Production-ready hardware and boards
Developing hardware that is secure, durable, and robust is a demanding task for manufacturers and development partners alike. We will get specific and show the facets of developing industrial, series-ready devices.
Production-ready hardware for the highest demands
Control units and onboard computers for defense, automotive, and industry
PICKPLACE provides the development of production-ready hardware for manufacturers of components in complex system environments.
Typical use cases include:
Control units with microprocessor technology for safety-critical applications in the rail, automotive, or defense sectors. Board computers typically perform more complex signal processing tasks (audio, video, sensors) and offer diagnostic interfaces and sometimes user interfaces. Ethernet-based interfaces are typically used.
Electronic control units based on microcontroller technology for the implementation of control and regulation algorithms. ECUs typically have industrial bus protocols such as CAN, SPE, EtherCAT, or Profibus.
Edge devices are devices for use in very data-intensive environments that collect video and sensor data, which is used for condition detection. This condition data can be provided via a cloud connection.
We develop analog and mixed-signal hardware for the evaluation of sensor data and its provision on industrial bus protocols such as ioLink, Modbus, Profibus, or EtherCAT.
Project Progress
In our projects, we follow a consistent procedural model that ensures high design quality and long-term availability, and guarantees requirements are met throughout all phases of the lifecycle. We always adapt our approach to the application area and target production volume of the electronics. Typical annual target volumes for us range from 1,000 to 50,000 units, which we take into account throughout the entire development process.
Specification
The development process always begins with a precise specification, which is developed in close cooperation with the customer. This involves defining the functional requirements and performance characteristics of the control unit. It is also important to consider factors such as size, temperature range, cost framework, and EMC requirements.
Design Freeze
After the specifications are set, the so-called design freeze occurs, where the final design is fixed. All changes must be carefully reviewed from this point on to adhere to schedules and avoid unnecessary costs.
Architecture and Bill of Materials (BoM)
Hardware development begins with the creation of the architecture and the Bill of Materials (BoM). In this phase, the team defines the main components and circuit design. When selecting components, we also pay attention to the longest possible availability, as many of our electronics have a lifecycle of 15 years or more.
Schematics
Based on the architecture, the detailed circuit diagrams (Schematicscreated. This step allows for a technical review of the design and ensures it meets specifications. We also consider electromagnetic compatibility (EMC) aspects from the outset, supported by our comprehensive laboratory equipment.
Layout
Subsequently, the PCB layoutPCB) is created. This step requires precision to ensure that all components are optimally placed and signal integrity is maintained. Especially with complex designs combining micro and power electronics, as is common in many of our projects, thermal challenges and handling hundreds of components are essential factors.
Hardware Production Preparation
After the layout is completed, preparation for hardware production begins. This includes prototyping and consultation with manufacturing partners. In this phase, PICKPLACE ensures that all materials are available and that the manufacturing process runs smoothly.
Hardware commissioning
The commissioning of the first hardware prototypes is a crucial moment in the project. Here, it is verified whether all functions work as desired and whether the design meets the specifications. Any errors are identified and fixed.
Optimization and further development
After the first version of the hardware is put into operation and tested, a comprehensive optimization and further development of the design takes place. Based on the test results and customer feedback, adjustments are made to further improve functionality, reliability, and cost structure.
Preparation for mass production
In this phase, it is ensured that the optimized hardware design can be produced smoothly and in large quantities. Production processes are refined, and close collaboration with manufacturing partners ensures scalability and efficiency.
Final functional test
Before final release, the optimized Control unit a recommissioning where all functions are thoroughly checked. This guarantees that the hardware meets the required specifications and is ready for series production.
EMC Pre-qualification
A critical part of development is electromagnetic compatibility (EMC). Before actual certification, EMC pre-qualification is performed to ensure the design complies with applicable EMC guidelines. We perform tests according to IEC 61000-4-2 for the implementation of burst, surge, and radiation requirements.
Environmental tests
In addition to EMC tests, the hardware undergoes environmental tests such as vibration, shock, and temperature. These tests verify functionality under extreme conditions like heat, cold, humidity, and mechanical stress, ensuring that the control unit operates reliably even in harsh environments.