Electronics Protection - November/December 2011 - (Page 6)

Feature Enclosure Design for Extreme Environments Maximizing Performance & Minimizing Risks Pete Werwick, VP Sales & Marketing ITE, LLC Successful enclosure and packaging design is directly related to the effectiveness of the product development process being employed, utilizing the right people for the task and incorporating the latest technologies. There are literally hundreds of best practices associated with new product development and the various stages of the process. However, there are a few that stand out because of the impact they have on maximizing product performance and minimizing risks, especially when there is a lot riding on the outcome. The case study profiled in this article symbolizes one of the most challenging packaging design projects and identifies some of the key best practices that made its development so successful. It’s hard to imagine a more extreme enclosure application than US Special Forces operations in harsh environments. The electronics gear soldiers wear and use must meet stringent military performance standards, their life depends on it. Aside from weapons and ruggedized computers, micro fuel cells have emerged as one of the most indispensable components in the foot soldier’s arsenal. They enable longer missions than batteries, are much lighter in weight and become part of the critical lifeline with mission control. These intricate and compact energy systems pose demanding packaging challenges and require a robust design and engineering process to achieve success. There are two words important to any product development program, no surprises! Design and engineering effectiveness and efficiency depend on our ability to fully understand what we are trying to do, why it’s being done and what the expectations are for final results. Knowledge about how to get desired results, including proper execution and accurate tracking, determines success or failure. There are certain fundamental Best Practices in product development that are familiar to most, including: • Doing Research, Creating a Product Strategy and Business Plan It is critically important to establish that demand exists for the new product idea and identifying what the value proposition should be. Additionally, understanding the market, how it’s evolving and what competitors are doing, cannot be ignored. Awareness of the latest technologies in materials, manufacturing processes and development tools enable effective execution, while understanding the patent landscape and opportunities for new intellectual property, help establish potential return on investment • Creating a Project Plan for Execution Creating a work breakdown structure as part of a project plan with a critical development path ensures that proper internal and external resource planning and scheduling is being done. Along with establishing product performance requirements and defining a product specification, these tools will enable accurate progress and budget tracking. • Regular and Frequent Communications Communications with all stake holders is critical and making 6 it available in real-time and on-line, facilitates not only decision making but also accurate project tracking. Continually assessing product feasibility throughout the project, with respect to performance, manufacturability and cost, will insure that there are no surprises at the end of the project and projected ROI is attainable. • Design and Engineering Development Implementing a Phase-Gate process will ensure that the project is completed successfully in stages and without scope creep or excessive budget consumption. Through the use of analytical software, computer simulation tools and rapid prototyping processes, a new product design can be assessed for performance prior to investing in preliminary tooling or functional prototype build. Once built, functional prototypes are extremely valuable for verifying product performance, supporting design optimization and establishing confidence prior to release to tooling and product launch. When defining a product development plan for complex systems like a fuel cell, the challenge can seem overwhelming just because of the number of components and subsystems in the final assembly. The scope of performance requirements is also challenging, including many design trade-offs, such as light weight vs. high strength housing, hot temperatures internally vs. cool to the touch, sensitive electronics vs. shock and vibration, critical air flow requirements vs. water submersion capability, and no detectable heat or electronic signature is permissible. Successfully navigating these design trade-offs demands a robust product development process and implementing fundamental best practices as outlined above. A recent packaging project for UltraCell (a Bren-Tronics company), a reformed methanol fuel cell manufacturer, is an excellent case-in-point to demonstrate how certain best practices applied to complex systems can achieve maximum performance with minimal risks. The XX55 fuel cell started as a rough concept, a study model illustration, based on UltraCell’s successful XX25 model. The scope of the project was focused on creating an effective packaging solution for the new, higher output fuel cell, with an aggressive timeto-market schedule, including the following design requirements: • Increasing the ruggedness of the fuel cell assembly for military applications. This includes water resistance and submersion, thermal management and heat signature reduction, shock and vibration resistance, insulation and noise signature reduction as well as EMI signature reduction and immunity • Integration of components, engineering of subassemblies and final housing assembly • Design for manufacturing and cost effective production • Improved ergonomics for use of battery, fuel cartridge, handling and controls/display • Enhancing aesthetics and brand identity through styling • Accessories development • Sourcing components and supply chain development • Supporting product testing and launch November/December 2011 www.ElectronicsProtectionMagazine.com http://www.ElectronicsProtectionMagazine.com

Table of Contents for the Digital Edition of Electronics Protection - November/December 2011

Raritan Introduces Data Center Rack Controller for Environment and Security Asset Management
Enclosure Design for Extreme Environments
The Power Monitoring Imperative
Protection Selection: Guidelines for Choosing Remote Monitoring Enclosures
Rittal Releases New Hygienic Design Enclosures
Emerson Network Power Introduces Data Center Cooling System
Falcon Electric Adds Lightweight 10-Year Rated Lithium-Ion Batteries to SSG Series UPSs
Crenlo Introduces IBC Kit to its Lineup of Emcor Accessories
Littelfuse Introduces SP1006 TVS Diode Array For ESD Protection in Ultra-Small Form Factors
2012 Electronics Protection Resource Guide
Industry News
Literature
Calendar of Events

Electronics Protection - November/December 2011