Abstract:
A system and a method for direct connection testing of wireless communication devices. The system includes a test connector mechanically and electrically connected to a testing device for insertion into a test port of a wireless communication device. An operator or automatic operation moves the wireless communication device to be tested into a position over the test connector such that the test connector is inserted into the test port of the device. Once inserted, the system can test the performance and operation of the wireless communication device. The leading edge and the outer surface of tip of the connector form a beveled shoulder so that during insertion of the connector into the test port, misalignment of the wireless communication device with the test connector will not prevent proper insertion of the test connector into the test port. In addition, a wire encircles helically the outer surface of the tip of the test connector and functions as both a spring mechanism during insertion of the test connector into the test port and as a grounding mechanism.

Description:
FIELD OF THE INVENTION  
         [0001]    The invention relates to a system and a method for testing wireless devices, such as wireless communication devices. More particularly, the invention relates to a system and a method for directly testing wireless devices by inserting a test connector into a test port of a wireless device.  
           [0002]    Description of the Related Art  
           [0003]    Wireless communication devices are becoming increasingly prevalent, with cellular telephones being a particularly notable example. With these devices, radio-frequency (RF) signals are transmitted and received to create a communication link between the device and another wireless device. During the manufacture of such devices, it is necessary to test functionally the RF signal generation and reception circuitry as well as the signal processing circuitry prior to shipment of the device to a customer.  
           [0004]    In general, two testing schemes are available: transmission testing and direct connection testing. In transmission testing, signals are transferred between a test set-up antenna and an antenna on the device under test. Accurate transmission testing is difficult to achieve in a mass production environment due to the mutual interference generated by testing many devices within close proximity to one another. In direct connection testing, the device under test is equipped with an accessible test port which allows for the direct physical coupling of the device under test to a testing device. Using direct connection testing, the device under test can be electrically and mechanically connected to test equipment using a test connector. Consequently, direct connection testing avoids the wireless transmission of signals and so overcomes the difficulties of transmission testing due to the mutual interference caused by the transmission of RF signals by the test system and the multiple devices under test.  
           [0005]    Direct connection testing has been achieved using a prior art test connector  100  such as that shown in FIG. 1. The prior art test connector  100  is intended to be permanently installed in the test equipment and to mate temporarily with the device under test during the testing process. Radiall, S. A. (101 Rue Philibert Hoffman, 93116 Rosny Sous Bois, France) manufactures the prior art test connector  100  (part number R 191 - 977 - 500 ).  
           [0006]    Referring to FIG. 1, the prior art test connector  100  has a cylindrical base  120  which is fixedly attached to the testing equipment. Mounted to the cylindrical base  120  is a body  130 . The body  130  can have multiple planar faces in order to allow a tool, such as an adjustable or customized wrench, to secure the body  130  and rotate the prior art test connector  100 , thereby allowing a user to install or to remove the prior art test connector  200  from testing equipment (not shown). Furthermore, a connector saver  140  has multiple planar faces in order to allow a tool, such as an adjustable or customized wrench, to secure the body  130  and rotate the prior art test connector  100 , thereby allowing a user to install or to remove the prior art test connector  100 . Furthermore, the connector saver  140  can act to protect the action of a tool from damaging the prior art test connector  100  when the prior art test connector  100  is inserted or removed from the testing equipment.  
           [0007]    Attached to the body  130  is a cylindrical shaft  150  with a cylindrical tip  160  with dimensions corresponding to a test port on a device to be tested. During the testing process, the cylindrical tip  160  of the cylindrical shaft  150  is inserted into the test port of the device under test. RF test signals are transmitted to the device under test via a transmitter passing through the center of the prior art test connector  100 . Once the prior art test connector  100  is inserted into the test port of the device under test, the transmitter mates with the test port to create an electrical connection and allow RF test signals to be transmitted to the device under test.  
