Many engineers have encountered situations where chip programming works perfectly during the R&D testing phase, but feedback indicates programming failures during mass production. Is this an issue with the chip itself? Or is it a problem with the programmer? Or are there other possibilities?
Many engineers face this issue: programming chips works fine during R&D testing, but once mass production begins, the production department frequently reports programming failures. So, what is the cause?
The common approach is to check:
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Whether there is a defect rate in the batch of chips;
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Whether the programming equipment is functioning correctly.
If no issues are found in these two areas, novice engineers may feel puzzled: Why does my chip work fine, and the mass production equipment is the same as the R&D testing equipment, yet it fails?
There are several implicit issues that are often overlooked:
1. Although your mass production programming equipment is the same as the R&D testing equipment, are both using the original manufacturer’s emulator? Or are there other dedicated programming devices that are not suitable for mass production?
It is important to distinguish that for programming a single chip, a dedicated mass production programmer can achieve one-click operation, suitable for mass production and for factory personnel with basic skills, ensuring a high yield rate. In contrast, the original manufacturer’s emulator is designed for R&D, and the operation process cannot be as simple; it may require manual operation of the computer interface each time or need to be connected for programming, which increases the likelihood of human error.
Moreover, the feedback from the emulator’s programming results is not obvious; it may only print strings, or use beeping sounds or light signals. For factory personnel with limited professional knowledge, there is a risk of misunderstanding these signals, leading to errors. Ultimately, the emulator is not a mass production device and does not guarantee yield rates.
(Reference image of an emulator)
(Reference image of a programmer)
2. If the selected programmer is indeed a mass production type, is it online programming? Or is it using a socket? If an adapter/chip fixture is required, is there a maintenance issue with the fixture? What is the current lifespan of the fixture?
This point is often overlooked. If the device is already a mass production programmer and previous programming was normal, then we need to check your programming fixture, commonly referred to as the programming socket or adapter. How long has it been in use? Programming fixtures have a limited number of uses, known as lifespan, but currently, most manufacturers in China do not provide professional operation manuals or maintenance documents for programming sockets/fixtures to customers, and it is difficult to find corresponding information online. The specifics of usage counts are often vague, leading to many programming failure issues being hard to diagnose. Many contact issues and minor faults stem from the programming socket.
Therefore, at the first sign of a problem, you can check how many times the programming socket has been used and its lifespan. Professional mass production programmers usually provide statistical data, as shown in the image below:
If the programming count is close to the fixture’s lifespan, check the contact points between the fixture and the chip pins for damage due to frequent insertion and removal or uneven pressure during operation. Most minor issues originate from this area. The simplest test method is to swap in another programming socket for comparison testing, which can quickly pinpoint the problem.
Other possible causes of programming failures include incompatibility between the programmer’s software and the chip, requiring firmware updates, etc. These will be discussed further later. Lastly, I remind all engineers to pay attention to the maintenance of the programming socket. Refer to the maintenance manuals of standard programming adapter manufacturers, and if necessary, use pressure devices to maximize the lifespan of the programming socket.
About Zhiyuan Electronics
Guangzhou Zhiyuan Electronics Co., Ltd. was established in 2001 and is a nationally recognized high-tech enterprise, as well as a research and development center for high-end industrial control measurement instruments in Guangdong Province.
Vision:To become a leading enterprise in the industrial internet ecosystem
We design high value-added modules, boards, and high-end measurement instruments using the “chip + AWorks software platform”. Through wired and wireless interfaces, we connect to the ZWS IoT cloud for big data processing, forming an industrial internet ecosystem.
Mission:To advance the process of China’s industrial internet with leading technology
Values:Professionalism and focus achieve dreams