Access Terminal Redesign

(Freescale Vybrid, WinCE, Cloud Computing)


LCI’s client required a re-design of a wall-mounted access control terminal for facilities that use employee RFID cards. The main goal was to design a new version with extended functionalities but with a lower BOM and manufacturing costs.


LCI conducted an analysis of the existing technology, Bill of Materials, manufacturing practices and associated costs, and the team proposed that several key elements can be improved with expected cost savings.

The original machined aluminum enclosure was replaced with an off-the-shelf hardened plastic frame with a high strength glass surface. This solution decreased the mechanical BOM cost significantly and provided a more visually pleasing, durable and scratch-proof package.

The resistive touch-screen used in the original product was replaced with a multi-touch capacitive integrated with a glass panel to provide a better user experience. Video driver circuits were designed to support multiple TFT displays to provide supply chain flexibility and longer solution life cycle.

The off-the-shelf small embedded PC was replaced with a custom base board that supported the Toradex Vybrid processor module. This solution provided performance flexibility with the ability to use several drop-in processor modules (choice of single core or double core processors) that can be optimized for each implementation. Designing all circuitry on a single base board also eliminated interconnecting cables.

The Windows Embedded operating system was replaced with Windows Embedded Compact (formerly known as WinCE). The Device Application was converted to .NET compact framework, supported by WinCE, with minimal re-design. Additional software features were implemented in order to connect to remote servers running in a cloud.

Winning Result:

The LCI design team met all the requirements and developed a product with new and improved features that ensured a more than 30% reduction in manufacturing costs for the client. Design costs were also made manageable by leveraging existing software design.

Markets Served:

• Manufacturing (end customers include KIA Motors Europe)
• Banking
• Retail (end customer – IKEA)