Case Study (PDF) - FUSE

2,4GHZ SPRE AD SPE CTRU M FREQU ENCY HOPPI NG MI CROS TRIP RADIO DES IG N HIGH PE RFOR MAN CE WITH LOW B ILL OF MATER IAL

FUSE Application Experiment Nr. 27565

Project File Date Author Approved Date

2.4GHz demo27565_7.doc May 1999 Ing. M.M.J. Schijven Ir. N.W.J. van Egmond May 1999 Ingenieursbureau Sys Com bv Apeldoornseweg 30A Postbus 113, 8050 AC Hattem Tel: 038-4445033 Fax 038-4445996

Ingenieursbureau SysCom bv voor technische automatisering

Contents Abstract.................................................................................................................................................................................................3 1. Company name and address.....................................................................................................................................................4 2. Company size ..............................................................................................................................................................................4 3. Company business description.................................................................................................................................................5 3.1. Consultancy and engineering in microelectronics .......................................................................................................5 3.2. Interactive Voting System................................................................................................................................................5 4. Company markets and competitive situation at the start of the AE...................................................................................6 5. Product to be improved and its industrial technical sectors ...............................................................................................6 6. Description of the technical product improvements ............................................................................................................9 7. Choices for the selected technologies, tools and methodologies.....................................................................................11 7.1. Choices of design technologies and test methods, with comparison of options and motivation for the option chosen 11 7.2. Motivation for the option chosen .................................................................................................................................12 7.3. Choices of CAD tools with comparison of options and motivation for the option chosen................................13 7.4. Choices of Test tools with comparison of options and motivation for the option chosen.................................16 7.5. Critical Choices of components with comparison of options and motivation for the option chosen ...............16 7.5.1. Substrate choice......................................................................................................................................................16 7.5.2. Down Converter choice.........................................................................................................................................17 7.5.3. Test Equipment and accessories choices............................................................................................................18 8. Expertise and experience in microelectronics of the company and the staff allocated to the project .......................18 9. Workplan and rationale ...........................................................................................................................................................19 10. Subcontractor information..................................................................................................................................................22 11. Barriers perceived by the company in the first use of the AE Technology............................................................23 12. Steps taken to overcome the barriers and arrive at an improved product..................................................................23 13. Knowledge and experience acquired................................................................................................................................23 14. Lessons Learned...................................................................................................................................................................23 14.1. Specifications importance .........................................................................................................................................23 14.2. “First-time right” microwave engineering..............................................................................................................24 14.3. Measurement Tools ....................................................................................................................................................24 14.4. Supplier information, availability components .....................................................................................................24 15. Resulting product, its industrialisation and internal replication...................................................................................24 16. Economic impact and improvement in competitive position.......................................................................................25 17. Target audience for dissemination throughout Europe .................................................................................................26

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Abstract We, Ingenieursbureau SysCom bv, have developed a spread spectrum 2.4GHz frequency hopping radio module to integrate within our wireless Interactive Voting System. Ingenieursbureau SysCom bv its business can be divided into independent consulting respective engineering in microelectronics based solutions and design, production, sales and marketing of SysComs own Interactive Voting System IVS®. The consulting and engineering expertise covers subjects such as intelligent man-machine interfaces, ultra reliable computer configurations, control units for building control and voting systems. There is design expertise for analogue and digital, CAD for SMT PCB, embedded software, PLC software and PC software. Our IVS® system is used as presentation support system to obtain interactions with the attendants by giving them the possibilities to ask their opinion and get this presented immediate on the presentation screen. A 2.4 GHz version is needed to have an interactive voting system with approval for Japan and the US. Frequency hopping improves security of the system, e.g. against external jamming. Using microstrip design technologies offers lowest possible BOM( Bill of materials), mechanical fit, power consumption fit and a data transmission technique optimised for the type of data. Microstrip technology was completely new to SysCom and its first application for a product development required external training and support. The opportunity to contact other persons working on this special technology has been facilitated through the participation in FUSE. Before we started this application experiment we had experience in designing RF amplifiers using lumped elements. This technique can not be used anymore at frequencies of 2.4GHz. Designing a radio module at 2.4GHz using microstrip technologies looks like an art when you see the microstrip amplifiers and other microwave circuitry at the first time Photo 1 shows a 2.4GHz low noise amplifier.

Photo 1 With help from Satelliet Televisie Nederland bv, a company with microwave design experience, investment in training, investment in microwave Test & Measurement equipment and support by FUSE we have accomplished the design of a 2.4GHz radio development board. The Application Experiment took 15 month and the prototype development costs were 59kECU. We expect a payback period of 18 month and a return on investment of 250% for a minimum product life time of 5 years. This board forms the basis for further product development related to mechanical dimensions, cosmetic outlook, software design and power management design and therefore the basis for our new generation wireless interactive voting system. Some example markets for our products are product marketing departments and training institutes whose effectiveness depends on the interaction with the attendees of a presentation. A debt of gratitude to the following is acknowledged with pleasure: Mr. A. van Dijk and his colleagues / CME Veenendaal for their support in preparing and successfully submitting our FUSE project proposal. Mr. ing. H.F. van Rees and his colleagues / Satelliet Televisie Nederland B.V. Hulst for sharing his microwave experience and equipment with us.

