The design and layout of the printed circuit board (PCB) for a wireless product is crucial to its ultimate performance.With the ever increasing demand for higher levels of integration, PCB design is something that cannot allow for short cuts to be taken.It is not a stretch to say that the PCB is the functional foundation within a wireless product.Cutting corners on this critical component is something that will result in program delays, returned products, and increased costs. While everyone understands the downside of cutting corners, it is amazing how often it is done.It can be attributed to old habits, not understanding the benefits of new technology, or simply looking for short term gain in light of significant risk of long term loss.OneOak Design, Inc recently worked to help a client break free of some old habits and achieve better performance than the reference design on the first board spin.What is the secret? OneOak applied good design practices in combination with proper use of any layer via PCB technology in order to provide performance results far beyond expectations.
The level of integration in a mobile phone is astounding when you step back and think about it – WAN, Bluetooth, WiFi, UMTS, GPS, camera, and all the typical mobile storage interfaces as well.You cannot take the integration of all these competing technologies in an enclosure that fits in the palm of your hand lightly. Communication amongst team members is key to adopting a flexible, front-loaded design approach.A good analogy is to think of the program like dominos.The designers need to set them up properly and effectively in order to knock them down and have everything work as planned.
The first task OneOak set out to work on was the plan for circuit schematic and board-level shielding design.The high level design progressed as most programs do - there are always some issues to work out, but the reference design mostly mapped the way.The biggest hurdle facing this program was that the team had to produce a PCB that was less than half of the square area that was achieved based on the form factor compliant reference design.The concept of improving on the reference design is not new.Every new product wants to push the limits and do better than the company before them, but a 50% reduction in size requires the typical design and engineering practices to be challenged.
Simply fitting all the required components into an envelope as small as desired by the marketing team was a challenge.Once it was determined that the parts could even fit, figuring out how to connect the components within the PCB needed to be tackled.In order to achieve the goals for this program, something other than standard High Density Interconnect (HDI) layout practices was required.Based on One Oak’s past experience and some educating of our client, it was agreed that the program was going to require the use of an Any Layer Via technology.There are several companies that provide competitive any layer via solutions, but the one chosen for this program was ALIVHTM from Panasonic.It has been our experience that Panasonic’s ALIVH provides a proven technology that allows for the ability to achieve the level of integration required for a handheld wireless device.In the case of this product, ALIVH provided several solutions to issues that were critical to the success of this program:
Signal Integrity – Enabling multiple high speed interfaces and technologies to co-exist without negatively influencing each other
Layout Efficiency – Fitting all the components of a wireless phone onto real estate smaller than the size of a credit card means components must be placed more aggressively than traditional layout techniques can allow.
Flexibility of component placement – getting all the chips and connectors to fit and work within the scope of the whole project is difficult in the best of times.The ALIVH technology allowed for leeway on issues like button and connector placement.
During the planning phase, iterations between the team disciplines occurred to overcome several design challenges and achieve the desired product requirements.OneOak worked hard to ensure that the best solution for all was achieved. Fractions of a millimeter were often discussed.A team that understands how a millimeter can drastically change the outcome of a wireless product on several technical levels is critical to a program.The location of a button can affect the user’s overall satisfaction with the product as much as not having enough RAM to allow it to effectively function, or poor reception due to compromises on the antenna design dictated by the Industrial Design.Changes late in the development cycle are what will ultimately prematurely end a program.OneOak worked hard to achieve an overall product design that was locked down before any effort in the circuit layout of the product had started.
When a Plan Comes Together
With the planning stage complete the program continued to the realization of the product. Working with the Mechanical Designers, our Electronic Designers established an outline for the PCB and began the component layout.The choice of using ALIVH was one that contributed heavily to the success of this program.ALIVH provided the ability to tightly pack components on the board as well as to utilize several layers of the board for isolation and shielding of different systems.This flexibility and layout control is something that would not have made the ambitious size requirements for this product achievable otherwise.It was OneOak Design’s experience working with the Any Layer Via technology that gave the client a solution that would not have occurred without previous experience working with this technology.
The design progressed with very few issues allowing the product to prepare for prototyping.Housings and PCBs were assembled for the first time.Smoke tests were performed on the circuit board and software was installed on the boards to get that first glimpse into what the final product was going to look like.With the core design looking to be complete, the product was ready for its big debut at one of the large wireless industry trade shows.What the team didn’t realize yet was the depth of the success.The following functional test results provide insight into how successful the design choices had been.
