Manufacturing:X2V2 Device Manufacturing and Programming Process

Copyright Information

This document contains proprietary information that is protected by copyright. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Idrive Inc.

About This Document

This proprietary document contains the information necessary to produce an Idrive X2V2 series camera. This includes all programming, testing, focus of lenses and bar code label.

About Idrive X2V2 Production Process

The production process for the Idrive X2V2 cameras has been created with purpose in mind of tracking all work in progress as well as finished goods. This information is sent over the internet to the Idrive AdminCenter website where it is logged and configuration information is obtained for each device. As much of the testing as possible has been automated however certain steps will require human intervention. Wherever possible a bar code reader is used to reduce input errors.

To facilitate this tracking each X2V2 Main board MUST HAVE a unique serial number assigned to it. Idrive produces the range of serial numbers for each build and allocates them to the assembly vendor when a purchase order is issued. Each serial number must remain unique and track through the production process all the way to a finished camera (which will inherit this serial number) or to scrap of the PCB assembly due to defect. A serial number should NEVER be reused.

Idrive X2 Camera Processing Overview

Idrive X2 Main Board Assembly

Assemble PCB

X2V2 Main Board PCB Assembly Materials
All components as listed in "Idrive X2V2 REV 1.3 Main Board" Bill of Materials
Pre-printed Bar Code Labels with Serial Number

1. SMT Assembly steps - Use the supplied pick and place information provided by Idrive Inc.

2. Manual Assembly Steps (Through Hole components etc)

3. Place Barcode label in the S/N box located on the "Road" side of the PCB next to the Power Connector

Top Level X2 Main Board Assembly

Top Level Main Board Assembly Materials
4GB Pre-Programmed Micro SD card (Contains OS for camera)
32GB Micro SD card (No pre-programming, used for event storage)
2 Metal Lens Holders (11mm Height)
2 Lens Holder Gaskets
4 Lens Holder screws (2 for each lens holder)
DSL-218A-670-F2.0 Lens for Road side of the camera (side of the PCB with the power connector)(Lens has Text on it)
DSL-180A-NIR-F2.0 Lens for Driver Side of the camera (side of the PCB with the Processor on it)(Lens has NO Text on it)
X2 LED board assembly
Flat flex Cable

1. Insert the Pre-programmed 4GB Micro SD card into the SD socket on the Driver Side of the Main Board.

2. Insert the 32GB Micro SD card into the SD socket on the Road Side of the Main Board.

3. Mount two of the Lens Holders to the board

4. Insert the proper lens in the correct side in the Lens Holders(Lenses are glued after programming and focus)

DSL-180A Lens for Driver Side (No markings) ---------------------DSL-218A Lens for Road Side (Note Markings)

----------------------------

5. Connect the LED Board to the Main Board with the Ribbon Cable

- Slide cable into the connectors with the contacts up as shown

- Slide the brown tabs at the sides of the connector to secure cable in place.

The LED Board has been modified and the connector is now on the opposite side of the board.

We will update the picture once we receive the boards

6. Advance the Top Level X2 Main Board PCB assembly to the X2 Programming Station

Idrive X2 Main Board Initial Programming

Idrive X2 Programming & Lens Focus Materials
Idrive X2 Programming Station
I/O Test Loopback Board
Idrive Top Level X2 Main Board Assembly
Lens focus targets
Super Glue (for fixing lenses) (Loctite Control, Extra Time or equivalent)

Initialize Firmware Programming Station

X2 Programming Station Setup

Setup X2 Main Board

1. Place the Idrive X2 Main board into the Device holding Fixture.

2. Connect the Power cable between the Idrive X2 Main Board and the Programming Fixture.

3. Connect the serial programming cable between the Idrive X2 Main Board and the Programming Fixture. (observe polarity)

4. Connect the USB Network Adapter to the Idrive X2 Main Board.

5. Plug in I/O Test board Into Accessory Connectors

Need a new Picture with I/O board shown

<br\><br\>

X2 Automatic Install and Configuration

Notes: The Automatic install performs the following:

installs the boot loader into the X2 board. (The Kernel and filesystem are pre-installed on the 4GB SD card)

gets device configuration from the Idrive AdminCenter (IP address configuration)

