All posts tagged: Hardware

Here at the LX Group we have a wide variety of experience and expertise in helping organisations and individuals move their ideas and electronics prototypes into products and solutions. During this time we have developed methods of decreasing the time and budget required to develop prototypes, and distilled this into a system we call the LX Hardware Compiler. This is a mixture of our engineering expertise and advice combined with a range of pre-built electronic modules.

At this point we’re very proud to announce to the public the availability of a wide range of electronic modules that form part of the LX Hardware Compiler via our new online store – located at
https://lx-group.com.au/solutions/. Using the modules is easy and will save you time, money and accelerate your prototype design.

How? It’s simple. Browse through the range of modules to find a particular function that forms part of your circuit – for example a power supply, real-time clock or a level converter. You can review the data sheet for the major component of the circuit, and also download the Altium file to integrate the module into your parts library. Each module is designed to be placed on a PCB just like any surface-mount component. Once selected, the module(s) can easily be added to your prototype circuit, then once the PCB returns from the board house – simply drop in the module and solder it to the PCB.

At launch we have just over fifty modules available, in the following categories:

Analogue – such as OpAmps
Audio – including digital audio, MP3, amplifier and MEMS microphone units
Display – a great full-colour OLED module
Drivers – starting with our dual DC motor driver modlue
I/O Peripherals – including port expanders, multiplexers and optoisolators
Memory – add flash memory or a microSD card interface
Processors – a range of popular microcontrollers from various vendors
Programmable Logic – starting with Altera CPLD modules
Power supplies – a wide range of single, dual, SMPS and linear supplies and voltage references
Sensors – measure temperature, current, position heading and more
Switching – a variety of solid-state relays and FET switch modules
Wired communications – add Ethernet and USB easily
Wireless communications – including Wi-Fi, GSM/GPRS and Infrared receiver modules
Miscellaneous – starting with accurate real-time clocks and user-input

By using our range of modules wherever possible you can “let us do the work”, so you don’t have to spend the time designing your own common circuits or attempt to source parts in low volume at a good price – letting you can get on with your project and bringing it to life.

To get started, click here to visit our new online store and start exploring how our modules can fit in with your design. Or for more information and a confidential discussion about your ideas and how we can help bring them to life – click here to contact us, or telephone 1800 810 124.

LX is an award-winning electronics design company based in Sydney, Australia. LX services include full turnkey design, electronics, hardware, software and firmware design. LX specialises in embedded systems and wireless technologies design. https://lx-group.com.au

Published by LX Pty Ltd for itself and the LX Group of companies, including LX Design House, LX Solutions and LX Consulting, LX Innovations.

Building prototypes of your product idea during the design process is naturally important and something that is a necessity for many reasons – including physical conceptualisation, demonstrations to possible financiers, proof of concept, usability testing in later stages, and project inspiration. However like all stages of the design process (as discussed last week) doing so requires a level of knowledge and expertise that not every organisation possess.

This is not a criticism, but should be taken as a positive observation. And like any skill – if you can’t do it properly yourself, find someone who can. Here at the LX Group we will take the time to understand your needs and ideas which can then be transformed into one or even a range of prototypes – setting you up for success. As part of this process a decision needs to be made with regards to the type of prototype required, so let’s examine them in more detail and the benefits of each.

Proof-of-concept prototypes

This is often a very basic example that will function in a similar manner to the final product – to prove that it is feasible and can be done. We say that the key purpose is to focus on, understand and address identified risk areas with the prototype. For example selecting an appropriate microcontroller to ensure processing speed and I/O requirements are adequate, or power consumption levels fall under a required maximum. During this level of prototyping it is important to remove design faults and technical risks otherwise the costs involved to make changes later on will be exponential compared to doing so now.

Demonstration prototypes

When you need to show someone what “it’s all about” – a demonstration prototype will be required. This is the model you shop around to potential investors and future customers, document or show during grant applications, and generally spruik to the outside world. Those of you in larger organisations may also require this to “sell” the concept to decision makers in the upper echelons of management. The prototype may not function as the final product, however it should appear to do so. For example the housing and cosmetic look will match the final product as much as possible, however embedded software may be very basic or “emulate” the required functions.

