Difference between revisions of "X1 Manufacturing Procedures 2013"

Latest revision as of 23:01, 22 April 2013

Please see the new documents:

X1 V7 Series Main Board Manufacturing and Programming

Materials Requirement by Station

Station 2 – “WiFi” Mechanical Subassembly
802.11b/g USB WiFi Module
WiFi cable
Antenna with cable
Low Static Hi-Temp Kapton Polyimide Film Tape 2.7 Mil, 3/8"
Wifi Plastic Carrier Lid
Double sided Tape for Antenna (Specify Type)

Station 3 – “Road Case” Mechanical Subassembly
Idrive Road Side Case
Idrive Support
Idrive Half Bracket Screw Side
Idrive Half Bracket Nut Side
M4 Nut (2x)
N4 Flat washer (2x)
M4x25 screw (2x)
3M very high bond double adhesive tape, 100C temp. resistant, 48mm width (for windshield mounting)
Super glue ( to attach the flat lid to the windshield support)
Retainer and Retainer Lid (pin in the middle of the support arms)
Station 5 – “Final Assembly” Mechanical assy
GPS or GPRS Assembly ( Depends on Camera Version)
Wi-Fi Assembly (from Station 2)(with Label for case)
Idrive Road Case Assembly(from Station 3)
Low Static Hi-Temp Kapton Polyimide Film Tape 2.7 Mil, 3/8"
Idrive X1 PCB –pre-programmed PCB with Focused Lenses (from Station 4)
Idrive Driver Side Case
M3x18 screw
1 Label with bar coded serial number for camera case

Station 6 – “Final Test” (Wifi, GPS, Transfers)
Idrive X1 unit (from Station 5)

Station 7 – “Final Packing”
Completed Idrive X1 (From Station6)
Idrive Power Cable harness Assembly
Idrive Wired Panic Button Assembly

Equipment Requirements and Setup

Software and special files - provided by Idrive

Required Tools and supplies

Screwdrivers

Tweezers

Side Cutting pliers

Allen wrench

Difference between revisions of "X1 Manufacturing Procedures 2013"

