Abstract:
A method for arranging test stages in a production line for the assembling and testing of wireless communications devices comprises: determining a plurality of tests for testing an assembled wireless communication device; allocating each test requiring a physical actuation or mechanical dynamics for testing the assembled wireless communication device from the plurality of tests to an interactive test stage in the production line; and, allocating each remaining test requiring no physical actuation or mechanical dynamics for testing from the plurality of tests between the interactive test stage and a non-interactive test stage.

Description:
FIELD OF THE INVENTION 
   This invention relates to the field of mobile device testing, and more specifically, to the testing of wireless devices using multiple function specific test pads and palettes. 
   BACKGROUND 
   Current wireless mobile communication devices include microprocessors, information storage capability, and run one or more software applications. Examples of software applications used in these wireless devices include micro-browsers, address books, and email clients. Additionally, these generations of wireless devices have access to a plurality of services via the Internet. A 3G wireless device may, for example, be used to browse web sites on the Internet, to transmit and receive graphics, and to execute streaming audio and/or video applications. The transfer of Internet content to and from wireless device is typically facilitated by the Wireless Application Protocol (“WAP”), which integrates the Internet and other networks with wireless network platforms. 
   Before a manufacturer can sell wireless devices to consumers, the wireless devices must be fully tested. This is especially important for the newer generations of wireless devices which have increased functionality as described above. 
   Once a wireless device is assembled in full plastics, it typically progresses through various test stages to qualify each of its components. For mobile cellular devices these tests may include the following: Keys, Internal Mic (microphone), Internal Speaker, Charger, Buzzer, Vibrator, Vision, Radiated RF (radio frequency), etc. 
   Depending on the initial path of test development, most testing systems execute a series of test stages wherein each stage sequentially executes a subset of tests drawn from a test plan. As development progresses some of these test stages are consolidated depending on the compatibility of function, fixture, or process. For example, consider the following two exemplary testing system flows: 
   EXAMPLE 1 
   
       
       
         
           Stage 1: Keys, Buzzer, Charger, Vibrator, Vision, Current Levels 
           Stage 2: Internal Mic, Internal Speaker 
           Stage 3: Radiated RF 
         
       
     
  
   EXAMPLE 2 
   
       
       
         
           Stage 1: Charger, Vibrator, Vision, Current Levels 
           Stage 2: Buzzer, Internal Mic, Internal Speaker, Radiated RF 
         
       
     
  
   Thus, as may be observed from the examples above, there is generally no standard, efficient method for defining test stages along with what tests are executed at any particular stage. In Example 1, the Radiated RF test is performed in a separate Stage 3 whereas in Example 2, the same test is performed in Stage 2. 
   A need therefore exists for a method and system for efficiently testing fully assembled wireless devices. Accordingly, a solution that addresses, at least in part, the above and other shortcomings is desired. 
   SUMMARY 
   According to one aspect of the invention, there is provided a method for arranging test stages in a production line for the assembling and testing of wireless communications devices comprising: determining a plurality of tests for testing an assembled wireless communication device; allocating each test requiring a physical actuation or mechanical dynamics for testing the assembled wireless communication device from the plurality of tests to an interactive test stage in the production line; and, allocating each remaining test requiring no physical actuation or mechanical dynamics for testing from the plurality of tests between the interactive test stage and a non-interactive test stage. 
   Preferably, the step of allocating each remaining test comprises allocating all remaining tests to the non-interactive test stage in the production line. 
   Preferably, the method further includes situating the interactive test stage in the production line together with a stage for final assembly of the device. 
   Preferably, the stage for final assembly comprises activity of a human operator to assemble the device, wherein the interactive test stage comprises activity of a human operator to perform the interactive test stage tests, and wherein the situating facilitates the activities by a single human operator. 
   Preferably, the method further includes providing a test fixture for bearing the wireless communication device during the non-interactive test stage, the fixture comprising no mechanical dynamics for actuating the wireless communication device. 
   According to another aspect of the invention, there is provided a method of testing assembled wireless communications devices in a production line comprising: receiving an assembled wireless communications device in the production line for testing in accordance with a plurality of tests comprising: a) one or more interactive tests each requiring a physical actuation or mechanical dynamics to perform the interactive test; and, b) one or more non-interactive tests; at an interactive test stage, performing each of the interactive tests; and, at a non-interactive test stage, performing the non-interactive tests. 
