The challenge
The module tells a monorail’s control system that a passenger’s restraint is latched, so it is safety-critical. It lives outdoors, with vibration, shock, moisture, rain, temperature cycling and constant handling by passengers.
Unlike most of BSU’s work, this wasn’t build-to-print. The customer needed the whole module designed: the PCB, the cable assembly and a way to protect the electronics in that environment.
What BSU did
- Design. BSU designed the complete module: the PCB, the cable assembly and the potting approach.
- Potting. The electronics are encapsulated to protect against moisture, vibration and tampering.
- Cable. The cable assembly is built to IPC/WHMA-A-620 Class 2.
- Test. Every module gets a 100% functional test at BSU before it ships.
Result
The customer reorders every year, with 20–50 modules built per year. Every module shipped has passed functional test at BSU.
