The client is a start-up inventor and manufacturer of consumer garment processing robots. The electronics and controls console of the appliance had a complex assembly of individually mounted and wired off-the-shelf components to accomplish switching and modulation of numerous AC loads. The setup was non-scalable, non-modular and prone to failure with the use of difficult-to-source components for critical circuit functions
Requirements capture
The solution to this challenge required the development of a system that would allow for:
Scalable manufacturability
Ease of automated assembly
Reliability
Modular and expandable switching hardware
Design for ease of maintenance
Our
PROCESS
Mapping and analysis of existing system architecture, including dependent systems, control inputs and outputs as well as electrical and mechanical constraints
Specification of components for optimal functionality, manufacturability and lifecycle requirements.
Development of electronic circuitry schematics
Iterative design of optimized PCB layout including EMI/EMC management and footprint constraint management.
Development of exhaustive testing documentation along with in-depth analysis of use cases and application conditions
Iterative solution prototyping to identify risk areas, roadblocks and improvement opportunities.
Solution & Benefits
The project result was a high-current power distribution board designed to be retrofitted into the existing system with plug-and-play architecture that addressed the major challenges faced by the client in the prior product development and manufacturing.
500%
estimated improvement in reliability (increase of component lifespan and reduced connection failure rates)
80%
reduction in contract manufacturer labor hours (time required for assembly reduced from complex wiring and install operations to single board mounting operation and plug and play connections)
Additional functionality of DC-DC converter module added for expandability of USB-powered loads
Expandable switching channels added (this was not possible with the earlier system)
