Demonstrator Document
AE25119DD08
DC-Motor Controller. Analogue ASIC reduces
production costs.
AE number 25119 associated to TTN: IMC/SGA, Sweden.
Abstract
NDC Netzler & Dahlgren Co AB develops general methods, systems and products for the control of
Automated Guided Vehicles (AGV:s). An AGV is an unmanned truck for material handling. The overall market
for AGV-systems is material handling industry all over the world. NDC has in total about 100 employees and a
turnover in 1999 of 120 MSEK (about 14 MEUR). The industrial sector for AGV-systems is: VL, Vehicles for
land transportation.
The AE involves modification of FSA (FET Servo Amplifier), a DC-motor controller with four quadrant control
designed and produced by NDC. The FSA is used in all AGV-kits delivered by NDC. The FSA is realised with
surface mount and hole-mount standard components on PCB.
The main objective when modifying the FSA is to reduce production costs. This is needed in order to meet
competition from standard controllers.
An analogue, array based ASIC has been developed in co-operation with Svenska Grindmatriser AB. Major
parts of the controlling and monitoring parts of the FSA has been integrated in the ASIC. The AE duration
was 14 months and the cost 80 kEUR.
The payback period for the development of the new FSA version will be 32 months based on the FUSE
investment of 80 kEUR. The Return of Investment in 3 years will be 113%, while it will be 350% over a the 10
years product lifetime.
NDC has further acquired knowledge about partitioning and designing an analogue ASIC and in evaluating an
analogue design with computer simulations.
Keywords
Analogue ASIC, Motor control, Servo amplifier, Pulse Width Modulation
1. Company name and address
NDC Netzler & Dahlgren Co AB
429 80 SÄRÖ
SWEDEN
Contact person: Gert Sjöberg
Tel: +46 31 938000
Fax: +46 31 938100
www.ndc.se
2. Company size
NDC who is an independent privately owned industrial company, has in total about 100 employees and a
turnover in 1999 of 120 MSEK (about 14 MEUR). The company is represented by the departments, R&D,
marketing &sales, service, IT and administration. The R&D department is the largest with 30 employees. In the
other departments the number of employees are 20 in marketing & sales, 25 in service, 20 in administration and
5 in IT.
NDC Netzler & Dahlgren Co AB, IMC/SGA
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AE 25119
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3. Company business description
NDC develops general methods, systems and products for the control of Automated Guided Vehicles,
(AGV:s). An AGV is an unmanned truck for material handling. NDC is a supplier to AGV manufacturers who
use their technology when creating complete automated vehicle installations for their customers.
An AGV in use transporting paper rolls.
The product Lazerway is a platform which consists of a number of integrated products and functions, forming
the core of an Automated Guided Vehicle System, (AGVS). This core supports different navigation principles
for AGV:s. The four navigation principles supported are Inductive loops, Magnetic/Metallic loop,
Painted/Reflecting line and Laser. NDC also offers service to the AGV manufactures in terms of support
during set-up and start-up of large complex systems as well as troubleshooting.
NDC supplies all parts of a complete AGV-system including: software for administrating several AGV:s,
software and hardware for navigation and motor drive hardware. Training, carried out also by the service
department, in use of an AGV-system is also supplied by NDC.
The manufacturing of the systems are subcontracted.
The industrial sector for the AGV-application is: VL, Vehicles for land transportation.
4. Company markets and competitive position at the start of the AE
Markets
The overall market for AGV-systems is material handling industry all over the world. Different AGV-model can
carry a load ranging from 0 to 40 000 kg. Typical applications can be found in paper-mills and steelworks as
well as with car manufacturers and in other mechanical industry. The complete AGV is manufactured by
customers to NDC. NDC co-operates with several AGV-manufacturers all over the world. The main
geographical areas that are covered by NDC is Europe and Japan. Korea and China are also important markets
for NDC. The total market for AGV:s in the world is about 4500 (1999) complete vehicles a year. NDC parts are
used in about 600 of these giving a market share of about 13%.
NDC Netzler & Dahlgren Co AB, IMC/SGA
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AE 25119
Demonstrator Document
The DC-motor controller (FSA) involved in this AE is developed by NDC for use in their AGV-systems. This
gives several advantages like for example full control over the complete drive system. The motor controller is
an important part in the AGV-system and has significant impact on overall performance. NDC has always used
their own controllers. Other AGV-manufacturers tend to also use their own controllers. There are however
standard controllers on the market that would be possible to use and that have a comparatively low price due
to much higher production volumes. The FSA is used in all AGV-system produced by NDC.
