Engineering by Market

Engineering by Market - Consumer

Project

Advanced Electronics

Application

LED Lighting

Customer Need

A sporting series of portable flashlights that combines the latest rechargeable battery technology along with high-brightness white LEDs to give consumers the next level of advanced lighting solutions. The electronics provide the dimming, spot/flood control, and battery chemistry detection, monitoring and recharging functionality. With previous designs, the light dims as the battery voltage declines, but with smart electronics, a constant current can be maintained until the battery is exhausted and needs to be recharged. The electronics need to be small and efficient to fit in a handheld package while minimizing the production cost. Recharging alternatives include AC, vehicle power, and flexible solar panels.

AVID's Solution

Incorporating a switched-mode converter technology, the LED brightness can be maintained while the battery voltage is declining. By implementing a battery gas gauge and intelligent charging algorithms, the Li-Ion batteries can be recharged quickly within safe operating conditions. A variable current limit is implemented for multiple LEDs to control the light intensity and to provide various light patterns. Special thermal techniques including metal clad boards are implemented to address the heat rise of the electronics, and specifically the LED boards.

Value Added or Technologies Applied

Microprocessor Control for LED Dimming and Smart Charging Algorithms
Switched Mode Power Conversion to Maximize Light Output even as the Battery Voltage Declines
Special Charge Algorithms for Quick and Safe Charging, as well as Optimization Depending on the Recharge Power Source
Metal Clad Boards and Other Mechanical Thermal Packaging for Heat Rise due to Concentrated Power of the LEDs
AVID Supported the Product Specification with the Client, Completed the Hardware and Firmware Design and Prototyping, Validated the Design, and Supported Introduction to Manufacturing

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Project

Control Electronics

Application

Home Air Filter/Purifier

Customer Need

As a high end home air filter, this new product required intelligence for functions such as variable fan speed control, dust sensing, filter life monitor, remote control interface. The system has the ability to automatically adjust the fan speed based on the dust in sampled air in addition to a user settable manual mode. A special high speed “turbo” mode is also included for maximum air cleaning. A user panel of LEDs and pushbuttons provides for system monitor and user adjustment. Low cost, high reliability is a requirement.

AVID's Solution

A microprocessor-based system was implemented with PWM-controlled output to the fan motor. The micro monitored a dust sensor as well as the user pushbuttons. Control loops were implemented in the firmware for fan speed control. The firmware also controlled the operating modes, kept track of filter life, illuminated user panel LEDs and interfaced via an IrDA port to a remote control device and allows for field upgrades.

Value Added or Technologies Applied

Electronics Specification
Hardware/Firmware Design
Prototype and Validation
Manufacturing Engineering Support, Production Test Procedure

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Project

Li-Ion Battery Control/Charger Electronics

Application

Portable Appliance

Customer Need

The consumer appliance in this case is powered from a removable battery pack which requires a charger. A spare pack may be kept charged and a quick swap allows the user to continue use. The removable pack may also be used to power different appliances. Li-Ion batteries require special care to prolong their life as well as prevent dangerous flare up. Low cost is a key driver in the design.

AVID's Solution

A low cost microcontroller was implemented to perform the battery monitoring and charging functions. Provisions for various use cases involving plugging and unplugging, erratic contact during insertion, power draw from the battery during charge cycles, and temperature monitoring for safe operation were implemented. Additionally, a communication channel was added to allow specific battery data to be transferred for status indication.

Value Added or Technologies Applied

Hardware and Firmware Architecture
Hardware and Firmware Design and Documentation
Prototype and Validation
Production Test System Development
Manufacturing Support
Manufacturing Techniques and Process Research/Definition

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Project

RF Electronics

Application

Audience Response System

Customer Need

Live audience participation in presentations provides a valuable enhancement to the presentation experience. However, large audiences require the ability to accurately collect large amounts of data real-time and the response devices must not interfere with each other. Battery life and cost are two critical design parameters beyond the primary ability to send reliable RF.

AVID's Solution

Our customer had the basic design architecture, but the implementation delivered unacceptable performance. AVID performed a complete review of the design, looking for ways to achieve the required performance while also evaluating the design with regard to cost; either by improvements to the BOM or production processes. AVID also managed initial engineering builds which provided our customer with production-level devices for demonstrations and field trials.

