EXAMPLE PROJECT / CONTROL BOARDS

Embedded controller
& HMI.

A production-board redesign focused on finding and correcting the causes of a high field-failure rate while reducing manufacturing and assembly cost.

01 / PROJECT OVERVIEW

Correct the failures.
Improve the product.

The project involved root-causing and correcting a high field-failure rate in an existing production board while reducing manufacturing and assembly cost.

The system included a 32-bit microcontroller, power conditioning, actuator and motor drivers, input/output control firmware, per-channel current sensing, and a user display.

02 / FROM DESIGN TO PRODUCTION

The controller through each stage.

3D design rendering of the custom embedded controller circuit board — Design

Panelized embedded controller circuit boards in production — Production

Embedded controller undergoing functional testing with its display illuminated — Testing

Assembled embedded controller with display and membrane controls — Assembled production unit

03 / PROJECT SCOPE

Designed as a complete product.

01 / MITIGATIONS

Corrective actions

Redesign circuits where needed
Adjust component selection to meet design demands and improve reliability
Update firmware for additional monitoring and control
Add black-box incident recording capability for debugging and assessment
Improve assembly and testing for higher quality

02 / CONTROL BOARD

Custom control electronics

32-bit microcontroller
Power conditioning and voltage regulation
Actuator and motor drivers
I/O and control-logic firmware
Per-channel current sensing
User display

03 / ENVIRONMENT

Built for physical demands

Sealed connectors
Potting for vibration and moisture
IP-rated membrane panel

04 / PRODUCTION

Sourced and built for volume

Panelized for contract-manufacturer assembly
Custom functional test fixtures
End-to-end sourcing for the customer

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