Original
Set-Top-Box from Concept to Production
"The
Project"
Video
Networks Limited provide a "Video-on-demand"
service called "HomeChoice"
via an Asymmetric Digital Subscriber (telephone) Line
(ADSL).
They
are doing this using a conventional 380mm x 270mm x
45mm sized "Set-Top-Box".
At
the end of 1999 we were asked by them to design their
next generation of box. The plan was to take the
project from their conceptual design sketches to the
production version of the box in ten months.
"The Concept" The conceptual
sketches supplied by
Video
Networks required that the unit was to be no
larger than 206mm x 130mm x 30mm.
Was capable of
operating in four different positions.
Was to have
square sides, if possible, with no angular draft and to
have no screws or screw holes visible to the user.
The overall "look"
of the unit was to be similar to a "Standard VHS
Video Cassette Box".
The complete
unit was required to make a considerable manufacturing
cost saving, compared with their current unit, while
meeting a higher standard of finish and supply an
increase in the number of services provided to the
customer.
"The
Design"
Solid
Edge was chosen as the design software for
the project. The ability to design the whole unit in
an assembled condition meant complete control over the
component part development.
The
ease of being able to supply rendered images for
styling approval, while still maintaining all the
engineering information required to produce actual
prototypes, was extremely important in an effort to
meet the proposed targets for development.
Early
on in the project it was decided that the unit would
only be used in two possible positions, instead of the
four first conceived. This meant that the Logo end
became the "main" viewable face and only two
surfaces were then required onto which to stand the
unit.
Apart
from the single Printed Circuit Board, the remaining
seven components that made up the box, were all
designed completely using the different modules within
Solid Edge.
All
components were prototyped using STL and Vacuum
Casting technology. The plastic components were all
modelled for development purposes and initial trials
by "Iota Sigma Developments Limited" To
achieve the required look and feel it was decided that
the main enclosure of the box was to be produced from
Die Cast Aluminium.
Working
closely with the die casting company, a very low draft
angle was achieved on the outside of the box to try
and meet the original styling request of "square
sides, if possible, with no angular draft.".
The
Cable Cover parts were produced in PC/ABS, clipping
onto a formed metal bracket, without the need for
screws to hold it in place. There are five screws
holding the unit together including mounting the PCB,
none are visible to the user after clipping the Cable
Cover in place.
The
completed unit closely matched the original styling
request.
The
Video
Networks concept to produce "the
smallest foot print Set-Top-Box currently available"
was achieved on time and within the allocated budget.
HomeChoice
Printed
Circuit Board - Layout Service
We
are expanding our services and can now offer a
complete PCB Design/Layout facility. It will
encompass, PCB layout, Single Sided, S.M.T. and P.T.H.
technologies complemented by Small Batch
Prototyping and Assembly.
We can offer the
service on a Fixed Cost Basis or at an extremely
competitive hourly rate.
E-mail us or
phone for more details
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