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Nexgen 2000 Plus Industrial Computer
The product
The
product is a programmable logic controller (PLC), a compact
dedicated computer for industrial applications. It is used for
automation of processes and provides extended controls for machines
and its parameters. Users vary from Electrical, Maintenance
engineers to wiremen and shop floor workers. It is used by companies
to automate processes and bring in reliability, efficiency and
reduce human errors in machine usage. Some applications include
Production monitoring systems, Equipment testing jigs, etc. This
device connects to various other devices like sensors, switches,
motors etc. to communicate and control them. It is programmable to
perform checks and send required signals to control and run
processes. This product is a vital part of any modern shop floor.
The Challenge
As a finding from the user and field research, strong competition
and crowded market demanded a very strong perceived quality for the
product. Our challenge was to build it through a robust design make
it simple to use and clutter free. The product works in an
industrial environment with high demands on performance and
functionality. The focus was on creating a simple, usable, clean yet
a reliable product.
One of the biggest challenges was ease of wiring and user safety.
The old design used an exposed connector with each module having
about 20 connections. Making the connections was tedious. Trouble
shooting and diagnostics was even more difficult. Accidental contact
with live wire was common. A better solution for safe handling of
wires during installation was highly needed.
Simplify Modularity in the product. Often a customer adds on modules as
and when his need arises. Addition of modules was difficult and
causes a significant downtime. This modularity was not easy to handle at
the user level. The PCBs would be exposed and lead to product damage
while handling.
Enhance user feedback for diagnosis, installation and servicing.
The electronics (PCBs) of the current design was a constraint, could
not be changed as they had already been tested on the previous
design cycle. The challenge was to enhance diagnostic assistance in
an ergonomic intuitive manner. Overall the objective was to create a
product which would be easy to wire, safe to handle, provide ease of
diagnostics and be distinct in styling to create differentiation in
the market.
The Process
To ensure the most effective design solution, Ticket Design
conducted extensive study with end users, control panel builders
to understand their needs and requirements. From these studies, the
interface, product packaging and feature parameters were explored
and defined, establishing the foundation for preliminary concepts
and sketches. The result was a product that is useful for the end
users as well as the technicians and installation engineers.
The Benefits
The redesigned product is a clean, safe and simple design with
enhanced ergonomics. The modular product has a new removable
front wiring module that takes the complexity out of wiring a PLC.
All the wiring can be done separately and PLC assembled later on.
Diagnostics now can be done without complicated rewiring. The
product now has no exposed connectors or wires; no accidental shocks
any more. The product styling has been carefully worked out to
position the product as an intelligent, contemporary and a
differentiated product in the market. The product has been designed
for an international market using engineering plastics
and uses latest
technologies of injection moulding mass production to achieve
economy of scale.
Ergonomics:
Modules can be easily replaced and removed. A unique front wiring
module can be removed without touching a single wire.
Modularity The
product is modular and expands depending upon the requirements of
connections upto 128 input/outputs.
The product is being
rolled out and the sales are expected to double this year.
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