BEC 755C
Module 5: Embedded Design
- A Systems Perspective
The Product Development Roadmap
• The Foundation: The Systems Perspective
• Phase 1: Ideation & Planning
• Identifying the 'Need'
• From User Requirements to Technical Specifications
• Phase 2: The Core Design Process
• Integrating Mechanical, Hardware & Software
• Designing for the User: Ergonomics
• The Hardware Workflow: From Schematics to PCB
• Phase 3: Verification & Validation
• The Critical Role of Testing & Design for Testability (DFT)
• Phase 4: Scaling to Production
• Bulk Manufacturing, Yield, and Delivery
A Systems Perspective
• 'Systems perspective’ : Refers to the thinking that
the 'relationship' between the parts of a system is more
important than the parts by themselves.
• The whole is more than just the sum of the individual parts.
Focus: Shifts from what a component is to what it does in
relation to others.
• Example: A Washing Machine
• The user sees a single machine that washes clothes.
• They are unaware of the microcontroller, memory, sensors, or motor
drivers.
• The system's success is defined by the seamless integration of these
invisible parts to perform a visible function.
The Guiding Philosophy: A Systems
Perspective
Phase 1: From Idea to Engineering
• The process begins by answering a series of critical questions:
• The 'Need': Why are we building this? (Market demand, competitive
response, user problem).
• User Requirements: What does the user want the product to do?
(Expressed in non-technical terms, e.g., "It should be easy to hold").
• Feasibility Study: Can we build it? (Considering technical,
budgetary, and time constraints).
• Technical Specifications: How will we achieve the requirements?
(Translating user needs into measurable engineering targets, e.g.,
"Weight < 200g, Casing from ABS plastic").
• This structured approach converts ambiguity into a clear,
actionable plan.
Phase 2: The Core Design Process -
Specifications
Phase 2: The Design Process
• Aspects of the product which attracts the user:
❖ Physical appearance, Special features etc
❖ Here user is not concerned about the processor used,
algorithms used etc
• Example: mobile phone, washing machine etc
• Aspects in products used for critical applications like space and
biomedical applications:
❖ Functionality, reliability, ruggedness, safety, power
consumption etc are important
❖ All these data will be used to fix the specifications of a
product
Phase 2: The Design Process
• Design proceeds in three parallel, interdependent streams:
• Mechanical Design: Defines the physical form factor, enclosure,
materials, and thermal properties. It creates the physical "sandbox"
the electronics must live in.
• Software Design: Creates the logic, algorithms, and intelligence
that control the hardware to deliver the product's features.
• Hardware Design: Selects the components and designs the
circuitry (the PCB) that fits the mechanical constraints and provides
the platform for the software to run.
• These are not independent paths. They require constant, iterative
communication.
A Key Design Pillar: Ergonomics
• The word ‘ergonomics’ comes from two Greek words:
i) ERGO: meaning work
ii) NOMOS: meaning laws
• Definition: Ergonomics is a branch of science drawn from
physiology, engineering and psychology studies
• Ergonomics is a branch of science focused on the study of
human fit
• It seeks to harmonize the functionality of tasks with the human
requirements of those performing them.
• Goal: To engineer products that are comfortable, efficient, and
intuitive for the target user.
A Key Design Pillar: Ergonomics
• Anthropometry is the science that measures the range of body
sizes in a population
• Anthropometric Data (measurements of the human body) to
make informed design decisions about size, shape, and weight.
• Examples:
• The height of washing machine designed for an Indian user might have
different height than that is designed for a North European user
• While designing a mobile phone, its size, position of its
keys/buttons,etc., are decided after considering the size of a human
palm
• The design of a keyboard to reduce wrist strain (Fig 18.10).
• The feel and balance of a power tool.
• A great product feels right to use, and that feeling is a
result of deliberate engineering.
