implementation, testers and testing of satellite phoneavots/juuni_2010/maarja_laos_mag.pdf ·...

TALLINN UNIVERSITY OF TECHNOLOGY

Department of Radio and Communication Engineering

Code: IRT70LT

Implementation, testers and testing of satellite phone

Satelliittelefoni tootmiskorraldus ja testimine

Maarja Laos, 030770IATM

Master’s thesis is written at the Chair of Telecommunication

Supervisor: Avo Ots

Thesis is defended in the committee at the Department of Radio and Communication

Engineering

The author is applying for the Technical Sciences Master’s degree

Presented: 01.06.2010

Defending: 10.06.2010

Tallinn 2010

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ABSTRACT

Present master’s thesis “Implementation, testers and testing of satellite phone” introduces

main challenges of satellite phone implementation. The purpose of the thesis is to analyze and

describe a satellite phone manufacturing processes and to find out what kind of actions are

needed in production area to start producing a new product.

Secondly the author shows what kind of testers and testing processes are needed to assure the

quality and functionality of the product and describes main problems related with satellite

phone testing.

The thesis is written in English and consists of 75 pages, 33 figures, 12 tables and 3

appendixes.

Keywords: Inmarsat’s handset - IsatPhone Pro, Inmarsat-4 satellites, satellite orbits (GEO,

MEO, LEO), GMR-2+ protocol, ETSI requirements, proto-production, board testing, GMR

antenna testing, final testing, customisation, troubleshooting.

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REFERAAT

Käesolev magistritöö “Satelliittelefoni tootmiskorraldus ja testimine” tutvustab peamisi

etappe satelliittelefoni juurutamisel. Töö eesmärk on analüüsida ja kirjeldada uue seadme

tootmiskorraldust ja tootmise teostamiseks vajaminevaid protsesse.

Teise osana tutvustab autor testreid ja testimist, mille abil tagatakse toote kvaliteet ja

töökindlus. Samuti tuuakse välja põhilised kitsaskohad sateliittelefoni testimisel.

Magistritöö on kirjutatud inglise keeles ja koosneb 75 leheküljest, 33 joonisest, 12 tabelist ja 3

lisast.

Võtmesõnad: Inmarsati telefon – IsatPhone Pro, Inmarsat-4 satelliidid, satelliitorbiidid (GEO,

MEO, LEO), GMR-2+ protokoll, ETSI nõuded, proto-tootmine, plaadi testimine, GMR

antenni testimine, lõpptoote testimine, kohandamine, vea selgitamine.

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PREFACE

Besides of studies at Tallinn University of Technology I have been working for Elcoteq

Tallinn AS NPI (New Product Introduction) department 4 years. Elcoteq is EMS (Electronic

Manufacturing Services) provider and operates in 15 countries on four continents. Past one

and half years Elcoteq has been developing (main design has been provided by Sasken),

manufacturing and testing a new satellite phone – IsatPhone Pro.

Present work tasks and growing interest about this topic have been main purposes to start and

write the current master’s thesis. The thesis consists of overall information about satellites,

satellite phone and GMR-2+ protocol and beside of wider overview it also gives deeper

review about IsatPhone Pro implementation challenges, manufacturing and testing.

I would like to thank my supervisor Avo Ots and my colleagues who helped to create the

thesis.

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CONTENTS LIST OF FIGURES.................................................................................................................... 6 LIST OF TABLES ..................................................................................................................... 7 ABBREVIATIONS.................................................................................................................... 8 1 INTRODUCTION................................................................................................................. 10

1.1 TASK DEFINITION...................................................................................................... 10 1.2 THESIS STRUCTURE.................................................................................................. 11

2 IMPLEMENTATION OF SATELLITE PHONE................................................................. 12 3 OVERVIEW OF SATELLITE COMMUNICATION ......................................................... 14

3.1 SATELLITE INDUSTRY.............................................................................................. 14 3.2 SATELLITE TECHNOLOGY ...................................................................................... 16

3.2.1 How does a satellite get into space?........................................................................ 16 3.2.2 Satellite orbits: LEO, MEO and GEO..................................................................... 16 3.2.3 Since the distance to satellite is about 36 000 km, how can a phone work?........... 18

3.3 FREQUENCY BANDS ................................................................................................. 19 3.4 INMARSAT, ISATPHONE PRO AND INMARSAT-4 SATELLITES....................... 20

3.4.1 IsatPhone Pro........................................................................................................... 20 3.4.2 Inmarsat-4 satellites................................................................................................. 23

4 GMR-2+ GENERAL OVERVIEW ...................................................................................... 25 4.1 FREQUENCY BANDS AND CHANNEL ARRANGEMENTS.................................. 25 4.2 L-BAND FREQUENCY DESIGNATION AND NUMBERING SCHEME................ 25 4.3 EXTENDED L-BAND FREQUENCY RANGE........................................................... 28 4.4 GMR-2+ PARAMETERS SPECIFICATION FOR ISATPHONE PRO ...................... 30 4.5 CALIBRATION AND RF TEST SETUP OF ISATPHONE BOARD TESTER FOR GMR-2+ ............................................................................................................................... 31 4.6 CALIBRATION AND RF TEST SETUP OF ISATPHONE FINAL TESTER FOR GMR-2+ ............................................................................................................................... 33

5 GMR-2+ HANDSET IMPLEMENTATION REQUIREMENTS, DEVELOPING AND MANUFACTURING............................................................................................................... 35

5.1 INMARSAT DEVELOPING AND MANUFACTURING PARTNERS FOR ISATPHONE PRO: SASKEN AND ELCOTEQ ................................................................ 35

5.1.1 Sasken...................................................................................................................... 35 5.1.2 EMS (Electronic Manufacturing Services) provider Elcoteq Tallinn AS............... 35

5.2 IMPLEMENTATION REQUIREMENTS FOR ISATPHONE PRO ........................... 37 5.3 MANUFACTURING OF ISATPHONE PRO............................................................... 40

5.3.1 Project steps............................................................................................................. 41 5.3.2 Production flow....................................................................................................... 43

6 ISATPHONE PRO TESTERS AND TESTING................................................................... 49 6.1 BOARD LEVEL TESTING........................................................................................... 52 6.2 GMR ANTENNA TESTING......................................................................................... 55 6.3 FINAL TESTING .......................................................................................................... 60 6.4 CUSTOMISATION ....................................................................................................... 64 6.5 REPAIRING / TROUBLESHOOTING......................................................................... 67

7 CONCLUSION ..................................................................................................................... 70 REFERENCES......................................................................................................................... 72 Appendix A. Main PCB SMA manufacturing and testing process flow ................................. 73 Appendix B. GMR antenna assembly manufacturing and testing process flow...................... 74 Appendix C. FA manufacturing and testing process flow ....................................................... 75

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LIST OF FIGURES

Figure 2-1. New product introduction process......................................................................... 13 Figure 3-1. Satellite industry overview by SIA [2] .................................................................. 15 Figure 3-2. LEO, MEO and GEO orbits [4]............................................................................. 17 Figure 3-3. Inmarsat’s global handheld satellite phone - Isatphone Pro [7] ............................ 21 Figure 3-4. The geographic locations of I-4 satellites [8] ........................................................ 23 Figure 4-1. L-Band Narrow Beam Downlink Frequency Plan [9]........................................... 27 Figure 4-2. L-Band Narrow Beam Uplink Frequency Plan [9]................................................ 27 Figure 4-3. L-Band Regional Beam Downlink Frequency Plan [9] ........................................ 27 Figure 4-4. L-Band Regional Beam Uplink Frequency Plan [9] ............................................. 28 Figure 4-5. Current (classical) and extended MSS L-band spectrum [9]................................. 29 Figure 4-6. RF test setup for board level test [15] ................................................................... 31 Figure 4-7. RF test setup for final test [15] .............................................................................. 33 Figure 5-1. NPI as a part of product lifecycle [13] .................................................................. 37 Figure 5-2. Main milestones for IsatPhone Pro........................................................................ 41 Figure 5-3. IsatPhone Pro manufacturing and testing structure ............................................... 44 Figure 5-4. Quality Management System ................................................................................ 45 Figure 5-5. FA line layout on picture during prototype manufacturing................................... 47 Figure 5-6. Flow chart for production area .............................................................................. 47 Figure 6-1. Production tester flow............................................................................................ 50 Figure 6-2. Both side assembled PCB for IsatPhone Pro......................................................... 52 Figure 6-3. Board tester test rack - front and rear view [16].................................................... 54 Figure 6-4. The view of board tester: 1 – RF chamber and 2 – DUT adapter ......................... 55 Figure 6-5. Divider Disc SMA (20 PCBs) and GMR antenna subassembly ........................... 56 Figure 6-6. GMR antenna connection diagram........................................................................ 57 Figure 6-7. GMR antenna tester test rack - front and rear view [16]....................................... 58 Figure 6-8. The view of GMR antenna tester – front view and inside view............................ 58 Figure 6-9. GMR antenna - RF adapter locking and fixture closing........................................ 59 Figure 6-10. Final tester test rack - front and rear view [16] ................................................... 62 Figure 6-11. The view of final tester........................................................................................ 63 Figure 6-12. Customisation station test rack - front and rear view [16] .................................. 66 Figure 6-13. The view of customisation station....................................................................... 67 Figure 6-14. Repairing / troubleshooting station test rack - front and rear view [16] ............. 68 Figure 6-15. The view of repairing / troubleshooting fixture .................................................. 69

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LIST OF TABLES

Table 3-1. LEOS (Low-Earth Orbit Systems) [4] .................................................................... 17 Table 3-2. MEOS (Medium-Earth Orbit Systems) [4]............................................................. 17 Table 3-3. GEOS (Geostationary-Earth Orbit Systems) [4] .................................................... 18 Table 3-4. Physical and battery specifications for IsatPhone Pro [7] ...................................... 21 Table 3-5. Service specifications for IsatPhone Pro [7]........................................................... 22 Table 3-6. Other features and accessories for IsatPhone Pro [7] ............................................. 22 Table 4-1. Current and proposed L-band frequency ranges [9] ............................................... 28 Table 4-2. RF calibration outcome for board tester [15].......................................................... 32 Table 4-3. RF calibration outcome for final tester [15] ........................................................... 34 Table 5-1. IsatPhone Pro product structure .............................................................................. 43 Table 5-2. Production data management.................................................................................. 46 Table 6-1. Testers for IsatPhone Pro........................................................................................ 50

