Success Stories

HART IP Gateway

Solution Description

• 6L 1.6mm PCB design with mechanical constraints
• Modular & Small form-factor design – 99*80mm
• Interfaces – Ethernet, Wi-Fi, HART, LEDs
• Requirement analysis, Schematics & Layout design, Customisation of off the shelf Mechanical design, Firmware development
• Critical placement & routing to accommodate 4 HART modems, HART multiplexer in small form factor.
• One PCB design with two different assemblies for two products.
• Initial bring-up of the board followed by detailed Electrical interface validation(EVT)
• Easy configuration of Multiplexer using Web server

Outcome and Benefits Delivered

• Designed a system with high reliability, modularity and performance
• The system is undergoing field trials and a formal product certification process will follow

Hart IP Gateway - System Description

• Requirements Gathering & Analysis, competitive product study, H/W Architecture development and finalization, Firmware architecture development and finalization, Power requirement analysis via power estimation, component selection of all major components with CBOM with MOQ, LT etc., Customization of off-the-shelf mechanical enclosure

Hardware design(Schematics), Cadence OrCAD Capture CIS 

• Critical placement & routing to accommodate 4 HART modems, HART multiplexer in small form factor
• Isolated designs for HART devices
• Part selection to minimal footprint as possible to accumulate all components for two products in required PCB dimensions
• One PCB design with two different assemblies for two products.

PCB design(Layout)

• Modular & Small form-factor design – 99*80mm, 6 layer 1.6mm thick PCB  
• Complexity in routing all the interfaces for two products in tightly packed PCB
• Isolation plane cutting for HART devices

Fab and Assembly/BOM

• DFM and DFA reviews 
• Low cost CBOM’s with low cost alternatives identified for high cost parts, lifetime check for critical components in design including NAND and NOR flashes
• Manufacturing support with alternates identified for components going to EOL/obsolesce

FW development 

• Operating System - RTOS
• Development of Bootloader and HART-IP Gateway application
• Web interface available for device configuration
• Implemented firmware upgrading logic for the TiVA processor
• Implemented stack-able architecture to interface upto 16 HART devices (One gateway and upto 3 add on boards)

Bring-up and Testing 

• Initial bring-up of the board followed by detailed Electrical interface validation(EVT) including  interface validation for the various interfaces

Mechanical and 3-D design 

• Prepared the 3-D model of the board
• Customization of off-the shelf mechanical enclosure to fit for the two products

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