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10 Tips to Squeeze your Embedded Design or Product

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Pallav Aggarwal
Pallav Aggarwal

Read this article to know 10 different way of reducing the size of an embedded product. Let me know your feedback and if you like it please share with your friends.

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10 tips to squeeze your embedded design or product Many a times there is a need to reduce the size of the electronics circuit due to various reasons like, to reduce bulkiness, to reduce space it takes on the table, to eliminate the mounting challenges with a bigger & heavy design, reduce shipping cost, etc. Below are 10 ways which can help you reduce the size of your existing design easily: Smaller Footprint Pallav Aggarwal Dec 23, 2018 · 6 min read 1.
The easiest way to reduce the size of your circuit is replace the components with its smaller counter part. If you are using through hole components you can switch to SMD components. If you are already using SMD, you can use smaller foot print. 2. Reduce Inter-component Spacing Reducing the space between the components while placing the components on PCB will have signi cant impact on the overall size. On the other hand you should not compromise with min. clearance spec, this might impact high voltage circuits or will make your circuit di cult to solder or repair. 3. Increase PCB Layers You need space on the PCB to route the tracks from one component to another and when you have more layers you get more space for routing. For example if board is of two layers, you can switch to 4 layer and easily reduce the size of the board as now you can route your signal quite easily and shift power /ground place to the inner layers. Now power and ground tracks will not interfere with the signal traces.
4. Both side component mounting Often times, in other to keep the manufacturing challenges and cost low, designers choose to make PCBs with components mounted only on one side. In case you are can handle little more e ort and cost of manufacturing due to component mounted on both sides of the PCB, this option greatly helps reduce the size of the over all PCB. 5. Integrated chips or modules Think about way to reduce the number of components on your board. Can you combine few parts with chip having combo? Some examples are: Image Courtesy: Wiki
Use an MCU with an integrated RTC Miniature Power Supply module instead of making with discrete. BLE/WiFi combo module Chips with integrated ESD and other protection instead of using discrete RS232 / RS485 Transceiver with Isolation and protections inbuilt Use driver chips instead of using transistor, resistor based discrete circuit 6. Review Connectors In general connector takes signi cant part of the PCB space, review all connectors used and see if their is a smaller alternate or you want to combine few connectors together with a combo? • • • • • •
7. Optimize Flexibility While designing a circuit, every designer keeps some exibility in mind to handle EOL of a component, fall back options, uncertain behavior of a chip or circuit, easy of test (test points) in mind and keeps those options on the circuit. Once the design is proven you can remove such options and reduce the over all circuit size. 8. Split the design Some times to reduce the size, it becomes mandatory to split the design into two to more board and then connect them (piggyback) via appropriate connectors or cables. Need to be aware of need of special board to board connectors or cables, etc.
9. Reduce the over all design, think out of the box Some time you need to think about the way you have designed the circuit, like is there a way to reduce the over all complexity or circuitry? some examples could be: Image Courtesy : RS-Online & Research Gate Image Courtesy : Robotics USC
In case your existing design input power is from AC to 24V adapter and then in your circuit you are using a DC-DC converter + heat- sink to make it compatible with 5/3.3V chips. Can you change to AC to 5V adapter and use LDO/DC-DC with reduced heat-sink? In case you have multiple power rails(5V/3.3V/1.8V) in your circuit is there a way to reduce those to min.? Some time using multiple capacitor values instead of one bigger value gives you more space. It might be possible to remove all the connectivity interfaces / connector like if you have RS232 & USB connector to connect your device to PC, you may have an opportunity to move to WiFi/BLE. Remove all heat sink and use metal enclosure to dissipate all the heat by touching all chips to enclosure using thermal pads. 10. Redesign You might need to re-architect and redesign in some cases, no other way. Common Challenges There are various common challenges which we might face while attempting to reduce the size of the components or PCB which one need to be aware of, are as mentioned below: Soldering: Make sure you are aware of soldering challenges with smaller components. Hand soldering is going to be di cult with SMD component like in case you want to replace 0805 passives to 0603/0402 size. You might need to hire more skilled soldering person or even go for machine soldering like in case you are replacing DIP/SOIC package chips to QFN packages or other lead- less packages. • • • • • •
Cost could be a factor. When choosing a di erent package make sure you have noted the cost di erence. Sometimes cost gets o set with the space saving bene t it gives, example with smaller board your PCB cost might reduce, your packaging/shipping cost might reduce. So, consider the over all impact. Lead time is another constraint you must be careful about as many a times these smaller footprint components have longer lead times. Component Spec: Be careful while replacing components(specially power components), with smaller footprint parts power handling capability reduces, if you miss this critical parameter you might have reliability issues in the eld. Don’t compromise on the component spec or make sure you are aware of the impact while making decision of changing the spec. Thermal Compatibility: While working on reducing the size of your design, make sure you have considered how the heat produced from di erent components will be handled, how it will e ect other near by components and e ect your over all circuit’s performance. Often time we ignore this parameter and end up with a design with thermal issues. EOL / Alternates: It is always good to select a component whose replacement part is also available. While reducing size of the PCB you mind end up choosing a part where alternate part might not be available so be aware of this risk. Testing Time & E ort: You might end up increasing the testing e ort or di culty with reduced size, so consider this important parameter. Increased Production e ort: Make sure you have considered the impact you will have on your production e ort and cost because of the changes in your design's reduced size. • • • • • • •
Do you know more ways, please do share in the comments section? Hope this helps! Support me with your claps and share with your friends so they can learn too. Let’s connect on LinkedIn | Instagram I am working on some more interesting articles, so I encourage you to follow me, you will be noti ed as soon as a new article is published. Thanks for reading. Happy Learning to you!

