Difference between revisions of "X1 Manufacturing Procedures 2013"

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=='''This manual has been split to support separate MB and Camera Processing'''==
 
  
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Mark here, I am splitting this manual into two separate documents.
 
  
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Reasons:
 
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This will support one vendor producing fully programmed main boards and another to build up the final camera.
 
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We can then order separate main boards to support upgrades, RMAs and export activities.
 
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By splitting the document into two a vendor will not have any additional information they do not require.
 
  
 
Please see the new documents:
 
Please see the new documents:
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'''X1 V7 Series Main Board Manufacturing and Programming'''
 
'''X1 V7 Series Main Board Manufacturing and Programming'''
  
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'''X1 V7 Camera Manufacturing and Test'''
 
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<br/><br/>
 
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==Important Information==
 
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The power supply 12V 1A for the programming board needs to be stabilized type.
 
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<br/><br/>
 
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==Assembly Station Workflow Chart==
 
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<br/><br/>
 
  
 
==Materials Requirement by Station==
 
==Materials Requirement by Station==
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* Allen wrench
 
* Allen wrench
 
<br/><br/>
 
<br/><br/>
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==Process Stations Step By Step==
 
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===Process Station 2 – Wifi Mechanical Subassembly===
 
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'''ADD New Pictures with correct antenna'''
 
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{| class="wikitable"
 
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!'''Station 2 – “WiFi” Mechanical Subassembly Materials '''
 
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|-
 
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|802.11b/g USB WiFi Module
 
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|-
 
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|WiFi cable
 
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|Antenna with cable
 
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|-
 
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|Low Static Hi-Temp Kapton Polyimide Film Tape 2.7 Mil, 3/8"
 
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|Wifi  Plastic Carrier Lid
 
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|Double sided Tape for Antenna (Specify Type)
 
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|}
 
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[[File:Wifi1.jpg|300px|]]
 
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'''1.''' Connect the WiFi Cable and Antenna Cable to WiFi module. Antenna Cable must be attached to the "MAIN" connector.
 
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[[File:Wifi4.jpg|300px]]
 
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'''2.''' Place the Wifi and antenna into the Wifi cover and route the antenna cable as shown.
 
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[[File:Wifi5.jpg|300px]]
 
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'''3.''' 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!'''
 
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[[File:Wifi6.jpg|300px|]]
 
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[[File:Wifi7.jpg|300px|]]
 
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Attention! Place the antenna in to the MAIN connector on the WIFI module! Not in the AUX connector!
 
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<br/>
 
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===Process Station 3 – Road Case Mechanical Subassembly===
 
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New Picture without flat lid
 
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{| class="wikitable"
 
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!'''Station 3 – “Road Case” Mechanical Subassembly Materials'''
 
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|Idrive Road Side Case
 
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|Idrive Support
 
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|Idrive Half Bracket Screw Side
 
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|Idrive Half Bracket Nut Side
 
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|M4 Nut (2x)
 
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|N4 Flat washer (2x)
 
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|M4x25 screw (2x)
 
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|3M very high bond double adhesive tape, 100C temp. resistant, 48mm width (for windshield mounting)
 
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|Super glue ( to attach the flat lid to the windshield support)
 
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|Retainer and Retainer Lid (pin in the middle of the support arms)
 
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'''1.''' 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.
 
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'''2.''' Attach the two Half Brackets with the Retainer and Retainer Lid. Press the retainer pins together to fully seat them.
 
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'''3.''' Attach the mated Brackets to the Road Case using a screw (M4x25), one M4 nut and one N4 washer.
 
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'''4.''' Attach the support on the other end of the brackets as shown in the picture.
 
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[[File:Road.JPG|700px]]
 
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<br/>
 
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===Process Station 5 – Final Assembly===
 
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'''Need new Picture(s)with the new board'''
 
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{| class="wikitable"
 
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!'''Station 5 – “Final Assembly” Mechanical assy'''
 
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|GPS or GPRS  Assembly ( Depends on Camera Version)
 
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|Wi-Fi Assembly (from Station 2)(With label for case)
 
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|Idrive Road Case Assembly(from Station 3)
 
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|Low Static Hi-Temp Kapton Polyimide Film Tape 2.7 Mil, 3/8"
 
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|Idrive X1 PCB –pre-programmed PCB with Focused Lenses (from Station 4)
 
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|Idrive Driver Side Case
 
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|M3x18 screw
 
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|1 Label with bar coded serial number for camera case
 
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'''1.''' Place the Wifi assembly ('''From Station 2''') into the Road Case ( '''From Station 3''') and align it with the 3 pins molded into the case.'''Need correct Picture'''
 
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[[File:Connect.jpg|300px|]]
 
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'''2.''' Fix the Wifi assembly to the Road Case using Kapton tape in order to prevent movement. Affix the Antenna to the case using the double sided tape as shown '''Need correct Picture'''
 
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[[File:Connect.jpg|300px|]]
 
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'''3.''' Connect the WiFi module to the main board (Idrive X1 PCB)'''Need correct Picture'''
 
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[[File:Connect.jpg|300px|]]
 
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'''4.''' Place the main Board into The Road Case. Insert the bottom first and then click in the top. Use tweezers to move the top tab so that excessive force is not needed to seat the board. Ensure that the Wifi cable does not obstruct the USB connector opening or the lens.'''Need correct Picture'''
 
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[[File:Connect.jpg|300px|]]
 
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'''5.''' Place the second Bar Code Label (Serial Number) on the back of the case (make sure that the label for the case matches the label on the SD Card Connector).'''Need correct Picture''' '''Do we need the Wifi Label on here too for FCC etc?'''
 
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[[File:Connect.jpg|300px|]]
 
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'''6.''' Insert the GPS Module into the Road Case '''Need correct Picture'''
 
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[[File:Connect.jpg|300px|]]
 
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'''7.''' Connect the GPS module to the main board (Idrive X1 PCB)'''Need correct Picture'''
 
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[[File:Connect.jpg|300px|]]
 
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'''8.''' 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.
 
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'''9.''' Fix the case with the central screw in the back.
 
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----
 
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===Process Station 6 - "Final Test" (Wifi, GPS, Shock Event, Transfers)===
 
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====Final Test Station Initialization====
 
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1. Turn ON the wireless router or access point
 
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2. Open the Event Test - Transfer and Play Section of Idrive Factory Tools application and keep it open for the entire testing.
 
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==== Testing the Unit====
 
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'''1.''' Scan the Bar Code label with the serial number (if no bar code scanner type the serial number from the bar code label into serial number input field from Idrive Factory Tools Application)
 
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'''2.''' Turn the device Idrive X1 ON - Power ON, Ignition ON.
 
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'''3.''' Wait the initialization (aprox. 30 seconds) until the both LED turn green and gently shake the 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.
 
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'''4.''' When both LED return to green turn the Ignition OFF.
 
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'''5.''' The camera device will automatically WIFI download the event to the computer station. The device will automatically show up in the connections list.
 
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'''6.''' Press "Play events" link for each device and play the events.
 
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<br/><br/>
 
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===Process Station 7 - Final Inspection and Packing===
 
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'''Final Inspection:'''
 
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'''1.''' The correct placement of the adhesive tape
 
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'''2.''' The correctitude of the assembly
 
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'''3.''' No spots, no scratches etc.
 
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'''4.''' The existence of the label SN and wifi on the back of the case
 
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'''Each Idrive X1 Kit needs to have one each of the following:'''
 
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'''1.''' Idrive X1 full unit
 
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'''2.''' Alcohol wipe
 
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'''3.''' Idrive Power Cable
 

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



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