Case Study: Industrial Electronics design for Laboratory Control Equipment
Industrial Electronics Redesign – Confidential Laboratory Product
The Challenge
We design industrial electronics regularly. But on this occasion, a confidential client came to RVL with a legacy laboratory instrument that needed a full internal redesign. The main challenge was to update the electronics due to obsolete components and declining quality. However, the client required that the product’s external appearance, structure, and functionality remain unchanged. Furthermore, since the product is used in a sensitive lab environment, high accuracy, reliability, and efficiency were essential. In addition, the updated version had to integrate seamlessly into the client’s existing workflow without requiring user retraining.
The Solution
To begin with, RVL’s engineering team conducted a detailed analysis of the original design. After thoroughly reverse-engineering the industrial electronics, we identified obsolete parts and developed a modern replacement using up-to-date processors and a new operating system. As a result, we were able to retain compatibility while significantly improving performance and long-term reliability.
Moreover, we worked in close collaboration with the client’s mechanical team to update the PCB layout without altering the physical footprint. At the same time, our software engineers redeveloped the firmware drivers for Windows CE to match the new hardware. This approach preserved legacy software compatibility while also enhancing system stability and responsiveness.
Next, we built and tested multiple prototypes, which went through a rigorous review process alongside the client. Once approved, our IPC-certified technicians moved forward with building and testing the final sub-assemblies. Additionally, we offered a touch-screen display option for future-ready usability. Finally, the client carried out the final assembly of each complete unit.
Industrial Electronics Project Deliverables
-
Redesign of sub-assemblies and updated part selection
-
New firmware drivers for Windows CE
-
Collaborative PCB design with client’s mechanical team
-
Prototypes, testing, and small-scale production
-
IPC-certified sub-assembly production and QA
The Results
-
Improved performance and long-term reliability
-
Longer product life and easier future updates
-
Touch-screen upgrade option
-
Higher product quality with no change in user experience