Latest revision as of 23:01, 22 April 2013

Materials Requirement by Station

Equipment Requirements and Setup

Required Tools and supplies

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@@ Line 1: / Line 1: @@
-==Important Information==
-*All SD cards need to be unlocked (all SD cards have a lock/unlock switch). It depends on the SD Cards‟ provider whether or not the card needs to be formatted. In all cases if the SD Card needs formatting do not use the quick version.
-The power supply 12V 1A for the programming board needs to be stabilized type.
-<br/><br/>
-==Assembly Station Workflow Chart==
+Please see the new documents:
+'''X1 V7 Series Main Board Manufacturing and Programming'''
-<br/><br/>
 ==Materials Requirement by Station==
@@ Line 15: / Line 12: @@
 <br/><br/>
-==Equipment Requirements and Setup==
+{| class="wikitable"
-===Short List===
+|-
+!'''Station 2 – “WiFi” Mechanical Subassembly '''
+|-
+|802.11b/g USB WiFi Module
+|-
+|WiFi cable
+|-
+|Antenna with cable
+|-
+|Low Static Hi-Temp Kapton Polyimide Film Tape 2.7 Mil, 3/8"
+|-
+|Wifi  Plastic Carrier Lid
+|-
+|Double sided Tape for Antenna (Specify Type)
+|-
+|
+|-
+!'''Station 3 – “Road Case” Mechanical Subassembly'''
+|-
+|Idrive Road Side Case
+|-
+|Idrive Support
+|-
+|Idrive Half Bracket Screw Side
+|-
+|Idrive Half Bracket Nut Side
+|-
+|M4 Nut (2x)
+|-
+|N4 Flat washer (2x)
+|-
+|M4x25 screw (2x)
+|-
+|3M very high bond double adhesive tape, 100C temp. resistant, 48mm width (for windshield mounting)
+|-
+|Super glue ( to attach the flat lid to the windshield support)
+|-
+|Retainer and Retainer Lid (pin in the middle of the support arms)
+|-
+|-
+!'''Station 5 – “Final Assembly” Mechanical assy'''
+|-
+|GPS or GPRS  Assembly ( Depends on Camera Version)
+|-
+|Wi-Fi Assembly (from Station 2)(with Label for case)
+|-
+|Idrive Road Case Assembly(from Station 3)
+|-
+|Low Static Hi-Temp Kapton Polyimide Film Tape 2.7 Mil, 3/8"
+|-
+|Idrive X1 PCB –pre-programmed PCB with Focused Lenses (from Station 4)
+|-
+|Idrive Driver Side Case
+|-
+|M3x18 screw
+|-
+|1 Label with bar coded serial number for camera case
+|-
+|
+|-
+!'''Station 6 – “Final Test” (Wifi, GPS, Transfers)'''
+|-
+|Idrive X1 unit (from Station 5)
+|-
+|
+|-
+!'''Station 7 – “Final Packing”'''
+|-
+|Completed Idrive X1 (From Station6)
+|-
+|Idrive Power Cable harness Assembly
+|-
+|Idrive Wired Panic Button Assembly
+|-
+|}
+==Equipment Requirements and Setup==
-* 2 computers with Windows XP or better, Windows 7 Professional preferred
 * Software and special files - provided by Idrive
-* Cables (USB, parallel, network crossover etc.)
-* Idrive X1 Firmware Programming Fixture
-* Idrive X1 Final Test Station Board
-* Stabilized Power supply 12V, 1A
-* Power supply 12V, 6A
-* Label Printer
-* Lens test charts
-* Wireless router
-<br/>
-===Firmware Programming Station Setup===
-<br/>
-====Hardware Setup====
-* Computer -Windows XP or better, Windows 7 Professional recommended
-:* Min. requirements: 1GB RAM, 100 GB HDD
-:* 2 Network adaptors (NICs)
-:* 1 Monitor recommended - need to support 1600X1200 screen resolution
-::* Windows Settings: autorun disabled, User Account Control disabled
-::* Internet connection - the internet connection is required for logging of firmware programming for each device
-:* Network Adapters LAN settings:
-:::*'''Connection one for the Programming Fixture'''
-::::*IP address: 192.168.0.10
-::::*Subnet Mask: 255.255.0.0
-::::*Default gateway: 192.168.1.1
-:::*'''Connection two is for the local network with access to internet:'''
-::::*DHCP or as required by location
-* Firmware Programming Fixture (See Appendix for detail)
-* ASIX Network Adapter
-* Mini HDMI to Mini HDMI cable - max. 1m
-* USB Cable type B to type A max. 1.5m
-* Cat5 regular cable to internet connection
-* Cat5 regular cable to ASIX network adapter
-* 12V/1A supply connected to Firmware Programming Fixture
-* Power Cable 6 PIN to 6 PIN
-* SD Card <nowiki>"Installer"</nowiki>
-* SD card reader – primarily for RMA activity to recover events from the SD card
-<br/>
-====Software Setup====
-* TeamViewer (http://www.teamviewer.com ) - personal license
-* A HyperTerminal application – Putty (http://www.putty.org )
-* Idrive Factory Tools - software application
