Engineering Design
Services

Product Design

In the field of Mechanical Engineering Services, we believe that the “Time-to-Market” is the key to mantra for all OEMs. Trends in current IT technologies also keeping this as focus area and provide solutions. At BBIPPL, we are concentrating to offer the following service offerings in Product Design and keep focusing to equip our professionals as per the trend and industry needs as well. Our Engineers are having experience in various modern software packages including CATIA, Pro/E, Solidworks, AutoCAD and many more.

• New Product Development – Analytic Studies, Evaluation
• 3D Modeling
• Model Based Definition (MBD)
• 2D and Detail Design
• Digital Prototyping Assembly (DPA) / Digital Mock Up (DMU)
• Knowledge Based Engineering (KBE)

Computer Aided Engineering

For faster business decisions during any product design Computer Aided Analysis and its methodologies and processes are taking their place as a vital role in Product Development. We have hands on experience in MSC Nastran, Altair Hypermesh, NX Femap, Ansys, Adams and Star-CCM+ etc. We have capabilities to perform the following analyses and also expand its offerings.

• Structural – Linear, Non-Linear Analysis
• Hand calculations and Design Validation
• Pre-Post Processing and Stress Notes, Documentation
• Multi-Body Simulations – Kinematics, Dynamics
• Product Sizing and optimization
• Noise, Vibration and Harshness (NVH) studies
• Fatigue, Durability Analysis
• Computational Fluid Dynamics – 1D Flow, Steady State, Transient Analysis
• Process Flow Capture and automation of repetitive tasks.

Design Automation

BBIPPL believes Design Automation and reducing human interaction is the key to add value to our services. We always emphasize to improve productivity and perform all repetitive and time consuming tasks by implementing macros, tools, utilities and batch jobs, thanks to Application Programming Interfaces (API) of respective software packages and open source libraries. These are implemented as per our customer requirements and BBIPPL shall follow SDLC (Software Development Life Cycle) phases and keeping future customer’s future roadmap in mind. The following are typical Design Automation areas but not limited to,

• Automating the creation of complex features
• Automate to create Design Reports, Bill of Materials (BOM), Drawings, and Manufacturing Instructions / Notes etc.
• Improving product quality by performing design rule verification based on inputs from an external Knowledge Based System or Rule Engine.

Embedded System

Brick and Byte is a dedicated design house that provides quality, cost effective & timely solutions, which include hardware and software, to a wide range of embedded systems. With extensive experience in Embedded Systems Development from simple micro-controller based designs to complex multi-tasking multi-processor Real Time Systems and ASIC / FPGA Development our services cater End-To-End Product development solutions or design sub-systems for hardware/software using various RTOS platforms with wide range of micro-processors, DSPs & FPGAs in consumer electronics & multimedia, Industrial systems and telecom domains.

Value Chain Focus

• OEMS´
• ODM´s
• Component Vendors
• ISV´s

Technology Expertise

Device Drivers : Embedded, host based, Networking

RTOS : VxWorks, pSOS, Nucleus, Embedded Linux, CMX, WIN-CE, Windows Mobile

Languages : C, C++, Assembly, JAVA, Tcl/tk

Processors : ARM, Intel, AMD, Motorola, MIPS, TI, Hitachi, Philips, Atmel, ST, Renesas

DSPs : Texas Instruments, Analog Devices, Motorola

Tools: Metalab softwareEnd-to-End Specialization

• Device Driver Development for host based, Embedded and Multiple Architectures
• Firmware Development and Integration
• DSP Application Development
• Optimization Expertise for best MIPS, Memory, Power Consumption
• Board Support Packages
• POST Diagnostics
• Boot Code
• Application Migration from 16 to 32 to 64 bit
• Processor Architectures from CISC to RISC
• Hardware Abstraction layer for interoperability with kernels
• Platform Migration
• Performance Tuning
• RTOS Porting
• Processor Dependent Assembly Optimization
• Integration of peripherals around processor and SoC
• Development of Reference Designs
• High Density FPGA / CPLD Design and Development
• Protocol Stack Development
• Component level re-engineering
• Obsolesce management
• Reverse engineering
• Rapid prototyping

Digital Manufacturing

Thanks to the advent of technologies and software packages, simulating Machining Processes and Manufacturing sequence are a key function in which all OEMs and Product Development Tier1, Tier2 companies are following. This brings very quick business decisions and avoids very costly rework efforts and delays in product development life cycle. There are popular software packages available in the market and BBIPPL has experience in taking up IT support on Digital Manufacturing areas.