   Preferably, the wireless communication device is received at the interactive test stage situated together with a stage for final assembly of the device; and wherein a single human operator fully assembles and interactively tests a wireless communication device. 
   Preferably, the method further includes utilizing a test fixture for bearing the wireless communication device to perform the non-interactive tests at the non-interactive test stage, the fixture comprising no mechanical dynamics for actuating the wireless communication device. 
   In accordance with further aspects of the present invention there is provided an apparatus such as a testing system and production line adapted for practising a method of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further features and advantages of the embodiments of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which: 
       FIG. 1  is a block diagram illustrating an exemplary testing system adapted for implementing an embodiment of the invention; 
       FIG. 2  is a flow chart illustrating a known method for testing wireless devices; 
       FIG. 3  is a flow chart illustrating a method for testing wireless devices in accordance with an embodiment of the invention; 
       FIG. 4  is a perspective view illustrating a test palette molding enclosure for forming the test palette of  FIG. 5  in accordance with an embodiment of the invention; 
       FIG. 5  is a perspective view illustrating a test palette for fully assembled wireless devices in accordance with an embodiment of the invention; 
       FIG. 6  is a perspective view illustrating a test pad for receiving the test palette of  FIG. 5  in accordance with an embodiment of the invention; and, 
       FIG. 7  is a front view illustrating a typical fully assembled wireless device. 
   

   It will be noted that throughout the appended drawings, like features are identified by like reference numerals. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   An aspect of the present invention provides a method for defining test stages for testing fully assembled wireless devices including which tests are to be executed during each particular stage. The method divides testing into two defined test stages. The division between each test stage is determined by the nature of the test. If the test requires physical actuation or mechanical dynamics in order to acquire a measurement, the test is classified as an “interactive” test (i.e., a mechanical test). Any test that does not require physical actuation/mechanical dynamics is classified as a “non-interactive” test (i.e., a non-mechanical test). This categorization of test type divides testing into two defined stages: the interactive test stage and the non-interactive test stage. 
   The advantage of grouping interactive tests into a single stage is that mechanical dynamics can be concentrated in one test fixture. In a complete testing system, this concentration minimizes the total number of drivers/actuators used since all moving parts are tested in one of the two test stages. 
   The advantage of grouping non-interactive tests into a single stage is that, theoretically, no mechanical dynamics need be designed into the test fixture for this stage. Mechanical dynamics in fixturing can cause unwanted variability due to changes in physical characteristics (i.e., actuators, moving cameras, etc.). By removing the mechanical dynamics in a test fixture, an increase in reproducibility and repeatibility of measurements can be achieved. This improves the efficiency of testing. 
   In addition, an aspect of the present invention provides a universal fixture for testing fully assembled wireless devices in conjunction with a testing system. In accordance with a method aspect of the present invention, labour costs associated with testing may be reduced by reducing multiple stage testing to a two-stage testing system. Fewer stages facilitates fewer human operators, faster testing, and more efficient production. 
     FIG. 1  is a block diagram illustrating an exemplary testing system  100  adapted for implementing an embodiment of the invention. The testing system  100  includes an input device  110 , a central processing unit or CPU  120 , memory  130 , a display  140 , and an interface  150 . The input device  110  may include a keyboard, mouse, trackball, remote control, or similar device. The CPU  120  may include dedicated coprocessors and memory devices. The memory  130  may include RAM, ROM, or disk devices. The display  140  may include a computer screen, terminal device, or a hardcopy producing output device such as a printer or plotter. And, the interface  150  may include a network connection including an Internet connection. The provisioning system  100  is adapted for testing wireless devices  700  (see  FIG. 7 ) in conjunction with a test palette  500  (see  FIG. 5 ) and a test pad  600  (see  FIG. 6 ). The interface  150  also includes various test connectors for coupling to the test pad  600  as will be described below. 
