Sean Zylstra created several engineering test fixtures and tools for software and hardware testing at BlackBerry, including a 1:16 USB multiplexer and 4:4 USB switch to automate loading software on up to 16 devices sequentially and 4 simultaneously, an audio test jig to securely hold and record sounds from a BlackBerry device during typing/clicking, an automated audio plug insertion tool to insert and remove audio plugs from devices in testing without user input, and an auto focus convergence test jig to precisely rotate a disc for camera module testing.

1. Project Portfolio:
Sean Zylstra
-Hardware Engineering Lab

2. 1:16 USB Multiplexer &
4:4 USB Switch

3. 1:16 USB Multiplexer &
4:4 USB Switch
Purpose:
• To automate the software loading of up to 4 devices
simultaneously, and 16 devices sequentially
Benefit:
• The multiplexer/switch removes the dependency of
user input for the connection and disconnection of
BlackBerry devices for various software testing/
application loading
Design Highlights:
• Schematic capture and PCB design completed in Protel
99
• USB signal lines routed precisely for 90 ohm
differential impedance (4 layer PCB design)
• USB 2.0 Compliant (480Mbit/s)
• ATMega88PA microcontroller firmware programmed
in C
Used By:
• Desktop SV&V - R&D
• OS Protocols - R&D
• HH Test Automation Development - R&D

8. Audio Test Jig

9. Audio Test Jig
Purpose:
• Create a test fixture that will securely hold
a BlackBerry handheld device and pick up
the audible sound of the touchpad and or
keys during typing/ clicking operations
Benefit:
• Audible typing/clicking sounds are easily
picked up by the adjustable microphone
and interfaced to a computer for analysis
Design Highlights:
• Designed and 3D modeled in Pro/E
• Microphone and arm assembly adapted to
work with custom base
Used By:
• Hardware Development- R&D

10. Automated Audio Plug
Insertion Tool

11. Automated Audio Plug
Insertion Tool
Purpose:
• Create a computer controlled test fixture that will
facilitate the automatic insertion and removal of an
audio plug into and out of an audio jack on a mobile
phone or tablet
Benefit:
• Automated function eliminates the need for user
input to insert and remove the audio plug
Design Highlights:
• Designed and 3D modeled in Pro/E
• Controller PCB schematic capture and PCB layout
completed in Protel 99
• ATMEGA88PA microcontroller firmware programmed
in C
• PC Graphical User Interface programmed in Visual
Basic
Audio plug insertion and removal operations controlled
by linear actuator
Used By:
• Hardware Engineering Software Tools - R&D

15. Auto Focus (AF)
Convergence Test Jig

16. Auto Focus (AF)
Convergence Test Jig
Purpose:
• Create a computer controlled test fixture that will
rotate a disc at a precise speed between 1-
120RPM
Benefit:
• Assists in the AF convergence testing of camera
modules
Design Highlights:
• Designed and 3D modeled in Pro/E
• Controller PCB schematic capture and PCB layout
completed in Protel 99
• ATMEGA88PA microcontroller firmware
programmed in C
• PC Graphical User Interface programmed in Visual
Basic
• Spinning of disc driven by stepper motor
Used By:
• Camera Metrology - R&D