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2Wire i3812V Outdoor VDSL Gateway Teardown

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

Overview / Main Features

The 2Wire i3812V is an externally mounted residential VDSL/VDSL2 gateway designed for FTTN service deployments such as AT&T's U-Verse triple-play (voice, broadband & television) service. The i3812V is designed as part of the larger HomePortal iNID (intelligent Network Interface Device) system which includes the 2Wire i38HG (indoor wireless access point) and iPSU power module (battery UPS). As opposed to earlier VDSL gateways (such as the HomePortal 3800HGV which we have previously analyzed), the i3812V is a purely outdoor design featuring weatherized enclosure and thermal designs. By transferring the VDSL modem functionality to the outside of the home, the HomePortal iNID system eliminates signal loss typical of in-home installations.

Overall, the i3812V functions as both the termination point of the VDSL/VDSL2 service from the telco as well as the primary gateway router for all voice, data and video services to the rest of the home. VDSL signal is converted by the i3812V to HPNA signals and routed through to the i38HG wireless access point(s) located throughout the home. A backup power iPSU unit is ultilized to retain the voice service in case of emergency outage situations to provide a line out for residential customers.

Like the HomePortal 3800HGV we analyzed in 2006, we see very similar electronic design which features a NXP Semiconductor (TriMedia Technologies) custom ASIC and a pair of CopperGate [now upgraded to HomePNA 3.1 capable] digital MAC and PHY integrated circuits.

2Wire i3812V Outdoor VDSL Gateway Main Image2Wire i3812V Outdoor VDSL Gateway Main Image

Target Market

Telco Carriers - specifically for VDSL / FTTN residential deployments

Released

Based on product literature; likely first released in 2008

2Wire i3812V Outdoor VDSL Gateway - Main PCB Top2Wire i3812V Outdoor VDSL Gateway - Main PCB Top

Pricing and Availability

Pricing - As with most telco or cable services, the cost of the equipment is rolled up in the overall service contract costs and therefore there is no clear market price for the unit.

Availability - North America (AT&T U-Verse)

Volume Estimations

For the purposes of this teardown analysis, we have applied a lifetime production volume of approximately 500K units.

As a reminder, teardown volume 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.

2Wire i3812V Outdoor VDSL Gateway - Main PCB Bottom2Wire i3812V Outdoor VDSL Gateway - Main PCB Bottom


Cost Notes

Main Cost Drivers ~75% of Total Materials Cost

CopperGate - CG3111QIR-10 - HomePNA 3.1 Digital MAC and PHY IC (Qty:2)

NXP Semiconductors (TriMedia Technologies Inc.) - ASIC

Elington Electronics Technology - 8-Layer - FR4, Lead-Free

Heatsink / Enclosure, Main, Rear - Die-Cast Aluminum, w/ 3 Integral Threaded Metal Standoffs

TII Network Technologies - 95S-A-01-0-2 - Customer Bridge Module - Sealed, Gray Injection Molded Plastic, w/ Integral RJ11 Jack, Discrete Insulated Wire Harness with RJ11 Jack (Qty:2)

Analog Devices (CopperGate) - CG3112LIR-10 - Analog Front End - HomePNA 3.1 (Qty:2)

PMC Sierra - PM4380D-WGC - Analog Front End - VDSL2 / ADSL2+ (Qty:2)

Enclosure, Main, Center - Injection Molded Polycarbonate, Clear Coat, Recyclable, w/ 1 Brass Insert

Enclosure, Main, Front - Injection Molded Polycarbonate, Recyclable

Monolithic Power Systems - MP3887x - DC-DC Converter (Qty:4)

Main PCB Shielding / Cover, Top - Stamped / Formed Stainless Steel, Painted, Printed

Ceramic Multilayer - C0G/NP0 (Qty:7)

Micron Technology - MT47H32M16HW-3 IT:F - SDRAM - DDR2-800, 512Mb, 8Mx64, 1.8V (Qty:2)

Zarlink Semiconductor - Le88276DLC - Telephone Line Interface IC - Dual Channel

Marvell Technology - 88E6063-RCJ1 - Ethernet Switch - 7-Port, 10/100BASE-TX, 802.IQ

Micron Technology - NAND512W3A2CN6 - Flash - NAND, SLC, 512Mb, 3V

Wurth Elektronik - 000-7090-37R-LF1 - Ethernet Magnetics Module - Single Port, 10/100 Base-TX (Qty:2)

Direct Materials + Manufacturing $172.68

2Wire i3812V Outdoor VDSL Gateway Cost Analysis2Wire i3812V Outdoor VDSL Gateway Cost Analysis


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 likely assembled in China. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also 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 RJ-45 connectors), 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

The 2Wire i3812V has an overall component count of 1600 (excluding box contents), of which 1515 reside on the main PCB.

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), where manufacturing costs are much more capital equipment intensive and driven by these investment costs.

Design Notes

Here is a summary of the major components used in the 2Wire i3812V design:

Main PCB

I/O & Interface

  • HomePNA 3.1 Digital MAC and PHY IC - CopperGate - CG3111QIR-10 (Qty. 2)
  • Analog Front End - HomePNA 3.1 - Analog Devices (CopperGate) - CG3112LIR-10 (Qty. 2)
  • Analog Front End - VDSL2 / ADSL2+ - PMC Sierra - PM4380D-WGC (Qty. 2)
  • Telephone Line Interface IC - Dual Channel - Zarlink Semiconductor - Le88276DLC
  • Ethernet Switch - 7-Port, 10/100BASE-TX, 802.IQ - Marvell Technology - 88E6063-RCJ1

Processing

  • ASIC - NXP Semiconductors (TriMedia Technologies Inc.)

Memory

  • SDRAM - Micron Technology - MT47H32M16HW-3 IT:F, DDR2-800, 512Mb, 8Mx64, 1.8V
  • Flash - Micron Technology - NAND512W3A2CN6, NAND, SLC, 512Mb, 3V

2Wire i3812V Outdoor VDSL Gateway - Disassembly View 12Wire i3812V Outdoor VDSL Gateway - Disassembly View 1



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