   The testing system  100  may be a server system or a personal computer (“PC”) system. The CPU  120  of the testing system  100  is operatively coupled to memory  130  which stores an operating system (not shown), such as IBM Corporation&#39;s OS/2™, Microsoft&#39;s Windows®, UNIX, etc., for general management of the system  100 . The interface  150  may be used for communicating to external data processing systems through a network (see  FIG. 2 ), such as the Internet. Examples of suitable platforms for the testing system  100  include iSeries™ servers and ThinkCentre™ personal computers available from IBM Corporation. The testing system  100  may include application server software (not shown), such as WebLogic® Server available from BEA Systems, Inc., for developing and managing distributed applications. 
   The testing system  100  may include a database system  160  for storing and accessing programming information. The database system  160  may include a database management system (“DBMS”) and a database and is stored in the memory  130  of the testing system  100 . It will be appreciated that the database system  160  may be shipped or installed without the database to or by end users. In general, the DBMS is adapted to read a query generated by the testing system  100  in response to a request for information submitted by a user typically through a user interface. The DBMS then executes the query against the database and provides a query result to the testing system  100  for presentation to the user. It will be appreciated that the database system  160  may be stored in the memory  130  of the testing system  100  or stored in a distributed testing system (not shown). 2). 
   Examples of suitable DBMSs include the Oracle® and DB2™ Universal Database Management System products available from Oracle Corporation and IBM Corporation, respectively. The DBMS is a software layer interposed between the actual database (i.e. the data as stored for use by the CPU  120  of the system  100 ) and the users of the system. The DBMS is responsible for handling database transactions thus shielding users from the details of any specific computer hardware or database implementation. Using relational techniques, the DBMS stores, manipulates and retrieves data in the form of table-like relations typically defined by a set of columns or attributes of data types and a set of rows (i.e. records or tuples) of data. The standard database query language for dealing with relational databases implemented by most commercial DBMSs is the Structured Query Language (“SQL”). 
   The testing system  100  includes computer executable programmed instructions for directing the system  100  to implement the embodiments of the present invention. The programmed instructions may be embodied in one or more software modules  170  resident in the memory  130  of the testing system  100 . Alternatively, the programmed instructions may be embodied on a computer readable medium (such as a CD disk or floppy disk) which may be used for transporting the programmed instructions to the memory  130  of the testing system  100 . Alternatively, the programmed instructions may be embedded in a computer-readable, signal-bearing medium that is uploaded to a network by a vendor or supplier of the programmed instructions, and this signal-bearing medium may be downloaded through the interface  150  to the testing system  100  from the network by end users or potential buyers. 
   The CPU  120  of the system  100  is typically coupled to one or more devices  110  for receiving user commands or queries and for displaying the results of these commands or queries to the user on a display  140 . For example, user queries may be transformed into a combination of SQL commands for producing one or more tables of output data which may be incorporated in one or more display pages for presentation to the user. The CPU  120  is coupled to memory  130  for containing programs  170  and data such as base tables or virtual tables such as views or derived tables. As mentioned, the memory  130  may include a variety of storage devices including internal memory and external mass storage typically arranged in a hierarchy of storage as understood to those skilled in the art. 
   A user may interact with the testing system  100  and its software modules  170  using a graphical user interface (“GUI”)  180 . The GUI  180  may be web-based and may be used for monitoring, managing, and accessing the testing system  100 . GUIs are supported by common operating systems and provide a display format which enables a user to choose commands, execute application programs, manage computer files, and perform other functions by selecting pictorial representations known as icons, or items from a menu through use of an input or pointing device such as a mouse  110 . In general, a GUI is used to convey information to and receive commands from users and generally includes a variety of GUI objects or controls, including icons, toolbars, drop-down menus, text, dialog boxes, buttons, and the like. A user typically interacts with a GUI  180  presented on a display  140  by using an input or pointing device (e.g., a mouse)  110  to position a pointer or cursor  190  over an object  191  and by “clicking” on the object  191 . 
   Typically, a GUI based system presents application, system status, and other information to the user in “windows” appearing on the display  140 . A window  192  is a more or less rectangular area within the display  140  in which a user may view an application or a document. Such a window  192  may be open, closed, displayed full screen, reduced to an icon, increased or reduced in size, or moved to different areas of the display  140 . Multiple windows may be displayed simultaneously, such as: windows included within other windows, windows overlapping other windows, or windows tiled within the display area. 