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Mrs. C. Südmeyer and her colleagues/ IAM F&E GmbH for their administrative support and hospitality during the dissemination days in Braunschweig. Prof. Antonello Sotgiu/ University of L´Aquila for his theoretical support in understanding the operational principle of our SHF VCO. Mr. P. Reynaert and his colleagues/European Commission for accepting and funding of our project. Keywords Microstrip, RF design, low noise amplifier, microwave, High frequency, radio control FUSE-Signature 2 0410 540 1172 1 3220 1 32 NL

1. Company name and address Company name: Company address:

Company telephone: Company fax: Company Email: Company www address:

Ingenieursbureau SysCom bv Apeldoornseweg 30A 8051 AD Hattem The Netherlands PO BOX 113 8050 AD Hattem The Netherlands +31-38-4445033 +31-38-4445996 [email protected] www.ing-bur-sys.com

2. Company size Number of personnel employed:

9 people

In Table 1 an overview of the functions within the company is given. Function Director Sales and Marketing Administration Microelectronics System Engineer Microelectronics Hardware Engineer Microelectronics Embedded Software Engineer Microelectronics Software Engineer Total

Number of people 1 1 1 1 1 2 2 9

Table 1 Company turnover: 1100 k€ About 60% of the turnover is generated by the interactive voting system.

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3. Company business description Ingenieursbureau SysCom bv its business can be divided into two parts:

1.

Independent consultancy and engineering in microelectronics based solutions

2.

Design, production, sales and marketing of the by SysCom owned Interactive Voting System

As an independent consultancy and engineering company we very often handle projects which consist out of the development of hardware and software. In the next 2 sub chapters we try to give an idea of our business.

3.1.

Consultancy and engineering in microelectronics

Since 1979 SysCom bv has experience in the use of the microcontrollers in all kinds of automation projects. Some examples are: -

Development and production of intelligent man-machine interface for controlling the airport aviation lights of Schiphol Airport.

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Development and production of a Hot Standby Switch, where a microcontroller controls 2 computers to form an ultra reliable computer configuration installed at Schiphol airport and Dutch Railways.

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Development and production of a compressor control unit for controlling the water pressure in large central heating systems such as used in office buildings.

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Development of ELSA, a voting system developed especially for a market research company

SysCom bv develops the hardware and software in-house. Sub-contractors always carry out production of systems. To give an idea in more detail of SysCom bv work we can identify the following core competencies within SysCom bv: -

Analogue circuitry design experience required e.g. instrumentation amplifiers, power supply design

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Digital circuitry design experience required e.g. uC board development 4/8/16 bit

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CAD SMT PCB design experience required for own PCB developments

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Embedded software design experience required e.g. uC board software development

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PLC software design experience required to built industrial automation systems

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PC software design experience required to built complete applications including user interface

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Industrialisation experience required to get a product on the market and control the production facility

Today SysCom bv indicates a trend of system integration. Analogue, Digital, Power management, uC part and sometimes RF must be integrated very often in a single housing preferable on one PCB. The broad range of experience available at SysCom bv is of interest for a large number of companies lacking of experience in integrating several electronics disciplines into one product.

3.2.

Interactive Voting System

For our IVS ® system we handle design, marketing, installation and maintenance. Distributors and one major OEM customer handle sales. External sub-contractors always carry out production. Because the AE is intended to strengthen the Interactive voting system market situation we will focus on this part of activity within SysCom bv.

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4. Company markets and competitive situation at the start of the AE An important aspect of SysComs activities are consulting and engineering for other companies. However, this section will be focused on our IVS ®. Worldwide there are about 10 producers for voting systems, which usually operate at a local scale. Syscom already established a network of distributors in different countries that take care of direct sales and sales through OEM customers. The overall market volume for interactive voting systems is about 50 Mio. €. Some typical customers are Ø Ø Ø Ø

Universities and high schools Training institutes Market research institutes Television producers.

