Automated continuity testing of flexible backplanes using a cable tester

In recent years, military computers have been widely used by ASELSAN. Flexible backplanes which have backplane connectors on one end (VPX or CPCI) and military connectors on the other end are used as part of the military computers along with processor boards, Input/Output boards, communication boards etc. To meet the requirements of various projects, backplanes with different form factors (3U, 6U and mixed) and different number of slots are used, thus bringing the challenge to test different types of backplanes. Continuity testing of these backplanes in production would be tedious and error prone without an automated and standard test infrastructure.Generic adaptor boards have been designed to connect 311 CPCI, 311 VPX and 611 VPX connectors on the backplane under test to 96-pin DIN connectors. Flat adaptor cables have been built to connect these DIN connectors to 32-pin connectors on the cable tester. For every backplane under test, particular test software is developed using the software of the cable tester enabling the automation of the continuity test. There were two problems with this infrastructure. The first problem was the deformation of flat adaptor cables which resulted in opens during continuity tests. There was a need to increase the reliability of the infrastructure. For this purpose new adaptor boards with 160-pin DIN connectors, which have crimp type receptacles, were designed. The adaptor cables were changed so that flat cables were no longer used. The reliability of the infrastructure was increased after the modification. The second problem was the need for a separate mechanical platform for every backplane being tested in order to increase the ruggedness of the infrastructure. This required mechanical designer labor. To eliminate the need for a separate mechanical platform for every backplane being tested, it was decided to test the backplane after being assembled in the chassis of the military computer. This approach provided a more rugged platform and eliminated the need for mechanical designer labor. In this article, the automation of the continuity testing of flexible backplanes using a cable tester is presented.