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Electronics integration

Eight sub-projects from practice

Client
Across industries
Sector
Capability
Scope
PCB · Drives · Control technology

Electronics are part of product development from the very beginning. Packaging space, heat, sealing and EMC significantly influence the design. That is why we develop mechanics and electronics as one coordinated unit — from PCB and wiring through motors and pumps to control technology. The following eight sub-projects show our competence across different applications.

LED circuit board

A circuit board fitted with LEDs, as used in lighting products. In designing the overall system we consider the electrical and thermal layout of the assembly as well as the mechanical integration of connecting leads and connectors.

LED board with connecting lead: assembly, heat dissipation and lead exit coordinated in the design.

Potted LED ring board

A ring-shaped LED board that is exposed to moisture and cleaning agents in operation is fully potted after assembly. Potting volume, cable routing and fixing points must therefore be considered in the design from the start. The potting not only protects electronics and solder joints permanently — it is an integral part of the part geometry from the beginning.

Potted LED ring board: potting volume, lead exit and fixing points are part of the part geometry, not the result of a post-process.

Waterproof loudspeaker

Coordination of sealing concept, housing geometry and electrical connection.

Waterproof loudspeaker: sealing concept and housing geometry solved as one design task.

PCB in a die-cast part

A powder-coated metal housing handles heat dissipation as well as mechanical and electromagnetic protection of the board.

Board in a die-cast housing: the metal housing serves as both heat sink and shield.

PCB in an aluminium extrusion

Cross-material design for manufacture with additional components in the same profile.

Board in an aluminium extrusion: profile geometry, board mount and additional components in one system.

Control unit

Control system planned and programmed in-house for an automated special-purpose machine.

Control unit of a special-purpose machine: axis control, wiring and layout planned and programmed in-house.

Power supply in the appliance chassis

An open-frame switching power supply is securely integrated into the appliance on a specially developed plastic carrier. The carrier positions the board, ensures the required isolation clearances and free convection, and at the same time provides clean separation and routing of the mains and signal leads to the adjacent dosing pump.

Power supply on a designed plastic carrier: positioning, isolation clearances, convection above the components and separate routing to the dosing pump solved in one part.

Integrated pump

Design coordination of mechanical mounting, electric drive and housing geometry.

Integrated pump: mechanical mounting, drive and housing designed as a coordinated unit.
Conclusion

Electronics are treated as an integral part of the overall design from the very beginning. Packaging space, heat dissipation, EMC, isolation clearances, cable routing and assembly and manufacturing requirements feed directly into the engineering. The result: technically robust solutions that work reliably and are optimised for economical series production.