This program required testing on 5 separate wide-area network (WAN) standards including three 2 G standards (GSM, GPRS, and EGPRS) and two 3G standards (WCDMA and HSDPA) along with WiFi and Bluetooth.
The following charts will show performance data of our two test subjects:
1.Manufacturer’s reference design platform
2.OneOak’s design based on the same reference design.
Figure 1)Receiver (Rx) sensitivity of the Reference Platform (left) vs. OneOak’s Layout (right)
In figure 1, conducted receiver sensitivity measurements were performed with the devices operating in the GSM850 band operating in GSM/ GPRS mode(s).From the results, we can see that the overall sensitivity of the OneOak device is at least 5dB (3x) better than the manufacturer’s reference design platform.This improvement translates into better range, higher throughput, and possibly improved battery life.
It should be noted that initial tests were not performed in a shielded environment which is demonstrated by the interference ‘spikes’ seen at the low end of the band. This interference does not degrade performance mid to high band (interference shown in the Reference Platform’s graph is caused by nearby base stations in the area).
The following charts the transmit performance between these two devices:
Figure 2)Transmit (Tx) Power Levels of the Reference Platform (left) vs. OneOak (right)
Figure 3) Tx Frequency Error for Reference Platform (left) and OneOak (right)
As seen above, the OneOak design falls within the standards mask for transmit output power levels coinciding from the data gathered from the reference platform. Also note an improvement in transmit frequency stability as shown in Figure 3.
The following graphic shows the performance at higher frequencies in different operating mode(s).
Figure 4) Rx sensitivity and Tx Power Level of OneOak device
Figure 5) WCDMA Rx sensitivity and Tx Power performance of OneOak device
The final set of data shifts our focus to the one element that can cause the biggest challenge for high speed, highly integrated designs: meeting regulatory emissions standards.The graphs show that, with a minimum of 5dB of margin, this device can be submitted for formal Regulatory testing and meet the standards outlined in the graphs above.
Figure 6) Receiver Radiated Emissions, WiFi On, Bluetooth Off, USB Connected to Laptop
Figure 7) Radiated Emissions, WiFi Off, Bluetooth On, USB Connected to Laptop
In the End…..
What has been achieved on this program is simple in principle but difficult in practice.Building and working within a team that understands the needs of all development disciplines involved was key to the success of this program.The data shown in this document shows how OneOak Design worked using proper practice, technique, and technology to provide the client with a product that laid the foundation for success on the first board spin.What this translates to is significant savings in both bottom line budget costs and program timeline.An outcome every program manager hopes to achieve.
OneOak Design, Inc. is a product design and engineering company based in the Vancouver, BC area.OneOak Design brings to the table a thorough understanding of the pain required to bring a product to realization.This understanding translates to a better product and long term profitability that can be lost through typical cost cutting measures found in many product development cycles.
A PDF version of this case study can be downloaded to review at your convenience by clicking here.
Thank you very much to everyone who applied for the Intermediate Hardware Designer. If you submitted a resume, we are considering all applicants for possible future contract work.
OneOak Design Inc., a Vancouver area product design and engineering company, has become an official sponsor for the University of British Columbia’s Supermileage Team by donating much needed equipment to aide in the team’s design efforts.
“The UBC Supermileage team lives breathes by the donations that are made to our group” says Kyle Philibert, a UBC Supermileage Team member. “We want to thank the OneOak Design Team for their generous donation that allows us to gain valuable real world experiences”.
OneOak Design has donated wheels and professional design guidance in an effort to support the student’s.“We hope our assistance helps the students towards another win for the competition which is to be held in the Spring of 2010”, says Craig Gauld, Director of Mechanical Engineering at OneOak Design.
About OneOak Design, Inc.
OneOak Design, Inc. is a product design and engineering company based in Delta, BC. Specializing in electronic product development, OneOak Design provides hardware development services in Industrial Design, Electrical Engineering, and Mechanical Engineering. For more information about OneOak Design, visit www.oneoakdesign.com.