-* SDFormat tool the ( http://www.sdcard.org/consumers/formatter_3/eula ) <span style="color: red">'''DO NOT USE THE QUICK FORMAT Use the “Full(rewrite) option!'''
-<br/>
-====Required Tools and supplies====
-* 2 Lens test targets (for the Driver side lens the focal length should be about 1 meter, for the Road side the lens should be focused as far as possible)
-* Loctite Super Glue, “Control – Extra Time”
-<br/>
-===Final Test Station – Setup===
-<br/>
-====Hardware Setup====
-* Computer - Windows XP or better, Windows 7 Professional recommended
-:* Min. requirements: 1GB RAM, 100 GB HDD, 2 Network adaptors (NICs)
-:* Windows settings: autorun disabled, User Account Control disabled - please see Config Windows 7 section of this document
-:* Network Adapters LAN settings:
-::* '''Connection one for the Programming Fixture '''
-::* IP address: 192.168.0.10
-::* Subnet Mask: 255.255.0.0
-::* Default gateway: 192.168.0.1
-::* '''Connection two for local network with access to internet: DHCP or as required by location'''
-* Idrive Final Test Station Board ( See Appendix for detail)
-* USB Port from computer to Final Test Programming Fixture
-* Cat5 regular cable to internet connection
-* Cat5 regular cable to a LAN port of wireless routing device
-* 12v/6a power supply into Final Test Programming Fixture
-* SD card reader
-* Monitor
-<br/>
-====Wireless router Setup====
-* LAN IP address 192.168.0.1
-* Network Mask 255.255.0.0
-* Default Gateway 192.168.0.1
-* SSID bwifi
-* No DHCP
-* No DNS
-* No encryption
-* No WAN settings (not in use)
 <br/>
-====Software Setup====
-* TeamViewer (http://www.teamviewer.com ) - personal license
-* Idrive Factory Tools ( Idrive supplied)
-<br/>
 ====Required Tools and supplies====
@@ Line 187: / Line 108: @@
 * Allen wrench
 <br/><br/>
-==Process Stations Step By Step==
-===Process Station 1 – Lens Holders + Lens===
-.1.1 Bar Code Label - After SMT Assembly all boards needs to be labeled with a bar code label that will contain the serial number in clear also. The Bar Code Labels will be pre-generated in 2 copies each by Idrive based on each order (number of boards). The Bar Code Label needs to be max. 22 mm x 10 mm. The Bar Code Label will be stick on the SD Card Connector.
-.1.2 LEDs TH Sodering (10x IR LEDs + 2x Bicolor LEDs)
-.1.3 Lens Holders Mounting
-.1.4 Lenses in Lens Holders
-<br/>
-===Process Station 2 – Wifi Subassembly===
-----
-[[File:Assy.JPG|600px|]]
-[[File:Wifi1.jpg|500px|]]
-[[File:Wiki2.jpg|500px|]]
-'''2. Connect the WiFi Cable to WiFi module. Avoid overlapping the wires.'''
-[[File:Wiki3.jpg|500px]]
-'''3. Add Antenna to WiFi module on MAIN connector as shown.'''
-[[File:Wifi4.jpg|500px]]
-'''4. Place the Wifi and antenna into the Wifi cover and route the antenna cable as shown.'''
-[[File:Wifi5.jpg|500px]]
-'''5.''' Apply two pieces of Kapton tape to secure the wifi module to the plastic wifi carrier. '''The tape should never touch any portion of the PCB or circuitry.''' One piece must attach to the metal can with the sticker on it and cross over the antenna connection and touch nothing but plastic on the other side as shown. The second piece of tape should touch only the top of the chips and wrap around to the other side and touch only plastic as shown. '''This care must be taken so as not to interfere with the wifi performance!'''
-[[File:Wifi6.jpg|500px|]]
-[[File:Wifi7.jpg|500px|]]
-Attention! Place the antenna in to the MAIN connector on the WIFI module! Not in the AUX connector!
-<br/>
-===Process Station 3 – Road Case Subassembly===
-[[File:Station3.JPG|600px]]
-'''1.''' Attach the Flat Lid to the Windshield support using Super Glue. (Ensure there is a flat surface)
-'''2.''' Stick the 3M double sided tape on the flat surface of the Bracket to cover the entire surface area. Trim the edges of the tape with a scalpel.
-'''3.''' Attach the two Half Brackets with the Retainer and Retainer Lid. Press the retainer pins together to full seat them.
-'''4.''' Attach the mated Brackets to the Road Case using a screw (M4x22), one M4 nut and one N4 washer.
-'''5.''' Attach the support on the other end of the brackets as shown in the picture.
-[[File:Road.JPG|700px]]
-<br/>
-===Process Station 4 – Programming Station Initialization===
-'''1.''' Open Factory Tools Application
-'''2.''' Turn fixture power on (SW1)
-'''3.''' The Firmware Programming Station is now ready to process idrive X1 boards
