In-Cabin Radar EOL Tester

Our customer has developed highly precise and reliable radar systems (radar sensors) that even recognise the vital signs of sleeping newborn babies. As soon as an unattended individual is detected in the vehicle, the vehicle‘s alarm and communication systems can alert carers or passers-by that there is still an individual in the car, thus saving lives.

An in-cabin radar test system was evaluated as part of the project. The tests focussed on validating object recognition, measuring the power emitted by the sensor and recording operationally relevant parameters such as power consumption.
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Additional requirements were integrated in further projects, including an interface for an automated loading system, the extension
to various DUT variants and the flexible adaptation of the test sequence.

Challenges:

• Analyse the production plant to optimise the performance and availability of each individual process
• Ensuring a sustainable increase in productivity
• Guarantee high quality standards and maximum capacity utilisation with lower investment costs
• Ensure a fast product start-up for new products

Objectives:

• The primary objective was to develop a test system with a high throughput of DUTs and low system costs.
• The valid test requirements are loaded dynamically at runtime via a connected MES (Manufacturing Execution System).
• Reproducible and repeatable measurement results across multiple radar test systems.

The solution includes the following functions:

• Measurement of power consumption in different operating modes
• Measurement of power radiation in different frequencies and different positions
• Simulation of a thorax
• Automated DUT handling (contacting, positioning, placement)
• DUT labelling
• DUT communication

The manufacturer of sensor solutions for detecting the presence of individuals in cars benefited from:

• Ensuring product quality
• Automated documentation and traceability
• Flexibility thanks to modular test sequences
• High test item throughput thanks to short handling and test time.

The successful implementation of the EOL system is largely based on our expertise in automation technology, which enabled the precise and efficient integration of the inspection processes. In addition, our many years of experience and in-depth knowledge of radar technology enabled us to address specific requirements.
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The use of our specially developed VROS system (60 GHz) as a cost-effective alternative to conventional radioheads
enabled a flexible and economical solution.
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In the course of the system integration, we also gained valuable knowledge in the field of in-cabin radar testing, which will be incorporated into future developments.

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