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ABBREVIATIONS

AC Alternating Current

AOI Automated Optical Inspection

BOM Bill of Material

BSS Broadcast Satellite Services

BT Bluetooth

COTM Communications on the Move

DB Database

DC Direct Current

DUT Device Under Test

EIRP Equivalent (Effective) Isotropically Radiated Power

EMS Electronic Manufacturing Services

ES Earth Station

ETSI European Telecommunications Standards Institute

FA Final Assembly

FPY First Pass Yield

FSS Fixed Satellite Service

G/T Gain to Noise Temperature Ratio

GEO Geostationary Earth Orbit

GEOS Geostationary-Earth Orbit Systems

GMR Geostationary Mobile Radio

GMR-2 Geostationary Mobile Radio Release 2

GMR-2+ Geostationary Mobile Radio Release 2+, enhanced variant of GMR-2

GPIB General Purpose Interface Bus

GPS Global Positioning System

GSM Global System for Mobile Communications

GSPS Global Satellite Phone Service

HW Hardware

HWID Hardware Identity

I-4 Inmarsat-4

ID Identity

IEEE The Institute of Electrical and Electronic Engineers

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IMEI International Mobile Equipment Identity

IMSI International Mobile Subscriber Identity

LAN Local Area Network

LARFCN L-Band Absolute Radio Frequency Channel Number

LEO Low Earth Orbit

LEOS Low-Earth Orbit Systems

MEO Medium Earth Orbit

MEOS Medium-Earth Orbit Systems

MES Manufacturing Execution System

MSS Mobile Satellite Services

NPI New Product Introduction

NSB Narrow Spot Beam

OS Operating System

PCB Printer Circuit Board

PCBA Printer Circuit Board Assembly

PI Product Identification

PISN Product Identification Serial Number

RF Radio Frequency

SBU Strategic Business Unit

SIA Satellite Industry Association

SMA Surface Mount Assembly

SMS Short Message Service

SN Serial number

SPC Statistical Process Control

SPI Serial Peripheral Interface

SQL Structured Query Language

SW Software

TN Timeslot Number

TRSH Troubleshoot

USB Universal Serial Bus

USW Ultra Sonic Welding

UT / UTH User Terminal / User Terminal Handset

UTCM User Terminal Core Module

VSAT Very Small Aperture Terminal

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1 INTRODUCTION

Satellite communications can complement existing terrestrial system and provide network to

regions that do not have adequate infrastructure, areas too far from the population, where

terrestrial network implementation is not economically reasonable. Satellite communication

makes possible to receive and transfer calls wherever you are. You can be on top of the

Mount Everest or in the middle of the Atlantic Ocean and you still have connection. In

emergency situations caused by floods, hurricanes, earthquakes or terrorism the regular

cellular network might fail, but the satellite phone will continue working.

Inmarsat provides global mobile satellite communication and they have launched three 4th

generation satellites to cover satellite mobile service globally. IsatPhone Pro is the first

Inmarsat’s global handheld satellite phone that uses next-generation satellite protocol –GMR-

2+ (Geostationary Mobile Radio Release 2+, enhanced variant of GMR-2) [7]. IsatPhone Pro

will be available in market this year June, the design for that phone is done by Sasken and the

manufacturing by Elcoteq.

1.1 TASK DEFINITION

The first goal of given master’s thesis is to describe and give a short overview of satellite

communication and satellite phone.

The second goal of this study is to show the new product manufacturing processes and

challenges. The purpose is to introduce the importance of NPI service and to describe

production steps to find out what kind of actions are needed in production area to implement a

new satellite phone.

The third goal is to show what kind of tests are needed to assure the product quality and

functionality and what are the main problems related with satellite phone testing. The purpose

is to describe why testing is so important and to analyze testing tools and measures used for

the IsatPhone Pro testing: board level test, GMR antenna test, final test, customisation and

troubleshooting.

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1.2 THESIS STRUCTURE

Current master’s thesis is divided into seven major parts; it begins by introduction of the

thesis. The second part analyses new product introduction process and shows how

implementation of satellite phone should function to assure customer satisfaction, committed

personnel, ethical conduct of business, continuous improvement and result orientation. The

third part gives an overview about satellite communication: satellite industry and technology.

Existing satellite services and frequency bands are described and author makes a short review

about following satellite orbits: GEO, MEO and LEO. In addition third part describes

contents of Inmarsat IsatPhone Pro and shows how Inmarsat-4 satellites are located. GMR-2+

protocol, frequency bands and channel arrangements are introduced to reader firstly in the

fourth part. The part five gives some information about Inmarsat’s partners: Sasken and

Elcoteq; and also IsatPhone Pro developing requirements and manufacturing steps are

described. Reader can find a short overview how IsatPhone Pro has been produced and what

were the challenges during that process. Practical part continues in the sixth chapter with

board testing, GMR antenna testing, final testing, customisation and troubleshooting – here

reader can find more information about testing and can see what are the main reasons to make

different kind of tests. Summary presented in the seventh part delivers a conclusion to the

given thesis.

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2 IMPLEMENTATION OF SATELLITE PHONE The author of present master’s thesis has opinion that new product implementation process is

always full of challenges: there is a need for large package of new knowledge and trainings,

need for new equipments and tools for manufacturing and testing purpose, need for new

software, need for new or enhanced production line and testing processes. NPI (New Product

Introduction) service has to implement a new product and solve all the “bottlenecks” and

problems before volume production phase.

Introductory research of product, market and background information is crucial to start

successful product implementation process. It makes possible to be professional when

communicating with customer and helps to give adequate feedback for all parties.

New satellite phone has to provide global coverage and therefore Inmarsat uses 4th generation

satellites that are located on GEO (Geostationary Earth Orbit) orbit. Third chapter of this

thesis describes how satellites get into space, what are the main characteristics and challenges

on GEO orbit and what are the coverage areas and positions of Inmarsat-4 satellites.

After larger pre-study the next step of satellite phone implementation is to start practical

work. Three following parties are related with IsatPhone Pro implementation:

Customer – Inmarsat -> Inmarsat provides and confirms all the information about new

satellite phone.

Design partner – Sasken - > Inmarsat appointed Sasken to lead the program, as well as

making a number of decisions to increase the development effort and ensure that a compelling

service offering is available at the earliest opportunity [7].

Manufacturing partner – Elcoteq -> Inmarsat signed a manufacturing contract with Elcoteq

and this gave following responsibilities and tasks to Elcoteq:

• Co-operation with Sasken – to implement together a new contemporary satellite

phone.

• Project specification and planning – to work through all the existing documents that

are connected with product design, manufacturing requirements and testing terms.

• Process flow – to agree all the milestones and deadlines with customer for all the

actions that have to be done before first proto-build.

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• Material management – to start ordering material according to preliminary provided

information from Sasken.

• Production engineering – to create/design new process, equipment, tool or production

line to secure successful manufacturing during each proto-build.

• Test engineering – to design, produce and implement all the needed testers for

IsatPhone Pro.

• Quality management - to guarantee high value design quality, material quality and

manufacturing quality.

• Trainings – to provide trainings for project related workers to decrease failures that

may occur in the work operations.

• Proto-builds – to fulfill customer expectations and to complete all the production steps

successfully. In addition the manufacturer should be able to improve the design or

give helpful advice to make the overall production more effective and product more

competitive.

• Testing – to test 100% manufactured items against the specifications. Only

successfully tested products are delivered to customer.

Following figure 2-1 shows author’s view about new product introduction process.

Figure 2-1. New product introduction process

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3 OVERVIEW OF SATELLITE COMMUNICATION

Satellites can help to provide many services for people and enable communication all over the

world.

Here are the main services provided by satellite communication [1]:

1. A satellite can carry a camera as it travels in its orbit and takes pictures of the whole

earth. Satellite pictures can also help experts predict the weather, because from the

satellite the camera can actually see the coming weather.

2. Satellites in orbit can send messages to a special receiver carried by someone on a ship

in the ocean or in a truck in the desert, telling that person exactly where he or she is.

3. A satellite can relay your telephone call across the country or to the other side of the

world.

4. A satellite can relay computer message, fax message or Internet data. With the help of

satellites, we can fax, e-mail or download information anyplace in the world.

5. A satellite can transmit TV programs from the studio where it is made to TV set.

When words, pictures or computer data are sent up to a satellite, they are first converted to an

invisible stream of energy, called a signal. The signal travels up through space to the satellite

and then travels down from the satellite to its destination, where it is converted back to a

voice message, a picture, or data, so that the receiver can receive it [1].

3.1 SATELLITE INDUSTRY

Telecommunication is a major application of satellite industry and space industry, but satellite

phone is a small part of satellite communication. Following figure 3-1 shows satellite industry

overview by SIA (Satellite Industry Association):

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Figure 3-1. Satellite industry overview by SIA [2]

MSS (Mobile Satellite Services) include mobile voice and data. Demand for data (mostly

internet) is growing same way as in terrestrial networks.

FSS (Fixed Satellite Services) connect small telephone and data networks of remote locations

to global telecom networks. These remote locations are for example isolated islands, villages,

oil- and gas fields.

Satellite TV is the major service within BSS (Broadcast Satellite Services). Satellite radio is

gaining popularity.

The niche of satellite telephone has some simple reasons. Terrestrial networks are covering

only small part of the surface of the Earth but vast majority of people spend their time on

those areas. Outside of those areas, there are not many people wealthy enough to buy and use

a satellite phone. Satellite phone is not competitive to cellular phone in urban areas because

of requirement to open sky.

