Hardware and Circuit Boards Ready for Mass Production
Production-Ready Hardware and Boards Developing hardware with the aspiration of being safe, durable, and robust is a demanding task for manufacturers and development partners alike. We will get specific and show the facets of development...
Production-ready hardware and boards
The development of hardware that aims to be secure, durable, and robust is a demanding task for both manufacturers and development partners. We will get specific and show the facets of developing industrially production-ready devices.
Production-ready hardware for the highest demands
Control units and onboard computers for defense, automotive, and industry
PICKPLACE offers 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 railway, automotive, or defense contexts. Board computers typically perform more complex signal processing tasks (audio, video, sensors) and offer diagnostic interfaces and, in some cases, user interfaces. Ethernet-based interfaces are generally 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 highly data-intensive environments that collect video and sensor data used for condition detection. This condition data can be provided via a cloud connection.
We develop analog and mixed-signal hardware for evaluating sensor data and providing it 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 that requirements are met throughout all lifecycle phases. We always adapt our approach to the application area and the target production volume of the electronics. Typical target production volumes for us are 1,000 to 50,000 units per year, which we take into account during the entire development process.
Specification
The development process always begins with a precise specification, 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 defined, 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 determines the main components and the circuit design. When selecting components, we also ensure the longest possible availability, as many of our electronics have a lifecycle of 15 years or more.
Schaltpläne (Schematics)
Based on the architecture, the detailed schematics are created. This step allows for a deep 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 printed circuit board (PCB) layout is created. This step requires precision to ensure optimal placement of all components and to guarantee signal integrity. Especially in complex designs with a combination of micro and power electronics, as is common in many of our projects, thermal challenges and the handling of hundreds of components are essential factors.
Hardware Production Preparation
After the layout is complete, hardware production is prepared. This includes prototyping and coordinating 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 identified will be corrected.
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 will take place. Based on the test results and customer feedback, adjustments will be 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 cooperation with manufacturing partners ensures scalability and efficiency.
Final functional test
Before final release, the optimized control unit undergoes recommissioning, during which all functions are thoroughly checked. This guarantees that the hardware meets the required specifications and is ready for mass production.
EMC prequalification
A critical part of development is electromagnetic compatibility (EMC). Prior to actual certification, an EMC pre-qualification is conducted to ensure the design complies with applicable EMC directives. We perform tests according to IEC 61000-4-2 for the implementation of burst, surge, and radiated 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.