IVS ® is used in a market where efficient communication structures are asked. Gaining time because of a more efficient preparation is one of the most important goals with IVS ®. Being able to do a quick evaluation during the communication process makes the process more powerful. IVS ® is an important tool in quality programs and educational processes. This market is increasing. Universities accept IVS ® as a tool for implementing educational method like Peer instruction etc. The product prices of the keypads for interactive voting systems range from about 300 € to 500 €. However, systems also differ with respect to technology and performance, i.e. the number of keypads that can be used and the time that is required for the voting process. The IVS ® products are superior to competition with respect to number of voting units and voting speed. In addition a base station and software for evaluation and visualisation is required. The weakness of the current IVS ® voting system result from its limitation to 433 MHz. This is responsible that today, even with a local market share of 70% in the Netherlands, the market share in the Rest Of World (ROW) area with our wireless IVS ® system is 0%. This also is responsible for a stagnation of sales figures over the past years in Europe, where there will be a 868 MHz frequency band for future voting systems. Sales figures for the existing IVS remained almost stable since introduction in 1997. With a fixed 868 MHz standard the market share for 433 MHz will decrease significantly. With the 433MHz technology we also do not even have a possibility to enter the ROW area due to the fact that the 433MHz ISM frequency band is not open in the ROW for wireless IVS ® systems. In order to acquire a significant share of the world market of wireless interactive voting systems it is crucial to develop a wireless IVS ® operating at the world-wide accepted 2.4GHz frequency band. A share of about 20% as already acquired in some European countries will be considered a success. We have investigated the USA market on competitive situation and see a good chance for our IVS ® concept and technological advanced product. There also is an evolving standard of 868 MHz in Europe, which also can be realised by using microstrip technology. The overall market volume is estimated to be more than 50 billion €. With its new product SysCom expects to participate in the development of these market segments.

5. Product to be improved and its industrial technical sectors The product to be improved is the 433MHz radio used within wireless 433MHz IVS ® system. The improvement consists out of developing a spread spectrum frequency hopping 2.4GHz version for the ROW area. The IVS ®-WLS 433MHz system, Figure 2, is CE approved and in compliance with the following standards for unlicensed data communication:

ETS300.220

433.052MHz-434.787MHz

Europe

In order to avoid jamming by other users it is possible to select from 4 different frequency bands. The keypads and base stations are microprocessor controlled.

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Figure 2

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IVS ®-WLS system operating frequency band: Range: Data Transmission technique:

433.052MHz-434.787MHz >100 metres in open areas -80kbit/s GFSK (40kHz deviation) -Time and Frequency Division Multiplexed -Simplex

The simplified block diagram of the 433MHz radio module from the existing product is as follows:

Figure 3 A photograph of the radio part excluding RF shielding is shown in Photo 2 below:

Photo 2

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Radio type approvals have been received from the countries: Ø The Netherlands Ø Belgium Ø Germany Ø Italy Ø Portugal Ø Denmark Ø Norway Ø Sweden Ø Finland Ø Austria Ø Switzerland Ø France Ø United Kingdom Ø Spain Ø Greece, pending The reason for innovation, implementing microwave radio technology, is a clear step for us to enter the ROW market. To keep the production costs of the 2.4GHz radio low we are forced to develop our own radio. Just buying a complete radio and integrating this technique with our own microcontroller board will fail on pricing. SysCom bv is operating in the Microelectronics as developer of the IVS ® product and in developing products for customers who consulted SysCom bv as engineering company. The product IVS ® is sold mainly to the Audio Visual Rental companies and end-users with their own Audio-Visual support department. For the end-user there are no differences between the old and new wireless IVS ® system except that the existing product may not be sold to the overseas markets while the new 2.4GHz product can be sold world-wide. In the existing product lumped elements such as coils and capacitors are used in combination with RF transistors for developing the RF circuitry. At 2.4GHz these techniques are difficult to use while microstrip techniques are used from 1GHz up to several hundreds of GHz. By implementing microstrip techniques a high performance radio can be built while maintaining a low Bill Off Material.

6. Description of the technical product improvements The technical improvements are based on the new frequency of 2.4GHz on which the new wireless interactive voting system will operate. To enter new overseas markets the development of new radio operating at 2.4GHz is vital. The new IVS ®-WLS 2.4GHz system, Figure 4, will be CE/FCC approved and in compliance with the following standards for unlicensed data communication: ETS300.328 FCC15.247 RCR033A

2.4 – 2.483GHz 2.4 – 2.483GHz 2.471 – 2.497GHz

Europe USA Japan

Additional improvements are: Ø Ø Ø

Frequency Hopping Implemented resulting in more reliable radio communication 83MHz offering a large qty of RF channels resulting in more reliable radio communication 2.4GHz radio propagation behaviour reduces risk of interference of long distance 2.4GHz users

Overall functionality, data rate and ranges are kept to the similar levels as used in the existing 433 MHz product. If feasible the effective data rate will be improved by improved base-band processing. The keypads and base stations are microprocessor controlled.

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Figure 4 IVS ®-WLS system operating frequency band: Range: Data Transmission technique:

2.4GHz – 2.483GHz >100 metres in open areas -80kbit/s GFSK (40kHz deviation) -Time and Frequency Division Multiplexed -Simplex

The functional specifications of the 2.4GHz radio module to be designed is as follows: SPECIFICATIONS of the Microwave 2.4GHz Radio Module Parameter Minimum Value Vcc 3.0V Frequency Range 2.4GHz ISM Channel Spacing 250kHz Number of channels 25 Power Consumption Idle Power Consumption during TX Power Consumption during RX Data Rate 80kbit/s (40kbit/s effective) Modulation method Direct FSK with Frequency Hopping Deviation +/- 40kHz Transmitter output power 20dBm Receiver sensitivity -95dBm, still communicating

Maximum Value 5.0V