About the UBC Supermileage Team
The Supermileage competitions provide engineering and technology students with a challenging design project that involves the development and construction of a single-person, fuel-efficient vehicle. Students build gas-powered fuel efficiency vehicles, and have the opportunity to set a world fuel economy record and increase public awareness of fuel economy and sustainability. Students become more sensitive to the environmental issues as well as develop important project management skills. For more information about the UBC Supermileage Team, visit www.supermileage.ca
We want to give a hearty cheer to our friends and collegues over at Energy Aware Technologies. We’ve been working together since their inception and it is fun to watch a company and project you have worked on for over two years achieve some well deserved recognition.
The British Columbia Technology Industry Association (BCTIA) recently announced their Technology Impact Awards and has awarded Energy Aware the prestigious “Most Promising Start-up” award for 2009. They have been working hard for the past couple of years and they deserve it. If you run into Janice, Lauren, Jon, Colby, or Collin…be sure to give them a hearty pat on the back!
We’re looking to hire an Electronics Designer in the near future. Have a read through the skills we’re looking for below and let us know if you’re interested. If you know of anyone who you would recommend that fits the bill, please pass them along to us.
Intermediate Hardware Design Engineer
We are seeking a highly motivated and talented Hardware Design Engineer to help develop mixed signal hardware for OneOak’s client base. The successful candidate will thrive in a fast paced, challenging, and rewarding environment.
Job Description:
• Assist with a variety of hardware design activities, covering all aspects of product development from conception through to volume production. The task set will depend heavily on the candidate’s existing skillset as well as our ongoing projects from clients.
• Mixed signal hardware design, including high speed digital, power supply, audio, interface, and RF circuitry.
• Design validation and reliability testing.
• Schematic capture and PCB layout.
Required Work Experience, Skills and Knowledge:
• 3+ years of hands-on technical experience in:
o High-speed digital and mixed signal hardware design
o Embedded systems
o Design, verification, and test cycles – with experience in successful delivering product to market
• Strong lab skills, experienced working knowledge of standard lab equipment (scopes, power supplies, etc). Experience with RF test equipment (spectrum analyzers, test sets) an asset.
• Accomplished problem solving and analysis skills. Able to multi-task effectively.
• Basic soldering and assembly skills, surface-mount and thru-hole.
• Self-motivated, able to work effectively in both a team environment and on your own.
• Excellent communications skills, written and verbal.
• Bachelor of Electrical Engineering, or Technologist degree plus additional work experience.
Highly Desirable Skills and Knowledge:
• RF analog design.
• Experience in wireless communication (ISM band, cellular, etc).
• Power electronics design.
• Working knowledge of PADS (or equivalent) schematic capture and pcb layout tools.
• Experience in designing for high volume production.
• Embedded software design (C/C++).
• Experienced in component selection — for performance, pricing, and reliability.
• Track record of delivering products from concept to production.
• Familiar with EMI/EMC requirements and how to mitigate in design.
• Signal integrity and simulation techniques & tools
Keep in mind that if you are interested in working with us, the ability to wield a +4 Axe of Destruction is an asset.
It is an on-going desire for us to constantly expand our capabilities so that we can best suit our client’s needs. Our latest addition to the fold is a new Programmable Environmental Chamber. Our new chamber is capable of the following:
Wide Temperature Range: -70° C to +200° C
Quick transitions: -70° C to +200° C in 1 hour
Humidity Testing: 30% - 90% Relative Humidity
Programmability
Environmental testing is another one of those often over-looked steps in the product development process that can save a significant amount of headache down the road.
For more information about the new addition to our family, contact Jon at conversations@oneoakdesign
Part of the OneOak product development methodology is the integration of all technical disciplines involved in product development to work side-by-side at the onset of every program. This is something that many people nod their heads at and “agree” with. The one thing we have found is that a typical corporate product development cycle involves a very short (maybe an hour or two) meeting with the key team members. Once this meeting is over, everyone scatters. Industrial Design goes to their desk on the 2nd floor, mechanical engineering goes to their desk on the other side of the building, electrical engineering goes back into the lab.
The issue with this separation of disciplines (we call it “discipline silos”) is that the most critical part of the development cycle is at the very beginning. Planning and evaluating what is needed to be done with the program is essential. Each discipline needs to deeply understand what the needs of the other group are. No one group has any aspect of their cycle that does not affect another.
Some examples using a cell phone as an example:
- Software requires a more RAM affects Hardware (HW) layout
- HW layout needs more space for RAM moving the camera by 5 mm
- Camera movement by 5 mm affects mechanical enclosure CAD model
- Camera movement by 5 mm throws off ergonomic placement of camera lens so it doesn’t get covered by fingers.