Research and Development prototype platforms

When you have the go-ahead to move forward with the project design, it’s time to get working on the design – which requires R&D prototypes. The algorithm development of the product can take place with these prototypes, and thus may not look like the finished product, but they will have the functionality and specified hardware to operate as one. Furthermore this type of prototype may be modified or altered during the research process to account for changes, updates and possible design changes.

Commercial Product Iterations

There are three iterations during this stage in the design process, including:

Alpha prototypes – these are the first revision of the design and generally meet all aspects of the product design. These will be used to test the design parameters, review the design and seek improvements, and seek internal suggestions and improvement ideas.
Beta prototypes – these will include any changes made during the alpha prototype stage, and be submitted for compliance testing, certification, stress testing and product trials. After the results of those operations more changes may be required to the design requirements and specifications.
Pre-production prototypes – these are manufactured during short runs and ideal for verifying the manufacturing process, component suppliers, determining production yields, product testing, and the supply chain. For more popular products security at all stages of the supply and manufacturing chain is vital to remove the possibility of information leaks, industrial espionage and intellectual-property theft. You don’t want fuzzy photos of your next great thing plastered over Internet pundit websites.

Where to from here?

Your project budget and prototype requirements will determine the method of creation and time required to do so. For many designs the speed of prototyping can be increased dramatically, in conjunction with reducing the budget requirement by using a mixture of standard components, development kits, a mixture of reference and custom designs and pre-designed hardware libraries. By not “reinventing the wheel” wherever necessary time and money can be saved without too much effort, leaving resources available for R&D or custom sections of the design.

So if you have an idea for a prototype and not sure about how to move forward and would like to have an experienced organisation take care of everything – we can “make it happen”. At the LX Group we have our own hardware compiler – a proven system of product design that will save you precious time and money. No matter what stage of design your team has achieved, we can partner with you to share our design and manufacturing expertise for your benefit.

To move forward with your prototype requirements, simply contact us for a confidential discussion about your ideas and how we can help bring them to life – click here to contact us, or telephone 1800 810 124.

Published by LX Pty Ltd for itself and the LX Group of companies, including LX Design House, LX Solutions and LX Consulting, LX Innovations.

For the inexperienced organisation or individual, the journey that is product design may appear to be either a simple task or something so complex that they suffer from the paradox of choice and the product fails to move forward from an idea to reality. Nothing could be further from the truth, and in both of these cases that is a shame, as with some thought, planning and the right partners – product design is achievable and your ideas can become products.

The old adage “proper planning prevents poor performance” is still true and certainly applies to product design. At LX we have our own six-stage planning process that has yielded in success for all of our clients. Let’s examine these stages in more detail.

Conceptual Development

This stage involves several areas, including intended market research, deciding on product specifications, basic prototyping and setting up the team to work together. The more information you can gather about the intended market for your final product, in conjunction with an understanding of the technology available – the better the final results. This step is crucial – you can’t go back in time to change features based on initial research – and redesigning from scratch will destroy your budget.

Design

After conceptual development the initial versions of the product can be constructed. This will involve several versions, and testing by the internal team. If the product requires embedded software many iterations may be necessary to meet the design requirements. Furthermore any industrial design for such things as enclosures or mounts will also need to take place in conjunction with the final physical design of the product.

Finally, during this stage you will be preparing for commercialisation assistance, and possibly external financing. Having some working beta version prototypes and marketing data created during the first two stages will assist in this.

However this is also an exciting stage, as you can see the birth of your product and understand the reality of it. As part of electronic product design you should consider the LX Hardware Compiler – a system designed to save money and an incredible amount of development time.