Value Added or Technologies Applied

Hardware and Firmware Architecture Design Review
Circuit Re-Design and RF Performance Testing
PCB Layout, Design for Manufacturability
Prototype and Validation
Patent Application Support
Volume Engineering Builds
Manufacturing Engineering Support

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Project

Product Design and Production

Application

Portable Reminder Device

Customer Need

There are situations relating to a person’s job that depend on certain tasks, a repetitive or single event, to occur on time. As people’s jobs take on more and more, remembering a multitude of tasks and specific times becomes more difficult. A very simple reminder device was requested that could be customized with special menu options for specific jobs. This is not a PDA and the targeted user does not need be technology driven. Also, cost must be low to make this a viable option for every user.

AVID's Solution

AVID took the customer concept and created the complete product design. This includes functional and physical implementation. AVID performed all of the electrical, mechanical and firmware design, as well as created a PC application and a web application to support upgrades and custom configurations. A touch screen provided a simple user interface. A USB port was used for battery charging and downloads from the PC. We set up the production house and provided all of the manufacturing engineering support required for ramping up the product to full production.

Value Added or Technologies Applied

Design Architecture, Component Selection, Battery and Touch Screen
Hardware, Firmware and Mechanical Design
PC Application / Web Application Development
Prototype and Validation
Manufacturing Engineering Support; Plastic Part Tooling, Production Test, AVL Management, Assembly, Process Review and Support

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Project

Wireless Battery Charging

Application

Cell Phone Case and Charging Pad

Customer Need

A leading cell phone accessory company needed assistance in the development of a wireless charging system for a number of common smartphones. The goal was to eliminate the need to plug in a charging adaptor to recharge the device. Having skills primarily in mechanical design, this customer came to AVID to help them develop this highly electronic-based line of phone cases and charging pads.

AVID's Solution

AVID has years of experience in wireless power design as well as charging circuitry for LiIon technology, and this project involved adapting the technology and packaging it for the product. AVID supported the mechanical concepts and performed the complete development of the electronics. We also evaluated the requirements of the various phone models related to charging such as charging current, battery capacity, protection, indicators, etc. to insure proper operation (similar to the charging adaptor). Once the design was complete and verified, AVID set up production with a Contract Electronics Manufacturer for the first 6000 pieces. Once the initial production was done and the kinks worked out, production was transferred to China.

System Architecture Review / Planning
Hardware and Firmware Design / PCB Layout / Coil Design / Packaging
Prototyping and Validation
Certification for Agency Standards and Phone Mfr Standards
CEM Evaluation and Selection, Engineering Build Support
Initial Production
Project Management

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Project

Wireless Battery Charging

Application

Adjustable Appliance Lighting

Customer Need

Certain high-end appliances have user conveniences such as adjustable shelves or options that desire to incorporate LED lighting into them. To eliminate the need to have wires or other non-desirable end user modifications, the vision is that regardless of the configuration, power is available. Exposed connectors can present user hazards and/or reliability concerns.

AVID's Solution

Incorporating a wireless power transmitter with multiple coils into the appliance with wireless power receivers integrated into the movable shelves. The transmitter coils were located such that regardless of what configuration the user chooses, the receiver coils in the shelf had adequate alignment with a transmitter coil. The wireless power solution includes intelligence to allow only the coils, which detected a receiver to be energized.

System Architecture Review / Planning
Hardware and Firmware Design / PCB Layout / Coil Design / Packaging
Prototyping and Validation
Integration of the Electronics Solution into an Appliance for Demonstration Purposes
Project Management

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Project

Wireless Battery Charging

Application

Proof of Concept Models and Demonstration Platforms

Customer Need

As wireless power is a relatively new concept for all sorts of mainstream products, many companies are looking to verify its viability, as well gauge the market acceptance. AVID has been asked by many companies, mostly consumer products manufacturers, to integrate wireless power transfer into existing products as working prototypes. These products include small office equipment, mp3 players, portable DVD players, small kitchen appliances (blender, crockpot), small LCD monitors, various cell phones, and so on. These are not production ready designs at this point, but they have a finished look and feel, and are fully functional.

AVID's Solution

AVID has years of experience in wireless power design as well as charging circuitry for various battery technology, and this project involved adapting the technology and packaging it for the product. AVID supported the mechanical concepts and performed the complete development of the charging electronics. AVID integrated the electronics required for power conversion and charging and created the proof of concept prototypes for the device and its charging base (sometimes integrated into vehicles, furniture, separate pads). These proof of concept platforms are used to demonstrate the technologies and provide opportunities to secure full product development funding.

System Architecture Review / Planning
Hardware and Firmware Design / PCB Layout / Coil Design / Packaging
Prototyping and Validation
Project Management

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