It’s very similar to throwing a rock into a still pond. The change ripples out and eventually affects every part of the lake.
What we suggest to our clients is a Product Specification. This product can, and is, used for several purposes. Marketing can use it to create an accurate business model for sales, all technical disciplines use it as the guidance for their development. All the needs of the product (features, physical size, etc.) are spelled out and signed off on.
If everyone is involved in the process, everyone gets an intimate understanding of how their needs affect every discipline. We’ve used this process to reduce product volume by 35% and timeline by 25% over previous generations, using the same team members. The difference was HOW and WHERE we worked. We worked (literally) side-by-side, elbow-to-elbow as opposed to in our separate silos. Not just a couple hours. A couple weeks doing this.
Many balk at the idea of paying an upfront “planning” cost when at the end of the day, that cost is saved many times over.
If you have frequented our website over the past several months, you will see many changes have taken place:
- A full revamp of our corporate look including an update of our logo.
- Addition of a Newsletter (for which you can sign up for on our main page). If you’re one of the first 200 to sign-up for our newsletter you will be entered for a draw to win a $75 gift certificate to the restaurant of your choice.
- We’ve expanded our portfolio and will be adding more in the near future.
- We’ve implemented a low cost Product Specification to our services (A post explaining that in more detail is to come).
- OneOak is now a British Columbia Industrial Design (BCID) accredited company. Jon recently passed the portfolio review and is now an active member of the BCID Board as a Member at Large.
Things that are coming that we yet to show:
- Case Studies (these will all be posted to this blog)
- More services that we believe will allow us to provide even better service to our clients
- Some more great products to be added to our portfolio that we’ve been working on over the past couple of years.
We’ve been busy working to show to the world that OneOak Design is making the transition from Newcomer to the Design Scene, to a world class design firm that is here to stay.
Please, do not hesitate to leaver your questions and comments here or forward them to conversations@oneoakdesign.com
DELTA, BC – November 13, 2007 – OneOak Design Inc., a multi-disciplinary design consultancy, has teamed up with Energy Aware Technology Inc., a producer of sustainability technology, to develop the PowerTab™ Monitor now on display in the future Vancouver 2010 Athletes’ Village. The PowerTab will potentially save thousands of dollars each year for homeowners and reduce CO2 emissions by allowing homeowners to control their power consumption.
A key benefit of the PowerTab Monitor is its ease of use. The user simply carries the PowerTab’s wireless display around the house while turning on or off a power-consuming device, such as a light switch or television. By the simple flick of a switch, users can instantly see on the display how much power that particular device consumed. The homeowners can then adjust their habits accordingly and make significant reductions in their power consumption.
“The PowerTab is designed to empower and educate the homeowner,” said Jon Winebrenner, Partner, OneOak Design. “We worked closely with the Energy Aware Team to design an easy-to-use product that allows the user to control their power usage. It has a direct impact on the pocketbook for homeowners, and it makes concerted effort at controlling harmful CO2 emissions. This is really how products today should be designed—achieving both usability and environmental-consciousness.”
Energy Aware wanted to create a user-friendly design that would be a natural extension of people’s daily lives. “OneOak Design helped us achieve the friendly look of the product, which we believe is key to getting the whole family involved in living sustainably,” said Janice Cheam, President, Energy Aware.
The PowerTab is currently in the final stages of development and is being considered for use in several local developments. A model can now be seen at the Millennium Water Presentation Centre in Vancouver.
About Energy Aware Technologies, Inc.
Energy Aware Technology Inc. is a Vancouver-based company founded in 2005 by graduates from the University of British Columbia. Energy Aware is a producer of demand side management products that raise energy awareness and reduce energy waste. For more information about Energy Aware, visit www.energy-aware.com.
About OneOak Design, Inc.
OneOak Design, Inc. is a multi-disciplinary design consultancy based in Delta, BC. Specializing in electronic product development, OneOak Design provides hardware development services in Industrial Design, Electrical Engineering, and Mechanical Engineering. For more information about OneOak Design, visit www.oneoakdesign.com.
###
PRESS CONTACT
Jon Winebrenner
media@oneoakdesign.com
604-529-1625
Welcome to the OneOak Blog. This is
our conversation about OneOak News
and events, the product design process,
and issues that are pertinent to the
Design Industry.