Product Lifecycle Management

PLM plays a vital role in discrete product development / manufacturing sector and through this OEMs can manage its products from concept to delivery and even the after sales market. Software companies propagate managing products from cradle-to-graveyard through its software solutions. Recently, the retail market has also taken PLM as a vehicle to manage its various and dynamic product requirements and managements. BBIPPL has expertise in popular PLM packages like Teamcenter, Enovia and Windchill.

Simulation Lifecycle Management

Similar to PLM, currently OEMs and software solutions developers are bringing this concept in order to manage Virtual Simulation related functions like Finite Element Analysis and its different versions of results and design optimization status in correlation with CAD design maturity. Where PLM once addressed only CAD data, resulted in disconnect between Design Maturity and its corresponding Analysis data and caused hefty rework costs and delay in product development, this is no longer the case.

Embedded Application Development

Consumer Electronics & Multimedia

• Set-Top-Box
• IP-TV
• Mobile TV
• DVB-H
• Smart Phones and other Multimedia Devices

Telecom & Wireless

• Application Development on Symbian and Brew

Industrial Controls

• Automatic vehicle location systems
• Motor Controls
• Power Electronics and Process Controls

Embedded Application Development

Consumer Electronics & Multimedia

• Set-Top-Box
• IP-TV
• Mobile TV
• DVB-H
• Smart Phones and other Multimedia Devices

Telecom & Wireless

• Application Development on Symbian and Brew

Industrial Controls

• Automatic vehicle location systems
• Motor Controls
• Power Electronics and Process Controls

Hardware Design

Brick and Byte is a dedicated design house that provides quality, cost effective & timely solutions, to a wide range of semiconductor manufacturers. With strong domain knowledge and technology expertise, in consumer electronics, industrial systems and wireless segments, Brick and Byte helps its customer in re-engineering and cost reduction of their existing products. Our expertise covers IC design and verification, chip layout, FPGA synthesis and system/hardware designs coupled along with our embedded software engineering capabilities. Our technology expertise and ready to deploy solution accelerators spans design, development and testing, prototyping and turnkey electronics manufacturing of hardware.

Value Chain Focus :

• OEMS’
• ODM’s
• Semiconductor Companies

ASIC/SOC

Our design expertise covers IC design and verification, FPGA synthesis and system/board designs that includes very high-speed & Multi-layer board design encompassing architecture and design to implementation, synthesis, physical design and silicon validation. Our tools expertise spans tool families of Cadence, Magma, Mentor, Synopsys and others.

• Behavioral modeling in VHDL/Verilog
• Physical Design
• RTL synthesis and timing analysis
• Micro Architecture
• Code Purification
• Logic synthesis and timing analysis
• Pre silicon Verification and validation
• System portioning for SoC designs
• Library Development
• Layout Design and Development of interfacing circuits
• Prototyping
• Component Sourcing and Electronics Manufacturing

FPGA

Our services include complete FPGA solutions from specifications to prototype to system. Our expertise as an Lattice partner and Xilinx program member along with an unmatched design methodology would ensure that your designs turn into winning products. We have extensive expertise in designing and porting complex multi-clock designs.

• Retargeting Services
• Proof of concept for Emerging Technologies/Standards

FPGA Design and Synthesis

Board Design

Using our robust in-house tools, design methodologies, component sourcing and electronics manufacturing, we provide solutions that help our clients take products to beta earlier than anticipated. During this process we ensure PCB designs are optimized for timing, signal integrity, power, thermal compliance and EMC/EMI compliance. Our expertise spans across new product development and value engineering.