Tests triggering on the yellow, blue and green wires

provides lens focus mode so both lenses can be focused and glued

1. Click on the Factory-New Devices-Auto button

2. Scan the Bar Code label on the device to be programmed and press Enter.

(if no bar code scanner is available type the serial number from the bar code label into the serial number input field )

3. Click on the Auto Install Button and the Automatic Install window will open, Click on Start Installation

If any of these steps fail the program will stop and give an error. Common errors are:

Missing or corrupt OS on 4GB SD card

Missing or corrupt storage SD card

Serial cable not connected or incorrect polarity

USB NIC or Internet connection missing

I/O ports tester board missing

Any assembly or incorrect component error

If all steps are successfully completed the program will enter into Lens Focus / LED test mode Mode.

Lens Focusing

1. Select "Inside Camera" Tab and Focus the Driver Side Lens(DSL-180A) (the same side as the Processor).

The focal length for the inside camera should be ~1.5 meters

2. Select "Outside camera" Tab and Focus the Road Side Lens (DSL-218A) (the same side as Power Connector).

Focus using the provided Idrive Focus Chart. Distance to chart can be 3,6,9 feet but the farther the better.

Use zoom mode to ensure accurate focus

4 Verify that the 4 IR LEDs are on (faint red glow in 4 places)

5. If images are focused and clear and the 4 IRLeds are on click on the "Lens Focus OK" button and the focus mode will close. If the image is not clear or any IRLeds are not functioning for some reason click on the "Lens Focus Not OK" the factory tool will exit focus mode so corrective action can be taken.

6. Once focused fix the each lens with a drop of super glue.Test the lenses after several minutes to ensure they have taken the glue and cannot be moved

7. Remove the assembly from the test fixture, remove I/O test board

8. Advance the Main Board Assembly to the Driver Side Case Assembly Station.

Idrive X2 Camera Top Level Assembly - Needs update to new case!!

Driver Side Case Assembly

X2 Drive Side Case Materials
Driver Side Plastic Case
LED Plastic Lens
X2 Main Board and LED Assembly

1. Snap the LED Lens into the Driver Side Case

- Ensure that the two LED indents are towards the bottom of the camera

- Clear LED lens is shown to enhance the view of indents

- Actual LED Lens is black/opaque as shown

2. Snap the LED Board Assembly into the Driver Side Case as shown

3. Snap the X2 Main board Assembly into the Driver Side Case as shown

Road Side Case Assembly

X2 Road Side Case Materials
Road Side Plastic case
Plastic Support Spur
Screw for Support Spur
FCC Compliance Label

Electronic Module Materials
SparkLan WiFi Module
WiFi cable
Dual Band WiFi Antenna
Screws for WiFi mounting
GPS Module Assembly

1. Attach Base Support Spur to the Road Side Case with the screw, Place FCC compliance sticker as shown.

Note correct orientation of Support Spur ("Gear" towards FCC sticker)

2. Install the Wifi Module with cable and antenna, secure with 2 screws as shown

3. Install GPS Module as shown. Ensure the cable is routed properly so as to avoid he power connector opening.

Top Level Camera Assembly

X2 Top Level Camera Materials
Driver Side Case Assembly
Road Side Case Assembly
Bar Code Label with Serial Number
Plastic Dust Cover for Accessory Connectors
Case Screw
Wifi Antenna

1. Connect the GPS and WiFi Cables to the Main Board. Remove the backing tape from the wifi antenna and affix the Antenna on the Driver Side Case as shown.

