CE TV presents Opto 22's G4 Handler Case Study video
Being new here at Opto, the G4 Handler case study and video was a great way for me to see how the SNAP PAC system actually works. Not only that, but it also helped me understand one of Opto's unique qualities: 200% testing.
I've taken the factory floor tour a couple of times since starting here at Opto, and the tour guide always says the products are 200% tested. Wow, that's a lot of testing but I didn't know what 200% tested really meant. As I watched the G4 Handler in the video and on the Opto factory floor, it all became pretty clear. This machine does test and assembly of every G4 I/O module Opto 22 makes (a G4 module is a single point I/O module used to sense and actuate digital signals). There are actually two rounds of testing of fifty modules per tray: In the first round, each module is tested under full rated loads before being filled with epoxy. If any module fails, it is removed from the group and reconstructed. The remaining modules are then filled with epoxy, which is the final assembly step. Then, after the epoxy is cured, the modules go back to the G4 Handler and are tested yet again, under the same load tests. Any modules that fail the second test are discarded, and therefore 200% testing is accomplished.
I also found that when the modules are tested, not just one test is performed. A bunch of different tests are done including in-rush current tests, current load tests, and inductive and resistive tests. I've never seen this before! Opto didn't let one single piece of product leave the factory without each of these modules being rigorously tested, twice!
Also, I found that the new SNAP PAC system really exceeded my expectations. The increased density is 16 times more compact than the older generation PAC System, making the G4 Handler smaller and easier to monitor and maintain. And the integrated motion control made it easy to automate the entire machine from a single software program, PAC Control.
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