An emerging market is the Lazerway Teach-In. This concept implies that the programming of drive routes and
loading positions is simplified. No computer skills will be needed. The transport layout is created by driving
the truck manually. All routes and loading positions are memorised and stored in the control and navigating
computer. Once the transport layout is ready, destinations and tasks can be keyed in and the transports are
automated. The Teach-In concept has a potential of increasing sales of AGV-kits significantly. The market is
however very young and it is hard to do accurate estimates of potential sales volumes. If the price of the FSA
is lowered the market for the Teach-In concept would be very potential for NDC. The performance in terms of
EMC and ECD protection and reliability that NDC can offer has a value of about 5 % of the net-price.
Therefore our Customers are ready to pay our DC-motor controller up to 5% more than our competitor’s
products. If our controller price is not lowered to such levels, the big opportunity of Lazerway Teach-In
market may be lost by NDC.
Competition
The main competition for the FSA comes from manufacturers of standard motor controllers. Copley Control
Corp. and Curtis are some examples of manufacturer of DC-motor controllers that can be used in AGVapplications. Competition also comes from the use of AC- (induction) motors as this requires another type of
controller.
The intention with the FSA is not to compete on the market for general purpose motor controllers. The FSA is
targeted mainly for use in AGV-kits from NDC even if a small amount of controllers are sold separately. The
market share for FSA controllers considering the total market for motor controllers is very close to zero. The
main reason is that the US manufacturers (Copley and Curtis) has penetrated the market first and delivers
enormous volumes. With these high volumes they also can offer low prices.
The FSA unit represents a value of 550 EUR to 1700 EUR depending on power rating. The competitive
strength compared to standard controllers is mainly that NDC has full control over the complete motor drive
system by using their own hardware. The FSA controllers are designed for use in an industrial environment
and are generally more robust than the competitors. This is specially the case concerning protection against
ESD-pulses. The motor controller has also large impact on system performance and NDC has gained from
many years of experience from DC-motor control when designing the FSA.
The NCD products has, in terms if good ESD/EMC protection and reliability somewhat better performance
than Copley and Curtis. Copley and Curtis is on the other hand ahead on the market with high volumes and
can therefore offer lower prices. The 5% value of the better performance and the lowered price with the AE
improvement can in conjunction with efficient marketing increase the market shares for NDC.
The total sales of FSA-units is completely controlled by sales of complete AGV-kits. The number of AGV-kits
depends on the number of AGV:s manufactured. The production volume (1999) is around 1800 units a year
and has only increased marginally during the last three years.
5. Product to be improved and the reasons to innovate
Product
The FSA Servo Amplifier is used for controlling DC-motors. The FSA has four quadrant control. This means
that the speed and acceleration/retardation of a motor is controlled in both forward and backward direction
without the use of contactors. The unit operates on the chopper principle (transistor pulsing of motor current)
and uses 17-70V battery supplied voltage to power DC-motors with variable voltage.
Some important items in the specification are:
•
Full control over the complete motor drive system
•
Fulfil EMC European Norm EN50082-2 : 1996 and EN50081-2 : 1992 for CE compliance.
NDC Netzler & Dahlgren Co AB, IMC/SGA
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AE 25119
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•
Resistance against high ESD levels.
•
Input signal level adapted to NDC system environment.
•
Output signal level adapted to NDC system environment.
•
17-70V battery voltage supply.
The FSA uses field effect transistors for high efficiency, which results in a compact design. The FSA is
available in five versions from 23A to 200A max. motor-current. The power transistor size differ but the control
part is basically the same. The design includes protection against short-circuit, overheating, over- and undervoltage. The controller is CE-marked and EMC-compliant.
The block diagram below shows the principle of the FSA. Both tachometer and armature feedback is possible.
All control connections are available on a connector (left). The picture below shows a picture of the FSA
before the AE. Most components are surface mounted on one PCB. Two additional PCB:s are included for
filter components to conform to EMC-regulations.
Picture of the FSA before the AE.