           [0008]    The prior art test connector  100  requires an accurate fit between the leading edge  180  of the cylindrical tip  160  and the inner wall of the test port (not shown) of the device under test in order to establish a ground path. The leading edge  180  of the cylindrical tip  160  of the prior art test connector  100  forms a ninety degree angle with a plane tangential to the outer surface of the cylindrical shaft  150 . The nexus between the leading edge  180  of the cylindrical tip  160  and the outer surface of the cylindrical shaft  150  forms a shoulder  185  which is abrupt and only slightly rounded. The abrupt shoulder  185  closely matches the dimensions of the test port and therefore requires an extremely accurate insertion of the cylindrical tip  160  into the test port. Due to the sharp angles formed at the shoulder  185  of the cylindrical tip, even the slightest misalignment during insertion of the prior art test connector  100  into the test port of the device under test will prevent the cylindrical tip  160  from entering the test port. As a result, this configuration provides little or no tolerance for positional inaccuracy during insertion of the prior art test connector  100  into the test port of the device under test.  
           [0009]    In a laboratory setting where the test equipment operator can manually insert the prior art test connector  100  into the device under the test, the prior art test connector  100  operates adequately. Manual insertion allows the operator to ensure that the prior art test connector  100  fits accurately into the test port of the device under test by allowing the operator to adjust the attachment angle and insertion pressure to ensure a proper connection.  
           [0010]    In the mass production environment, however, the prior art test connector  100  proves to be unsatisfactory. Typically, in the mass production setting, the device under test is mounted on a moveable mechanism. The moveable mechanism moves the device under test into position whereby the prior art test connector  100  is automatically inserted into the test port of the device under test. The prior art test connector  100  is fixedly attached to the test equipment which is designed to adjust along both the both the X and Y axes. Consequently, automatic insertion of the prior art test connector  100  into the test port of the device under test is adjustable in only two directions. The mass production environment does not allow for careful re-alignment of individual devices under test. As a result, misalignment can result when the prior art test connector  100  is inserted into the test port during this automatic process. As discussed above, even slight misalignment can prevent proper insertion of the prior art test connector  100  into the test port of the device under test. As a result of improper or inadequate insertion of the prior art test connector  100  into the test port, the conductive material of the outer shell of the cylindrical tip  160  cannot electrically mate properly with the test port. Consequently, misalignment can fail to provide an adequate grounding path between the prior art test connector  100  and the test port ground of the device under test. Additionally, misalignment can lead to misleading variations in the test results due to an improper electrical mating and thereby can cause false test failures. Furthermore, due to the sharp angles of the shoulder  185  and the test port, improper alignment may also cause damage to the prior art test connector  100 , the test equipment, or the device under test.  
           [0011]    Thus, it will be appreciated that there is a need in the technology for a means and a method for providing a direct connection test system using a test connector which overcomes the described deficiencies in the prior art. The improvement should allow for proper automatic insertion of the test connector into the test port of the device under test. Additionally, the improvement should allow for a direct connection test system which provides accurate results and reduces damage to the device under test.  
         SUMMARY OF THE INVENTION  
         [0012]    The invention defines a system and a method for direct connection testing of wireless communication devices. The system includes a test connector mechanically and electrically connected to a testing device for insertion into a test port of a device, such as a wireless device. The connector comprises a base having a hollow center, wherein the base is fixedly attached to the test device, a body having a hollow center, wherein the body is fixedly attached to the base, a tip portion fixedly attached to the body opposite the base and having a hollow center and a leading edge, wherein the tip portion is configured so as to mate with the test port, and a a conductive material passing through the hollow centers of the base, the body, and the tip portion, wherein the conductive material provides an electrical coupling with the test device when the tip portion is inserted into the test port. The electrical coupling can be implemented in a coaxial configuration. Additionally, the connector can comprise a wire encircling the tip portion, wherein the wire serves as a spring mechanism when the tip portion mates with the test port and as a grounding path for the electrical coupling with the test device when the tip portion is inserted into the test port. The tip portion and the leading edge of the connector define a beveled configuration.  
