Sasken developed industrial valve controller electronics that could be used in explosive atmospheres (ATEX rated, Ex d). The customer had an older product that would be replaced with this new product, and the new one should also incorporate some features from their newly designed flagship model.

The customer wanted a new product that would combine features from two different designs to fill the gap in their product portfolio. The new product needed some additional safety features as well. This new product was supposed to have an Atex rating with its enclosure, and all electronics should fit onto one printed circuit board instead of two, which would bring significant cost reduction compared to the old product. 

However, it was important for the customer that the manufacturing costs of this new product be significantly lower than those of the flagship model, enabling them to offer it at a more competitive price. 

Sasken combined two designs into one with necessary features using the PADS design schematic tool. We designed, simulated, and added safety features to this combined design. 

Sasken built two prototypes at a selected partner factory and verified that the entire design worked according to specifications. We arranged EMC type approvals and supported EMC measurements at the type approval laboratory. 

The new product was designed to incorporate most features from their flagship product but with a slightly smaller bill of materials (BOM) cost, along with added safety features. This would enable the customer to better serve their own customers and increase device sales. 

The goal was also to revamp the customer product portfolio to provide a suitable replacement for the older product, which was one of the two products combined. The structure was improved to be more straightforward to assemble in the factory, making the new design a superior product.