     FIG. 7  is a front view illustrating a typical fully assembled wireless device  700 . The wireless device  700  can be a data and voice-enabled handheld. The wireless device  700  includes a casing  750 , a display screen  760 , a user interface  770 , a keyboard  730 , a thumbwheel (or trackwheel)  710 , various select buttons  720 , and various signal inputs/outputs  740  (e.g., power connector input, microphone, speaker, data interface input, etc.). Internally, the wireless device  700  includes one or more circuit boards, a CPU, memory, a battery, an antenna, etc. (not shown) which are coupled to the signal inputs/outputs  770 , keyboard  730 , display screen  760 , etc. 
     FIG. 2  is a flow chart  200  illustrating a known method for testing wireless devices  700 . In a typical wireless device assembly and testing system, testing may be divided into board level testing  210  and fully assembled (“ASY”) level testing  220 . Board level testing  210  may include a DC test  211  and a calibration  212  test. During ASY level testing  220 , wireless devices  700  are assembled and processed through a series of functional, RF, and audio tests. Each stage of testing usually requires its own test fixture, however, recent advances in testing have resulted in the combination of RF and audio testing into one fixture. The resulting three stages of testing at the ASY level  220  are as follows: assembly  221 , MFT  222  (or Functional), and final/audio testing  223  (or RF+Audio). 
   According to an embodiment of the invention, individual ASY level tests are categorized as one of interactive tests and non-interactive tests. As referred to above, an interactive test may be defined as any test that requires a physical motion or mechanical movement in order to test the component. An example would be a thumbwheel  710  test currently executed at the functional  222  test station. In addition, a non-interactive test may be defined as any test that requires no physical motion or mechanical movement in order to test the component. An example would be an audio test currently executed at the final/audio  223  test station. In addition, and also according to an embodiment of the present invention, the assembly  221  tests and interactive tests are combined into one test stage. Finally, a new test fixture  400 ,  500 ,  600  for performing non-interactive tests is provided. 
     FIG. 3  is a flow chart  300  illustrating a method for testing wireless devices  700  in accordance with an embodiment of the invention. As in  FIG. 2 , board level testing  310  includes a DC test  211  and a calibration  212  test. However, ASY level testing  320  now includes only two stages: assembly+interactive testing  321  and non-interactive testing  322 . By classifying individual ASY level tests  320  as either interactive  321  or non-interactive  322  tests, the testing process can be reorganized based on the physical interaction requirements of the given tests. This allows for a reduction in current ASY level testing from three stages  221 ,  222 ,  223  to two stages  321 ,  322 . Since the assembly  221  stage is inherently interactive, it can be combined with the interactive tests to form a single stage (assembly+interactive testing  321 ) in a production line and the remaining non-interactive tests (non-interactive testing  322 ) can be performed using a new test station and fixture, for example, fixtures  400 ,  500 ,  600 . 
   The assembly+interactive testing  321  test stage is where the wireless device  700  is finally assembled and all interactive components are tested. Results are typically logged to the database system  160  of the testing system  100 . All physical operations performed at this stage are often performed by a test person, though persons of ordinary skill in the art will appreciate that equipment may be used to replace some or all human activity. 
   According to an embodiment of the present invention, the RF+audio test  223  shown in  FIG. 2  is classified as a non-interactive test. Functional  222  testing on the other hand has a combination of both interactive and non-interactive features. In particular, the functional tests  222  shown in  FIG. 2  typically include tests of the following features of the wireless device  700 : (1) Thumbwheel  710 ; (2) Magic Key  715 ; (3) Escape Key  720 ; (4) Keypad  730 ; (5) Keypad Backlight; (6) LCD calibration; (7) LCD Screen  760 ; (8) LCD Backlight; (9) Charge Current; (10) Buzzer; (11) Vibrator; (12) LED; (13) Infrared; and, (14) Holster. 
