DROP-IN REPLACEMENT FOR AN OBSOLETE PART

Problem background

Due to the obsolescence and lack of traceability on residual worldwide stock of a waveform generation Integrated Circuit (I.C.), the client wished to migrate to an alternative part.  Critically, vast stocks of the partially-populated Printed Circuit Board (PCB) which housed the obsolete part remained and, as the control software could not be easily changed, the client's position was that the replacement part had to be functionally transparent in all aspects - equal performance, that it used the existing PCB layout and power as well as using the same programming protocol.

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How the problem was approached

The physical and operational characteristics of the existing part were studied and a review with the manufacturer indicated that there was no successor part.  An alternative manufacturer's part was then identified, which was in-production, abundant, matched the functional requirements and available power supplies, but which differed in available package and programming protocol.

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The client was then presented with a solution to meet all of their requirements - a 'plug and play' mezzanine module, which would allow the different I.C. package form-factor to be used.  With the addition of a microcontroller and interpretation code developed for reception of the existing programming signals and broadcast in the new part's protocol, the extant system control software could be used without change.

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Results

After extensive in-house testing, characterisation and data analysis, the replacement module was delivered to the customer and was adopted.  The value of the PCB material saved from being scrapped  (in the event of a total refactoring) was tens of thousands of pounds and the environmental impact of doing so was mitigated.

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Key terms

• Obsolescence circumvention

• Peripheral interface controller

• Analogue signal processing

• Zero waste