Testing, Verification and Certification

During this stage you have the opportunity to test the product, not only for operation but also to comply with any relevant compliance standards and gain required certification for the target markets. Failure at this stage may render the product unsaleable in some markets and possibly lead to product recall or legal action. Furthermore all levels of hardware and software must be verified as working to specification otherwise the project will incur expensive re-designing and tooling costs. You will also need to finalise planning for moving from the laboratory to manufacturing, your organise the production team, suppliers and manufacturer.

Pre-production Manufacture

Here you will design the process for manufacturing, working with the manufacturer to prepare the production line, such things as test jigs, organise the required parts from the supply chain, run a small batch of pre-production items to test the factory processes and quality control – and generally be satisfied the product is ready for manufacture. Furthermore when dealing with offshore manufacturers it is important to confirm with them that the processes, procedures and suppliers decided upon after pre-production will be adhered to for the full production run. Finding a production partner you can trust can be a journey in itself, especially for those without any contacts or past partners in the industry.

Manufacture

Finally you can start manufacturing the product at full speed. However you can’t stand back and watch, a constant vigilance needs to be maintained with regards to quality control, meeting customer orders, logistics and also the quality of secondary items such as packaging, documentation and customer support vehicles needs to be taken into account.

Ongoing support

Even after selling thousands or more of your product, there will be times when software needs to be upgraded, new compliance standards introduced that will require a slight redesign, and new information from your marketing team that may required possible upgrades or changes to the final product. All these and more can and will require changes that require revisting the previous steps of the design process, and cannot be ignored otherwise the success of your product and reputation will be at stake.

When working through all the stages listed above, and more things that you may not even have considered, it will pay you to consult an organisation that has brought a wide variety of products to life in all fields of operation. And here at the LX Group we can be your partner and guide through the entire process – from an idea to the delivered product.

Bringing the right product to market at the right time and on budget can be done, and by not selecting the right parter you leave your organisation open to budget problems, production delays, quality issues and any manner of related problems.

So if you have an idea or prototype and not sure about how to move forward with your planning, inexperienced with product commercialisation and manufacturing – or would like to have an experienced organisation take care of everything – we can “make it happen”.

Simply contact us for a confidential discussion about your ideas and how we can help bring them to life – click here to contact us, or telephone 1800 810 124.

Published by LX Pty Ltd for itself and the LX Group of companies, including LX Design House, LX Solutions and LX Consulting, LX Innovations.

When fighting a warehouse fire in extraordinary temperatures, you don’t want to worry about the two-way radio breaking down. If a police car is broadsided during a high-speed chase, the on-board computer can’t be torn free to become a dangerous projectile. When staking out a remote location in the desert or on or drilling for oil in the North Sea, electronic equipment needs to withstand the extreme weather.

When designing projects for extreme environments such as the previous examples, you need rugged electronic designs. To make sure your clients and end users in the field have technology they can rely on, a number of organisations have developed stringent industry testing standards and procedures. This has an impact on product design as engineers are required to know, design and test their equipment to comply with set standards. The desired end here is for the products to survive “Torture Tests” and gain compliance certificates.

Ruggedisation is defined as “designed or improved to be hard-wearing or shock-resistant. There are four categories of rugged electronic equipment; commercial-grade; durable; semi-rugged and fully rugged. Today’s most widely used ruggedness standards include those from four highly respected sources: the International Electrotechnical Commission (IEC), the European Committee for Electrotechnical Standardisation (CENELEC) which publishes the European IP (Ingress Protection) standards for electrical equipment, and the United States military.

Most standards provide exceptionally detailed instructions and procedures for product testing. Major tests normally performed include:

Water Intrusion: When water or rain penetrates a device, they can cause short circuits and corrosion. Many manufacturers test their rugged products against both MIL-STD-810F and IP54, IP64, IP66 water and rain intrusion standards. Testing for rain intrusion is normally done in a rain chamber that drenches products with jets of water of varying intensities from all possible angles, as well as for dripping water for different periods of time. Fully rugged models are also tested with full immersion, to IP68 and MIL-STD-810F, Method 512.4.

Salt and Fog: In coastal and marine environments, salt and fog can cause electronic equipment to short circuit or rust, affecting performance both short and long-term. Engineers normally test to the MIL-STD-810F Method 509.3 standard using the specified five percent saline solutions.

