance changes measured across any two test points or groups of test points. This aids diagnosis of the points that are the source of the fault condition.
The optional distance to fault analysis incorporates a spread spectrum TDR to locate the falut to within 1% accuracy.
By detecting and isolating the root cause of intermittent faults, the Voyager technology has repeatedly shown double digit or more return on investment and dramatically increased mean time between failures (MTBF).
The US Air Force utilized the Voyager technology on one of its least reliable Line Replaceable Unit (LRU), the F-16 AN/APG-68 Radar System Modular Low Power Radio Frequency (MLPRF). The maintenance depot had determined 147 units could not be repaired and were removed from service. With a replacement cost of over $300,000.00, the defective units represented a huge replacement cost to the depot.
AN/APG-68 Radar System
After testing using the Voyager technology, the results were dramatic. 400 LRUs were subjected to intermittent fault detection and over 60% were found to have intermittent connections which previously had escaped detection by conventional test methods. The units have been returned to service and the Mean Time Between Failure (MTBF) has more than tripled representing an additional savings of $11 million dollars.
The Voyager technology has been voted by the Department of Defense as the winner of its Great Ideas competition. With such a huge success and cost savings, it is easy to see why.
About Intermittent Faults
An intermittent fault, or momentary “open,” can be due to a number of defects including a cracked solder joint, a corroded contact, a sprung connector receptacle, a loose crimp connection, a hairline crack in a printed circuit trace, a loose wire wrap, a broken wire, or various other conditions. These defects result in field failures which cannot be duplicated during testing. There have not been tools to find this kind of fault until now. Only the Voyager has a proven ability to find these defects and eliminate “No Fault Found” test results.
How can the Voyager find otherwise undetectable faults?
Only Voyager incorporates state of the art technology to monitor all test points continuously. With it’s exclusive “All Lines - All the Time” architecture, even disruptions in a circuit as short as 50 nanoseconds will be detected and reported by the Voyager’s graphical software. You can even use voice synthesis to hear the fault detected while you are inspecting the assembly.
What causes intermittent test results?
There are a lot of things that happen in the real world that are difficult to simulate on a tester. Thermal expansion due to temperature changes can stress solder joints and lift pads. Repeated vibration can cause the best contacts to loosen over time. Damage can result from simple handling and disassembly which may not be observed until a later time. Corrosion can literally eat away metal in connectors and on circuit boards.
Why doesn’t my test system find intermittent contacts?
It might, if you are lucky but the odds are against it. With traditional testing, stimulus is only applied to one circuit at a time. It is highly unlikely that the intermittent connection will happen at exactly that point in time. And even if it does, your test system will continue the measurement while the intermittent vanishes. Traditional test systems just don’t have the ability to detect and analyze such short disruptions in the measurement.
|Standard||Integrated single board computer
17” monitor with touch interface
Graphical user interface
|Optional||Portable vibration table with module frequency response 5 – 200 Hz|
|Test Points||128, 256 and 512 (8,000 in cabinet configuration)|
|Power Requirements||AC: 90 – 132, 175 – 265 @ 47-63 Hz auto switching
DC: 12 – 30 V
|Enclosure||Watertight, crush proof and dust proof.
Press and pull latches
|Size and Weight||Voyager 128 and 256: 22" x 17" x 8" (60 x 43 x 20 cm) at 35 lbs. (16 kg)
Voyager 512: 22" x 17" x 8" (60 x 43 x 20 cm) at 35 lbs. (16 kg)
||32°F to 110°F (0°C to 45°C)|
|Storage Temperature||-5°F to 180°F (-20°C to 85°C)|
|Humidity||10% to 90% RH non-condensing|