   Thus, in accordance with the present embodiment, reclassifying each functional test  222  as either an interactive  321  or non-interactive  322  test results in the following tests being classified as interactive tests  321 : (1) Thumbwheel  710 ; (2) Magic Key  715 ; (3) Escape Key  720 ; and, (4) Keypad  730 . In addition, the following tests are classified as Non-Interactive tests  322 : (1) LCD Calibration; (2) LCD Screen  760 ; (3) LCD Backlight; (4) Charge Current; (5) Keypad Backlight; (6) Buzzer; (7) Vibrator; (8) LED; (9) Infrared; and, (10) Holster. 
   Consequently, the new assembly+interactive testing  321  stage requires the test person to add the testing of four components to their list of duties. To assist the test person, the test station for performing the assembly+interactive testing  321  stage can have access to the testing system  100 . The testing system  100  is adapted for: (1) displaying photographs of current defects on its display screen  140  to assist test personnel with identifying such defects in wireless devices  700 ; (2) displaying step-by-step procedures during assembly; and, (3) logging each test and assembly operation by operator or personal ID to the database system  160 . 
   The non-interactive testing  322  test stage includes all non-interactive tests which are performed at a single test station. According to an embodiment of the present invention, and in preparation for full automated testing, the design of the test station for performing non-interactive testing  322  includes minimal mechanical requirements. The test station for this testing includes the testing system  100  which is coupled to a test pad  600  which is in turn adapted to receive a test palette  500  which holds the wireless device  700 . 
   By incorporating the non-interactive tests currently performed during functional testing  222  with RF+audio testing  223 , time, resources, and labour may be saved. The following are non-interactive tests now included at the new non-interactive test stage  322 : (1) LCD Screen  760 ; (2) LCD Backlight; (3) LCD Calibration; (4) LED; (5) Infrared; (6) Buzzer; (7) Holster; (8) Vibrator; (9) Keypad Backlight; (10) Charger Current; (11) All Audio Testing; and, (12) All RF Testing. 
     FIG. 5  is a perspective view illustrating a test palette  500  for fully assembled wireless devices  700  in accordance with an embodiment of the invention. Since non-interactive tests don&#39;t involve moving parts, the only physical motion required during this stage of the testing process is placing the wireless device  700  into the test fixture and subsequently removing the wireless device  700  from the text fixture. This handling is reduced to a pick and place movement by the palette-oriented text fixture  500  according to an embodiment of the present invention. 
   In general, the test palette  500  is formed from silicone and internally houses all cable connections required for testing the wireless device  700 . On the bottom of the palette  500  are a series of acoustic and vision cavities along with a connector pad. The palette&#39;s footprint mates with a test pad  600  thus establishing all necessary connections required for performing the non-interactive tests. In turn, the test pad  600  is coupled to the testing system  100 . All tests will performed within the confines of a RF shielded enclosure which will partially or fully encapsulate the wireless device under test (“DUT”)  700 . 
   In more detail, the test palette  500  is a custom form fitted silicone mold with several cavities  510  and internal components  520  to facilitate a seamless mate to the test pad  600 . The test palette  500  provides a simple and universal physical interface between test equipment  100  and the DUT  700 . The footprint of the silicone test palette  500  is preferably identical for all wireless products to promote easier set-up of the production line. 
   In order to reduce the mechanical dynamics required for automated handling of the test palette  500 , devices  700  are prepped into palettes  500  before entering an automation stand. An operator is required to insert all cables and a battery emulator into the device  700  prior to use of the palette  500 . The ability to prep devices  700  into palettes  500  allows the operator to accumulate handling time into a single bulk session before submitting the palettes  500  to the automation stand for processing. 
   Each palette  500  includes four internal columns  530 ,  531 ,  532 ,  533  that allows two or more palettes to be stacked on top of each other. Therefore, palettes can either flow via a queue (i.e., in-line conveyer belt flow) or via stacking (i.e., pile-up devices for block processing). 
   Test palettes  500  can be handled manually by operators or by vacuum power. Each palette includes two internally mounted aluminium rods  531 ,  532  each having a flat circular surface  540  at one end. The aluminum rods  531 ,  532  act as support columns for stacking purposes and also provide adequate surface area for lifting of the palette with a vacuum suction device. 
