Building a complex product like an automobile, airplane or embedded computer application can be broken down at the internal level to reveal hundreds of smaller systems that must be coordinated for success…

WIN was awarded the design and production of a complex embedded computer to be used in the mining industry where the customer insisted on following the PPAP methodology originally developed for use in the automotive industry to deal with the complexity and detail. PPAP helps ensure consistent design, development, production, and testing across the various systems so they can be seamlessly integrated at the production phase. PPAP also ensures a consistent base-line platform for the inevitable later revisions to come. It should be mentioned that PPAP is highly detailed.

The PL-8204B is a compact, versatile server. WIN’s expertise
was invaluable in bringing it to market with rich PPAP support.

The particular customer here specializes in embedded systems within the mining industry where IoT was implemented long before it became a hot acronym. As in other IoT systems, this one features an array of sensors of a variety of types that monitor mining production, bearings as well as conveyor usage, looking for the introduction of impurities, production flaws or failures. In addition, sensors monitor device speed, temperature and vibration to ensure consistent system maintenance. Because of the extreme environments in which the new unit had to function it was imperative that it be IP67 sealed and certified. This was challenging, but WIN succeeded in making the unit appropriately water and dustproof to meet the IP-67 standard. As for waterproofing, IP67 means the unit can be dropped into a body of water up to a meter deep for half an hour. Dustproof hasn’t got qualifiers.

These anomalies are gathered and operated on automatically by the device, which qualities it as an IoT gateway server. Where appropriate, alarms are forwarded to initiate any human intervention that may be necessary.

High-level data can be send to Cloud servers to provide the more corporate view which can consolidate the field input across time, distance, and systems. Industry standards and protocols enable smooth integration of the different systems. WIN Enterprises, with over forty years in the embedded industry was able to leverage its standards expertise to reduce the time required for developing design iterations. As is often the case, DFI, one of WIN’s world-class PRIMES, recommended WIN for this job. This solution uses a modified DFI motherboard, the Al-253.WIN designed the chassis and made modifications to motherboard as we saw fit.

Earlier in the process, a proposal was presented to WIN. DFI worked directly with the customer to develop the required specifications. When approved specifications were developed, they were presented to WIN who tweaked them for the requirements of the production phase. A number of prototypes were developed, but as mentioned, WIN’s experience was able to limit the number of the design iterations that were required.

After an initial evaluation, WIN built and engineering run of 20 proof-of-concept devices for customer testing. With approval of the design, we moved to full production of this successful product.