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3.2 SATELLITE TECHNOLOGY

3.2.1 How does a satellite get into space?

A satellite is launched on a launch vehicle, which is like a taxicab for satellites. The satellite is

packed carefully into the vehicle and carried into space, powered by a rocket engine. Satellites

are launched from only a few places in the world, primarily Cape Canaveral, Florida; Kourou,

French Guiana; Xichang, China and Baikonur, Kazakstan. The best places to launch satellites

are near the ocean, so that when the launch vehicle falls away, it lands in the water and not on

people. At launch, the launch vehicle’s rockets lift the satellite off the launch pad and carry it

into space, where it circles the earth in a temporary orbit. Then the spent rockets and the

launch vehicle drop away, and one or more motors attached to the satellite move it into its

permanent geosynchronous orbit. A motor is started up for a certain amount of time,

sometimes just one or two minutes, to push the satellite into place. When one of these motors

is started, it’s called a "burn." It may take many burns, over a period of several days, to move

the satellite into its assigned orbital position. When the satellite reaches its orbit, a motor

points it in the right direction and its antennas and solar panels deploy - that is, they unfold

from their travelling position and spread out so the satellite can start sending and receiving

signals [1].

3.2.2 Satellite orbits: LEO, MEO and GEO

The generally known technically feasible options of providing a communication service to

handheld satellite phones are:

� LEO (Low Earth Orbit) - up to 900 km [3].

� MEO (Medium Earth Orbit - 5000 to 12000 km [3].

� GEO (Geostationary Earth Orbit) - 36 000 km [3].

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Figure 3-2. LEO, MEO and GEO orbits [4]

Following tables 3-1 – 3-3 show characteristics and challenges of LEO, MEO and GEO

systems.

Table 3-1. LEOS (Low-Earth Orbit Systems) [4]:

+ Low latency or transmission delay + Higher look angle (especially in high-latitude regions) + Less path loss or beam spreading + Easier to achieve high levels of frequency re-use + Easier to operate to low-power/low-gain ground antennas - Larger number of satellites (50 to 70 satellites). Thus higher launch costs to deploy,

build, and operate - Harder to deploy, track and operate - Shorter in-orbit lifetime due to orbital degradation

Table 3-2. MEOS (Medium-Earth Orbit Systems) [4]:

+ Less latency and delay than GEO (but greater than LEO) + Improved look angle to ground receivers in higher latitudes + Longer in-orbit lifetime than LEO systems (but less than GEO) - More satellites to deploy than GEO (10 to 18) - Ground antennas are generally more expensive and complex because of the need to

track satellites

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Table 3-3. GEOS (Geostationary-Earth Orbit Systems) [4]:

+ UT (User Terminal) do not have to track the satellite + Only 3 satellites can provide almost global coverage + Maximum life-time (15 years or more) + Often the lowest cost system and simplest in terms of tracking and high speed switching - Transmission latency or delay of 250 milliseconds to complete up/down link - Satellite antennas must be of larger aperture size to concentrate power and to create

narrower beams for frequency reuse - Poor look angle elevations at higher latitudes

Three geostationary satellites spaced equally around the equator can cover the Earth

excluding Polar Regions. GEO satellite travels in the same direction and at the same speed as

the Earth's rotation on its axis, taking 24 hours to complete a full trip around the globe. Since

GEO satellites revolve at the same rotational speed as the earth, then appear stationary from

the earth’s surface and radio signal can be transmitted to and from them with highly

directional antennas pointed in a fixed direction. This is the property that makes satellite

communication practical with a single satellite. The distance of a GEO satellite above the

earth causes a propagation delay of 0.25 second (36000 km / 300000 km/s = 0.120s one way)

for a round trip up to the satellite and back to earth. Propagation delay is one area where

systems based on MEO or LEO satellites have an obvious advantage [5].

3.2.3 Since the distance to satellite is about 36 000 km, how can a phone work?

Satellite reflector in space is large. Big solar panels and lots of power are needed. Phone

(handheld) antennas are bigger and more directional than in terrestrial systems. Also sensitive

low-noise receivers are needed. Handheld output power does not generally exceed terrestrial

models, probably because of safety reasons. Capacity is increased by clever antenna design.

Spot beams enable reuse of precious frequencies. Transmission delay is noticeable in real-

time communication.

Basically satellite network is similar to every cellular network. The difference is how the

signal moves between satellite phone and satellite. When you make a call from a satellite

phone, the signal is sent to the satellites of that particular company. These satellites process

the call and relay it back to Earth via a gateway. The gateway then routes the call to its

destination using the regular landlines and cellular networks. If you use a satellite phone to

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call another satellite phone then the call is sent up to the satellite from the caller's phone. The

satellite then routes the call back down to the receiver's phone without using any land

infrastructure. Therefore satellite phones can be used to call each other without using any

landline or cellular phone infrastructures.

3.3 FREQUENCY BANDS

Following frequency bands are used for satellite communication. L-band is used for mobile

communication.

L-Band

As defined by IEEE (The Institute of Electrical and Electronic Engineers) std 521, the

frequency range from 1 to 2 GHz. The L-band term is also used to refer to the 950 to

1450MHz frequency range used for mobile communications. L-band is used for MSS and

offers good penetration through adverse weather conditions and foliage [6].

C-Band

The frequency range from 3.7 to 6.2 GHz. Transmission is less affected by atmospheric

conditions such as snow and rain. C-band transmissions have low power, so ES (Earth

Station) must be rather large to compensate dish size. Applications include public switched

networks and Internet [6].

X-Band

The frequency range from 8 to 12 GHz. The X-band frequency enables high power operations

with very small terminals. Applications include COTM (Communications on the Move),

manpacks, emergency communications and airborne and shipboard platforms. X-band is also

less vulnerable to rain fade and adjacent satellite side lobe interference than other frequencies

[6].

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Ku-Band

The frequency range from 11.7 to 14.5 GHz. Ku-band has higher power than C-band allowing

for smaller dishes to be used. However, the higher frequency of Ku-band makes it more

susceptible to adverse weather conditions than C-band. Applications include VSAT (Very

Small Aperture Terminal), rural telephony, satellite news gathering, videoconferencing, and

multimedia [6].

Ka-Band

The frequency range from 17.7 to 21.2 GHz. Has a higher power than Ku-band allowing for

smaller dishes to be used and therefore it will be used for high-bandwidth interactive services

such as high-speed Internet, videoconferencing, and multimedia applications. Ka-band

transmissions are more sensitive to poor weather conditions than Ku-band [6].

3.4 INMARSAT, ISATPHONE PRO AND INMARSAT-4 SATELLITES

Inmarsat is the world's leading provider of global mobile satellite communications. Inmarsat

provides voice and high-speed data services to almost anywhere on the planet - on land, at sea

and in the air. Inmarsat owns and operates 11 satellites in geostationary orbit that are

controlled from London via ground stations located around the globe. Inmarsat uses

geostationary satellites and in this case, the phone's antenna must point directly at the satellite

with a clear, unobstructed view to get transmission [7].

3.4.1 IsatPhone Pro

IsatPhone Pro is first Inmarsat’s global handheld satellite phone, which will be in the market

in June 2010. IsatPhone Pro will offer satellite phone service with additional applications like

Bluetooth for handsfree use, voicemail and email messaging. Location data will also be

available to the user to look up or send in a text message. Designed primarily for professional

users in the government, media, aid, oil and gas industry, mining and construction sectors,

this is the first handset to be purpose-built for the Inmarsat network. IsatPhone Pro has been

optimized to deliver the best performance over the world’s most advanced mobile satellite

network. It will be available on a global basis over the three I-4 (Inmarsat-4) satellites, which

have an operational lifetime into the 2020s [7].

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The ultimate combination [7]:

Global coverage;

Robust handset;

Clear voice quality;

Reliable network connection;

Long battery life;

Easy to use.

Figure 3-3. Inmarsat’s global handheld satellite phone - Isatphone Pro [7]

Handset specifications

Following tables 3-4 – 3-6 show IsatPhone Pro physical and battery specifications, service

specifications, and all the other features and accessories that are included of IsatPhone Pro

sales package.

Table 3-4. Physical and battery specifications for IsatPhone Pro [7]:

Dimensions Length: 170mm, width: 54mm, depth: 39mm

Weight 279g – including battery Display High visibility color screen

Interfaces

Micro USB Audio socket Antenna port Bluetooth 2.0

Water and dust ingress protection IP54

Operating range -20ºC to +55ºC

Storage range -20ºC to +70ºC (with battery)

Charging range 0ºC to 45ºC Humidity tolerance 0 to 95 per cent Type Lithium-ion, 3.7 volts Talk time Up to 8 hours Standby time Up to 100 hours

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Table 3-5. Service specifications for IsatPhone Pro [7]:

Satellite telephony

2.4kbps voice codec Speakerphone option

Voicemail Speed dial 1

Supplementary voice services

Call history, caller ID (Identity), call waiting, call divert, call holding, conferencing, call barring, speed dialling, fixed number dialling.

Text-to-text

160 Latin / ~74 non-Latin characters up to 10 concatenations Standard and predictive text

Text-to-email

160 Latin / ~74 non-Latin characters up to 10 concatenations Incoming email – 160 characters

Web message-to- IsatPhone Pro

Free from www.message.inmarsat.com

GPS location data View position, send as text/email

Table 3-6. Other features and accessories for IsatPhone Pro [7]:

Features Calendar, alarm, calculator Minute minder – in-call alert Microphone muting

Contact synchronization

With MS Outlook 2007 O/S compatibility: Windows XP Pro SP3 and Windows Vista SP1

Languages supported

Arabic, Chinese, English, French, Japanese, Portuguese, Russian, Spanish

Security At the keypad, phone, SIM and network level

In the box

Battery Chargers: Mains universal AC charger, car charger – 10-30 volts, PC charger – micro USB cable Wired handsfree headset Wrist strap Quick start guide (8 languages) Warranty documentation Support CD

Also available Carry case; Docking units; Bluetooth headset; Solar charger

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3.4.2 Inmarsat-4 satellites

Inmarsat 4th generation satellites (launched 2005 - 2008) - the first two I-4 satellites were

launched in 2005 and the third I-4 satellite launched on 18th of August 2008. I-4 satellites are

the most advanced commercial communications satellites ever launched [8].

