How to teardown Cummins INLINE 6 Data Link Adapter

IHS Insight Perspective

Cummins Inline 6 data link adapter is an automotive interface device that's designed to connect an external computer to a vehicle's onboard computer for diagnostics purposes. This adapter is fully compliant to the Technology and Maintenance Council's RP1210 standard. It links vehile computer (SAE J1708/J1587 and 2 CAN/J1939 data links) via a 25-pin serial connector and communicates with a PC through a 9-pin serial or 4-pin USB connector.

Cummins INLINE 6 Data Link Adapter Main Image

Per Cummins - The main features of Inline 6 data link adapter are:

• Supports SAE J1708/J1587 and J1939/CAN data links
• Supports USB full speed port at up to 2M baud rate
• Custom USB cable includes thumbscrews for secure mounting to INLINE 6
• Supports RS-232 PC serial port at up to 115.2k baud rate
• Is fully compliant with TMC's RP1210 standard
• Small enough to fit in pocket
• Attractive black powder coated aluminum housing provides ruggedness
• Derives 8 V to 50 V DC power from vehicle
• Controlled by advanced 140 MHz 32-bit Freescale processor for maximum speed and performance
• Internal Flash memory allows firmware upgradeability
• Includes 6 LEDs to indicate status of power, USB, RS-232, J1708/J1587, and two CAN communication ports
• Both CAN ports support SAE J1939, SAE J2534, and ISO 15765 protocols
• INLINE 6 is certified to meet European CE requirements
• Rated for -40° to +85° C operating temperature
• INLINE 6 meets rigorous Cummins in-cab environmental test requirements

PROTOCOL SUPPORT:

• CAN - J1939/CAN125/CAN250/CAN500
• 2nd CAN - J1939/CAN125/CAN250/CAN500
• J1587/J1708
• ISO 15765
• J2534

Design Significance

At the core of this device is the Freescale (MCF5253CVM140) 32-Bit MCU. The device also contains 2 memory components - ISSI 16Mb SRAM, Spansion 8Mb NOR Flash, along with a number of discrete I/O components such as TI RS-232 Transceiver, TI CAN Transceiver, and Analog Devices RS-485 Transceiver.

Target Market

Automotive after-market

Released

December, 2011 per press release

Cummins INLINE 6 Data Link Adapter - Main PCB Bottom

Unknown

No pricing found for this particular device. The previous generation, Inline 5 adapter is ~ $600 at e-tailer.

Worldwide

This device is believed to be available worldwide

Volume Estimations

7,500 Annual Units
5 Total Years

For the purposes of this teardown analysis, we have assumed an Annual Production Volume of 7500 units and a Product Lifetime Volume of 5 year(s).

Teardown volume and production assumptions are primarily used for our cost analysis in terms of amortized NRE and tooling costs, especially for custom components specific to the model being analyzed (mechanical components especially). Unless assumed volumes are different by an order of magnitude, minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis because of this.

Cummins INLINE 6 Data Link Adapter Cost Analysis

Our analysis accounts for low volumes in pricing, however, keep in mind that in low volumes, pricing disparities from one customer to the next, for the same parts, can be huge, and make the job of estimating such purchases prices much harder.

Total BOM: $36.91
Top Cost Drivers below: $27.72
% of Total BOM 75%

Main Cost Drivers below

ISSI IS61WV102416BLL-10MLI SRAM - 16Mb, Asynchronous, 3.3V- (Qty: 1)
Freescale Semiconductor MCF5253CVM140 MCU - 32-Bit, ColdFire V2 Core, 140MHz, 128Kb SRAM, 6-Ch x 12-bit ADC, USB 2.0 OTG, CAN/I2C/SPI/UART, 0.13um- (Qty: 1)
Enclosure, Main, Housing - Extruded Aluminum, Painted- (Qty: 1)
Vishay - General Semiconductor SM8S10AHE3 Transient Voltage Suppressor - Unidirectional, 24V, 8W- (Qty: 2)
Century PC Board Co., Ltd 4-Layer, FR4, Lead free- (Qty: 1)
Texas Instruments SN65HVD234D CAN Transceiver - Up to 1Mbps, 120 Nodes- (Qty: 2)
Texas Instruments LM2575HVS-5.0 Regulator - DC-DC Converter, Step-Down, 5V, 1A- (Qty: 1)
TDK ZJYS81-2PL25T-G01 Inductor - Common Mode Choke, w/ Plastic Carrier, for CAN-Bus- (Qty: 2)
Analog Devices ADM3493ARZ Transceiver - RS-485/RS-422, Half Duplex, 250 kbps- (Qty: 1)
TE Connectivity miniSMDC014F-2 Polyfuse - Resettable PTC, 0.14A- (Qty: 10)