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Signal connector
+12 V
-12 V
SS+
10
+6.2 V
11
-6.2 V
14
16
Sin
18
FB2 in
+
4
Feedb
net 1
1
Feedb
net 1
FB0 in
5
FB0o u t
6
GND
Power
connector
15
Sout
FB1 in
I out
T+
TTout
Tin
Arm. V+
Arm. V-
Inh M1>M0
Inh M0>M1
Inh
Failure
Pulsewidth
modulator
+
Power transistor
fly-back diode-bridge
21
BATT +
-
Quadrant
Control
Logic
M1 motor
(QCL
Low Current
Limit
M0 motor
20
7
Current
Sensor
2
3
BATT -
Overcurrent
Sensor
19
17
9
Armature
Feedback
8
Fan
Overtemp.
override/Reset
+
+
-
Signal ground
I low
DC/DC
Converter
Temperature
Sensor
24
Latch
(memory)
13
25
12
Enable
QCL
Logic
Voltage
Sensor
LED, green
23
LED, red
Block diagram for the FSA.
Reason
The major reason to modify the FSA is to reduce production costs. The improved FSA will have the same
performance from the user point of view. Old and new FSA-units should be directly replaceable and
compatible. A reduced production cost is needed in order to meet competition from standard controllers. A
cost reduction in the range of 40 EUR per unit would lower the price by 50 EUR. The FSA would thereby be
more competitive for use in AGV-applications. A cost reduction in this range would decrease the difference in
cost between an FSA and a low cost standard controller to that extent that the technical advantages with an
FSA are clearly motivated. The consequences of these facts will generate increased market share for NDC.
6. Description of the product improvements
The improved FSA is mechanically and electrically compatible with the older versions from the user point of
view. The improvement lies in the use of new technology to reduce production costs. This has been achieved
by:
•
Integrating the controlling and monitoring parts in an analogue ASIC. This releases valuable PCB-area for
the following modifications. The PCB-area used for the parts in the ASIC decreases from 2000 mm2 to 200
mm2 by the introduction of an analogue ASIC.
•
Introducing a power supply with ”planar magnetic” transformer. This is significantly less costly than an
ordinary transformer but occupies more area on the PCB.
•
Introducing a power connector that is mounted directly on the PCB instead of connected with wires. This
does also occupy more PCB-area but is less costly to assemble.
•
Integrating all filter components for EMC-compliance onto the main PCB.
The ASIC contains all major components for controlling and monitoring the DC-motor. Power transistors are
not integrated and the components that determine control parameters for the motor are also external to the
ASIC. The block diagram below shows what parts of the FSA that has been integrated in the ASIC. Please
compare with the FSA block diagram in the previous section.
NDC Netzler & Dahlgren Co AB, IMC/SGA
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AE 25119
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+6.2 V
Reference
(6)
-6.2 V
Shunt BC
(5)
+
Sin
(3)
+
+
Pulsewidth
modulator (1))
+
-
A
Ti n
Quadrant
Control
Logic
FB0 out
(2)
Low Current
Limit (4)
B
C
D
I low
Current
sensor
NTC
SCHI
Temperature
monitoring
(8)
Fan
Overtemp.
override/Reset
Inh M1>M0
Inh M0>M1
Inh
SCLO
Latch
( memory)
+B
(9)
Inhibit
Logic
(10)
Voltage
monitoring
(7)
LED, voltage
Failure
Block diagram for the ASIC.
The ASIC is realised in an analogue array from Svenska Grindmatriser AB (SGA). The SLA-arrays from SGA
are bipolar, high voltage, arrays with integrated thin film resistors. There are two metal layers where one is
application specific. The arrays are available in two different sizes. NDC has used an S-16 array that has 451
bipolar transistors, 490 SiCr thin-film resistors with a total resistance of 7.14 MO and 46 bonding pads. The
chip size is 4.62 x 3.16 mm.
The array approach with one custom metal layer makes it possible to design an ASIC also for the low
production volumes expected for this product.
The ASIC is assembled in a 44 lead MQFP package for surface mount.
Interior of the improved FSA.
NDC Netzler & Dahlgren Co AB, IMC/SGA
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New FSA with motor.
7. Choices and rationale for the technologies, tools and methodologies
Technology
An upgrade of the FSA-system must mean a significant reduction in the number of components used. This
will, besides from lowered component cost, release valuable PCB-area to implement the additional
improvements discussed in section 6. The following options were investigated:
•
A microcontroller solution would be technically possible. This would however represent a major step
from the previous FSA design. The technical and economical risk was, for this reason, considered very
high for the microcontroller alternative. Initial calculations did also show that this alternative would not
occupy significantly less PCB-area than the existing solution.