Humidity: Conditions of extreme humidity can cause electronic devices to corrode and malfunction over time. Typical tests are to MIL-STD-810F Method 507.3 specifications, which specify 95 percent relative humidity and worst-case scenario high temperatures up to 75°C.

Dust Intrusion: Dust and sand intrusion in deserts, shorelines, mines, construction sites, or other environments can cause movable parts like buttons and keypads to clog and malfunction. Often manufacturers test to both MIL-STD-810F, Method 510.3 for sand and dust testing and IP standards for blowing dust.

Drop Testing: In the field, it’s common for handheld devices to be knocked over or dropped. Manufacturers test to MIL-STD-810F Method 516.5 with around 90- to 120 cm free-fall drops to concrete, and also with tip-over tests. The equipment is expected to remain fully operational after multiple drops.

High and Low Temperatures: Manufacturers test their technology under operating conditions of minus 35°C (MIL-STD-810F Method 502.3) and plus 60°C (MIL-STD-810F 501.3). In addition, equipment is often stored under extreme temperature conditions, and is expected to work to specification when put into service. Many manufacturers tests equipment storage in extreme low temperatures down to minus 57°C (also MIL-STD-810F Method 502.3) and high temperatures up to 85°C (also MIL-STD-810F 501.3).

Temperature Shock: Equipment is often transported by aeroplane, or used outdoors and brought inside, meaning it can be under extreme cold for long periods of time, then deposited or stored in extreme heat. Equipment is tested under these precipitous temperature fluctuations to MILSTD- 810F Method 503, testing equipment that has gone from storage of minus 57°C to 80°C and vice versa.

Sun Exposure: Equipment that is installed in, or must work in, unrelenting sunshine is tested to MIL-STD-810F Method 505.4 standards for enclosure and performance damage from solar radiation. Tests normally last from three to seven days, and are conducted in a specially designed solar chamber.

Shock and Crash Testing: Mobile and vehicle mounted products are tested to make sure they are installed correctly by subjecting them to worst-case scenario accident impact tests. MILSTD- 810F Method 516.4 tests are exceptionally stringent. Equipment must continue to operate correctly under 75Gs, or 75 times the force of gravity. Drop tests of varying heights to a steel floor are also conducted. Equipment must stay intact, mounted and continue to be 100 percent functional.

Vibration: Vibration testing to MIL-STD-810F Method 514.5 measures how equipment reacts to different levels of vibration, which can cause wire chafing, intermittent electrical contacts, display misalignment and other issues. Tests are conducted in both standard vehicles such as cars and trucks and under the more severe vibrations caused by more vibration-prone vehicles such as motorcycles, tanks and others.

Low Pressure: High altitudes and dropping pressure, such as in aircraft or on mountains, can cause membranes in parts such as speakers, microphones and keypads, to malfunction. Manufacturers conduct low-pressure performance tests to MIL-STD-810F Method 500.3 that ensure 100 percent equipment functionality

To ensure that products go to market quickly and don’t suffer costly delays, engineers should include relevant testing consideration as part of the design process. By confirming assumptions of the product’s compliance—such as the market and classification of the area in which the equipment will be used (Class I, Division 1, Class I, Zone 0 etc.), determining the appropriate protection concept (intrinsic safety, flame-proof, etc.), and establishing the indicative environmental considerations (enclosure ratings, extended ambient temperature range and so on) product development will be smoother and not require reworking to meet aforementioned standards.

The recommendation is for engineers proceeding into research and development stages to keep the submission for final certification in mind. This could mean reaching out to consultants who will help you through your submission process and follow their advice and guidelines.

At the LX Group we can carry out product testing, verification and compliance certification. We also partner with a number of NATA-certified local and international partners to provide independent product compliance and environmental testing.

LX has a range of equipment to support environmental and certification testing including an environmental test chamber, EMC test equipment, ESD simulator (CE testing), and various electrical input simulation devices such as environmental testing, design verification and compliance testing.

