Rugged HMI for Collision Avoidance Radar

SGW’s initial work focused on definition of a look and feel compelling to Preco, that was new but at the same time compatible with legacy Preco products. While multiple industrial design concepts were developed, engineering efforts focused on the highest-risk item: achieving the IP-69K rating in a product that incorporated a button, lights, and a speaker.

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A winning design language was developed by the team, and the engineering team incorporated it into the preliminary design. Next, a clever mounting system was developed and integrated. With the form-factor defined, multiple engineering paths to achieve the IP rating were explored.

In addition to the rating requirements, the SGW team identified a new challenge: Tolerance stack-up. How would the contract manufacturer be able to deal with material and component variances while still achieving the seal required for the IP-69K rating? The answer was to design the assembly for a sonic welding process. This meant a vent would need to be incorporated, which SGW Designworks defined in collaboration with W.L. Gore, the pioneers of Gore-Tex. The vent was incorporated into the housing design.

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Next, the team identified a speaker that could provide the volume, in which the speaker diaphragm could provide a IP-69K compliant seal.

Incorporation of the speaker into the design required special engineering considerations. To function properly, the speaker mounting points were designed so that the speaker is maximally exposed, but with minimal capture.

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This had a big impact on the overall internal design of the housing. The user-interface button was designed with the actuator built into the main housing element, and then over-molded for sealing.

Incorporation of light pipes was the most effective way to provide the right visual alerts to drivers while still achieving the durability targets of the product. Like other design decisions, this would impact the production and assembly methods used to manufacture the product. SGW Designworks engineers collaborated with Preco and with contract manufacturers throughout the design development process. This was critical, because the complex assembly could become costly to produce without incorporating manufacturer input along the way.