-----
-===Process Station 6 - Step by Step Programming Idrive X1 Board===
-====Setup Device ~5 seconds====
-'''1.''' Place the Idrive X1 board in to the Programming Device Holder.
-'''2.''' Connect the Power cable between the Idrive X1 Board and the Programming Fixture.
-'''3.''' Connect the MINI HDMI cable between the Idrive X1 Board and the Programming Fixture.
-====Program the board (bootloader, kernel, filesystem, configuration)====
-'''1.''' Insert the SD Card Installer into the X1 board.
-'''2.''' Press Start Installation on the Factory Tools App. You will have confirmation status for each step and the application will enter directly in Focus Lens section if programming and configuration succeed.
-====Lens Focusing====
-'''1.''' Focus camera 1 (Driver Side) (the one on the same side of the camera as the LEDs).
-'''2.''' Focus camera 2 (Road Side) (the one on the side of the camera without LEDs).
-====Verify That the IR LEDS are working (optional)====
-'''1.''' Use a camera phone or camera and view the IR LEDs and verify that they are all on.
-[[File:IR LEDs.jpg|700px|]]
-====Finish Programming====
-'''1.''' Press Finish button on the Factory Tools
-'''2.''' Remove the SD Card Installer
-'''3.''' Disconnect the power cable and the adapter
-====Secure Lenses====
-'''1.''' Fix the road lens with a drop of super glue.
-'''2.''' Fix the driver lens with a drop of super glue.
-'''3.''' Verify that the lenses can not move.
-'''4.''' Advance the board to the next station.
-----
-===Process Station 5 – Final Assembly===
-'''1.''' Connect the GPS cable to the GPS module
-'''2.''' Place the Wifi assembly ('''From Station 2''') into the Road Case and align it with the 3 pins molded into the case.
-'''3.''' Fix the Wifi assembly to the Road Case using Kapton tape in order to prevent movement. The tape must be placed from the plastic wifi carrier across the fat metal potion of the antenna to the road case. Ensure nothing other than plastic touches the thin metal portion of the antenna and that the thin portion of the antenna is straight.
-'''4.''' Insert a blank SD Card in to the SD Card connector on the Idrive X1 board
-'''5.''' Connect the GPS module connector then the WiFi connector to the main board (Idrive X1 PCB)
-[[File:Connect.jpg|700px|]]
-'''6.''' Insert Idrive PCB into the Road Case starting with the bottom hook and then the upper hook, press it until it clicks in and is secure. Use tweezers to deflect the top hook so that excess pressure is not used on the motherboard. Ensure that the wifi cable does not obstruct the USB connector opening.
-'''7.''' Close the case starting with the top hooks. Ensure that the LEDs are aligned with the holes in the Driver Side Case and do not get bent and that they protrude through the case evenly. When the case is properly closed there should be no gap in the seam between halves of the case.
-'''8.''' Fix the case with the central screw in the back.
-----
-===Process Station 6 – Final Test Station Initialization===
-'''1.''' Open the Idrive Factory Tools application and keep it open for the entire testing.
-'''2.''' Be sure that the correct USB communication port is selected. ( Verify in Control Panel/Devices/Ports if you are not sure)
-[[File:Port.jpg]]
-[[File:Port2.jpg]]'''(GREEN is good)'''
-'''4.''' Turn ON the wireless router or access point
-<br/><br/>
-===Process Station 6 - Final Testing of Idrive X1===
-'''1.''' Turn Off the Power Switch (Right Position)
-'''2.''' Connect the Idrive X1 power cables from the Fixture to the camera(s)
-'''3.''' Turn ON the Power Switch (LEFT Position) (The 6 Ignition LEDs will light up RED)
-'''4.''' Push the “Automatic Mode” button and the process will start (12V ON and IGNITION LEDS turn GREEN)
-'''5.''' All attached cameras will be booted (~37 seconds)
-'''6.''' Sequentially, each camera‟s ignition will be turned off for configuration. If the device is configured correctly then after 25 seconds the camera will shut off and the next camera will begin configuration. If the device is not configured correctly there will be an error beep after 45 seconds and the next camera will begin the configuration process
-'''7.''' If the device fails to connect to the Device Tool or if there is no device attached to that location in the fixture you may push the “Manual Mode” button to advance to the next camera.