To reflect the geographic locations covered by the satellites, Inmarsat will refer to its three I-4

satellite regions as [8]:

• I-4 Americas – covering the Pacific and Atlantic Oceans (the position 98W)

• I-4 EMEA (Europe, Middle East, Africa) – covering the Atlantic and Indian Oceans

(the position 25E)

• I-4 Asia-Pacific – covering the Indian and Pacific Oceans (the position 143.5E)

Figure 3-4. The geographic locations of I-4 satellites [8]

Inside the Inmarsat-4 satellites

I-4 satellites are unique in their ability to generate hundreds of high-power spot beams. Each

I-4 can generate 19 wide beams and more than 200 narrow spot beams. These can quickly be

reconfigured and focused anywhere on Earth to provide extra capacity where needed [7].

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Some of the spacecraft's impressive features include [7]:

• The I-4 body - approaching the size of a double-decker bus at 7m x 2.9m x 2.3m;

• Solar arrays - approaching the width of a football pitch, with an immense wing span of

45 meters;

• Solar panels - combining conventional silicon with advanced gallium arsenide cells

for optimum efficiency;

• Digital signal processor - controlling the antennas, beam forming and channel

allocation;

• Reflector - 9 meters wide and designed to unfurl in orbit like a giant flower;

• Antennas - 120 helix elements combined in a single flexible array;

• Thrusters - both chemical and plasma ion for orbital station keeping.

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4 GMR-2+ GENERAL OVERVIEW

The Inmarsat GSPS (Global Satellite Phone Service) is a mobile satellite voice and data

communications service. The GSPS will provide satellite communication services on a global

basis using the I-4 satellite constellation. The GSPS network architecture aligns closely with

the ETSI (European Telecommunications Standards Institute) specification for the GMR

(Geostationary Mobile Radio) interface, which is a derivative of the terrestrial GSM (Global

System for Mobile Communications) standard for operation in a satellite environment

(increased delay, more challenging link budget, and different power specifications). More

specifically, the GSPS will use an enhanced version, called GMR-2+. GMR-2+ is the next-

generation satellite protocol delivering optimum line of sight connection to the most extreme

of global locations. GMR-2+ standard enable Inmarsat to offer a high quality and best

handheld mobile satellite service.

4.1 FREQUENCY BANDS AND CHANNEL ARRANGEMENTS

According to ETSI standard following frequency bands and channels are usable. The GMR-

2+ system is required to operate, at least in the following frequency bands with polarization

schemes as specified [9]:

Forward link - downlink: 1525 - 1559 MHz Right Hand Circular Polarization.

Return link - uplink: 1626.5 – 1660.5 MHz Right Hand Circular Polarization.

Return link - downlink: 3550 - 3700 MHz Right Hand and Left Hand Circular Polarization.

Forward link - uplink: 6425 - 6575 MHz Right Hand and Left Hand Circular Polarization.

For narrow beams, the carrier spacing is 200 kHz on the forward link, and on the return link,

the carrier spacing is 50 kHz. For regional beams, the carrier spacing is 50 KHz on the

forward link, and on the return link, the carrier spacing is 12.5 KHz [9].

4.2 L-BAND FREQUENCY DESIGNATION AND NUMBERING SCHEME

According to ETSI standard the L-band carrier frequency is designated by the LARFCN (L-

Band Absolute Radio Frequency Channel Number), a parameter which can take on values

between 0 and 169. The forward links in NSB (Narrow Spot Beam), carriers are channelised

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on the basis of 200 kHz bandwidth carriers. The definition of the carrier frequency in terms of

the LARFCN is determined by the following relationship:

NB Downlink Frequency (MHz) = 1 525.1 + LARFCN * 0.2; where 0 � LARFCN � 169 [9].

For the return links in NSB, the definition of the L-band carrier frequency also requires

specification of the TN (Timeslot Number) in order to identify which of the four 50 kHz sub-

carriers is selected from the corresponding 200 kHz channel.

NB Uplink Frequency (MHz) = NB Downlink Frequency + 101.425 + (TN modulo 4) * 0.05;

where 0� TN � 7 [9].

Or equivalently, as a function of LARFCN and TN:

NB Uplink Frequency (MHz) = 1 525.1 + LARFCN * 0.2 + 101.425 + (TN modulo 4) * 0.05;

where 0 � LARFCN � 169 and 0� TN � 7 [9].

The forward links in regional beams are based on 50-kHz channel bandwidths. In order to

uniquely identify the regional beam 50-kHz forward channel, an additional parameter is

needed. This parameter is the FOext, which can take on any of the integer values from 0 to 3,

thus identifying which of the 50-kHz channels within a 200-kHz bandwidth is the correct

carrier. The following relationship applies:

RB Downlink Frequency (MHz) = 1 525.025 + LARFCN*0.2 + FOext * 0.050; where

0 � FOext � 3 [9].

The return links in regional beams are based on 12.5-kHz channel bandwidths. In order to

uniquely identify a 12.5 kHz frequency channel within a 50-kHz channel, another parameter,

the RPAGING Group, is used. The RPAGING Group parameter takes on any integer value

between 0 and 3, and is derived for each handset from the IMSI (International Mobile

Subscriber Identity). With these parameters, the regional beam return link carrier frequency

can be determined from the following relationship:

RB Uplink Frequency (MHz) = 1 626.50625 + LARFCN*0.2 + FOext * 0.050 + RPAGING

Group * 0.0125; where 0 � LARFCN � 169 and 0 � FOext � 3 and 0 � RPAGING Group � 3

[9].

The L-Band frequency plans are graphically depicted in figure 4-1 through figure 4-4:

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Figure 4-1. L-Band Narrow Beam Downlink Frequency Plan [9]

Figure 4-2. L-Band Narrow Beam Uplink Frequency Plan [9]

Figure 4-3. L-Band Regional Beam Downlink Frequency Plan [9]

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Figure 4-4. L-Band Regional Beam Uplink Frequency Plan [9]

4.3 EXTENDED L-BAND FREQUENCY RANGE

According to ETSI standard in the extended L-band range, shown below in Table 4-1, an

additional 7 MHz of spectrum is allocated for MSS. This would represent an additional 35

200-kHz channels. The extended L-band frequency range can be implemented by using values

of LARFCN from 170 to 204 [9].

Table 4-1. Current and proposed L-band frequency ranges [9]:

The current allocated frequency band and the extended frequency band are illustrated in next

figure 4-5.

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Figure 4-5. Current (classical) and extended MSS L-band spectrum [9]

In the extended MSS frequency range, the forward links in narrow spot beams are channelized

on the basis of 200 kHz bandwidth carriers in the same fashion as the original frequency

range. For the extended frequency range, the definition of the carrier frequency in terms of the

LARFCN is determined by the following relationship:

NB Downlink Frequency (MHz) = 1 518.1 + (LARFCN - 170) * 0.2; where 170 � LARFCN

� 204 [9].

The return uplink segment of the extended frequency range is separated from the forward

downlink frequency range by 150 MHz. Additionally, as in the original frequency range, the

carrier frequency of return links in narrow spot beams requires specification of the TN in

order to identify which of the four 50 kHz sub-carriers is selected from the corresponding 200

kHz channel:

NB Uplink Frequency (MHz) = NB Downlink Frequency + 149.925 + (TN modulo 4) * 0.05;

where 0� TN � 7 [9].

Or equivalently, as a function of LARFCN and TN:

NB Uplink Frequency (MHz) = 1 518.1 + (LARFCN - 170) * 0.2 + 149.925 + (TN modulo 4)

* 0.05; where 170 � LARFCN � 204 and 0� TN � 7 [9].

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For regional beam forward downlinks, channels are based on 50-kHz channel bandwidths.

The FOext parameter issued, which can take on any of the integer values from 0 to 3, thus

identifying which of the 50-kHz channels within a 200-kHz bandwidth is the correct carrier.

The following relationship applies:

RB Downlink Frequency (MHz) = 1 518.025 + (LARFCN - 170)*0.2 + FOext * 0.050; where

170 � LARFCN � 204 and 0 � FOext � 3 [9].

The frequency of return uplinks in regional beams, using a 12.5-kHz channelization, is

determined using the following relationship:

RB Uplink Frequency (MHz) = 1 668.00625 + (LARFCN-170)*0.2 + FOext * 0.050 +

RPAGING Group * 0.0125; where 170 � LARFCN � 204 and 0 � FOext � 3 [9].

4.4 GMR-2+ PARAMETERS SPECIFICATION FOR ISATPHONE PRO

The UT should comply with the GMR-2+ air interface specification. In particular, the

following RF parameters should apply:

• I-4 frequency bands:

The UT should meet the relevant technical requirements over the following transmit and

receive frequency bands as defined in the GMR-2+ specification:

1626.5 – 1660.5 MHz transmit (return)

1525.0 – 1559.0 MHz receive (forward)

• Extended MSS band:

In addition to the I-4 satellite operational band defined above, future Inmarsat satellites are

planned operate in the extended band. Therefore the UT should also meet the relevant

technical requirements over the following transmit and receive frequency bands:

1668.0 – 1675.0 MHz transmit (return)

1518.0 – 1525.0 MHz receive (forward)

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4.5 CALIBRATION AND RF TEST SETUP OF ISATPHONE BOARD TESTER FOR

GMR-2+

Below figure 4-6 shows RF test setup at the board level test.

Figure 4-6. RF test setup for board level test [15]

Target is to find RF path loss between reference points [15]:

• A – C = GMR Tx

• A – D = GMR Rx

• B – D = GPS Rx

Measured RF path loss values can be used during the test as compensation factors. Path loss

has to be measured at GMR Tx/Rx frequency and at GPS frequencies as specified in test

specification. Following table 4-2 shows RF calibration outcome.

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Table 4-2. RF calibration outcome for board tester [15]

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4.6 CALIBRATION AND RF TEST SETUP OF ISATPHONE FINAL TESTER FOR GMR-2+

Following below figure 4-7 shows RF test setup at the final test.