•
An analogue array based ASIC can integrate large parts of the FSA-design and thus release PCB-area for
other use. The basic design of the FSA can be kept and the technical risk with the modification is then
minimised. A high voltage process is an advantage as signal levels then can be kept unchanged to
maintain compatibility with existing FSA. The array approach makes it possible to design an ASIC also for
the comparatively low production volumes that applies to the FSA.
•
A full custom analogue ASIC would give some additional advantages but to a very high price. More
components may be possible to integrate as the fixed limits introduced by the size and pad count of the
array would disappear. The additional cost for designing and prototyping a full custom ASIC can
however not be motivated for this application.
NDC decided to use an SLA-array from Svenska Grindmatriser AB (SGA) for the upgrade of the FSA. The
SLA analogue arrays use a 60V bipolar process with integrated thin film resistors. One metal layer is
application specific. The FSA-application is a good example of what can be integrated in this type of analogue
array.
Tools and methodologies
The electrical design was performed using schematic capture and electrical simulation software on a personal
computer (PC). Well characterised libraries of the components of the SLA-arrays are available for PSpice. The
complexity of the design is well within the limits of what can be handled on a PC. PSpice is a well known tool
for analogue ASIC design.
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Breadboard components (kit-parts) from the SLA family are available from SGA. A breadboard has been built
and evaluated in its application before ASIC-prototypes were manufactured. This minimises the risk for
specification and design errors.
The workflow recommended by SGA for SLA-designs has been followed. This includes evaluation of the
design both with simulations and measurements on a breadboard. Formal design reviews have been held after
completed specification, schematic and layout. The design work aims at ”right first time” prototypes.
8. Expertise and experience of the company and the staff allocated to the project
NDC has a long experience in developing servo amplifiers and other equipment for AGV:s used in an industrial
environment.
The first servo amplifier with through-hole mounting and bipolar power transistors was developed in 1975.
The FSA-controller before the AE represents the fourth generation of servo amplifiers within NDC. This
design incorporates SMD-components and FET-power transistors.
All electronic development is done in-house by the development department (25 persons). Most of these work
with software for the AGV-applications. Seven employees are electronic engineers and work with electronic
hardware. The NDC engineers have deep knowledge in power electronics and rather good knowledge in
general electronics and microcontroller technology. No ASIC development had been performed by NDC prior
to the AE.
9. Workplan and rationale
Table 1 below shows a summary of each task within the AE together with columns for:
•
•
•
•
•
•
Task description
Main responsible party, FU stands for First User and SubC for subcontractor (SGA).
FU labour, plan versus actual.
Subcontractor cost, plan versus actual.
Equipment cost, plan versus actual.
Total effort, plan versus actual.
Table 2 below shows a Gantt chart, plan versus actual, for the AE. Planned duration is indicated with “X” and
actual duration is indicated by underline.
The following deviations from plan can be noted:
•
Much more efforts than anticipated were spent on Work Package 4, Design. Breadboard manufacturing
and evaluation consumed much more efforts than anticipated and did also delay final simulations.
•
PCB-manufacturing was delayed because of long lead time for the evaluation PCB. This caused a slip in
calendar time but no additional efforts.
•
The services from subcontractor SGA were ordered at a fixed price in SEK. The deviation in EUR is
caused by fluctuations in the exchange rate between quotation and invoice date.
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Workpackages and Tasks
Description
WP 1
1.1
1.2
WP 2
2.1
2.2
2.3
WP 3
3.1
3.2
WP 4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
WP 5
5.1
5.2
Management
Project management and reporting
Dissemination activities
Specification
System specification definition
ASIC specification definition
Test specification definition
Training
CAD-tools installation and training
Training in ASIC design work
Design
Schematic entry
ASIC Simulation
System Simulation
Breadboard fabrication
Breadboard evaluation
ASIC layout
ASIC prototype manufacturing
PCB prototype manufacturing
Evaluation
Functional evaluation
Parameter evaluation
Total (days)
Total (kEUR)
Resp.
