Acquired Electronics360

Mobile Devices

Netgear DG934G ADSL22+ 802.11bg Router Teardown

30 November 2012
The following is an overview of a teardown analysis conducted by IHS Technology Teardown Services.

Overview / Main Features

The Netgear DG934G is a wireless router provided by Sky Broadband for their ADSL subscribers. This is one of two wireless routers currently provided by Sky Broadband to their ADSL subscribers, while the other being the Sagem F@ST 2504. These two routers are aesthetically identical with the exception of the name inscribed on the enclosure and the label affixed to the bottom. The Netgear DG934G features ADSL2/2+ with the help of the Texas Instruments" TNETD7200ZDW chip and supporting chipset. User's login information was preprogrammed onto the firmware, prior to customer delivery, for ease of installation but also limits the router to be used on Sky Broadband network.

Netgear DG934G ADSL22+ 802.11bg Router_(iSi) - Main PCB TopNetgear DG934G ADSL22+ 802.11bg Router_(iSi) - Main PCB Top
Target Market


The target market for this specific product is obviously the captive market of BT subscribers, specifically ADSL subscribers.

Released

2007 assumed. Exact date unknown. BSkyB rollout in UK - Q4 2007. Cannot find any other announced rollouts for this box.

Pricing and Availability

Pricing for this kind of product (at the consumer level) is meaningless as it is typically a completely subsidized part of a service package, and since it cannot function without being properly set-up by a service provider, after market product and prices have no validity.

The product should be available in the UK (via BSkyB). It may be available more broadly - but evidence of this was not found in Netgear literature and press releases.

Market / Sector Performance

In the broadband market, ADSL represents, as of Q3 2007, 56.5% of new subscribers worldwide. Furthermore, 42% of new subscribers in the same timeframe were from Europe, representing the largest share of new subscriber base worldwide. We estimate a total of 17.4 million new broadband subscribers were added during Q3 2007. While the mix of ADSL and VDSL is growing in favor of VDSL, iSuppli does not expect it to replace ADSL for some time.

Cost Notes

Main Cost Drivers (Representing Approximately 50% of Total Materials Costs)

$4.42 - Texas Instruments - TNETD7200ZDW - ADSL2-to-Ethernet Bridge/Router Device - Single-Chip - Qty(1)

$2.72 - Texas Instruments - TNETW1350A - WLAN Baseband & MAC - Single-Chip, IEEE802.11b/g - Qty(1)

$2.03 - Circuitech Precision - Main PCB - 4 Layer - FR4 - Qty(1)

$1.66 - Marvell Technology - 88E6060-RCJ1 - Ethernet Switch - 6-Port - Qty(1)

$1.15 - LANKom - LJ-H17S4H-04-F - Jack - RJ-45, Quad, Right Angle, w/ Metal Housing - Qty(1)

$1.08 - Spansion - S29GL032A90TFIR4 - Flash - NOR, 32Mb, 3V, Pb Free - Qty(1)

$1.05 - EtronTech - EM639165TS-6G - SDRAM - 128Mb (2M x 16 Bits x 4 Banks), 3.3V, 6ns, 166MHz - Qty(1)

$0.99 - Texas Instruments - TNETW3422 - RF Transceiver - ZIF, 802.11b/g - Qty(1)

Total Materials Costs$30.91

Total with Manufacturing$32.41



What Is Not Included in our Cost 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.

Manufacturing Notes

Country of Origin / Volume Assumptions

Based on markings, the unit was assembled in China. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc. were sourced in China.

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 Power Supply), 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.

Remember also that 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 for Manufacturing / Device Complexity

We use component counts as the one measurable and clearly defined "metric" by which we can compare and judge the relative complexity of devices and comment as to where a given device fits in the spectrum of overall manufacturing cost and complexity between devices.

With both devices, most of the complexity, component count, and cost are all part of the main PCBA. The packaging / enclosure plastics and mechanicals are not especially complex on either device and did not seem unnecessarily overdesigned or costly to assemble. The bulk of complexity and manufacturing cost is therefore with whichever EMS provider produces the PCBA. These are simple devices which should be inexpensive to manufacture.

Overall the component count is not especially elevated because this device represents the most basic functionality available. The total component count was 474 components in the device itself. However, only 24 components are mechanical in nature. The most direct comparative analysis is against the comparably featured Sagem F@ST 2504 ADSL Router, a "drop-in" replacement or second source for BSkyB and their clientele which features a few more components at a total of 526 componentsof which 18 are mechanical in nature.

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. The cost of manufacturing is also, to some extent, decreased in this case because of assumed labor rate applied for China.

Note that manual labor has a much smaller effect on auto-insertion assembly lines (for the Main PCB, for example

Design Notes

The design revolves around a core Texas Instruments AR7 chip performing the ADSL2+ core processing with a Flash and a SDRAM memory for data storage. In the WLAN section, the functions are split amongst 3 major chips; Baseband, Transceiver, and PAM. The TI TNETW1350A is the processing unit for the WLAN function and is directly interfaced to the AR7 chip. The TI TNETW3422 transceiver is responsible for transmit and receive functions of WLAN. Lastly, the TI TNETW3427 PAM is the power amplifier for the WLAN signal.

Netgear DG934G ADSL22+ 802.11bg Router_(iSi) - Main PCB TopNetgear DG934G ADSL22+ 802.11bg Router_(iSi) - Main PCB Top

Netgear DG934G ADSL22+ 802.11bg Router_(iSi) - Main PCB BottomNetgear DG934G ADSL22+ 802.11bg Router_(iSi) - Main PCB Bottom
This is our first time seeing this TI chipset.

The power supply is external in this unit (see beneath for details).

Here is a summary of the major components used in the Netgear DG934G design:

Main PCB

MPU

  • Core - Texas Instruments - TNETD7200ZDW - ADSL2-to-Ethernet Bridge/Router Device - Single-Chip

Host Interface

  • Switch - Marvell Technology - 88E6060-RCJ1 - Ethernet Switch - 6-Port

Memory

  • Flash - Spansion - S29GL032A90TFIR4 - NOR, 32Mb, 3V
  • SDRAM - EtronTech - EM639165TS-6G - 128Mb (2M x 16 Bits x 4 Banks), 3.3V, 6ns, 166MHz

WLAN

  • Baseband - Texas Instruments - TNETW1350A - WLAN Baseband & MAC - Single-Chip, IEEE802.11b/g
  • Transceiver - Texas Instruments - TNETW3422 - RF Transceiver - ZIF, 802.11b/g
  • PAM - Texas Instruments - TNETW3427 - WLAN 2.4GHz, 802.11b/g

Other Sub-Assemblies

Power Supply

  • External AC Power Adapter - DVE - DSA-12RN-12 - 200-240 VAC ~50/60Hz 0.3A, 12 Vdc, 1A, 12 Watts


Netgear DG934G ADSL22+ 802.11bg Router_(iSi) - Box ContentsNetgear DG934G ADSL22+ 802.11bg Router_(iSi) - Box Contents



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