           [0013]    The invention also includes a method of providing a direct connection between a test device and a device to be tested. The method comprises mounting the device to be tested onto a moveable mechanism, moving the moveable mechanism and the device to be tested into a position such that the tip portion of the connector can insert into and mate with a test port of the device to be tested, inserting the tip portion of the connector into the test port of the device to be tested such that the connector is electrically and mechanically coupled with the device to be tested, and testing the device to be tested. The method of the invention can be automated such that the test device operates automatically and the moveable mechanism moves automatically. Once inserted the connector is inserted into the device to be tested, the system can test the performance and operation of the device.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    The features, objects, and advantages of the invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify correspondingly throughout and wherein:  
         [0015]    [0015]FIG. 1 is an elevational view of a prior art test connector.  
         [0016]    [0016]FIG. 2 is an elevational view of a test connector.  
         [0017]    [0017]FIG. 3A is an elevational view of a test connector affixed to a test device prior to being inserted into a test port of a wireless communication device under test, wherein the test port is depicted in a cutaway view.  
         [0018]    [0018]FIG. 3B is a partial cutaway elevational view of a test connector taken along lines  4 - 4  of FIG. 3A affixed to a test device as inserted into a test port of a wireless communication device under test, wherein the test port is depicted in a cutaway view.  
         [0019]    [0019]FIG. 4 is a partial cutaway elevation view of a test connector taken along lines  44  of FIG. 3A, illustrating the test connector as inserted into the test port of a device under test.  
         [0020]    [0020]FIG. 5A is a side view of a device test system with a wireless communication device under test mounted to a moveable mechanism device prior to insertion of a test connector into a test port of the wireless communication device under test.  
         [0021]    [0021]FIG. 5B is a side view of the device test system of FIG. 5A showing a compression spring under compression as the wireless communication device under test is moved into position for testing.  
         [0022]    [0022]FIG. 5C is a side view of the device test system of FIG. 5A with the test connector fully inserted into the test port of the wireless communication device under test. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0023]    Preferred embodiments of the invention will now be described with reference to the accompanying figures. The terminology used in the description presented herein is intended to be interpreted in its broadest reasonable manner, even though it is being utilized in conjunction with a detailed description of certain specific preferred embodiments of the present invention. This is further emphasized below with respect to some particular terms. Any terminology intended to be interpreted by the reader in any restricted manner will be overtly and specifically defined as such in this specification.  
         [0024]    As discussed above, FIG. 1 depicts the prior art test connector  100 . FIG. 2 depicts one embodiment of a test connector of the invention. Referring to the embodiment illustrated in FIG. 2, a test connector  200  has a cylindrical base  210  which is fixedly attached at one face to a connection port (not shown) on a unit of testing equipment  220 . Mounted to the other face of the cylindrical base  210  is a body  230  surrounded by a connector saver  240 . In one embodiment, the test connector  200  may be attached to the testing equipment  220  by manually screwing a threaded portion (not shown) of the cylindrical base  210  into a cylindrical opening of the connection port (not shown) in the testing equipment  220 . In this embodiment, the cylindrical opening of the testing equipment  220  has similar dimensions to the threaded portion of the cylindrical base  210  and a threaded inner surface to accommodate the threaded portion of the cylindrical base  210 . Moreover, in this embodiment, the body  230  can have multiple planar faces in order to allow a tool, such as an adjustable or customized wrench, to secure the body  230  and rotate the test connector  200 , thereby allowing a user to install or to remove the test connector  200 . Furthermore, the connector saver  240  can act to protect the action of a tool from damaging the test connector  200  when the test connector  200  is inserted or removed from the testing equipment  220 .  
         [0025]    As depicted in FIG. 2, a three-tiered cylindrical shaft  250  is affixed to the body  230 . Each tier of the cylindrical shaft  250  has a decreasing diameter. The primary tier  252  has the largest diameter and is affixed to the body  230 . The secondary tier  254  has a smaller diameter than primary tier  252  and is affixed to primary tier  252 . The tertiary tier  256  has a smaller diameter than the secondary tier  254  and is affixed to the secondary tier  254 . This three-tiered configuration allows the diameter of the cylindrical body  230  to be large enough to accommodate a manual manipulation of the connector  200  (such as with a tool) while also providing the smaller diameter of the tertiary tier  256  for insertion into a test port.  