FU
FU
FU
FU
SubC
SubC
SubC
FU
FU
FU
FU
FU
SubC
SubC
FU
FU
FU
FU labour
(days)
Plan
Actual
30
25
5
22
8
12
2
12
6
6
66
10
12
10
4
10
SubC cost
(kEUR)
Plan Actual
Equipm. Cost
(kEUR)
Plan
Actual
Total effort
Plan
Actual
25
21
12
103
5
4
1
4
2
2
32
4
8
2
2
2.2
2
2.2
6
12
20
24
12
12
154
37
21
182
41.5
41
37.3
154
80
182
81
Table 1, Task description.
A short description of the workpackages and the division of work between NDC and subcontractor SGA is
included below:
•
Management: Management and dissemination (1.1 and 1.2) has been performed by NDC.
•
Specification: System specification (2.1) was defined by NDC. SGA assisted in defining the ASIC
specification (2.2) but main responsibility for this lay by NDC. Subcontractor knowledge is important to
partition the ASIC correctly and to determine what performance to expect from the ASIC. The test
specification (2.3) is defined with the ASIC specification as a base. SGA must assure that the test is
possible to perform and NDC must assure that important parameters are tested.
•
Training: CAD-tools (3.1) were installed by NDC. The PSpice tools were recommended by SGA. SGA
provided training in use of PSpice for analogue array design. Training in analogue ASIC design (3.2) was
also given by SGA partly as training sessions at both SGA and NDC facilities and partly as continuos
support during the initial design phase.
•
Design: Schematic entry (4.1) and simulation (4.2) was performed both by NDC and by SGA. The finished
schematic was issued by NDC but SGA has contributed with design and simulation of some blocks. NDC
has simulated functionality and performance of the complete design and also on system level (4.3). The
design work has been performed in close co-operation between NDC and SGA. SGA contributes with
extensive experience in analogue design and NDC with application expertise. The knowledge transfer in
the area of analogue ASIC design is performed in these tasks in addition to the Training workpackage.
Breadboard fabrication (4.4) and evaluation (4.5) has been performed by NDC using kitparts supplied by
SGA. It should be noted that much efforts have been spent on these tasks and that breadboard
evaluation is considered important to reduce risk when manufacturing ASIC prototypes. The design
review before layout was performed by NDC and SGA. ASIC layout (4.6) was performed by SGA. NDC
was interacting only in the issues covered by design review after layout. ASIC prototypes (4.7) was
manufactured and tested according to the test specification by SGA. The PCB prototype (4.8) was
manufactured by NDC using own resources.
•
Evaluation: Functional (5.1) and parameter (5.2) evaluation was performed on the prototype PCB by NDC.
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Feb.
WP 1
1.1 X X X
1.2
WP 2
2.1 X X X
2.2
2.3
WP 3
3.1
X X
3.2
WP 4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
WP 5
5.1
5.2
March
April
May
June
July
Sept.
Oct.
Nov.
Dec.
Jan.
Feb.
March
April
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
X X X X
X X X
X X X X X X X
X X X X
X X X X X X
X X X X X X X X X
X X X X X X X X
X X X X X X
X X X X
X X
X
X
X
X
X
X
X
X
X
X X X X X
X X X X
X
X X X X
X X X X X
X X X X X X X
X X X X X X X X X X X X X X X
X X X X X X X X
X X X X X X X
Table 2, Gantt chart.
The knowledge transfer process included training in the following areas:
•
•
Training in use of PSpice software for simulating analogue designs was provided by subcontractor SGA.
Training in analogue ASIC design work was provided by subcontractor SGA.
To perform the AE in this way is in itself a constant transfer of knowledge from the subcontractor to the first
user. The first user is trained in the task of developing an analogue ASIC by actually performing the
development work. All issues are discussed and/or resolved by the first user with assistance from the
subcontractor.
The perceived risks at the start of the AE included:
•
The risk of an iteration caused by non-functional prototypes. This risk is low for an array based ASIC
compared to a full custom component. The impact (economic and calendar time) is also much lower for an
array based ASIC. The design work does anyway aim at right-first-time prototypes. The fact that
breadboard prototyping was carried out lowered the risk quite a lot. An iteration was also taken into
account in case of non-functional prototypes.
•
The risk of not meeting the requested performance because of limitations in the base array. This issue
was thoroughly discussed with subcontractor SGA before the AE started. The first user has to rely on
the subcontractor at this stage. Also this risk was partly reduced by tests carried out with the breadboard
connected to the target system with heavy current load. Performance not meet in terms of signal levels
somewhat out of limit could also be accepted.
