Service Provided
- Hardware Design: Electrobit developed a precise schematic and optimized PCB layout, ensuring thermal efficiency and signal integrity. Detailed Gerber files and a comprehensive BOM were prepared for manufacturing.
- Prototyping & Validation: The PCB was fabricated, assembled, and rigorously tested through board bring-up and Design Verification Testing (DVT) to meet all performance criteria.
- Firmware Development: A custom PoE algorithm was developed to comply with IEEE 802.3bt, ensuring efficient power management and flawless integration with the hardware.
- Mass Manufacturing: Electrobit provided seamless transition from prototyping to mass manufacturing, ensuring consistent quality and performance at scale.
Challenges Overcome
Thermal Management Without Active Cooling:
Electrobit’s engineers developed an innovative heat sink design that efficiently dissipated heat, ensuring stable operation from -40°C to 75°C without fans. This passive cooling was essential for reliability.
Maintaining Power Integrity:
The PoE Injector was designed to operate consistently across a 10-60VDC input range. Advanced power conditioning and regulation ensured stable 90W output, crucial for fluctuating outdoor power sources.
Comprehensive Protection:
Multi-layered surge, pulse, and overcurrent protection were integrated to safeguard the injector and connected devices, ensuring long-term reliability and industry compliance.
Technology Deployed
- IEEE 802.3bt PoE Compliance: Ensured 90W power delivery compatible with all 802.3bt devices.
- Passive Cooling: Heat sink design for operational integrity without active cooling.
- Advanced Power Management: Regulated power stability across the voltage range.
- Embedded Firmware: Custom algorithms for power delivery, device status, and fault protection.
Conclusion
- Electrobit successfully engineered a cutting-edge PoE Injector that not only met but exceeded the client’s rigorous specifications. Delivered within a tight 9-week timeline, the project showcased Electrobit’s prowess in both hardware and firmware development. The final product, validated through extensive testing, now forms a crucial component in outdoor power solutions. The collaboration highlights Electrobit’s capability to deliver complex, high-stakes projects with precision and reliability, solidifying their position as a leader in advanced electronic engineering solutions.
Electrobit Engineering Team
Our hardware, firmware and software engineers design embedded products for OEMs across the United States, from concept to production.
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