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10 Tips to Squeeze your Embedded Design or Product

  • 1. 10 tips to squeeze your embedded design or product Many a times there is a need to reduce the size of the electronics circuit due to various reasons like, to reduce bulkiness, to reduce space it takes on the table, to eliminate the mounting challenges with a bigger & heavy design, reduce shipping cost, etc. Below are 10 ways which can help you reduce the size of your existing design easily: Smaller Footprint Pallav Aggarwal Dec 23, 2018 · 6 min read 1.
  • 2. The easiest way to reduce the size of your circuit is replace the components with its smaller counter part. If you are using through hole components you can switch to SMD components. If you are already using SMD, you can use smaller foot print. 2. Reduce Inter-component Spacing Reducing the space between the components while placing the components on PCB will have signi cant impact on the overall size. On the other hand you should not compromise with min. clearance spec, this might impact high voltage circuits or will make your circuit di cult to solder or repair. 3. Increase PCB Layers You need space on the PCB to route the tracks from one component to another and when you have more layers you get more space for routing. For example if board is of two layers, you can switch to 4 layer and easily reduce the size of the board as now you can route your signal quite easily and shift power /ground place to the inner layers. Now power and ground tracks will not interfere with the signal traces.
  • 3. 4. Both side component mounting Often times, in other to keep the manufacturing challenges and cost low, designers choose to make PCBs with components mounted only on one side. In case you are can handle little more e ort and cost of manufacturing due to component mounted on both sides of the PCB, this option greatly helps reduce the size of the over all PCB. 5. Integrated chips or modules Think about way to reduce the number of components on your board. Can you combine few parts with chip having combo? Some examples are: Image Courtesy: Wiki
  • 4. Use an MCU with an integrated RTC Miniature Power Supply module instead of making with discrete. BLE/WiFi combo module Chips with integrated ESD and other protection instead of using discrete RS232 / RS485 Transceiver with Isolation and protections inbuilt Use driver chips instead of using transistor, resistor based discrete circuit 6. Review Connectors In general connector takes signi cant part of the PCB space, review all connectors used and see if their is a smaller alternate or you want to combine few connectors together with a combo? • • • • • •
  • 5. 7. Optimize Flexibility While designing a circuit, every designer keeps some exibility in mind to handle EOL of a component, fall back options, uncertain behavior of a chip or circuit, easy of test (test points) in mind and keeps those options on the circuit. Once the design is proven you can remove such options and reduce the over all circuit size. 8. Split the design Some times to reduce the size, it becomes mandatory to split the design into two to more board and then connect them (piggyback) via appropriate connectors or cables. Need to be aware of need of special board to board connectors or cables, etc.
  • 6. 9. Reduce the over all design, think out of the box Some time you need to think about the way you have designed the circuit, like is there a way to reduce the over all complexity or circuitry? some examples could be: Image Courtesy : RS-Online & Research Gate Image Courtesy : Robotics USC
  • 7. In case your existing design input power is from AC to 24V adapter and then in your circuit you are using a DC-DC converter + heat- sink to make it compatible with 5/3.3V chips. Can you change to AC to 5V adapter and use LDO/DC-DC with reduced heat-sink? In case you have multiple power rails(5V/3.3V/1.8V) in your circuit is there a way to reduce those to min.? Some time using multiple capacitor values instead of one bigger value gives you more space. It might be possible to remove all the connectivity interfaces / connector like if you have RS232 & USB connector to connect your device to PC, you may have an opportunity to move to WiFi/BLE. Remove all heat sink and use metal enclosure to dissipate all the heat by touching all chips to enclosure using thermal pads. 10. Redesign You might need to re-architect and redesign in some cases, no other way. Common Challenges There are various common challenges which we might face while attempting to reduce the size of the components or PCB which one need to be aware of, are as mentioned below: Soldering: Make sure you are aware of soldering challenges with smaller components. Hand soldering is going to be di cult with SMD component like in case you want to replace 0805 passives to 0603/0402 size. You might need to hire more skilled soldering person or even go for machine soldering like in case you are replacing DIP/SOIC package chips to QFN packages or other lead- less packages. • • • • • •
  • 8. Cost could be a factor. When choosing a di erent package make sure you have noted the cost di erence. Sometimes cost gets o set with the space saving bene t it gives, example with smaller board your PCB cost might reduce, your packaging/shipping cost might reduce. So, consider the over all impact. Lead time is another constraint you must be careful about as many a times these smaller footprint components have longer lead times. Component Spec: Be careful while replacing components(specially power components), with smaller footprint parts power handling capability reduces, if you miss this critical parameter you might have reliability issues in the eld. Don’t compromise on the component spec or make sure you are aware of the impact while making decision of changing the spec. Thermal Compatibility: While working on reducing the size of your design, make sure you have considered how the heat produced from di erent components will be handled, how it will e ect other near by components and e ect your over all circuit’s performance. Often time we ignore this parameter and end up with a design with thermal issues. EOL / Alternates: It is always good to select a component whose replacement part is also available. While reducing size of the PCB you mind end up choosing a part where alternate part might not be available so be aware of this risk. Testing Time & E ort: You might end up increasing the testing e ort or di culty with reduced size, so consider this important parameter. Increased Production e ort: Make sure you have considered the impact you will have on your production e ort and cost because of the changes in your design's reduced size. • • • • • • •
  • 9. Do you know more ways, please do share in the comments section? Hope this helps! Support me with your claps and share with your friends so they can learn too. Let’s connect on LinkedIn | Instagram I am working on some more interesting articles, so I encourage you to follow me, you will be noti ed as soon as a new article is published. Thanks for reading. Happy Learning to you!