10. Subcontractor information
NDC has been discussing the product improvement with several subcontractors at different conferences and
exhibitions. NDC demanded an analogue ASIC solution where voltage levels fitted. The subcontractor should
also offer good test possibilities and be Swedish. During a Fuse seminar discussions with SGA took place and
some different solutions were presented. NDC concluded after this seminar that their demands were fulfilled.
Svenska Grindmatriser AB has developed the SLA-family of analogue arrays and is therefore a good choice
for design assistance, layout and prototype manufacturing. SGA has an extensive experience from more than
40 analogue or mixed signal ASIC designs during the last 10 years. No other company in Sweden has a
comparable experience of analogue arrays. General training in use of the selected CAD-software can be
provided by several sources. SGA can however provide training focused on what is required for analogue
ASIC design.
The application specific design is owned by NDC. No license fees of any kind is paid to SGA or to anyone
else. The base array design for the SLA-arrays is owned by SGA. This is the normal case for an array based
ASIC.
Payment to SGA was divided in three parts: one third in advance when ordering the development work, one
third after completed layout and one third after delivered prototypes. No penalty clause was defined in the
order to SGA.
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11. Barriers
NDC was under the pressure of reducing costs in manufacturing the FSA. In order to lower the cost, and also
in conjunction increase the reliability, an array based ASIC was found to be the solution. The increase in
reliability was also seen as an opportunity to lower the warranty support costs.
The concept of analogue, array based, ASIC was not very well known to NDC before the AE. The idea of
integrating the FSA further had been discussed but the real feasibility of such a task had not been thoroughly
investigated neither concerning technical feasibility nor concerning efforts needed during the design work.
The FSA was also initially in an early production stage where small necessary modifications in the design
would have made the specification of an ASIC a troublesome task.
The perceived risks included:
•
The uncertainty if the desired functionality could really be integrated in an ASIC.
•
The uncertainty of what efforts (cost, manpower, calendar time) that was needed.
•
The risk that a future change in the FSA-specification would give additional NRE-costs and lead time.
12. Steps taken to overcome the barriers and arrive at an improved product
The FUSE-program and the AE has had the following impact on the above barriers.
•
The possibility to use analogue array based ASIC for this type of application was communicated by SGA
to NDC through the seminars arranged by the TTN.
•
Feasibility and partitioning of the ASIC was discussed with the possible subcontractor SGA. These
discussions led to a suggested design that was used for calculating development and production costs.
•
The FSA was now in a state where no further changes where considered necessary. This fact was
considered important to reduce the risk of future changes (and additional NRE-costs) to the ASIC.
NDC is already planning for new similar projects. When higher volumes are reached it will be even easier to
motivate similar projects without FUE financing.
13. Knowledge and experience acquired
NDC has acquired knowledge and/or experience concerning the following:
•
General design of an array based analogue ASIC. The goal was to be able to participate actively in the
design of an array based analogue ASIC. The goal was met. The design principles used are also applicable
for analogue ASIC design in general.
•
Use of PC-based software for simulating analogue designs. The goal was to be able to evaluate
performance of blocks in an analogue ASIC using PSpice. The goal was met. The simulation technique
used is also suitable for other types of (discrete) analogue design.
•
Partitioning of an analogue ASIC. The goal was to acquire sufficient experience to do an initial partitioning
and feasibility study for an analogue ASIC. The goal was met. Final partitioning and feasibility study must
however always be performed in co-operation with the ASIC subcontractor.
14. Lessons learned
The following could be used as general advice to a First User investigating the possibilities to use analogue
ASIC.
•
Partitioning of a suggested ASIC design is most important early in the development project. A First User
must perform this together with the suggested subcontractors. Analogue partitioning is much more
complicated than partitioning a digital design.
•
The subcontractor plays an important role in the development work. The subcontractor should be able to
show success stories and should assist in defining a work plan for, and actively assist in, the
development project. The First User will depend on the subcontractor to reach a good result.
•
Formal design reviews during the development work are important. The reviews should serve as
milestones where important documentation (specification, schematic, layout) is defined.
NDC Netzler & Dahlgren Co AB, IMC/SGA
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•
Evaluation of an analogue design with a breadboard can consume a lot of time. This type of evaluation is
anyway considered important as a complement to simulations. It has also been discovered that a
breadboard can generate “false alarms”. An example is malfunctions on the breadboard caused by
parasitic capacitors that are not present in the actual ASIC design.