Figure 4-7. RF test setup for final test [15]

Target is to find RF path loss between reference points as stated below [15]:

• A – C = GMR CON Tx

• A – D = GMR CON Rx

• B – D = GPS CON

• F – C = GMR ANT Tx

• F – D = GMR ANT Rx

• E – C = BT ANT Tx

• G – D = GPS ANT

Measured RF path loss values can be used during the test as compensation factors. Path loss

has to be measured at GMR Tx/Rx frequencies, at GPS frequency and at BT frequency as

specified in test specification. Following table 4-3 shows RF calibration outcome using

calibration adapter.

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Table 4-3. RF calibration outcome for final tester [15]

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5 GMR-2+ HANDSET IMPLEMENTATION REQUIREMENTS, DEVELOPING AND MANUFACTURING

5.1 INMARSAT DEVELOPING AND MANUFACTURING PARTNERS FOR ISATPHONE PRO: SASKEN AND ELCOTEQ

5.1.1 Sasken

The IsatPhone Pro handset has been developed by Sasken.

Sasken is an embedded communications Solutions Company, that helps businesses across the

communications value chain accelerate product development life cycles. Sasken offers a

unique combination of research and development consultancy, wireless software products and

software services [10].

Established in 1989, Sasken employs approximately 3200 people. Sasken is operating from

state-of-the-art research and development centers in Bangalore, Pune, Chennai and Hydrabad

in India, Kaustinen, Tampere and Oulu in Finland and Monterrey in Mexico. Sasken is also

present in Beijing (China), Bochum (Germany), Kanagawa (Japan), Guildford (UK) and

Chicago, Dallas & Santa Clara (USA) [10].

Committed to innovation, Sasken works with customers to help them get to market ahead of

the competition, and stay focused on new product development and manufacturing. With deep

understanding of the communications industry, access to current and emerging technologies,

mature development processes, global resources and a proven track record, Sasken creates

complete solutions to help clients succeed. Clients choose Sasken for the comprehensive

range of application solutions and services, backed by a proven reputation for expert support

and high quality [10].

5.1.2 EMS (Electronic Manufacturing Services) provider Elcoteq Tallinn AS

The production of IsatPhone Pro is being undertaken by Elcoteq.

Starting as a pilot production in 1992, Elcoteq Tallinn AS was established as legal entity at

1993. Elcoteq Tallinn AS is Estonian subsidiary of Elcoteq Network SA Swiss Branch [11].

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Elcoteq Tallinn AS is now only on one production facility, measuring 4000 m² and personnel

about 160. Currently typical products are: Telecom Infra, handsets, satellite handsets. The

management system of Elcoteq Tallinn is established proceeding from the requirements of

standards ISO 14001:2004, ISO 9001:2008, OHSAS 18001:2007 [11].

Elcoteq has two main business areas: Consumer Electronics represents approximately 75% of

the company’s net sales and System Solutions represents approximately 25%. Both SBUs

(Strategic Business Unit) are responsible for managing and developing their existing customer

relationships and applicable service offerings [12].

Elcoteq’s service network covers altogether 15 countries in Europe, Asia-Pacific and

Americas. It includes high-volume manufacturing plants, units specializing in smaller series,

as well as product development units and NPI (New Product Introduction) centers [12].

NPI is a part of Elcoteq pre-manufacturing services. NPI was created for product

industrialization. IsatPhone Pro development and manufacturing started in Elcoteq Tallinn

NPI department in January 2009 and transfer to volume production has been started by end of

May 2010. NPI is meant for producing products, which have not been produced earlier or not

in volumes yet. NPI purpose is to achieve the lowest possible manufacturing cost, highest

possible yield and improvements in projects schedules.

Following figure 5-1 shows how NPI is a part of product lifecycle. NPI has to be flexible and

efficient and the main aim is to implement product design and to transfer fully working

product to volume production.

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Figure 5-1. NPI as a part of product lifecycle [13]

5.2 IMPLEMENTATION REQUIREMENTS FOR ISATPHONE PRO

This part outlines the product requirements for a UTH (User Terminal Handset) designed to

operate fully with the GMR-2+ network and to provide an attractive and fully functional

device for users. This part specifies the technical, operational, and functional requirements for

the GSPS UT.

The UT system is composed of the following:

• UTH;

• UTCM (User Terminal Core Module);

• Power Supply;

• User Manual and Product Documentation;

• UT Commercial Packaging;

• Peripherals and Accessories.

The UTH is intended to be a fully featured device, supporting a range of features and

functions found on contemporary handsets.

Life Cycle Engineering

Production Ramp up

Product Usage

End of useful

Complexity management

Product launch predictability

Efficiency

Flexibility

Testing expertise

Sustained manufacturability

Volume Manufacturi

Feasibility check

Testing System development

Product Design

Joint Research & development

Project Management

Prototyping

Industrialization

Design for X

NPI

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The UTH should support:

• Inmarsat GSPS GMR-2+ service capabilities. The GSPS network architecture should

align closely with the ETSI specifications for the GMR interface.

• SMS (Short Message Service) capability in GMR-2+ modes.

• Voice calls (the UT should include a microphone for voice calls), emergency calls,

call history and voice mail.

• Call waiting, call divert, call forwarding and call hold.

• The UT should have an IMEI (International Mobile Equipment Identity) number and

password number.

• The UTH should have a numeric keypad for normal handset operations and keypad

lock.

• The display screen should be suitable in strong sun light with minimum power

consumption.

• The UTCM should support audio output from an earphone and a speakerphone (For

hands-free phone conversations). The UTCM should include echo cancellation for

proper hands-free operation.

• The UT should support multiple languages, Bluetooth wireless technology and

polyphonic ring tones.

• The UT should support data and fax modem functions for a computer attached via the

“USB (Universal Serial Bus) port” and also power and recharging through the “USB

port”.

• The UT should support personal information management functions: phonebook, real-

time clock, alarm functions, address book, calendar, calculator etc.

• The UT should support silent mode and vibrator mode, low battery warning or alarm,

minute minder, SMS receipt signal, etc.

• The UT should include a GPS (Global Positioning System) receiver.

• The used antenna has to be omni-directional, because the phone's antenna must point

directly at the satellite with a clear view.

• The design of the UTCM memory subsystem should support the maximum allowable

memory configuration.

• Following accessories should be in the UT „basic accessory kits“: AC (Alternating

Current) and car charger, USB cable, headset, support CD and lithium-ion battery.

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EIRP (Equivalent Isotropically Radiated Power) requirements [14]:

The UT shall be capable of transmitting an EIRP of 5dBW within the operational band and

3dBW within the extended MSS band, and considering the following requirements:

• The EIRP value shall be met over the coverage range of 0 to 360 degrees azimuth and

20 to 90 degrees elevation (where this coverage is obtained from a combination of

antenna field of view and handset orientation).

• The EIRP value shall be met over a solid angle of 60° from both sides of the

mechanical axis of the antenna.

• The EIRP requirement shall be met when the handset antenna is tested with a perfectly

circularly polarized antenna.

• The EIRP value shall be met over the range of UT operational conditions including

(but not limited to) temperatures and battery charge state.

G/T (Gain to Noise Temperature Ratio) requirements [14]:

Overall the UT shall meet or exceed G/T of -24 dB/K within the operational band and -27

dB/K within the extended MSS band, and considering the following requirements:

• The G/T value shall be met over the coverage range of 0 to 360 degrees azimuth and

20 to 90 degrees elevation (where this coverage is obtained from a combination of

antenna field of view and handset orientation).

• The antenna G/T requirement shall be met when the handset antenna is tested with a

perfectly circularly polarized antenna.

• The G/T value shall be met over a solid angle of 60° from both sides of the

mechanical axis of the antenna.

• The G/T value shall be met over the range of UT operational conditions including

temperature range.

Antennas [14]:

The UT shall include the following antennas:

• GMR-2+ antenna (satisfying the G/T and EIRP requirements stated above)

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• GPS antenna (satisfying industry standard antenna requirements)

• Bluetooth Antenna (satisfying industry standard antenna requirements)

External RF interfaces should be provided to support GMR-2+ transmission and reception.

The connection of an external antenna must not limit the operation of the UTH in any way.

Core Processor [14]:

The UT shall include a Core Processor (also called baseband processor). The baseband

processor forming part of the UT shall support the following processing requirements:

• The baseband processor shall support the full implementation of the GMR-2+ air

interface, and full set of GMR-2+ services.

• The baseband processor shall support the full set of services and functions of GMR-2+

modes.

• An echo canceller shall be incorporated to facilitate a future 2-wire interface (for

example, for fixed or maritime installations). This echo canceller shall in addition

effectively cancel both residual acoustic echo from earpiece to microphone when the

UT is in (4-wire) handset mode, and room echo during UT speakerphone mode

operation.

• An analogue line level 4-wire test-point shall be included as part of the UTCM for

testing the voice coder.

5.3 MANUFACTURING OF ISATPHONE PRO

Satellite phone can be manufactured with normal handheld product procedures. The

production consists of many subassemblies and those are unique for each product

manufactured in Elcoteq Tallinn AS. The manufacturing of the IsatPhone Pro is more

complicated because 3rd party, Sasken, is responsible for design; the product is difficult and

consists of mainly manual assemblies; and 100% testing on different assembly levels is

required.

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IsatPhone Pro development and manufacturing started in Elcoteq Tallinn NPI department in

January 2009 and transfer to volume production has been started by end of May 2010. NPI

combines all needed actions in development phase of a product and the main purpose is to

introduce new product to the market at the right time. NPI production consists of proto-builds

until the final design phase is exceeded. In final design phase product engineer controls and

protocols all the changes that are made during proto-builds and then the product transfer to

volume production can follow. Some changes can come out also in volume production phase,

but the design and BOM (Bill of Material) should be fixed.

5.3.1 Project steps

Following figure 5-2 shows the milestones and spins between NPI process phase and

customer process plan. Corresponding timeframe is very important to establish successful

project as market situation does not allow having long development time.

Figure 5-2. Main milestones for IsatPhone Pro

C0 –> Concept Freeze

The start up meeting with Inmarsat, Sasken and Elcoteq. During that meeting all the details

and milestones agreed between each party. C0 is defined as product pre-study and

introduction. Sasken provided first BOM for IsatPhone Pro.

