An automated method for assembling and testing a ring of coupons adapted for inclusion in a thermoelectric generator, the method comprising steps of:
- A. robotically assembling an un-bonded coupon that includes at least:
- i. a pair of wafers;
- ii. a hot fin that is juxtaposed on one side thereof with one of the wafers;
- and
- iii. a cold fin that is juxtaposed on one side thereof with the wafer that is juxtaposed with the hot fin;
- B. using a computer, testing electrical resistance of said un-bonded coupon by:
- i. robotically attaching a volt meter to said un-bonded coupon via a probe;
- ii. robotically connecting an amp meter in series with said un-bonded coupon;
- iii. without any external electrical current applied to the un-bonded coupon, using the volt meter to measure a first voltage produced by said un-bonded coupon;
- iv. while applying a known forced electrical current externally through said un-bonded coupon in a direction current would flow if the un-bonded coupon were short circuited, using the amp meter to measure the forced current, and using the volt meter to measure a second voltage of said un-bonded coupon;
- and
- v. calculating electrical resistance for said un-bond coupon using:
- a. the first voltage measured in step B.iii. above while no external current flows through said un-bonded coupon;
- b. the second voltage measured in step B.iv. while the forced current flows through said un-bonded coupon;
- and
- c. the known, externally applied forced current flowing through the un-bonded coupon measured in step B.iv. using the amp meter;
- C. if the electrical resistance calculated for said un-bonded coupon is less than a pre-established coupon resistance threshold, transferring the un-bonded coupon to a furnace for bonding;
- D. repeating steps A. through C. until a number of un-bonded coupons required for assembling said ring have been bonded;
- E. robotically assembling the bonded coupons into said ring of coupons;
- F. using a computer, testing electrical resistance of said un-bonded ring of bonded coupons by:
- i. robotically attaching a volt meter output terminals of said un-bonded ring of bonded coupons;
- ii. robotically connecting an amp meter in series with output terminals of said un-bonded ring of bonded coupons;
- iii. without any external electrical current applied to the un-bonded ring of bonded coupons, using the volt meter to measure a first voltage produced by said un-bonded ring of bonded coupons;
- iv. while applying a known forced electrical current externally through said un-bonded ring of bonded coupons in a direction current would flow if the un-bonded ring of bonded coupons were short circuited, using the amp meter to measure the forced current, and using the volt meter to measure a second voltage of said un-bonded ram of bonded coupons;
- and
- v. calculating electrical resistance for said un-bonded ring of bonded coupons using:
- a. the first voltage measured in step F.iii. above while no external current flows through said un-bonded ring of bonded coupons;
- b. the second voltage measured in step F.iv. while the forced current flows through said un-bonded ring of bonded coupons;
- and
- c. the known, externally applied forced current flowing through the un-bonded ring of bonded coupons measured in step F.iv. using the amp meter;
- and
- G. if the electrical resistance of said un-bonded ring of bonded coupons is less than a pre-established ring resistance threshold, transferrin the un-bonded ring of bonded coupons to a furnace for bonding.