•
Evaluation with simulations (PSpice) should be performed on a block level. It may show difficult to
simulate the complete design in all aspects because of very long simulation runs. Measurements on a
breadboard can serve as a complement here.
15. Resulting product, its industrialisation and internal replication
The improved FSA-controller is now in production. Two out of three PCB-designs that uses the ASIC are in
production and the third has been prototyped. EMC-tests have been performed, and approved, on all FSAversion. Environmental (temperature) tests have also been performed with good result. All defined goals
concerning increased integration with the ASIC have been met and there is therefore reason to believe that
the desired price reduction will actually be achieved. The time frame from the first produced ASIC prototypes
to product on the market is 11 months.
The modified FSA-controller is already industrialised. The tasks to reach this that were not included in the AE
are:
•
•
•
•
•
Redesign of the parts outside of the ASIC.
Redesign of all PCB-versions.
Redesign of the case.
Environmental testing of FSA-prototypes.
EMC-testing of FSA-prototypes.
The total budget for the complete redesign of all FSA-controllers is about 200 kEUR including the AE that
had a budget of 80 kEUR.
No immediate actions are currently planned concerning internal replication. NDC will definitely consider an
ASIC solution also for other products in the future. Several NDC products would technically benefit from an
ASIC solution but will need higher production volumes to be economically motivated.
16. Economic impact and improvement in competitive position
Expected sales of the FSA-controllers is totally dependant on sales of complete AGV-kits. The price reduction
on the FSA-unit achieved by the AE does not significantly affect sales of AGV-kits. NDC sales of complete
AGV-kits is in the range of 600 units a year (1999) with only a small increase during the latest three year
period. Every AGV kit consists of 2-4 FSA-units giving an average sales of about 1800 FSA-units per year.
Sales forecast for the coming three years includes only a minor increase for complete AGV-kits. The
potentially big market concerning Lazerway Teach-In is coming but has not yet affected sales significantly.
The modifications made to the FSA-units in this AE enables them to continue to be competitive compared to
standard motor controllers from other manufacturers. Sales of the FSA-units would have been dropping
significantly starting next year without this modification.
The production cost reduction caused by the modifications to the different versions of the FSA has been
determined to be in average more than 40 EUR per unit. The intended additional improvements with planar
magnetics transformer and a connector integrated on the PCB has been implemented. The value of these
modifications alone is hard to estimate as they were made possible by the introduction of the ASIC. When
lowering the sales price by 25 EUR an increased gross profit of 15 EUR can still be achieved. With the lower
price the Teach-In market will be somewhat covered and thereby increase the number of units sales.
Expected sales without the AE innovation
Year
Sales of product
( No of units )
2000
1600
NDC Netzler & Dahlgren Co AB, IMC/SGA
2001
1200
2002
850
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Total
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Expected sales with the AE innovation
Year
Sales of product
( No of units )
2000
1800
2001
2000
2002
2200
Total
6000
The total gross profit (GP) improvement due to the AE within 3 years will be 90 kEuro.
The total FUSE investment is 80 kEUR.
RO =
90
80
= 1,13
The return on investment will be 113 % within a period of three years.
The payback period of the total investment will be 32 months.
This period will be significantly shorted when the Teach-In market opens up completely.
The technical life of the modified FSA is estimated at 10 years. This comparatively long life-time is motivated
by the actual life time of the previous versions of the servo amplifiers manufactured by NDC.
Thus we forecast an additional gross profit (GP) improvement of 200 kEUR over the total product lifetime,
which gives a ROI over product lifetime in the area of 350%.
17. Added value to the portfolio and target audience
The technical part of the AE is of interest to companies developing hardware for motor control and other
types of control systems. The pulse width modulating principle also applies to other types of loads.
The workplan and project description is of interest to companies considering an analogue ASIC for any
application regardless of industrial sector.
This AE is a good example of what can be integrated in an analogue array-based ASIC. A comparatively small
company has managed to develop a fully functional ASIC component and has also managed to introduce this
component in their products following an impressive time schedule. It has also been shown that an analogue
ASIC is profitable also for production volumes in the range of 2000 units a year.
NDC Netzler & Dahlgren Co AB, IMC/SGA
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