S1 –> First Proto-build

First production in Elcoteq NPI line according to provided information from Sasken. Only

SMA (Surface Mount Assembly) production without any plastic parts, accessories, etc.

C1 -> Specification Freeze

Based on the feedback from the 1st Spin the production specification has been enhanced and

confirmed.

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Sasken provided new BOM with needed changes and final functional approval based on S1

proto-build.

S2 -> Second Proto-build

First samples are reviewed by Sasken and improvement plan has been agreed between each

party (Inmarsat, Sasken and Elcoteq). Second SMA production started according to provided

information from Sasken.

C1.5 -> Hard-Tool Release

In this milestone Sasken provided preliminary evaluated mechanics parts and gave the

approval to order hard-tool parts.

S3 –> Third Proto-build

Functionality reviewed and improvement plan agreed between each party. The proto-build for

fully functional phone: final mechanics and sales package.

C2 -> NPI Release

Final components added to BOM. Product had full electrical performance and it was ready for

Certification test.

PP1-> Pre-production1

Pre-production split into two phases because of last minutes changes on SMA board, during

production the main problem was unfinished product design. Small number of satellite phone

was produced during this proto-build before last pre-production.

C2.5 -> Mass-production Release

The quality of hard-tool parts met the requirements with all samples and Elcoteq received the

approval to start ordering most of the needed components/parts for volume production.

PP2 –> Pre-production2

Final verification for materials completed and all the results during proto-builds analyzed.

This was last proto-build before volume production.

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C3 -> Delivery Release and C4 -> Program Completed

After pre-production2 Sasken found some problems in design. Project deadline was not met

and extra layout changes were made by designers from Sasken. First volume build postponed

one week and Inmarsat paid some extra money of previously ordered components (including

Main PCB and GMR antenna PCB) that were not cancelable and suitable because of last

minute design changes. Finally product full electrical performance with all samples met

requirements and certification tests passed. All the documents reviewed and NPI program

closed.

5.3.2 Production flow

Product structure

IsatPhone Pro has been divided into several subassemblies. Each subassembly and main

assembly has own Elcoteq product code and structure in Elcoteq system. Production manager

can open and close production orders according to needed demand. All the subassemblies

have to be completed before main assembly process can start. The IsatPhone Pro

manufacturing consists of automatic, semiautomatic and manual processes. Following table 5-

1 shows how IsatPhone Pro product structures have been set up. Production has to be started 7

days before shipping date: first step is to complete memory programming – this will take only

a day; second step is to start with Divider disc SMA assembly, Domesheet SMA assembly,

Main PCB (Printer Circuit Board) SMA assembly and battery charging – those actions will

take two days; third step is to continue with A-cover assembly, B-cover assembly, Antenna

assembly, Main PCB SMA assembly and Gift box assembly – those assemblies will take two

days; last step is to complete all of those assemblies under Isatphone Pro Main assembly - this

final step will take also two days.

Table 5-1. IsatPhone Pro product structure

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Following figure 5-3 shows IsatPhone Pro manufacturing and testing.

Additionally appendixes A, B and C can give closer overview about Main PCB assembly,

GMR antenna assembly and FA (Final Assembly).

Figure 5-3. IsatPhone Pro manufacturing and testing structure

Quality

Before and after manufacturing the most important part is quality inspection. Systematic

approach has been implemented in order to be able to:

• Reach assigned quality targets;

• Identify potential problems before they occur and take actions to make sure that these

risks are reduced to a minimum;

• Increase quality level and lower costs;

• Assure that no non-conforming products are shipped to customer.

Following figure 5-3 shows Quality Management System. To secure high level product

quality Elcoteq needs to guarantee very good design quality, materials quality and

manufacturing quality.

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Figure 5-4. Quality Management System

Production data management

Following information has to be collected as part of the genealogy of the product. The

genealogy contains information from defined operations within the production flow. The data

is linked to the specific PISN (Product Identification Serial Number). The PI (Product

Identification) allows collecting unique information directly related to the product from all

assembly and inspection stages during production. The PI allows for controlling the sequence

of operations within production to ensure that all assembly and inspection operations are

performed in the specified sequence. Additionally the PI allows linking of production related

data to the product for later retrieval.

The data of security keys is collected in the Elcoteq Manufacturing Database called MES

(Manufacturing Execution System) and after shipment the security keys related to the shipped

products are retrieved from the database and sent to customer in a secure way.

Table 5-2 shows what kind of data has been collected during IsatPhone Pro production.

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Table 5-2. Production data management

FA line capacity and strategy

Following data is used for FA line capacity calculation:

• production value per year – 40 000 pieces

• production peak value per month – 5000 pieces

• weeks per year - 52

• working days per week – 7

• shifts per day – 3 (8 hours)

Needed line capacity per shift is: 5000 / [4 (weeks per month) x 7 (working days per week) x

3 (shifts per day)] = 60 pieces per shift. That means to produce 5000 pieces per month one

shift has to be able to assemble 60 fully functional products. Currently the target is to ship out

at least 5000 handsets per month.

Elcoteq implemented a new FA line that was unique for IsatPhone Pro production. The target

of the line design was to use manual operations and multi-skills operators. Line layout is

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designed using assembly cells where one operator can work on many workplaces. All the cells

are product dedicated and designed for one product only.

Figure 5-5. FA line layout on picture during prototype manufacturing

Main challenges during proto-builds

One of the main goal during proto-builds is to adjust or develop all the needed actions in

production area to start producing a new fully functional product. Firstly, there has to be

enough resources, workers and free space to cover all the steps. SMA/FA line layout and

settings have to be adjusted or developed before both assemblies. A well working and

efficient testing, repairing, customisation, final inspection and packing areas have to be settled

in before first proto-build. Figure 5-6 shows the basic of production area set up process.

Figure 5-6. Flow chart for production area

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Elcoteq designed a unique product dedicated FA line to implement a new satellite phone; the

target of the line design was to use manual operations and multi-skills operators.

The most challenging subassembly was semiautomatic operation “Metal Thread Inserts

assembly” (part of A_Cover_Assembly). To heat press 8 metal thread inserts into plastic

Elcoteq built a new tool. This process required the temperature 250o C on tool head. The

assembly step was designed so that operator can perform other assembly steps while machine

is performing pressing (the needed time of the pressing process was 120 second per product).

IsatPhone Pro consists of approximately 360 different components and all of those items are

unique for this product (not used in other products manufactured by Elcoteq). Most of the

items were ordered for each proto-build separately, therefore many small reels and bulk

packages were used during build. Elcoteq did not have approval to order full reels for proto-

builds, because Sasken made many changes on design and Inmarsat did not want to waste

some extra money. The result of this was that operators had many challenges to use small

packages during production: they mixed up two items with each other and mounted wrong

component on SMA board.

One of the big problem was readiness of final design of the product. Project deadline was not

met and extra layout changes were made by designers from Saksen at the end of last proto-

build. Due to this first volume build had to be postponed by one week.

To conclude it can be said that Inmarsat was satisfied and had positive feedback towards

Elcoteq during proto-builds. It is possible that co-operation between Elcoteq and Inmarsat

will continue with other version of satellite phone.

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6 ISATPHONE PRO TESTERS AND TESTING

The purpose of the test system is to assure quality of manufactured products. This is done by

100% testing of manufactured items against the specifications. Only successfully tested

products are delivered to customer. Test results are logged into database for analyses and

storing. Test instruments are calibrated according to manufacturer’s instructions, have a valid

calibration sticker and are traceable to national wide recognized standards.

Elcoteq did not test “RF in signaling mode”, because it requires higher investment into the

test equipments and increases the test time at final testing.

Test result format

The following fields should be stored:

• User ID (Identity), system ID and fixture ID,

• Date and time,

• DUT (Device Under Test) serial number,

• DUT IMEI number,

• DUT BT (Bluetooth) MAC-address,

• Measurement results,

• Pass/fail information,

• Other required information.

Test systems

Whole test strategy is composed from:

• Board tester -> tester code T160

• Final tester -> tester code T161

• GMR antenna tester -> tester code T162

• Customisation station -> tester code T163

• Repair / TRSH (Troubleshoot) station -> tester code T164

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Next table 6-1 shows all the testers used for IsatPhone Pro testing, each test fixture has a

unique ID and license number.

Table 6-1. Testers for IsatPhone Pro

Tester Test station name Fixture ID Test Stand lic.no.

IsatPhone: Board tester IsatBoard_TS_01 SATBRDFX01 M73X11901

IsatPhone: Final tester IsatFinal_TS_01 SATFNLFX01 M73X11899

IsatPhone: GMR antenna tester IsatGMR_TS_01 SATGMRFX01 M73X11900

IsatPhone: Customisation station IsatCust_TS_01 SATCSTFX01 M73X11898

IsatPhone: Repair / TRSH station IsatTRSH_TS_01 SATTRSHFX01 M73X11897

The stations have a connection to SQL (Structured Query Language) database and the last one

has a connection to Elcoteq LAN (Local Area Network). All subassemblies have a label

attached with unique identification number.

Following figure 6-1 shows the scenario that Elcoteq has been used for test implementation.

Figure 6-1. Production tester flow

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User Categories

There are different user categories, having different privileges:

• Operator is allowed to start and shut down test system and perform testing of the

product as it is specified in the respective operation instruction.

• Troubleshooter has ability to run test cases step by step, force test to pass or fail or

temporary change test limits. Test data are not logged in troubleshooting mode.

• Maintenance has rights to change all test system parameters except user privileges and

test limits.

• Administrator has all privileges allowed by test system manufacturer.

Reporting and Data Collection System

All test results as well as all repair actions are collected in the single database. This allows

continuous process monitoring and analyzing. Several client applications have been

developed for that purpose:

• Product specialist client – this application supports all reporting actions and all

activities related to product management.

• Test specialist client – an application dedicated to test system handling, it includes test

limit defining, measurement system analyzes, test system maintenance.

• Repair and troubleshoot client is the software, running on the repair or

troubleshooter’s PC and providing troubleshooter all test results for particular product,

fault specific repair statistics and also a form for repair order placement and action

success confirmations.