• Component Sourcing
• Symbol Creation
• Layout
• Design Simulation and Analysis
• Prototype and Manufacturing
• Prototype Testing
• System Integration
• Value Engineering for cost Reduction for Obsolete Components
• Performance Optimization

Our hardware expertise can provide you with a full range of services including functional specifications and requirement documentation, schematic layout, prototype manufacturing and testing. We have also designed embedded control systems that employ 8 bit micro-controllers and system interface control logic either in discrete logic or CPLD's / FPGAs.

Our designs include 8/16/32 bit microprocessors from almost all the major vendors; Static Ram, Flash memory, communication interface devices, display controllers. Many designs also incorporate multiple controllers with necessary handshaking and using common resources such as memories etc. Some products are designed using DSP's from TI, NXP and Analog Devices for high speed analog signal processing, Math applications and algorithms.

The control logic for each design has been implemented utilizing an appropriate technology, such as PAL's, CPLDs or FPGA's. We offer Altera, Actel, Xilinx and Quick-Logic FPGA based designs, including converting discrete logic circuits into FPGAs.

Our design expertise span around mixed signals using extensive analog circuits to process high frequency, low level signals & interfacing the same using ADC's up to 16 bits resolutions. The power supplies required for these designs are also designed in-house. Designs are implemented using multiplayer boards & using SMT & designed to meet various EMI/EMC requirements for high speed mixed signal circuits.

Digital design

• 8, 16, 32 bit microprocessors & controllers (Freescale /N ational/NXP/ TI / Microchip / Dallas etc)
• High speed bus - > 133MH

Analog designs

Analog circuit designs for signal conditioning

ADC & DAC interface

Filter design

Power supply design - SMPS, Liner, DC-DC Switchers, Battery charging and monitoring

Mixed signal designs handling both high speed digital and analog circuits and interfaces

FPGA/ CPLD designs

• Designs up to 1 Million gate; 85% utilization
• Verilog & VHDL coding
• Xilinx, Altera,

Power electronic

• Interface Power Electronics Devices (Triacs, MOSFETs, Power Transistors etc.) with Bus Logic
• Relay, Solenoid, IGBT drives

Communication interfaces

• RS232C
• RS485
• RS422
• GPIB
• SPI / I2C
• Ethernet 10/100Mbps Tx/Fx
• USB
• CAN
• MODEM
• IrDA

Component Engineering (Decision analysis & resolution)

• Functionality
• Cost
• Availability
• Device road map / EOL
• Real estate feasibility
• Design Conformance to RoHS
• Lead free component selection including PCB

Hardware design review

• Performance - Product standards
• EMI / EMC, Safety
• Reliability
• DFM/ DFT
• Integration testing (S/W & H/W)
• Test diagnostics development
• Functional test kit development
• Prototyping

PCB Design Expertise

Technology Services offers a wide range of PCB Design services, including Centralized Component Library creation, Schematic creation, PCB routing, Gerber reviews and Prototype development. Most of our engineers are IPC certified and have extensive experience in PCB design services. Our Product Development Cycle ensures that the electrical engineering team and PCB team work together to ensure that the components are placed to meet the mechanical constraints and the PCBs are routed to meet the required safety and EMI / EMC Standards. Technology Services has close relations with many of the PCB vendors who deliver high quality boards within our required time. Technology Services also has close relationship with the contract manufacturing facilities in India who can assemble our boards and deliver it to us as per our requirement. Technology Services has license for almost all the major tools that are being used in the current PCB design industry. Some of them have been listed below.

Schematic Capture Tools

• ORCAD CIS
• Altium Designer

PCB Capture Tools

• PADS Layout
• ORCAD Layout
• Altium

Some of our PCB Design related Capabilities include

• Design Multilayer boards with proper PCB stack-up for Signal Integrity
• Design boards for DFM (Design for Manufacturability)
• Design boards for DFT (Design for Testability)
• Route high speed boards to meet EMI / EMC Standards
• Review and provide findings for PCB designs & Gerber files sent by clients

Technical Publication and Manuals

Brick and Byte’s writers are degreed engineers and are cross-trained in several disciplines. Highly specialized leads are responsible for technical content in a particular discipline. Contingent upon technical manual requirements and delivery schedule, leads draw qualified writers from the technical writing pool to prepare technical manuals for individual projects or programs.

