Project: Industrial Design Concept Table

Project: Automated Test Systems

At Minck Design Services we design our own test jigs in the 3D modeling software AutoDesk Inventor. This jig design is easily adapted to support many projects. It is locally made, reduces cost and is a better fit than an of-the-shelf import.

Project: Eye Lens Removal Instrument

Project: Beam-forming Microphone Array

The project objective was to create a very narrow beam microphone. This was done by mounting 4 small hearing aid microphones on a pair of eye glasses.

Because the microphones were placed at a distance from each other, The sound from different directions would have a different time of arrival at each microphone. Using digital signal processing the aim was to filter out sounds from only one direction, hence, beam forming.

Project: Embedded Software Design

Our embedded software is written in the C language

We analyse the project requirements and specifications to understand the system’s functionalities and constraints. Next, we design the software architecture. The final step is to conduct rigorous testing and debugging to identify and rectify errors or glitches, ensuring the software operates flawlessly in real-world scenarios.

We collaborate with hardware engineers, firmware developers, and other stakeholders throughout the development lifecycle.

Project: Electric Hot Water System Heating Controller

Minck Business Services specialises in smart hot water system heating controllers. The controllers have sophisticated automation and control mechanisms. This automation reduces energy consumption and the risk of Legionnaires’ disease compared to traditional hot water systems.

Building regulations require multi-dwelling apartments in Europe to reduce their carbon emissions. Heating is a significant contributor to these emissions.

MBS works with South Australian manufacturer, ELWA, to deliver smart hot water heaters to apartments in Europe.

Hot water heating systems using smart automation have reduced energy consumption and thereby carbon emissions, satisfying the European energy efficiency directive.

Hot water systems can increase the risk of Legionnaires’ disease by providing an environment where this bacteria thrives. Not only has the smart system reduced carbon emisisons, it has also reduced the risk of Legionnaires’ diseaase through a sophisticated heating and timing cycle.

Through a sophisticated automation process MBS has delivered a safe and effective control system for the hot water systems in multi-dwelling apartments in Europe.

Project: EV Battery

Lithium battery charge and discharge controller

A solution was adopted to use fibre-optical instead of electrical wiring between the units. This made the system far less prone to electrical noise and galvanically separated the cells.

The system has a 4 line, 20 character display, a battery backed-up real time clock / calendar, and 2 CAN bus interfaces. One for the charger and one to communicate with the car.

All measured data can be stored on a FAT32 micro-SD Card for easy data analysis using a PC.

The battery pack will be charged with the maximum current of the charger until the first cell reaches its maximum voltage. then the current will be tapered off step by step.

After the current has reached zero the balancing algorithm will equalize all cells. The balancing method uses switch-mode power supply method to move energy of full cells in to cells that are not full yet.

When cells are equalized, the charger will top the whole pack up again.

See pictures of the hardware with optical communication:

The PC based Graphical user interface (GUI) to test messages to and from the battery management system.

Project: Supermarket Point of Sale Security Board

The following project was developed by Jan Minck for NCR in The Netherlands. Although not under the MBS banner it does add to the knowledge and experience pool of MBS and therefore worth mentioning.

Jan developed the electronics for a Security Processor Board. This board is housed in a multibus branch computer. This computer is connected to several Point of Sale terminals in a supermarket which handles electronic fund transfers. Jan also developed a new version of the Security Module. This module stores the encryption keys and handles account number and PIN number encryptions. For security purpose, most of the electronics is integrated in a custom designed IC (gate array ASIC) which Jan developed.

Project: Memory Seat Controller

For GM Holden MBS developed a Memory Seat Controller. This unit is used in the Holden Caprice / Statesman. When pressing the remote control of the vehicle, both driver seat and outside mirrors travel to a memorized position. No more adjusting seat and mirrors after someone else used the car.

To reduce the number of wires to the door, the seat module communicates with the outside mirrors via a one wire serial link. This also prevents wire-loom changes when new features are added to the system.

For Schefenacker Vision Systems (previously Britax Rainsfords) MBS developed the electronics for their smart memory mirror and mirror switch. This system is used in the same car as the seat controller. The electronics use Hall sensors and ferrite magnets to determine mirror glass position. This method is much more durable than potentiometers. Mirrors and switch also communicate via a one wire serial link.

Lear Seating was the seat supplier to GM Holden before they were taken over by Air International. For these companies MBS has built three different testers to support the memory seat product.

• A bed-of-nail tester to verify and calibrate the memory seat module electronics
• A functional tester to test the side cover assembly
• A functional tester/ calibrator to test a complete memory seat

The bed-of-nail tester is used at the factory where the electronics are assembled. It consists of an in-circuit and a functional tester, which are both housed in in same test jig. The in-circuit tester checks every individual component and accurately pinpoints the location of any fault or bad solder joint. This makes rework very easy.

IC’s, relays and software are tested by a functional tester. Even the volume level of the beeper is measured at this stage.

The tester issues a serial number to every module and will log all test results. Full statistical process control is performed on every unit and every assembly run.

Due to the specific requirements, we have designed our own test jig in AutoDesk Inventor. This jig design is easily adapted to support other projects. It is locally made, reduces cost and is a better fit than an of-the-shelf import.

All 3 testers perform a functional test. Because they had so many things in common, only one PCB was designed. Placing the DIL switches into a different position, turns the circuit into another tester. This modular design makes it very easy to adapt this circuit to test target boards of other (future) projects. It is even capable of verbally passing on the error messages to an operator via a wireless head set if this makes product assembly more efficient.

For backup we made a spare tester which can do all 3 jobs.

Apart for the developing tasks, MBS also manages, and is responsible for the production of the memory seat controller.

Kevin Hooper, General Manager of Air International at the time, summarised his experiences of working with MBS.

MBS developed a number of different production testers. These testers were used in various stages of the seat production. The testers not only comprehensively test and calibrate the seat or seat sub-assembly but also made use of a test-pass-token system in which each tester passed on a test result message to the next tester. The result of this scheme, together with an excellent quality memory seat controller, is that over a period of 4 years, building thousands of memory seats, a Memory Seat controller has never caused a valid warranty claim.

 

MBS was to us a very creative and reliable developer / supplier. They manage their work professionally and have shown great care for detail. Their products have proven to be robust and of excellent quality.

 

Kevin Hooper
General Manager
Air International
2002