Some common compliance standards include:

EMC emissions and immunity testing (including C- Tick, FCC and CE)
Electrical safety (mains certification)
UL certification
RoHS and WEEE compliance
Industry-specific standards (including medical and mining)
Ingress Protection (IP) rating
Packaging and labelling requirements

For more information or a confidential discussion about your ideas and how we can help bring them to life – click here contact us, or telephone 1800 810 124.

Published by LX Pty Ltd for itself and the LX Group of companies, including LX Design House, LX Solutions and LX Consulting, LX Innovations.

Making your Home Smarter: Automation

The convenience and security of home automation are undeniable, and more and more people are
using it. Not only that, a smart home can be an energy-efficient one, as you have more control of your appliances. It is always nice to have your lights automatically dim as you leave your room or play your favourite song just by clapping your hands. Home automation might cost a bit to install but the benefits are worth the investment.

Defining a “Smart” Home

A smart home incorporates a network that connects appliances and devices. This network allows anything that utilises electricity to
communicate with each other and respond to your commands. Controlling the devices could be done using a computer, wireless controller, or by voice. The system can be similar to a personal assistant who awaits your every beck and call. Lighting, home theatre, security, temperature regulation and entertainment are the most common systems to be automated.

A Short History of Home Automation

It was just a few years back when only society’s well-off could afford an automated house. But now, the developments in electronics technology have paved the way for much cheaper systems, enticing more families to convert their abode to smarter homes. How did smart homes begin?

It was in 1975 when Scottish company Pico electronics created X10, the technology that gave birth to home automation. X10 allowed compatible appliances and devices to “talk” to each other using the existing electricity connections inside a house.

Receivers are installed in the appliances and devices, and a remote control or keypad acts as the transmitter. Pressing the remote control sends out data wirelessly, encapsulating simple codes like 0010 for “on” and 0011 for “off”. The X10 was revolutionary during that time although it has its limitations. For instance, communication among the devices using electrical wires can be unreliable – the signals are heavily attenuated by the 120/240 volt system that is used in American homes.

More technologies emerged since then, all trying to overcome the limitations of the X10. Z-wave and ZigBee moved away from using power lines and used a special frequency channel for sending out radio waves. Both technologies used low-power and low-cost modules that are connected, following a mesh topology. Being low-power allowed ZigBee modules to be manufactured in small sizes and use smaller batteries. Mesh networking provides reliability and a more extensive communication range.

Software

Choosing the right automation software is very important. Modules follow the same technical standard and they all work the same, but programs do not. You must choose a program based on ease of use. Activhome is recommended for beginners, as the user interface is simple to follow. You can control your appliances through your computer using it. If you want more customization, then Powerhome could be for you. This program allows you to create timed sequences as well as routines that fit your preference.

Adding other systems would require new programs. For example, if you choose to add a weather monitor, you will need Virtual Weather Station. This program allows your automation software (e.g. Activhome) to communicate with your climate sensors.

Hardware

The server, interface and modules are the hardware of your automation system. The server acts as the brain of the system and will always include controllers, timers and computers. Servers have become more intelligent over the years and may now accept commands from smartphones. E-home Automation products are examples of systems that can process commands from Apple’s iPhone. Interface refers to the connection between the different components of the system, while modules receive the commands for the devices.

Smart Grid and the Future

The term “smart grid” refers to a node in a network of electrical systems that can analyse behaviours and do actions based on what it sees as necessary to maintain the efficiency of the system. The ability to control home appliances and lighting is viewed as an integral addition to the smart grid as it is being rolled out in a few countries.

A combination of home automation systems and smart grids will pave the way for better energy management in the future. A possible application could be turning on the air-conditioning system using the high power derived from a solar panel on a hot day. Smart grid technology will also evolve just like home automation so that this so-called “green automation” can be utilised in more homes.

Published by LX Pty Ltd for itself and the LX Group of companies, including LX Design House, LX Solutions and LX Consulting, LX Innovations.