Electronic Design Cost Case Study

A transparent breakdown of engineering fees, prototyping, and manufacturing preparation for a professional electronic product.

In this page, you see an example of a design successfully started in 2004. In 22 years, over 600.000 units have been manufactured. Hardware and firmware were continuosly updated updated every 3 years. The original components are no longer available, but no single detail has changed from the original design.

ON-SITE TEST SETUP

We added compatible features, and customers appreciate the product when replacing a 20-year-old controller working 24-7-365. Let's dive into Be24A's secrets.

THE MANDATORY SPECIFICATIONS EXAMPLE

For a panel mounting, the controller must be enclosed in a standard DIN96 plastic case. It must work between -30°C and 70 °C. It is about an engine Key-Start, Auto-Start, that provides basic safeguards for a diesel or a gasoline engine coupled to an alternator. It also monitors the alternator voltage and frequency. For a wide range of applications, it must feature a rich set of adjustable parameters and settings. Bernini Design notes its own experience, adds extra features and remarks on unhealthy features that should be removed.

The final cost for this specific service is our "business card": $0 / Free of charge.

CLEAR SPECIFICATIONS MEAN FAST DELIVERY

It may seem unusual, but the first step in designing an electronic product at Bernini Design has nothing to do with engineering. If your goal is to minimise development costs, you must follow our core advice:

Write the user manual first.

This approach forces you to crystallise your ideas into a real, functional device. With our guidance, we review the draft manual with team members from diverse technical backgrounds. This internal feedback is a valuable tool for you: it locks in the final product specifications. Clear specifications can reduce development costs by up to 50%. In other words, an approved user manual is the ultimate compass for delivering an excellent product.

The cost for this specific phase is $500

THE EXTERNAL ASPECT: HOW WILL IT LOOK?

During this phase, the Bernini Design team assists in visualising the finished product: aesthetic, practical, and back shape perspective. The front panel needs to be an affordable, user-friendly, and pleasant product.

A USER-FRIENDLY CONTROLLER

The front panel features a military-grade LED display operating at extreme temperatures. Led with over 1300mcd luminousity made by KingBright LTD has been chosen.

For industrial applications, the focus is on endurance in harsh environments. Never underestimate the rear part, especially for an electronic controller: a good connector's positioning will simplify the installation.

A CRYSTAL CLEAR REAR VIEW

You can easily observe the INPUTS (yellow), the OUTPUTS (orange), the alternator INPUTS (green), the power supply (grey) and the protective overlay LEXAN membrane for avoiding short-circuits.

The final cost for this specific phase is $1,800

A STATE-OF-THE-ART HARDWARE DESIGN

Mechanical & Electronic Architecture

The internal structure developed by Bernini Design utilises a robust, vibration-proof 3D arrangement of 5 interconnected electronic boards positioned at 90-degree angles. Each board is dedicated to a specific function: DC inputs, AC inputs, DC outputs, and the power supply system.

A ROCK-SOLID CONTROLLER

EMC & Signal Integrity

This optimised PCB layout ensures exceptionally low EMC emissions and high immunity to electrical noise. Beyond its mechanical ruggedness, the system features a highly resilient electronic design, including short-circuit-proof outputs and high-precision measurement inputs.

On-Site Calibration

To achieve zero-error precision in voltage and frequency measurements, the controller supports direct, "on-site" offset and gain calibration.

Hardware Design Cost $ 2,900

A STATE-OF-THE-ART HARDWARE DESIGN

Software & Firmware Architecture

Creating flawless hardware is a massive challenge. Often, smart software acts as the ultimate safety net—executing a 'Plan B' to prevent catastrophic failures. But which side is harder to master?

The truth is, there is something even more complex: the final, combined system test. This is where Bernini Design steps in. We look at the product from the outside in, driven by a single, obsessive question:

What if?

We stress-test the edge cases so your product works flawlessly in the real world.

MICROCONTROLLER I/O SETUP