B-201,Phase-II,Noida-201305(U.P.)
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If we look to our routine, we often use remotes to control our home appliances, be it a TV, AC, Washing machine, Fan, almost every gadget now a days is remotely controlable. But have you ever thought how these small remotes are manufactured. So, today we will have a brief overview on remote control manufacturing process .
Remote Control works on simple technique which could be understood through simple example: when you press remote key then that key press is translated into infrared light signals which is received by dedicated device .You can also check its internal parts by removing back cover of the remote which consist of PCB and electronic components with battery contacts. Let’s look in these components one by one deeply:
IR (Infrared) remote control are based on Light and it requires line of sight to operate the destination device. For Example: When we operate remote control it require to aim to the direction of dedicated device. Infrared light is also known as plain-old "heat." Infrared light is in the invisible portion of the electromagnetic spectrum. An IR remote control transmit pulses of infrared light that are specific binary codes i.e. commands such as Power On, Power Off and Volume Up etc. The IR receiver in the targeted devices decodes the pulse of light into the binary data that the device's microprocessor can understand and then it carries out the corresponding command.
RF stands for Radio Frequency remote control, used to control distant objects using a variety of radio signals transmitted by the remote control device. The application of Rf remote control can be seen in electric garage door or gate openers, automatic barrier systems etc. Rf remote controls use their own coding hence, transmitter used in these can be universal, meaning they can work with different coding.
PCB stands for printed circuit board which is an electronic circuit with lines and pads that connects various points together allowing signals and power to be routed between physical devices. It is made by combining different sheets of non-conductive material, such as fibreglass or plastic coated with a very thin layer of Copper on the Top side that easily holds electronic circuit. The PCB process starts with heating and cutting of CCL sheets, chemical pre-treatment and brushing, CCL sheets are then sent for masking, etching and drying. After whole manufacturing process PCBs are sent for Bear board testing and Visual QC check. Then these PCBs are sent for mounting.
Mounting is done by two ways:-
Once mounting is done these PCBs are again tested and are sent for further proceedings. These all steps integrate and provide error free PCBs.
Electronic components are assembled on printed circuit boards. The components which are assembled on most remotes are integrated circuit also known as an IC. This IC comes in a different packages (SOP, SSOP, QFP) consist of 8,16,20,24...etc or a DIP. To the right of the IC -diode, a transistor (black, with three leads), a resonator (yellow), two resistors (green) and a capacitor (dark blue) are assembled. Next, to the battery contacts there is a resistor (green) and a capacitor (tan disk). In this circuit, the IC works when a key is pressed. It then translates the key into a sequence code, with a different sequence for each different key. The IC then sends these signals out through the IR/RF to its receiving end or dedicated device for which remote is made for.
Plastic cabinets are used to protect remotes and also provide user friendly interference. The Plastic used by companies generally depends on the product requirement. There are many options available in market for making cabinets such as acrylic, polycarbonate plastic, ABS, nylon, silicone, styrene and thermoplastic polyurethane, known as TPU and thermoplastic elastomers, or TPEs. After selection of plastic, injection moulding is done to mould cabinets. Then on the cabinets deco printing, screening and designing is done to get desired result.
Keypad are made of Silicon Rubber. Keypad consist of carbon pills on the backside of the silicon pad, when we press any key on keypad these key get short with PCB and then send signal to IC through which we get desired result.
Remote Battery Contact Springs are manufactured on precision CNC forming machines by using high quality material such as steel and stainless steel wire. These springs are majorly used in Tv Remote, Ac Remote and other allied applications.
This was a basic overview of manufacturing and working of remote controls. The process, material and specifications all depend on specific requirements. Keep checking our blogs for more tech updates.
