An aging electronic architecture
More than twenty TTL ICs brought cost, supply and component-obsolescence risks.
Project Example / Scientific Instrument
Digital photogate timer
Redesigning an Established Timer for Continued Production
To take over production of an established timer, Actech proposed an updated electronic architecture and developed the mechanical design to support production and assembly, reduce product cost and enable later technical improvements.
- Product
- Digital photogate timer for physics education and laboratory use
- Starting point
- An existing product and functional descriptions
- Actech’s scope
- Redesign proposal, mechanical development, specialist coordination, assembly and verification
- Design & delivery responsibilities
- Partner-developed electronics and firmware; finished hardware assembled, tested and packaged by Actech
01 / THE STARTING POINT
Challenge
The request was to take over production. Actech identified an opportunity to update the architecture while preserving the established functions and interface.
Incomplete engineering records
Functions needed to be established through testing the existing product and confirming its behavior with the customer.
An established user interface
The internal design needed updating while retaining the familiar front panel and its four operating modes.
02 / OUR RESPONSE
Actech’s Approach
Actech proposed the redesign, developed the mechanical structure and commissioned specialist electronic development.
Propose an updated architecture
Actech proposed replacing TTL hardware logic with a microcontroller and firmware.
Coordinate specialist development
A specialist partner developed the electronics, firmware and PCBA. Actech coordinated integration and handled mechanical development.
Confirm function through testing
Existing-product tests and customer confirmation established the four modes and informed the finished-product functional-test method.
03 / PUTTING IT INTO PRACTICE
Engineering to Production
Functional definition guided the electronic and mechanical redesign, sample preparation and verification of every finished unit.
Functional definition
Gate, Pulse, Pendulum and Stopwatch modes were confirmed against the behavior of the existing product.
Electronic and mechanical redesign
More than twenty TTL ICs were replaced by one main CPU and three auxiliary ICs, with firmware implementing the four modes. The PCBA comprised main, LCD and I/O boards. Housing changes improved screw fixing, assembly, component retention, wiring and the battery cover.
Samples and manufacturing preparation
Approximately 1–2 sample versions supported preparation of injection tooling and plastic parts, SMD/DIP assembly, component integration and wiring.
Assembly and functional verification
Actech assembled and packaged the finished hardware. A purpose-built fixture tested every unit’s four modes and two signal-input sockets before shipment.
04 / WHAT CHANGED
Results & Impact
~6 months
From initial engagement to first production
100% functional testing
Every unit tested before shipment
~50% lower product cost
Following the electronic and mechanical redesign
This reduction applies to product cost, not to an individual rear-housing component or total project expenditure.
Project context
Cost savings on the first production batch nearly offset development and tooling expenses. Historically reported annual sales were approximately 504 units; this is not a first-batch quantity or a statement of current sales.
Long-term value
In 2010, the specialist partner further updated the microcontroller, firmware and PCBA in response to a need for improved timing precision. Comparative verification records were not retained, so no quantified precision improvement is claimed.
05 / KEY TAKEAWAY
Redesigning for cost and product longevity
A production-transfer request became an opportunity to update the architecture, reduce product cost and support continued technical development.