-[[File:Excl.jpg|70px|]]
-'''**''' Only push the “Manual Mode” button to advance to the next camera/location after the current camera has completely shut down (both of its LEDs are off) (The skipped camera will not be booted in the next step for wired events testing)
-'''8.''' After all cameras have been configured they will be automatically turned on again for wired events and transfer testing.
-'''9.''' After ~75 seconds from the beginning of reboot the three wired events will be activated at a 30 second intervals.
-'''10.''' After the wired events are recorded the cameras will sequentially enter into transfer mode ('''ORANGE''' Left '''GREEN''' Right LEDs) one by one at a 25 second intervals.
-'''11.''' 25 Seconds after the last camera finishes transferring there will be a final beep if all 6 cameras have been successfully tested. If any camera fails a test there will be a beep after 100 seconds. The failing device will be shown in the Factory Device Tool.
-'''12.''' Using the Idrive Control Center Factory Version verify that the images from both sides of the cameras have good, clear, full, bright image and are correctly focused.
-'''13.''' Turn Off the Power Toggle Switch (Right Position)
-<br/><br/><br/>
-====Manual Mode portion ~5:00 with single camera====
-'''14.''' Turn on the Power Toggle Switch (Left Position) (The 6 Ignition LEDs will light up RED)
-'''15.''' Push the “Manual Mode” button (Manual Mode LED will turn on)
-'''16.''' Turn on 12V to the Cameras by Pressing the 12V ON/OFF Pushbutton (12V LED will Turn on)
-'''17.''' Turn on the Ignition for each camera by pressing the corresponding “Ing.” Push Button
-'''18.''' Wait ~30 sec. for the camera to initialize (Both LEDs must turn Solid Green)
-'''19.''' Gently shake the first camera to create a shock event and observe the LEFT LED to be RED and the RIGHT LED to be GREEN indicating the camera is recording.
-'''20.''' When both LEDs return to GREEN use a paperclip and depress the Remote Panic programming button and hold it until the LEDs are RED on the LEFT and GREEN on the Right.
-'''21.''' Within 5 seconds press the remote panic button two times. Each time the '''RIGHT LED''' will flash '''ORANGE.'''
-'''22.''' When BOTH LEDs return to '''GREEN''' press the panic button for the first camera and observe the '''LEFT LED''' to be '''RED''' and the '''RIGHT LED''' to be''' GREEN''' indicating the camera is recording.
-'''23.''' Place the label with the camera‟s serial number on the back of the Remote and on the back of the camera.
-'''24.''' Once BOTH LEDs turn GREEN press the ignition button for the camera to enter transfer mode ( '''LEFT LED ORANGE and RIGHT LED GREEN''')
-'''25.''' Verify the events transferred successfully in the Factory Device Tool...
-'''26.''' Repeat steps 19- 25 for each camera.
-'''27.''' Turn Off the Power Switch (Right Position)
-'''28.''' Disconnect the power cables from the idrive devices.
-'''29.''' Advance the Idrive devices to the next station.
-<br/><br/>
-====Full Manual Mode====
-'''1.''' Turn Off the Power Toggle Switch (Right Position)
-'''2.''' Connect the Idrive X1 power cables from the Fixture to the cameras
-'''3.''' Start the Idrive Factory Device Tool in Manual Mode
-'''4.''' Turn on the Power Toggle Switch (Left Position) (The 6 Ignition LEDs will light up RED)
-'''5.''' Push the “Manual Mode” button (Manual Mode LED will turn on)
-'''6.''' Turn on 12volts to the Cameras by Pressing the 12V ON/OFF Pushbutton (12V LED will Turn on)
-'''7.''' Turn on the Ignition for the first camera by pressing the corresponding “Ing.” Push Button
-'''8.''' Wait ~30 sec. for initialization - Both LEDs must turn Solid Green.
-'''9.''' Wait >10 sec.
-'''10.''' Press the “Ing. 1” pushbutton (IGNITION OFF on the first camera) and wait until the camera connects with the Idrive Factory Device Tool.
-'''11.''' Select “Configure Device” to program the device to the default idrive standard configuration
-'''12.''' The Camera will shut off ( initial configuration complete for this device)
-'''13.''' Repeat Steps 7 – 12 for each camera connected to the fixture
-'''14.''' After all the connected devices are configured (all of them turned off), Press the” Ign” pushbutton for each and wait until all of the devices have GREEN-GREEN LEDs (~30 seconds).