A Key Design Pillar: Ergonomics
The Hardware Workflow: From Block
Diagram to Board
• Component Selection: Choosing ICs and passives based on a
trade-off of performance, cost, power, and availability.
• Schematic Design: Creating the logical "blueprint" of the circuit
in a CAD tool. This defines every electrical connection.
• PCB Layout: Designing the physical board.
• Placement: Strategically positioning components for signal integrity
and thermal management.
• Routing: Drawing the copper traces that connect the components.
• Design for Manufacturability (DFM): Throughout the layout
process, adhering to the factory's rules to ensure the board can
be produced with a high yield.
Phase 3: The Critical Role of Testing
• Testing is the process by which it is confirmed that the designed
product meets all the required specifications.
• It consumes up to 70-75% of the design cycle time.
• Design for Testability (DFT) :
➢ All the features should be testable
➢ Special components, circuit, software etc are added in the initial
stage
➢ Intentionally adding features (test points, JTAG ports) during the
design phase to make testing easier and more thorough.
Phase 3: The Critical Role of Testing
• Levels of Testing :
• LEVEL 1
• Hardware and Software unit tests. (separate, but all the features can’t be
tested)
• Hardware-Software Integration Testing (software is ported to the hardware
and then testing is done)
● LEVEL 2
• System testing in simulated and real-world scenarios. (Individual features are
tested in detail)
• LEVEL 3
• Regression testing:
Same feature is tested multiple times to ensure that the product passes the test always
Phase 3: The Critical Role of Testing
Corner Case Testing:
• Testing with the conditions which occur rarely
• Verifying operation at min/max voltage, temperature, and load.
Reliability Testing:
• The product is tested to make sure that it performs its functionality for
the specified ‘life time of the product’.
✓ Since test can’t be done for life time, it is tested for shorter time
durations in elevated conditions.
✓ For instance, the product is continuously tested for 48 or 72 hours
with full load, minimum voltage and a high temperature. These
conditions will be above the maximum specified value.
Phase 3: The Critical Role of Testing
• Standards Testing:
✓ The product will have some standards that have to be met
✓ These are to be tested and certified by external agencies
✓ Special types of testing like vibration testing, shock testing, etc. are included
in this.
• Field Trials:
✓ Testing by using in pre-fixed customer for specific duration
✓ Different modes of operation, user inputs, indications etc are also tested
• Signature testing:
✓ Product should be tested for invalid inputs, invalid conditions, etc. to make
sure that it will refuse to function in such situations.
• Finding a bug after launch is exponentially more costly than
finding it in the lab.
Phase 4: From Prototype to Product
• Prototype:
✓ The product samples manufactured initially and mainly used for
different kinds of testing
✓ Different levels of prototype may exist (first prototype, second
prototype etc)
• Bulk Manufacturing:
✓ Different parts like PCB, casing, etc. are manufactured in bulk
✓ Different tasks like PCB assembly, software porting, mechanical
assembly, etc. are performed in bulk
✓ The total time taken for all these processes affects the
manufacturing time and hence the cost of the total product.
Phase 4: From Prototype to Product
Manufacturing Tests:
• Difficult to perform entire test cycle on all the pieces of product.
• Conduct a selected set of tests on every individual piece of
product
• A simplified, automated set of tests performed on every single
unit that comes off the assembly line to catch manufacturing
defects.
• Later perform entire test cycle on selected pieces (1 in 100 or 1
in 1000 etc)
Phase 4: From Prototype to Product
• Yield:
• All the pieces manufactured might not be usable
• Some of them will definitely be found to be useless because of
bad components, manufacturing issues, quality of parts used,
etc.
• Yield = (Number of Usable Products) / (Total Number of Products
Manufactured)
• High yield is the goal
• Using of reliable components, simple manufacturing steps, use of
commonly available, easily processable and quality materials, etc. are
some of the steps towards achieving high yield.
• Product Packing & Delivery: The final step, ensuring the
product reaches the customer safely and in perfect condition.