The system is built around server computer, which acts as a project specific domain controller

and also runs database engine.

Test Cases

Following defaults are applicable for all test cases:

1. If test case PASSES, test sequence jumps to next test case.

2. If test case FAILS, test program will ask operator to retry, continue or abort

(described for every test case separately).

3. Test results are logged into database.

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4. Measured values are not critical for manufacturing process control.

6.1 BOARD LEVEL TESTING

This section describes all tunings and test cases done in board level testing. Board level

testing can start if the Main PCB SMA and keyboard frame assembly are finished. This

production step is fully automatic.

Following figure 6-2 shows both side assembled PCB for IsatPhone Pro.

MAIN PCB SMA, side 1

MAIN PCB SMA, side 2

Figure 6-2. Both side assembled PCB for IsatPhone Pro

Board tester

The purpose of the station is to assure GSPS handset PCB and keyboard/LED frame assembly

quality in volume manufacturing and verify it’s functionality before assembly into the

plastics. The test time per DUT is 360 seconds + 30 seconds for handling.

HW (Hardware):

• Tester consists of test rack, measurement instruments and fixture.

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• Instruments are controllable from PC via GPIB (General Purpose Interface Bus).

• Following measurements have to be performed:

1. Production identification.

2. Memory test, SW (software) test, SIM tests and antenna position switch test.

3. DC (Direct Current) current and voltage measurements.

4. Audio measurements.

5. Temperature sensor test.

6. Clock test, vibra test and BT self - test.

7. RF measurements: GMR-2+ Tx/Rx tuning and measurements in non-signaling

mode.

8. GPS measurements.

• RF isolated fixture is in use. Adaptation to the product in the fixture is done via test

points, audio connector test pads and GPS, GMR RF external connectors.

• Fixture has pneumatic fingers for testing keyboard function of keyboard/LED frame

subassembly.

• Fixture has integrated fiber optic solution for testing LED function of keyboard/LED

frame subassembly.

It is non-conveyor system. Operator has to place subassembly manually into fixture product

test before the test. Required electrical connections start automatically when test is started.

Using present system it is possible to test only one product at the time.

Layout of board tester

Test instruments are assembled into the test rack using standard rack mount kits and test rack

accessories. Following picture 6-3 presents rear and front view of the test rack layout:

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1 15" LCD2 Keyboard3 Display/keyboard arm4 Test rack5 VAC panel6 R&S SMBV 100A7 Agilent N9010A8 Keithley 2015THD9 R&S NGMO210 Empty panel11 Working table12 Empty panel13 PC14 Deflor toru15 Barcode reader16 Agilent 53131A17 Board fixture18 ID reader19 Interface PCB shelf

Figure 6-3. Board tester test rack - front and rear view [16]

External connections

The test system needs connection to the following external interfaces:

• 230VAC

• 10MHz reference

• LAN

• Compressed air

Handling procedure

Following steps are needed during board testing:

• Operator has to read barcode from the PCB label (it can be done either by barcode

reader or from the keyboard).

• Operator has to place a product into the fixture and close the cover of the fixture.

• Test starts immediately after PCB serial number identified and RF chamber cover is

closed.

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• When test is completed fixture automatically will open the cover and operator can

remove DUT from the fixture.

If DUT passed all tests successfully, operator interface will present message “Passed”,

otherwise – message “Failed”. Pass/Fail indicators are also available in the test rack front

panel.

Figure 6-4. The view of board tester: 1 – RF chamber and 2 – DUT adapter

Main problems

• Design issues from Sasken side.

• Following two measurements caused low FPY (First Pass Yield):

o Switching transient measurements;

o Phase error measurements.

The main problem was not with the measurements itself; the problem was the poor

yield because of the measurements.

• Route cause is still unclear. Both sides (Elcoteq and Sasken) are still making

investigations to find out a route cause for the problem.

6.2 GMR ANTENNA TESTING

Antenna assembly is a part of mechanics assembly. The testing is needed to check GMR

antenna functionality and parameters as an individual part in volume manufacturing before it

is assembled into the final assembly mechanics.

Following figure 6-5 shows assembled PCB (Divider Disc) for GMR antenna and GMR

antenna subassembly.

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Figure 6-5. Divider Disc SMA (20 PCBs) and GMR antenna subassembly

SMA assembly consists of Divider Disc PCB, 100R chip resistor and Ultra Small Surface

Mount Coaxial Connectors. Before GMR antenna testing the Divider disc SMA and Antenna

assembly has to be finished.

GMR antenna tester

The purpose of the station is to check GMR antenna parameters in volume manufacturing

before assembly it into final product and to improve measurement accuracy in following test

cases: S11, S21_L, S21_C and S21_R. The test time per DUT is 20 seconds + 30 seconds for

handling.

Hardware:


• Instruments are controllable from PC via GPIB.


1. S11 (reflection coefficient - refers to the ratio of signal that reflects from GMR

antenna for a signal incident on port one). Network analyzer supplies stimulus

signal from port 1 to the DUT and measuring the response at the same port. The

purpose of the test is to measure reflection coefficient of GMR antenna.

2. S21_L (insertion loss - refers to the response at port 2 due to a signal at port 1).

Network analyzer supplies stimulus signal from port 1 to the DUT and measuring

the response through the left antenna at port 2. The purpose of the test is to

measure GMR antenna insertion loss (the response at port 2 due to a signal at port

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1) and check if the beam width at the left side is corresponding to specified

requirements.

3. S21_C (insertion loss - refers to the response at port 2 due to a signal at port 1).


the response through the center antenna at port 2. The purpose of the test is to


1) and check if the beam width at the center is corresponding to specified

requirements.

4. S21_R (insertion loss - refers to the response at port 2 due to a signal at port 1).


the response through the right antenna at port 2. The purpose of the test is to


1) and check if the beam width at the right side is corresponding to specified

requirements.

Figure 6-6. GMR antenna connection diagram It is non-conveyor system. Operator has to place subassembly manually into fixture product

test and connect it to the RF connector before the test. Using present system it is possible to

test only one product at the time.

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Layout of GMR antenna tester



Figure 6-7. GMR antenna tester test rack - front and rear view [16]

Figure 6-8. The view of GMR antenna tester – front view and inside view



• 230VAC

• LAN

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Handling procedure

Following steps are needed during GMR antenna testing:

• Operator has to read barcode from the label attached to the DUT (it can be done either

by barcode reader or from the keyboard).

• Operator has to place the DUT into adapter and lock RF adapter into DUT RF

connector.

Figure 6-9. GMR antenna - RF adapter locking and fixture closing

• Test is started immediately after product serial number entered and OK button is

pressed.

• When test is completed operator can lift up RF adapter and remove DUT from the

fixture.



panel. During testing Pass/Fail statistics is collected and presented to operator graphically. In

case of abnormal growth of the fault rate, operator has to interrupt testing and call test

maintenance personnel to check test system conditions.

Main problems

• One big challenge was to make an adapter for GMR antenna. Antenna connector has

very small dimensions and fixture mechanics should be precise enough to get in

contact with antenna connector.

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6.3 FINAL TESTING

Each unit is tested under normal test condition after final assembly is finished.

Final tester

The purpose of the station is to assure GSPS handset quality in volume manufacturing and

verify its functionality when it is assembled into the plastics. The test time per DUT is 150

seconds + 30 seconds for handling.

Hardware:



• RF isolated fixture is in use. Adaptation to the product in the fixture is done via

available external interfaces: battery contacts, antennas, antenna ext connectors, USB,

audio connector.

• DUT position during the tests: GMR antenna has to be opened 180 degrees.


1. OFF state current - the purpose of the test is to verify current consumption before

connecting USB connector to the DUT.

2. Activate Engineering Mode - the purpose of the test is to establish communication

with the DUT via USB interface and to activate engineering mode of the DUT.

3. Read GSPS Serial number - the purpose of the test is to verify if serial number in

the DUT memory is corresponding to the serial number on the label.

4. Read HWID (Hardware Identity) - the purpose of the test to read HWID stored in

the DUT memory.

5. Read SW version - the purpose of the test is to verify SW version stored in the

DUT memory.

6. ON state current - the purpose of the test is to verify current consumption when

DUT has entered into engineering mode.

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7. Vibra function check – the purpose of the test is to check whether vibra control

circuit works properly or not.

8. Display contrast test - the purpose of the test is to verify display contrast.

9. Keypad LED tests - the purpose of the test is to verify if keypad’s backlight is

working.

10. Keypad test - the purpose of the test is to verify that the keys are working properly.

11. Audio plug detection test - the purpose of the test is to verify that the detection of

the audio jack working properly.

12. Microphone test - the purpose of the test is to verify if microphone and relevant

circuits are working properly when mounted in plastics.

13. Earpiece test - the purpose of the test is to verify if DUT earpiece and relevant

circuits are working properly when mounted in plastics.

14. BT Tx power test - the purpose of the test is to verify that Bluetooth antenna is

mounted and relevant BT circuits are working properly during transmission.

15. GMR Tx/Rx antenna - the purpose of the test is to check if electrical connection

between GMR antenna and PCBA (Printer Circuit Board Assembly) is made

properly.

16. GMR, Tx/Rx, extCONN - the purpose of the test is to check RF transmission via

GMR external connector.

17. GPS antenna - the purpose of the test is to check if electrical connection between

GPS antenna and PCBA is made properly.

18. GPS extCONN - the purpose of the test is to check RF reception via GPS external

connector.

It is non-conveyor system. Operator has to place subassembly manually into fixture product

test before the test. Required electrical connections start automatically when test is started.

It is possible to test only one product at the time.

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Layout of Final tester



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Figure 6-10. Final tester test rack - front and rear view [16]



• 230VAC

• 10MHz reference

• LAN

• Compressed air

Handling procedure

Following steps are needed during final testing:

• Operator has to read barcode from the label (it can be done by barcode reader).

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• Operator has to place the DUT into fixture and press button to close the cover of the

fixture.

• Test starts automatically after PCB serial number identified and fixture cover is closed

and pop-up window disappears from the screen.