2. Snap the two halves of the camera together ensuring no cables interfere with or block the Lens, Power Connector, I/O Connectors, USB opening or case screw

3. Install Plastic Dust Cover for Accessory Connectors - move to after final test.

4. Secure the cases to together with the case screw. Do not over torque the screw.

Windshield Support Assembly

X2 Windshield Support Materials
Plastic Windshield Support
Plastic Support Back Plate
Screw for Support Back Plate
3M Adhesive Tape
Screw for Support attachment to Spur
Washer for Support Screw
Hex nut for Support Attachment

1. Assemble Windshield Support Base Assembly (Windshield support not attached to the camera until after final test or else the power connector would be inaccessible

Snap plastic back plate into support

secure with screw

Apply 3M tape and trim flush with scalpel

Idrive X2 Final Assembly/Packaging (Windshield support attachment, Final Inspection, Packaging)

X2 Final Processing Materials
Windshield Support Assembly
Screw for attachment of Support to X2 Camera
Hex nut for Support Attachment
2 serial number barcode labels

Attach Windshield support to camera

1. Attach Windshield support to the Support Spur using the supplied screw and nut. (Note correct orientation of the window mount)

2. Check the "Final Box" in AdminCenter to make the camera eligible for shipment.

X2 Camera Final Inspection and Packaging

No smudges

put in plastic bubble wrap bag & place sticker on the outside with the serial number

Place in box and put serial number sticker on outside of box

Shipping and Device Assignment

Using the idrive admincenter to ship idrive devices from the factory.

Log in with your user name and password to http://admincenter.idriveglobal.com

Click on shipping and then click ADD to start the process

Use the Pull-down fields to select: Company, Location, Quote, Date, Address, Contact, Shipping Company (Tracking Number(s) can be entered later if it is not yet available). Click on "Add S/N" to open the form for device selection.

We really need the scanner to do this to reduce the errors.

In the device selection form check the box next to the device(s) to be shipped. You can search the list by typing the last 3 characters into the "S/N" box which will highlight the device you are searching for. Once ALL of the devices are selected click on the "X" to close the window.

Verify the correct number of IDRX2 units (the other items ship from elsewhere) and Click "Next(Confirm shipping)"

New Picture

After Confirmation a Shipping form will come up. This should be printed and included with the shipment of the devices to the customer.

New Picture

Select the "Shipping List" Tab. If you need to add tracking information you must do it before closing out the shipment using the edit button. Select "Close" to assign the cameras to the customer as well as send the automated notification of the shipment to the people on the distribution list. The "Close" process will be performed by Idrive after our review of the shipment.

Done.

<br\><br\>

Appendix A - SD Card Preparation

The X2 Micro SD cards need to be be formatted with the EXT4 filesystem and have the system image placed on them. There are several ways to accomplish this

SB Shark Duplicator

Using a Linux system (a virtual machine is installed on the programming station for this purpose)

A windows PC with a third party driver the recognizes the EXT4 filesystem (not recommended)there is an open source Windows driver for ext3/4 that can be used to read these cards: http://www.ext2fsd.com/ ensure to check the write option at installation time. This often cause system crashes with "the blue screen of death"

Purchase SD cards that are preprogrammed (not economical base on the quotes we received)

After duplication affix label or stamp with version so there is a difference between programmed and unprogrammed cards.

Use of a Linux System for MicroSD copying

Overview - Any Linux system can be used for staging the Idrive X2 filesystem on the MicroSD card. The filesystem type on the SDcard needs to be EXT4 format (Linux filesystem). There are open source drivers available that allow windows to recognize the EXT4 file system but they very unstable and cause system crashes. It is therefore recommended that Linux be used for the microSD programming. The programming station has Ubuntu Linux installed on it using VMWare (virtual system).

Using VMware for access to Ubuntu Linx

Double Click on the VMware Icon on the desktop, Click "Ubuntu-64bit" to launch the virtual machine, login at the prompt with username (ubuntu) and password (none)(the word, not blank)

Ensure the removable devices are assigned to the virtual machine and not windows ("check mark" means connected to virtual machine)

Player> Removable Devices> SuperTop Mass Storage> Connect (Disconnect from Host)

Number of devices will vary based on hardware and the number of MicroSD cards inserted

"SuperTop" is the name of the SD adaptor in use. This will vary depending on the adapter used

Host is the windows system

once the removable device is attached to the virtual machine it should stay assigned for the entire session

Click on the X2 MicroSD Programming Icon.

A terminal window will open and the MicroSD card(s) will be formatted and the filesystem (OS) written to them. While this is happening you will see "Still Waiting for Cards..."

Upon successful completion you will see Cards are done! The amount of time for the process will depend on the number of cards being programmed at the same time.