Not Included in Analysis

The total materials and manufacturing costs reported in this analysis reflect ONLY the direct materials cost (from component vendors and assorted EMS providers), AND manufacturing with basic test. Not included in this analysis are costs above and beyond the material manufacture of the core device itself - cost of intellectual property, royalties and licensing fees (those not already included into the per component price), software, software loading and test, shipping, logistics marketing and other channel costs including not only EMS provider and the OEM's margin, but that of other resellers. Our cost analysis is meant to focus on those costs incurred in the manufacture of the core device and exceptionally in some circumstances the packaging and literature as well.

We do provide an Excel tab 'Overall Costs' where a user can enter their known pre and post production costs to build a per unit cost reflective of theirs actual expenditures.

Manufacturing Notes

For the purposes of our analysis, our cost structures in manufacturing represent the cost to the manufacturer, without markup. If an EMS is involved, one would have to add a fair margin for the EMS provider, on top of our cost assessment, in order to provide a 'fair price' to the manufacturer. EMS providers often operate in the low single digits on margins, but tend to make up for such low margins when working with low volume products such as this.

Country of Origin

For the purposes of this analysis, we are assuming the following country(ies) of origin for each level of assembly, based on a combination of 'Made In' markings, and/or assumptions based on our knowledge of such equipment.

Main PCB - United States
Other - Enclosures / Final Assembly - United States

Country of origin assumptions relate directly to the associated cost of manufacturing, where calculated by iSuppli. In the cases of 'finished' sub-assemblies (such as cable assembly), we do not calculate internal manufacturing costs, but rather assess the market price of the finished product in which case country of origin assumptions may or may not have a direct effect on pricing.

Labor rates are applied directly only to hand inserted components and systems in our bill of materials, and although regional assumptions do, these new rates do not have a direct effect on our modeled calculations of placement costs for automated SMD assembly lines. "Auto inserted components (such as SMT components) placement costs are calculated by an iSuppli algorithm which allocates a cost per component based on the size and pincount of the device. This calculation is affected by country or region of origin as well.

Design Complexity

Component counts by assembly and the number of assembly are indicators of design complexity and efficiency.

Component Qty: 358 - Main PCB
Component Qty: 9 - Other - Enclosures / Final Assembly
Component Qty: 367 - Grand Total

Component counts have a direct bearing on the overall manufacturing cycle times and costs, and also can increase or decrease overall yields and re-work. Our calculations of manufacturing costs factor counts and more qualitative complexities in the design.

Note that manual labor has a much smaller effect on auto-insertion assembly lines (for the Main PCB, for example), where manufacturing costs are much more capital equipment intensive and driven by these investment costs.

Design Notes

At the core of this device is the Freescale 32-Bit MCU (MCF5253CVM140) - ColdFire V2 Core, 140MHz, 128Kb SRAM, 6-Ch x 12-bit ADC, USB 2.0 OTG, CAN/I2C/SPI/UART, 0.13um. In addition to this MCU, the device also contains 2 memory components - ISSI SRAM (IS61WV102416BLL-10MLI) - 16Mb, Asynchronous, 3.3V, and Spansion (S29AL008J55BFIR2) - NOR Flash, 8Mb, along with a number of discrete I/O components such as TI (MAX3232IPW) - RS-232 Transceiver, TI (SN65HVD234D) - CAN Transceiver, and Analog Devices (ADM3493ARZ) RS-485 Transceiver.