• When test is completed fixture automatically will open the cover and operator can



otherwise – message “Failed”.

Figure 6-11. The view of final tester

Main problems

• Main challenge was that GPS antenna test did not work in pre-production build. GPS

signal during the test was suppressed by interference (32 MHz clock) radiated via test

probe connected to test point on SPI (Serial Peripheral Interface) bus. Problem

appeared after Sasken made changes in PCB layout. Problem was fixed by removing

one of the test probes on SPI bus from the system (test probe was not in used before).

• Current material of side keys was too strong for fixture cylinders. Specified pressure

on side keys was ~5N. In reality it is above 15N. Problem was fixed by changing

cylinders to support pressure 15N-20N

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• Audio measurements in the final fixture are still challenges. Small volume inside of

fixture and presence of mechanical parts applies significant limitation on handling

audio measurements in volume production.

6.4 CUSTOMISATION

Separate customisation station is needed for IsatPhone customisation.

Customisation station

The purpose of the station is to perform GSPS handset customisation when it is needed in

volume manufacturing or when returned from the field. The test time per DUT is 35 seconds

+ 30 seconds for handling.

Hardware:

• Tester consists of measurement instruments and fixture.


• Simple fixture is in use. Adaptation to the product in the fixture is done via battery

contacts and USB connector.


1. OFF state current - the purpose of the test is to verify current consumption before

connecting USB connector to the DUT.

2. Read GSPS Serial number - the purpose of the test is to verify if serial number in

the DUT memory is corresponding to the serial number on the label.

3. Read HWID - the purpose of the test to read HWID stored in the DUT memory.

4. Read SW version - the purpose of the test is to verify SW version stored in the

DUT memory.

5. Backup calibration data - the purpose of the test is to backup DUT calibration data

before software upgrade execution.

6. SW upgrade - the purpose of the test is to upgrade DUT software if “Read SW

version” test has failed.

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7. Restore calibration data - the purpose of the test is to restore DUT calibration data

after SW upgrade.

8. Program product number - the purpose of the test is to write product number into

the DUT memory.

9. Antenna position test (open) - the purpose of the test is to verify antenna switch

function when antenna is in open position.

10. Antenna position test (close) - the purpose of the test is to verify antenna switch

function when antenna is in close position.

11. Program IMEI - the purpose of the test is to program IMEI into the DUT memory.

MES provide IMEI number to customization station and customization station

write it in the DUT memory. Test will be executed only if all previous steps have

passed result.

12. Password test - the purpose of the test is to generate and write personalization

passwords into the DUT memory.

It is non-conveyor system. Operator has to place DUT into fixture and make required

electrical connections manually before the test.

It is possible to test only one product at the time.

Layout of Customisation station

Test instruments are assembled into the rack using standard rack mount kits and test rack


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Figure 6-12. Customisation station test rack - front and rear view [16]



• 230VAC

• LAN

Handling procedure

Following steps are needed during final testing:

• Operator has to read barcode from the label attached to the DUT (it can be done either

by barcode reader or from the keyboard).

• Operator has to place the DUT into fixture, check that USB cable is not connected to

the DUT and close top cover of the fixture.

• Test starts immediately after product serial number is entered, test fixture cover closed

and OK button is pressed.

• When test is completed operator can disconnect USB cable, open fixture top cover and


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panel.

Figure 6-13. The view of customisation station

Main problems

• There were not any significant problems; this was the area where everything went

smoothly.

6.5 REPAIRING / TROUBLESHOOTING

All failed products are undergoing repair and re-test. The person, who is responsible for

locating faults and determining repair actions, is called troubleshooter. He or she will be

equipped with appropriate hardware and software tools.

Repairing / troubleshooting station

The purpose of the station is to provide required HW/SW tools for the person who is going to

handle repair of the phones that are failed on one of the testers described above. At once

repair is completed products have to be retested at the tester it failed.

Repairing / troubleshooting station includes following equipments [16]:

• Troubleshooting/repairing fixture;

• Industrial computer with monitor;

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• Barcode reader;

• Battery/Charger simulator;

• Oscilloscope;

• Multimeter;

• Vector Signal Analyser;

• Vector Signal Generator.

Layout of repairing / troubleshooting station



1 15" LCD2 Keyboard3 Display/keyboard arm4 Test rack5 VAC panel6 R&S SMBV 100A7 Agilent N9010A8 DSO 1022A9 Keithley 2015THD10 Working table11 Empty panel12 PC13 Deflor toru14 Barcode reader15 R&S NGMO216 ID reader17 Interface PCB shelf

Figure 6-14. Repairing / troubleshooting station test rack - front and rear view [16]



• 230VAC

• 10MHz reference

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• LAN

Handling procedure

Following steps are needed during repairing:

• To handle measurements with using TRSH fixture, X110 has to be connected to X111.

• Operator has to place product into the fixture and close the cover.

• When troubleshooting is completed operator should remove product from fixture.

• To handle measurements outside of TRSH fixture X110 has to be connected to X301.

Figure 6-15. The view of repairing / troubleshooting fixture

Main problems

• RF shields have to be removed from board to get access to PCB components. Shields

removal process is time-consuming. Removed shields have to be scrapped.

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7 CONCLUSION

Satellite communication and satellite phone are very large topics and to cover those subjects

more deeply it requires more time and will be very voluminous.

The first goal of current thesis was to describe and give short overview about satellite

communications, satellite industries and satellite technologies. Global mobile satellite

communication provider Inmarsat was under survey to find out what kind of satellites and

satellite protocol Inmarsat uses and the process of developing, manufacturing and testing of

their new generation satellite phone was described.

The second goal was to study how new product manufacturing process operates nowadays to

implement a new satellite phone. The aim of this study was to introduce production steps and

manufacturing problems of IsatPhone Pro. The production was more complicated because 3rd

party Sasken was responsible for design and they did not have very good results on

developing area; the product was difficult and consisted of mainly manual assemblies; and

100% testing on different assembly levels was required. To implement a new satellite phone

Elcoteq designed a unique product dedicated FA line and built up a new tool for the most

challenging subassembly “Metal Thread Inserts assembly”. One of the main problem was

readiness of final design of the product. Project deadline was not met and extra layout

changes were made by designers from Sasken at the end of last proto-build. Due to this first

volume build had to be postponed by one week and non-planned costs were created by not

suitable and not cancelable components that were already ordered for volume production

purpose. Another issue was that during proto-builds many small reels and bulk packages were

used and this caused challenges to production operators: they mixed up two items with each

other and mounted wrong component on SMA board. To conclude, despite previously

mentioned small obstacles that occurred during the project Inmarsat was satisfied with end

result and had positive feedback toward Elcoteq during proto-builds.

The third goal of this study was to find out what kind of tests are needed to assure the product

quality and what were the main problems with testing. All the test limits were specified by

Sasken and corresponded to ETSI GMR-2+ requirements. The most important testing parts

were board testing, GMR antenna testing and final testing - all of those parts were needed to

secure the quality and functionality of IsatPhone Pro handset. During testing the main

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problem was design issues of the product, which affected on low FPY (especially on board

level test) and caused extra work to Elcoteq. One big challenge was to make an adapter for

GMR antenna, because antenna connector had very small dimensions. In final test the most

problematic parts were GPS test and audio measurement test: GPS test did not work in last

proto-build, but the problem was fixed before volume manufacturing; audio measurement test

is still problematic because of small volume inside of fixture and presence of mechanical parts

applies significant limitations. Otherwise there were not significant challenges in testing of

IsatPhone Pro. One important test that Elcoteq did not implement was “RF in signaling

mode”, because it requires higher investment into the test equipments and increases the test

time at final testing. Exemption was agreed between Inmarsat and Elcoteq.

The given thesis gave many interesting and new facts about satellite phone implementation

and provided useful knowledge for the author of the master thesis.

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REFERENCES

[1] SIA. Satellite Industry Overview. (2007). 3-5pp

www.sia.org/industry_overview/sat101.ppt

[2] SIA. State of the Satellite Industry Report (June 2009). 3pp

http://www.sia.org/news_events/2009_State_of_Satellite_Industry_Report.pdf

[3] The Satellite Communication Applications Handbook, Bruce R. Elbert. (2004). 8pp

[4] SIA. Satellite Industry Overview. 5-9pp

http://www.sia.org/industry_overview/sat101.pdf

[5] Satellite Technology, Second Edition, Andrew F. Inglis and Arch C. Luther. (1997). 6pp

[6] First Responder’s Guide to Satellite Communications. 20pp

http://www.sia.org/guide.pdf

[7] Inmarsat homepage (May 2010)

http://www.inmarsat.com

[8] Inmarsat. I-4 satellite repositioning. (January 2009). 1-3pp

http://www.inmarsat.com/Partners/Downloads/Repositioning/I-

4_satellite_repositioning_Impact_on_MARITIME_users_DOCUMENT.pdf?language=EN&t

extonly=False

[9] ETSI standard - GMR-2+ 05-005 V2.6.0 (June 2009). 7-12pp

[10] Sasken homepage (May 2010)

http://www.sasken.com

[11] Elcoteq factory overview: Elcoteq Factory Overview January 2010.ppt. (January 2010).

5pp. http://eu.elcoteq.com/locations/tallinn/ee

[12] Elcoteq homepage (May 2010)

http://www.elcoteq.com/en/About+us

[13] Elcoteq service presentation: Elcoteq Service Presentation Jan 2010.ppt. (January 2010).

4pp. http://eu.elcoteq.com/locations/tallinn/ee

[14] Sasken document. GSPS_UTH_Sasken_2.4.doc. (January 2009). 12-13pp

[15] Elcoteq document. RF & Audio path loss calibration at the testers. (January 2010). 2-7pp

[16] Elcoteq document. Test rack layouts. (November 2009). 1-7pp

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Appendix A. Main PCB SMA manufacturing and testing process flow

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Appendix B. GMR antenna assembly manufacturing and testing process flow

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Appendix C. FA manufacturing and testing process flow

implementation, testers and testing of satellite phoneavots/juuni_2010/maarja_laos_mag.pdf ·...

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