Flexible Sensor Test Board for Autonomous Vehicle I/O Coverage
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Solution Overview
Problem
Conventional methods for testing sensor units in autonomous driving vehicles are inefficient, as they require a GPS signal and a large, complex sensor array, making factory testing challenging due to cost and physical connectivity issues.
Innovation Solution
A method and apparatus for verifying sensor unit functionality using emulated sensor data transmitted over channels, with error detection and failure indications displayed, allowing for testing without a GPS signal and simplifying the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a real GPS sensor and large sensor array are used for testing, then testing accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses emulated sensors that generate simulated sensor data to replace real physical sensors during factory testing. This copying approach allows the sensor PCB to be tested with fake sensor inputs without requiring actual GPS satellites, LIDAR, RADAR, cameras, or other expensive physical sensors, thereby reducing device complexity and cost while maintaining testing capability
Solution Approach 2:
The test board acts as an intermediary device between the sensor PCB under test and the testing system. It generates emulated sensor data and interfaces with the sensor PCB's data processing unit, allowing testing to occur without direct connection to real sensors or GPS satellites, thus simplifying the testing setup
2Reliability
If a real GPS sensor is used for testing, then testing reliability is improved, but cost increases
Solution Approach 1:
The patent replaces expensive real GPS sensors with emulated sensors that generate simulated GPS data on the test board. This copying approach eliminates the need to purchase and install costly real GPS hardware for factory testing purposes, significantly reducing testing costs while maintaining the ability to verify sensor PCB functionality
Solution Approach 2:
The emulated sensors on the test board provide a cheap, disposable alternative to expensive real GPS sensors. The test board with its emulated sensors can be used repeatedly for testing multiple sensor PCBs without degradation, providing a cost-effective solution that eliminates the need for expensive real sensor hardware
3Reliability
If the sensor PCB is installed into the ADV for testing, then testing accuracy is improved, but productivity decreases
Solution Approach 1:
The patent extracts the sensor PCB from the complete ADV system and enables it to be tested independently on a test board. By separating the sensor PCB testing from the full vehicle installation requirement, the testing process can be performed quickly in the factory without waiting for vehicle assembly, significantly improving manufacturing productivity
Solution Approach 2:
The patent enables preliminary testing of the sensor PCB at the factory before the ADV is fully assembled. By performing the connectivity and functionality tests early in the manufacturing process using the test board, potential defects are identified before final vehicle assembly, preventing rework and improving overall manufacturing efficiency
4Reliability
If physical sensor array connections are made for testing, then testing reliability is improved, but ease of operation worsens
Solution Approach 1:
The test board serves as an intermediary that provides simplified connectivity to the sensor PCB under test. It includes integrated connection interfaces that automatically establish communication with the sensor PCB, eliminating the need for operators to manually connect multiple physical sensors and their complex wiring harnesses, thereby improving ease of operation
Data Source
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AI summary
Systems and methods are disclosed for performing manufacturing testing on an autonomous driving vehicle (ADV) sensor board. A sensor unit of the ADV includes a plurality of sensor I/O channels that provide information to the ADV perception and planning module, to navigate the ADV. An array of sensors is emulated on a sensor unit test board. The sensor unit includes a small software that manages the flow of testing the sensor unit. The sensor unit test board provides emulated sensor data for, e.g., GPS, LIDAR, RADAR, inertial measurement, one or more cameras, humidity, temperature, and pressure, and throttle, braking, and steering inputs. Each emulated sensor includes its own data validity checker to ensure that each sensor I/O channel of the sensor unit is tested. The sensor unit test board can include an LED for each I/O channel that indicates a pass/fail status of the test for the I/O channel.