Our technical authoring services can help you turn technical documentation into competitive advantage, with our deep expertise in writing user-focused product documentation across various media – all with a global presence that makes us unrivaled in both authoring and translation.

With the transition of technical documentation toward SGML/XML virtual publishing environments. Brick and Byte provides the latest methods in our approach to Authoring. By managing multiple platforms, Brick and Byte offers you new ideas and solutions applied to a multitude situations.

Manuals We Produce

• Installation
• Operations
• Maintenance
• Service
• Flight
• Component Repair and Overhaul
• Depot Maintenance
• Fault Isolation
• Parts Books
• Support Equipment
• Job Guides
• Tear Down and Repair
• Time Compliance Technical Orders
• Training Documents
• E-Learning
• Fault Isolation

2D and 3D illustrations

The Illustrating group is a diverse team of professionals experienced in technical illustrating, graphic design and drafting, currently producing high quality camera-ready artwork for paper and electronic manuals. Technical Illustrators hold degrees in commercial art and graphic design and are well versed in various publication specifications. They have extensive experience creating illustrations for technical manuals for a variety of customers. Additional skills within the Illustrating team include 3D modeling, rendering and animation. Utilizing such programs as 3D Studio® Max, 3D Via, SAP visual Enterprises, and the Illustrating team can produce images for use within a 3D interactive environment.

All illustrators are trained on multiple software packages to enhance flexibility to accommodate peak workloads requiring specific software.

We use a number of CAD systems, including Arbortext IsoDraw, Adobe Illustrator, 3D Via, SAP Visual Enterprises, Adobe Photoshop and Tech Illustrator

3D Interactive Manuals

Customers Objective:

• Creation of 3D Interactive Manual for Equipment Maintenance, Parts Catalog, Installation, Service and Training purpose.
• Creation of 3D PDF.

Inputs Provided:

• Process Details.
• 3D Models

Solution:

• Functional Study of Equipment.
• Import 3DModels.
• Create Animations.
• Add comments tag (Instructions) for each of the activities for better understanding.
• Convert to 3D PDF.

Value to Customers:

• User Friendly.
• Interactive Live connectivity between Instructions and 3D Data.
• Reduced File Size.
• Animations, Explosions and Multiple Views can be provided.
• Real Time Visualization, Rotate/Pan/Zoom Components.

Interactive Electronic Technical Manuals

IETM / IETP technology puts information where it’s needed. Faster, better and more accessible. Interactive information – on-demand – is the most efficient, cost-effective method to control, deliver and maintain data.

Brick and Byte provides both IETPs and IETMs for a range of clients for a variety of products. Wespecialises in the preparation of Interactive Electronic Technical Publications (IETPs) which can range from a simple scanned image (PDF) through to the presentation of datasets compiled from a block of S1000D compliant Data Modules (DMs). The content of the datasets (maintenance tasks, schedules, parts lists, warnings, cautions, illustrations etc.) is generated from a Common Source Data Base (CSDB). The great advantage of utilising a CSDB, is that information can be reused time and again in the same publications and across different platforms.

We can deliver these digital documents securely, over encrypted data networks, in almost any format. Our IETP solutions can maximise revenue for your organisation by allowing distributors or customers easy access to spares catalogues and shopping-cart-type purchasing facilities. The IETP is also an effective way of delivering information and supplementing training for planners, operators and workshop maintainers.

We can write IETPs from scratch, or use existing guides or information as a base. The most common formats we write in are SGML and XML and we ensure our publications meet all the standards, depending on what your organisation requires. We also ensure publications can be printed by producing Electronic Technical Manuals (ETMs).

Content Management

Brick and Byte’s Content Management solutions focus on mapping the business objectives of the customer with their content management strategy. We believe in having a complete enterprise vision and strategy for ECM technologies across the information life cycle. Our Strategy is driven by a utility computing approach and is focused on creating a unified access layer for data Brick and Byte’s content management and distribution services aim to streamline the process for producing, managing, and distributing content, leading to workflows that are more efficient, integrated asset and rights management, and efficient storage and retrieval of data. This ultimately helps in increasing efficiency, improving control over information and in reducing the overall cost of information management for the enterprise.