   The silicone mold for each device includes cavities  510  that enable a wide variety of tests to be performed. All external features of each palette  500  are identical, however the internal cavities  510  can differ to accommodate different wireless device models. 
   Due to the nature of audio testing, air seals are critical for repeatable and reliable measurements. By molding the silicone to the exact form factor of the wireless device  700 , a snug fit (like a wetsuit for scuba diving) is provided to maintain the air seals. T2 Translucent Base Silicone can be used to form the test palette  500 . It, and other similar varieties of silicone, are light in weight (˜700 g), tear resistant, highly un-deformable, and provide protection for the wireless device  700  in the event that the palette  500  is inadvertently dropped. It is also a cost effective solution (&lt;$30 per palette) that is mass reproducible to suitable accuracy (&lt;0.1%). 
   As mentioned, the test palette  500  can contain a variety of internal components  520  and cavities  510 . The internal components  520  may include one or more of the following: (1) USB/Serial Cable; (2) Electro-Audio Cable (optional); (3) Battery Emulator; (4) PCB connector plate; (5) ⅜″ brass bushings; and, (6) Custom Aluminum Rods. The internal cavities  510  may include one or more of the following: (1) LCD Screen Cavity; (2) Keypad Backlight Cavity (optional); (3) Infrared Cavity (optional); (4) LED Cavity (optional); (5) USB/Serial Cable Cavity; and, (6) Electro-Audio Cable Cavity (optional). 
     FIG. 4  is a perspective view illustrating a test palette molding enclosure  400  for forming the test palette  500  of  FIG. 5  in accordance with an embodiment of the invention. The mold enclosure  400  is used to make and replicate silicone test palettes  500 . The footprint of the mold  400  is an exact replica of that of a test pad  600 , however it has mounting holes for internal cavity fillers (“ICFs”)  410 . Depending on the type of wireless device  700  to be molded, different combinations of ICFs  410  will be used. The four walls  420 ,  430 ,  440 ,  450  of the enclosure  400  are detachable for easy separation from the silicone. Certain walls that house cable through-holes can further detach into two pieces making it easy to remove any cabling with connector heads. Only one mold  400  is required for all wireless device models. All one has to do to make a mold  400  for a specific wireless device model  500  is to the change the configuration of ICFs  410 . 
     FIG. 6  is a perspective view illustrating a test pad  600  for receiving the test palette  500  of  FIG. 5  in accordance with an embodiment of the invention. The test pad  600  works in conjunction with the test palette  500  to provide physical connection between the DUT  700  and the testing system  100  or equipment. The top surface  610  of the test pad  600  matches the footprint of the test palette  500 . The test pad  600  is designed to work within a variety of available RF shielded and acoustically shielded boxes (not shown). 
   The test pad  600  includes a variety of connections  620 ,  630  to the DUT  700  and test equipment  100 . Connections between the test pad  600  and test palette may include one or more of the following: (1) Device Microphone Acoustic path; (2) Device Earpiece Acoustic path; (3) LCD and Keypad Vision path; (4) Infrared Transmitter/Receiver Vision path; (5) Photo-Resistor Vision path; (6) USB/Serial Electrical path (straight through); (7) Battery Emulator Electrical path (straight through); and, (8) Audio Jack Electrical path (straight through). Connections  620  between the test pad  600  and test equipment  100  may include one or more of the following: (1) Test Pad Microphone Electrical path; (2) Test Pad Speaker Electrical path; (3) CCD Camera Electrical path; (4) Infrared Transmitter/Receiver Electrical path; (5) Photo-Resistor Electrical path; (6) USB/Serial Electrical path (Straight Through); (7) Unit Detect Sensor Electrical path; (8) Battery Emulator Electrical path (Straight Through); and (9) Audio Jack Electrical path (Straight Through). 
   The test pad  600  is capable of completing a variety of non-mechanical tests including the following: (1) All RF Related Tests; (2) All Audio Related Tests; and, (3) Buzzer, LCD, LED, Backlight, Charger, Infrared, and Holsters Tests. 
   While this invention is primarily discussed as a method, a person of ordinary skill in the art understands that the apparatus discussed above with reference to a testing system may be adapted to enable the practice of the method of the invention. 
   The embodiments of the invention described above are intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.