         [0026]    A helical grounding mechanism  260  encircles the tertiary tier  256 . The shape of the grounding mechanism  260  allows the grounding mechanism  260  to serve both as a ground for the electrical connection between the test connector  200  and the test port of the wireless communication device under test and as a spring to improve the fit between the test connector  200  and the test port.  
         [0027]    The leading edge  257  of the test connector  200  in FIG. 2 and the outer surface of the tertiary tip  256  form a beveled shoulder  258 . In one embodiment, the shoulder  258  is beveled at an angle of 45 degrees. This configuration provides several advantages over the prior art. As described above and shown in FIG. 1, the leading edge  180  of the cylindrical tip  160  of the prior art test connector  100  forms a ninety degree angle with a plane tangential to the outer surface of the cylindrical shaft  150 . The shape of the prior art test connector creates difficulty when inserting the prior art test connector in a mass production environment as discussed above. The beveled surface of the tertiary tip  256  of the test connector  200  described herein avoids these difficulties. The improved shape of the test connector  200  provides for a more uniform mechanical coupling and therefor a more uniform electrical connection. The grounding mechanism  260  also serves to guide and align the wireless communication device  275  to the test connector  200 .  
         [0028]    [0028]FIGS. 3A and 3B illustrate an embodiment of the test connector  200  prior to insertion into a test port  270  of a wireless communication device  275  and as inserted into a test port  270  of a wireless communication device  275 , respectively. During the testing process, the tertiary tier  256  of the cylindrical shaft  250  is inserted into a test port  270  of a wireless communication device  275  under test as depicted in FIG. 3B. RF test signals are transmitted to the wireless communication device  275  under test via a transmitter passing through the center of the test connector  200  and through the leading edge  257  of the tertiary tier  256  of the cylindrical shaft  250 . Once the test connector  200  is inserted into the test port  270  of the wireless communication device  275  under test, the tertiary tip  270  mates with the test port  270  to create an electrical connection and allow RF test signals to be transmitted to the wireless communication device  275  under test. As described in more detail below and illustrated in FIG. 4, the dimensions of the tertiary tip  256  correspond to the dimensions of the opening in the test port to permit a snug fit between the test connector  200  and the test port. The grounding mechanism  260  and the beveled shape of the tertiary tip  256  serve to guide the tertiary tip  270  into the test port during this mating process. Moreover, the various components of the test connector  200  define a hollow shaft whereby RF test signals can be transmitted to the wireless communication device  275  under test via a transmitter passing through the center of the test connector  200 . In one embodiment, the electrical connection formed between the wireless communication device under test and the test connector  200  is a coaxial connection such as is well known in the art.  
         [0029]    [0029]FIG. 4 shows a cut-away side view of the test connector  200  positioned in the test port  270  of the wireless communication device  275 . As the tertiary tip  256  of the test connector  200  is inserted into the test port  270 , the outer end of the wall  272  of the test port  270  presses against the grounding mechanism  260 , reducing its helical shape to concentric rings encircling the base of the tertiary tip. At the same time, the receiver  274  of the test port  270 , mates into the opening on the leading edge  257  of the tertiary tip  256 . The diameter of the tertiary tip  270  corresponds to the inner diameter of the wall  272  of the test port  270 . In addition to improving the mechanical mating of the test connector  200  and the test port  270  of the wireless communication device  275 , the grounding mechanism  260  provides for direct and pressured contact between the wall  272  of the test port  270  and the grounding path of the test connector  200 .  
         [0030]    [0030]FIG. 4 also provides a basis for describing the improved performance produced by the test connector  200 . In the embodiment of FIG. 2 and illustrated in FIG. 4 during insertion into the test port  270 , the design of the test connector  200  incorporates a beveled tertiary tip  256  which allows for increased tolerance during initial placement of the test connector  200  into the test port. Furthermore, the test connector  200  includes a grounding mechanism  260  which also functions as a spring-like mechanism to guide and align the wireless communication device  275  to the test connector  200 . The action of the grounding mechanism  270  at initial placement therefore helps to reduce misalignment between the test connector  200  and the test port  270 .  
