Hardware Quality and Reliability of Map Collection Vehicles: Design, Production, and Testing Practices

1. Background and Terminology

Map collection vehicles are complex integrated systems where higher complexity often reduces reliability. This article shares hardware‑related measures taken to improve reliability, allowing these vehicles to work longer with fewer failures. It also explains key technical terms.

1.1 Map Collection Vehicle

These vehicles are equipped with multiple cameras, LiDAR, GNSS, IMU and other sensors, as well as power systems, control units and front‑end computers. They acquire images, point clouds, and pose data, which are later processed to generate maps.

1.2 Negative Correlation

In this context, complexity and reliability are negatively correlated: as complexity increases, reliability tends to decrease.

1.3 Quality

Quality refers to the degree to which the vehicle meets required and potential needs.

2. Hardware Quality of Map Collection Vehicles

To ensure that hardware quality and reliability meet expectations, tools and methods are applied during design, production management, and testing. Specific measures address key reliability factors.

2.1 Hardware System Composition

The hardware system typically consists of the carrier, mechanical structure, positioning devices, cameras, LiDAR, control system, and power system – essentially mechanical, electromechanical, and sensor subsystems.

2.1 Quality and Reliability Requirements

Low failure rate, stable operation, MTBF ≥ 2000 h.

Relative positioning accuracy of IMU and LiDAR components at sub‑mm level, attitude accuracy within 0.1° without deformation affecting precision.

MTBF (Mean Time Between Failures) is the key reliability indicator.

2.2 Reliability Implementation Analysis

Reliability is divided into inherent reliability (design/manufacturing) and usage reliability (environment, operation, maintenance). Both heavily influence overall system reliability.

2.2.1 Reliability Design

During design, mechanical simulations evaluate assembly feasibility, structural weight, and strength. Electrical design uses simulation tools and industry standards to verify circuit correctness and reduce rework.

2.2.2 Production Assembly Management

Management practices (planning, coordination, control) ensure orderly, controlled production.

2.2.3 Reliability Testing

Reliability tests expose hidden defects. Objectives include discovering design/component flaws and confirming quantitative reliability targets.

2.2.2 Product Lifetime Analysis Supporting Reliability

Electronic system lifetimes follow the “bathtub curve” with early‑failure, random‑failure, and wear‑out phases.

Strategies per phase:

Early‑failure: strict material and component inspection, use of military‑grade power supplies and automotive‑grade chips.

Random‑failure: maintain adequate spare parts inventory.

Wear‑out: replace aging components (computers, IMU, cameras, cables) to extend service life.

2.2.3 Electronic‑Electrical Reliability

2.2.3.1 Design Phase Guarantees

Derating Redundancy Design – Operate components below rated stress to lower failure rates.

(1) Power Capability – Vehicle generator provides sufficient current (e.g., 110 A rated, 80 % derating still meets 87 A demand).

(2) Computer Performance – Real‑time handling of multiple sensor streams; measured CPU and memory usage stay below 30 %.

(3) Power Module – Stable regulated supply (12 V nominal, 9‑18 V range) with 300 W capacity, 50 % redundancy.

(4) Battery Capacity – Additional high‑capacity backup batteries (≥100 Ah) ensure operation for 3‑4 h during engine off or idle periods.

(5) Cables & Connectors – Use oversized copper conductors, shielded twisted‑pair cables, and high‑life connectors (e.g., LEMO, ODU) to improve durability.

2.2.3.2 Simplified Design

Reducing component count simplifies manufacturing, testing, and installation, thereby lowering failure probability.

2.2.3.3 Thermal Design

Heat management includes large fans for computers, heat‑sinking for power modules, and leveraging vehicle airflow for roof‑mounted sensors.

2.2.3.4 Electrical Safety and EMC

Protection measures: circuit breakers, fuses, shielded cables, proper grounding, EMI shielding, and use of EMI‑rated connectors.

2.2.3.5 Maintainability Design

Design for easy fault location, modular replacement, and standardized parts to reduce repair time and cost.

2.2.4 Mechanical Reliability

Mechanical design addresses functional durability (e.g., camera adjustment mechanisms) and safety (vibration, corrosion). Materials such as aluminum alloy and stainless steel are selected, and fastening methods include thread‑locking compounds and spring washers.

2.2.5 Sensor Reliability

Key sensors (IMU, LiDAR, cameras) require robust enclosures (IP54), reliable connectors, and spare parts inventory (~10 % of total). Assembly includes careful cable routing, strain relief, and torque‑controlled fasteners.

2.2.6 Failure Prediction and Mitigation

Historical operation data (usage, condition, component performance, replacement records) are analyzed to predict failures, schedule maintenance, and extend vehicle lifespan.

3. Conclusion

Building quality into map collection vehicles is a complex system engineering effort that spans technology, management, and processes. Thoughtful design improves reliability while reducing downstream management and support costs.