Car

Definition

Block Diagram

Boards

• Four Boards

• Car-Computer
• Car-Calls
• Car-Calls-Expander
• Car-isolator

Components

• SMD

Leds,

resistors

small capacitors

• Conventional

Relays

Connectors

Power Driver ICs

Power PSU ICs

Car-Computer

• ~ 210 x 135 mm
• CPU ST8 48-LQFP
• Upper side of board free of connectors
• Clamp-connectors to other 3 sides
• About 70 connector pins
• VIN to 12V / 5A SMPS
• Connector to supply 12V from external stabilized PSU

In this case SMPS parts are not assembled to PCB

Car Calls

• ~ 100 x 200 mm
• CPU ST8 48-LQFP
• Connectors on the 2 long sides
• SPI 8-bit power drivers

Car Calls Expander

• ~ 100 x 180 mm
• No CPU, SPI controlled
• Connectors on the 2 long sides
• SPI 8-bit power drivers

Car Isolator

• ~ 70 x 70 mm
• RS485 line opto-isolation

Work to do

CAD

• Existing Preliminary Schematics
• Schematic

Transfer to other CAD

Check existing circuitry

Switching PSU

XTAL,

In-circuit programing connector

Connector compatibility with V07

Minor changes

Update Components Packages

Update 3D models

• PCB

Transfer from Schematic

Create PCB

Gerber Files

Inspect

Document

Pack all for pcb-manufacturer

PCB Manufacturing

• Order control
• Handle errors in data
• Handle Payment
• Receive PCBs

Part list Management

• Create part lists from CAD
• Create Purchase List

Multiply with number of each board

Unify lists of all boards to one

Add data

Manufacturer

vendors

Prices

Lead times

Exclude Available stock (...Relays, Clamp-connectors...)

• Order

Control Vendor(s)

Concentrate parts than are already available

Relays

Clamp-Connectors

Other

Wait and control order completion

Assembly

• Split parts for each board
• Assemble SMD
• Electric tests on CPU and other dense SMD ICs

Sort circuits

Circuit brakes

• Assemble Through-hole parts

Test

• Write test Code

for ST08

Car Computer

Calls computer

• Test Power Supply
• Test CPU functionality

Reset

Oscillator

• Test I/O

With multimeter

With Software

• Test UART
• Test RS485
• Test RS485 Board communication
• Test SPI board communication

Expenses

• Estimation of expenses
• PCB sizes are also predicted
• In "PREDICTED COST" collumn: no VAT and no-stencil for PCBs

ITEM	DESCRIPTION	DIMENSIONS	QUANTITY	COST FOR 1	PREDICTED COST FOR 2 PCS	PREDICTED TOTALS (FOR_2_PCS)
1	PCB CAR-Computer	210 X 135 mm	2	-	140
2	PCB CAR-CALLS	150 X 100 mm	2	-	100
3	PCB CAR-CALLS-EXPANDER	100 X 100 mm	2	-	100
4	PCB CAR-ISOLATOR	70 X 70 mm	2	-	60
	PREDICTED PCB TOTAL NO VAT				400	400
	QUOTED PCB TOTAL 2 PCBS
	QUOTED PCB TOTAL 3 PCBS
5	PARTS CAR-COMPUTER		2	50	100
6	PARTS CAR-CALLS		2	35	70
7	PARTS CAR-CALLS-EXPANDER		2	25	50
8	PARTS CAR-ISOLATION		2	10	20
	PARTS TOTAL FOR 2				240	240
	PART TOTAL FOR 3
	GRAND TOTAL					640

Time Schedule

• KEY-DATES

• Start of Project: 26/9/2011
• Delivered PCBs and Components 25/10/2011
• End of project 28/11/2011

Development-Cost and Expenses for PCB and Parts

• Cost is 2850 E

1/3 payed at every KEY-DATE

---

Below are expenses not included in the 2850 E cost

Expenses estimation for --2-- prototype PCB sets --NO-STENCIL--

• Estimated Expenses are 640 E additionally (not included in the 2850 E cost)

analyzed:

For PCBs 400 E (no VAT)

For Parts 240 E

Based on [this table]

Expenses estimation for [3] prototype PCB sets + STENCILS

As the previous estimation was for 2 sets of boards and finally 3 sets + stencils needed:

• For 3 sets estimated 1086 E (including PCBs VAT 21%)

Analyzed as:

• PCBs 600 E + 21% VAT = 726 E
• Parts 360 E

Expenses Final after PCBs and parts delivered

As the above was estimation, The final cost was 1115.23 E, Analyzed:

• PCBs 589.23 E

Reduced due to price difference from 2 to 3 boards

Include 3 Stencils

• Parts 526.00 E

Increased due to tapes, minimum-order-quantities, One-week-delivery