A snapshot of Brick and Byte’s content management services:

• Content management and distribution services to streamline the process of producing, managing, and distributing content.
• Solutions to create efficient workflows, integrated asset and rights management, and efficient storage and retrieval of data.
• Document management services (abstraction indexing/summarization) for publishing and business information services.
• HTML and XML conversion services as a part of content management for publishing and business information services.

XML and Legency conversation

SGML/XML makes it easier for businesses to reuse documentation and other information by enforcing structure and consistency. Our SGML experts will take your document, apply the appropriate structure based on a DTD, and output to SGML or XML. We have extensive SGML capabilities, authoring original documents and converting legacy data to SGML/XML.

We expertise in conversion of original data from paper, microfilm and electronic files.

• Convert legacy data to new specifications and create the required file types and establish or supplement file repositories and existing databases.
• XML & SGML Compliance – Our Information Management specialists are thoroughly familiar with all aspects of XML and SGML, publishing, and DTD and style specification structure.

Our Services Includes:

• Analyzing Your data.
• Data Developing/modifying DTD/Schema.
• Writing conversion specifications.
• Pre - Migration data clean-up.
• OCR / Capture the document.
• SGML/XML/HTML encoding.
• Proofing, Validation and QC Audits.

We Convert content to or from virtually any format including:

• XML
• SGML
• HTML
• Pagemaker
• FrameMaker
• Word
• Adobe InDesign
• PDF
• Other Formats

DTD and FOSI Development

DTD & Stylesheet Development – Brick and Byte develops information technologies in accordance with the latest best practices of XML stylesheets and formats your electronic delivery frameworks for maximum adaptability.

We expertise in developing DTD and FOSI for many customers in different domains.

End-To-End specialization

• Device Driver Development for host based, Embedded and Multiple Architectures
• Firmware Development and Integration
• DSP Application Development
• Optimization Expertise for best MIPS, Memory, Power Consumption
• Board Support Packages
• POST Diagnostics
• Boot Code
• Application Migration from 16 to 32 to 64 bit
• Processor Architectures from CISC to RISC
• Hardware Abstraction layer for interoperability with kernels
• Platform Migration
• Performance Tuning
• RTOS Porting
• Processor Dependent Assembly Optimization
• Integration of peripherals around processor and SoC
• Development of Reference Designs
• High Density FPGA / CPLD Design and Development
• Protocol Stack Development

Consumer Electronics & Multimedia

• Set-Top-Box
• IP-TV
• Mobile TV
• DVB-H
• Smart Phones and other Multimedia Devices

Telecom Wireless

• Remote Monitoring System for Telecom Tower

Industrial Controls

• Automatic vehicle location systems
• Air conditioner Automation system for Malls, Colleges, Offices etc
• Power Electronics and Process Controls
• Automatic Vehicle Classification

Application Software

Technology Expertise

Device Drivers : Embedded, host based, Networking

RTOS : VxWorks, pSOS, Nucleus, Embedded Linux, CMX, WIN-CE, Windows Mobile

Languages : C, C++, Assembly, JAVA, Tcl/tk

Processors : ARM, Intel, AMD, Motorola, MIPS, TI, Hitachi, Philips, Atmel, ST, Renesas

DSPs : Texas Instruments, Analog Devices, Motorola

RTOS / scheduler based custom software development

• Time / byte critical software
• Modular and upgradeable
• Compliance to safety standards
• Hardware Abstraction Layer
• Boot loader development
• Customization of BSP
• Device driver development
• Embedded HMI development
• Implementation and Communication Protocol Stack Development
• DSP based algorithms

Embedded Software

Designed for specific control functions, stand-alone and part of a larger system, embedded system designs are popular for its real-time computing constraints. We design software for embedded system devices and specialized in real time computing. Most of the old embedded software is migrated from custom-built to standard RTOS's. The impact of advancement in this area can be seen in all verticals - Automotive, Medical, Industrial Controls, Aerospace, Telecom / Datacom and Consumer Electronics. We work with leading RTOS's vendors in this space to deliver high quality and innovative solutions to embedded products.