         [0031]    Referring now to FIGS. 5A, 5B, and  5 C, a wireless communication device test system  300  is shown. The wireless communication device test system  300  includes a wireless communications device  275 , which is mounted on a moveable mechanism  320 . The moveable mechanism  320  is configured to have the capability to move horizontally along a foundation  340 . As examples, a test table, a work bench, and a customized surface could serve as the foundation  340 . Moreover, in one embodiment, the moveable mechanism  320  can be configured to move along a tracking mechanism (not shown) on the foundation  340 . Furthermore, the moveable mechanism  320  is configured to secure the wireless communication device in position such that the test port  270  is at a height which corresponds to the height at which the test connector  200  is positioned above the foundation  340 . In this embodiment, the moveable mechanism  320  can provide an attaching device  325  whereby an operator can securely attach the wireless communication device  275 . Such an attaching device  325  could include straps, a locking device, an adjustable gripping device, or a slot conforming to the size and shape of the wireless communication device, as examples.  
         [0032]    An operator can either manually move the wireless communication device  275  coupled with the moveable mechanism  320  or this action can occur automatically. In either case, the wireless communication device  275  coupled with the moveable mechanism  320  is moved towards the test connector  200  such that as the wireless communication device  275  passes over the test connector  200 , the test connector  200  is inserted into the test port  270 . The test connector  200  can be mounted on to a compression spring  350  positioned in the Z-axis so that the test connector  200  is flexible as the wireless communication device  275  is slid over the test connector  200 .  
         [0033]    In FIGS. 5A, 5B, and  5 C, the test connector  200  is at a fixed position in the horizontal axis. The fixed position of the test connector  200  is located precisely so that when the wireless communication device  275  coupled to the moveable mechanism  320  reaches a travel stop  360 , the test connector  200  is precisely positioned in the test port  270 . Consequently, the tertiary tip  256  of the test connector  200  penetrates the horizontal plane extending from the lower surface of the wireless communication device  275 . Therefore, as depicted in Figure  5 B, just prior to reaching the travel stop  360 , the wireless communication device  275  mounted on the moveable mechanism  320  will come into contact with the test connector and depress the test connector  200  in the Z-axis direction which will in turn compress the compression spring  350 . When the moveable mechanism  320  reaches the travel stop  360  as illustrated in FIG. 5C, the wireless communication device  275  will be in a position such that the opening of the test port  270  will receive the tertiary tip  256  of the test connector  200 . In this position, the compression force on the compression spring  350  will be at least partially released allowing the compression spring  350  to push the test connector  200  back into the original Z-axis position and thereby cause the tertiary tip  256  to be inserted into and mate with the test port  270 . When in this position, the connector  200  mates mechanically and electrically with the wireless communication device  275  through the test port  270 .  
         [0034]    One purpose of the test system  300  is to gather accurate test readings of the wireless communication device  275  at a production pace. To make the system more robust in this environment, human effort can be limited to mounting the wireless communication device  275  on to the moveable mechanism  320 . After test readings have been collected, the operator can remove the test connector  200  from the test port  270  of the wireless communication device  275  simply by pressing the test connector  200  down vertically, thereby compressing the compression spring  350  and allowing the tertiary tip  256  of the test connector  200  to come out of the test port  270 . Next, with the test connector  200  removed from the test port  270 , the operator can slide the moveable mechanism  320  in the reverse direction away from the test connector  200 . Once the wireless communication device  275  mounted on the moveable mechanism  320  has been moved horizontally away from the test connector, vertical downward pressure on the compression spring  350  can be released.  
         [0035]    In another embodiment, human intervention can be limited further by automating the process. For example, an automated process could be used to slide the moveable mechanism  320  forward and backward. Moreover, an automated process could be used to secure the wireless communication device  275  to the moveable mechanism  320 . Additionally, the testing process, including the beginning and ending of the transmission of the RF test signals, for example, could be automated as well.  
         [0036]    The invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning of equivalency of the claims are to be embraced within their scope.