-'''15.''' Press the Door Event Button and verify the Left LED turns RED during the event and returns to a GREEN-GREEN condition for each device)
-'''16.''' Press the Alarm Event Button and verify the Left LED turns RED during the event and returns to a GREEN-GREEN condition for each device)
-'''17.''' Press the W_Panic Event Button and verify the Left LED turns RED during the event and returns to a GREEN-GREEN condition for each device)
-'''18.''' Shake each Idrive device to create a shock event and verify the Left LED turns RED during the event and returns to a GREEN-GREEN condition for each device)
-'''19.''' Press Ing. 1 (IGNITION OFF on the first camera - the first Idrive X1 device will switch to Transfer Mode. (Orange Left and GREEN Right LED)
-'''20.''' Wait ~ 30 Seconds and repeat steps 19 & 20 for each device
-'''21.''' After the transfer(s) is complete, both LEDs will turn OFF (on all 6 devices), go to the Idrive Factory Control Center player and play the event.
-'''22.''' Check that the images from both sides of the cameras have good, clear, full, bright image and are correctly focused.
-'''23.''' Turn Off the Power Switch (Right Position)
-'''24.''' Disconnect the power cables from the idrive devices.
-'''25.''' Advance the Idrive devices to the next station.
-<br/><br/>
-===Final Inspection and Packing===
-'''Final Inspection:'''
-'''1.''' The correct placement of the adhesive tape
-'''2.''' The correctitude of the assembly
-'''3.''' No spots, no scratches etc.
-'''4.''' The existence of the label SN on the back of the case
-'''Each Idrive X1 Kit needs to have one each of the following:'''
-'''1.''' Idrive X1 full unit
-'''2.''' Alcohol wipe
-'''3.''' Idrive Power Cable
-==Appendix==
-===The Idrive Firmware Programmer Reference===
-[[File:Programmer.jpg]]
-*'''Idrive X1 Programming Holder (= “Holder”)'''
-[[File:Holder.jpg]] '''Holder base structure'''
-[[File:Hosterc.jpg|500px|]] '''Holder completely assembled, with Idrive PCB in position'''
-===Idrive Final Test Station Programmer Reference===
-[[File:Test station.jpg|800px|center]]
-'''1.''' Connect a 12V – 6A power supply at the green terminal block.
-[[File:Polarity.JPG|600px|]]
-'''2.''' Connect the USB Cable
-'''3.''' Connect the 6 Idrive Power Cables
-===Cat5e Crossover Cable pinouts===
-[[File:Pinouts.jpg]]
-====Program installation Notes====
-*'''Install the Idrive Factory Control Center (Factory CC) Application (transfer and player application for final test)'''
-'''1.''' Run setup.exe
-'''2.''' Follow the instructions on the screen.
-'''3.''' Finish/Close
-'''4.''' The setup will place a shortcut on the desktop.
-* '''Install TeamViewer - during setup you need to choose the Personal license installation!'''
-* '''Install the H-JTAG Application:'''
-'''1.''' Unzip the "H-JTAG V0.9.2.zip" file
-'''2.''' Run the "H-JTAG V0.9.2.exe" file
-'''3.''' Follow the installation instructions
-'''4.''' The setup will place H-JTAG and H-Flasher shortcuts on the desktop
-'''5.''' Delete the extra shortcuts
-'''6.''' H-JTAG settings LPT/USB selection – LPT
-* '''Install TFTP Server'''
-'''1.''' Accept the agreement
-'''2.''' Install Complete version
-'''3.''' Start> Programs>WinAgents TFTP Server 4>TFTP Server Manager
-'''4.''' Click OK and Start Server
-'''5.''' Select Manage Virtual Folders icon and point to C:\arm\tftp
-* Install Idriveprog
-'''6.''' Run setup in the directory Idrive programming tools\installer\volume\setup
-'''7.''' Run Setup for NI-Visa\ NIVISAruntime.msi file
-'''8.''' Add shortcut to the desktop for Idriveprog c:\Program Files\Idriveprog\Idriveprog
-'''9.''' run the program Idriveprog
-'''10.''' press the STOP PROG
-'''11.''' Change the COM4 port with your COM number
-'''12.''' Press -> for start program
-* '''Install Idrive Device Tool'''
-'''1.''' Run setup.exe
-'''2.''' Follow the instructions on the screen
-'''3.''' Finish/Close
-'''4.''' The setup will place shortcut on the desktop
-* '''Install Reglaj_V3.jar application (live cameras view for focusing lens)'''
-'''1.''' Place the folder in a known location
-'''2.''' Create a shortcut on the desktop that points to Reglaj_V3.jar file
-*'''Copy the nand.hfc file into C:/arm/tftp folder.'''
-* '''Copy u-boot, uImage and filesystem.yaffs files into C:/arm/tftp'''