Copper layers

Eltec sensor test rigs

Bench rigs and software that qualify Eltec pyroelectric IR sensors. Two rigs live in this repository, one top-level folder each:

• single_detector_rig/ — an ESP32 chops an IR emitter and streams a 24-bit ADS1256 ADC to a laptop; one Python desktop application runs the test procedure for the sensor model chosen in a dropdown, judges each part, and writes a CSV row per sensor.
• array_rig/ — fifty detectors at once: a 50-position buffer PCB read by an ACCES USB-AIO16-64MA DAQ; the same selector-plus-model-directory structure, testing offset and noise per tray (sensitivity waits for the emitter board).

Windows 11 and Xubuntu are both supported.

I'm a technician — run a batch

1. Laptop on AC power, ESP32 USB cable in, both batteries connected, no fans near the fixture.
2. Double-click the Eltec Test Rig desktop icon (or single_detector_rig\run_eltec_rig_tester.cmd / .sh). For a tray of fifty on the array rig use the Eltec Array Rig icon (array_rig\run_eltec_array_tester.cmd / .sh) — runbook §3b.
3. Pick the sensor model → Start tester → batch number, your name, filter setup → load a part → Enter.
4. Read the banner (PASS / PASS · NEAR LIMIT / FAIL) → load the next sensor → Next (Enter). The number only advances when a part passes.

Everything else — verdicts, the Stop / Next buttons, where files go, what to do when something fails — is in docs/TECHNICIAN_RUNBOOK.md.

I'm the engineer taking over

Start with docs/ENGINEER_HANDOVER.md (what you are inheriting, architecture, the copy-per-model rule, firmware lifecycle, open work). Then docs/CALIBRATION_RECORD.md before touching any limit.

Repository map

README.md                    this file — the index
CHANGELOG.md                 dated history, newest first (one entry per behavioural change)
CLAUDE.md                    ground rules for AI-assisted sessions
run_all_tests.py|.cmd|.sh    runs every test suite of both rigs, prints a summary
docs/
  TECHNICIAN_RUNBOOK.md      operator instructions
  ENGINEER_HANDOVER.md       engineering manual + open work
  CALIBRATION_RECORD.md      every limit/factor/gate state with provenance  ← source of truth for numbers
  DATA_MAP.md                where results & evidence live (outside the repo) + backup routine
  TP120(40623).pdf           test procedure of the 40623 (array rig); daq_usb_aio16_64ma/ = DAQ vendor docs
single_detector_rig/         THE single-detector application — selector + one directory per sensor model
  eltec_rig_tester.py        selector GUI (dropdown → launches the model app)
  sensor_versions.py         model registry + required firmware
  attempt_history.py         per-batch attempt log (shared)
  v1_single_sensor/          vendored signal-math engine (shared, frozen)
  m405m22/ m406mca/ m449m18/ one qualified tester each: GUI, backend, analysis, tests, launchers, README
  run_eltec_rig_tester.*     launchers; install_*_launcher.* = optional desktop icon
array_rig/                   THE array application — selector + one directory per detector model (same pattern)
  eltec_array_tester.py      selector GUI (model dropdown → launches the model app)
  sensor_versions.py         model registry + required hardware (DAQ)
  tray_history.py            per-lot tray event log (shared)
  m40623/                    the 40623 build: GUI, DAQ backend (ctypes AIOUSB.dll), numpy noise port, probe, bench readout + live viewer, tests, launchers
Arduino/Eltec/               firmware (single rig today; the array rig's emitter board will use it later)
  Eltec.ino                  live sketch (v3.2)        README.md = protocol, flashing, troubleshooting

Retired applications (LabJack-era v1–v4, ESP32 v5/v6/v6.1, the standalone 405m22 build, the pre-v2.0 unified app) were removed from the tree on 2026-08-28 and are preserved at git tag archive/pre-cleanup-2026-08-28: git show archive/pre-cleanup-2026-08-28:<path>.

Firmware

The single-detector bench board must run Arduino/Eltec/Eltec.ino v3.2 for all three models (the array rig has no firmware: its DAQ loads its own from the ACCES driver package) (it currently runs v3.1; the 405 M22 and 406 MCA modes work on v2.1–v3.2, the 449 M18 mode needs v3.2). Flash and verify with one command:

python Arduino/Eltec/flash_firmware.py          # --check to only ask what the board runs

Firmware guide: Arduino/Eltec/README.md. Which build belongs on which rig (legacy 406 rigs stay on v1.9): Arduino/Eltec/versions/README.md.

Tests

python run_all_tests.py

Six unittest suites (four for the single rig, two for the array rig), 705 tests, no hardware needed. On Windows the 406 MCA suite reports two known environment-only cases (they pass on Xubuntu) — see the handover doc §7.

Where the data is

Results, attempt logs, waveform snapshots, raw noise captures and calibration files are written outside this repository under Documents\Eltec_<model>_Test_Results\. They are the only copy of the evidence behind the production constants — the backup routine is in docs/DATA_MAP.md.

Documentation index

Dependencies

Python 3 with tkinter, numpy, pyserial, matplotlib (optional, nicer snapshots). The array rig additionally needs the ACCES USB-AIO16-64MA Install driver package (provides AIOUSB.dll) and a 64-bit Python; no extra Python packages. Xubuntu: sudo apt install python3 python3-tk python3-numpy python3-serial python3-matplotlib, user in dialout. Flashing needs the Arduino IDE 2.x installed (its bundled arduino-cli is used).