Reverse Engineering

In order to reduce time to Market and to deduce design decisions at early stages of product development, all OEMs and product suppliers apply reverse engineering techniques. Creation and Collection of cloud of points from existing physical parts, Design Optimization through existing product model, Material characterizations and re-material analysis and recommendations are few areas BBIPPL involved currently.

Product Design

BBIPPL is a dedicated design house & one stop solution for complete product development that provides quality, cost effective & timely solutions, which include hardware and software, to a wide range of embedded systems. With extensive experience in Embedded Systems Development from simple micro-controller based designs to complex multi-tasking multi-processor Real Time Systems and ASIC / FPGA Development our services cater End-To-End Product development solutions or design sub-systems for hardware/software using various RTOS platforms with wide range of micro-processors, DSPs & FPGAs in consumer electronics & multimedia, Industrial systems and telecom domains. Our team is well versed with DFM and DFSS practices to deliver defect free designs, which will take care of the reliability and manufacturability aspects.

A well executed design and development cycle for an electronic product requires travel through many stages before arriving at a successful conclusion. Here are the stages that we have determined are needed to create a well designed electronic product.

Concept

The stage where an idea for a new product, a variation on an existing product, or the identification of a need for an undefined product causes research to be done to define a product, a market, and an approach for manufacturing this product.

Research

The stage at which the product concept is utilized to fuel research that includes identifying the technology, methods, and vendors involved in producing the product. This stage of research must result in a detailed design specification that is used to cost the design process that follows as well as the estimated manufactured cost of the product. The agency compliance requirements (U.L., F.C.C., C.E., etc.) are defined now.

Circuit Design

The stage where a schematic diagram is created (usually via computer drafting software) and a preliminary parts list is created for costing and prototyping the product.

Packaging and Printed Circuit Design

This is the stage where the device under design gets a suitable enclosure designed or selected. This enclosure selection as well as connectors, controls, and displays must all be resolved before the printed circuit layout commences. The first step in designing printed circuits the mechanical pattern or outline of the board assembly itself.

The major steps in this process are:

• A package (housing) is selected or designed. If designed, the mechanical drawing must be produced of the assembly. If selected, this drawing will be supplied by the manufacturer.
• Nomenclature and graphics for the enclosure will be designed. This may be applied in the form of labels, overlays, silk-screens, or a combination.
• The printed circuit layout commences and resolves the requirements of the circuit diagram usage of electronic components with the form factor demanded by the packaging design process.
• The printed circuit artwork is processed on film and used by a manufacturer to etch printed circuit boards for the board assembler. A silkscreen of part locations to assist in the assembly process is normally applied on the printed circuit card by the manufacturer.

Prototyping or Trial Production

Sometimes prototypes are built before stage 4 (packaging and printed circuit layout) but the speed and cost advantages of computer aided design are making this more uncommon. A hand-wired prototype of all or a portion of the circuit may be required for the design process.

Design Review

The stage where the prototype and initial units are evaluated for function, appearance, build-cost, and possible enhancements. This process should result in minor changes but is a must to insure compliance with the original goals.

Manufacturing Setup including Test Setup

The stage is where the necessary test procedures and apparatus, fixtures if necessary, and detailed assembly instruction and documents are put in place in order to yield quality, tested products when quantity production takes place.

Documentation

The phase where circuit diagrams, parts lists, master printed circuit artwork, parts sources, software source code and documentation, mechanical drawings, assembly drawings, and all other items included as part of a project's deliverables are provided. This package should be sufficient so as to make the product producible by any qualified source, not just the parties involved in the design.

Followup

After a product is released into production; the manufacturing facility experience, the product support data, and the user responses, should all be reviewed for the purpose of steering future designs and marketing. Don't forget this crucial step on the road to improved quality, value, and often lower cost.

We also address Re-engineering existing designs to address one or more of the following problems

• Cost reduction
• Component Obsolescence
• Porting on new Hardware or OS Platform
• Adding new features