Acquired Electronics360

Set-top Box

Motorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box Teardown

30 April 2008
The following is an overview of a teardown analysis conducted by IHS Technology Teardown Services.

Main Features

The QIP6200 is a hybrid HD QAM/IPTV set-top box from Motorola that is a step above the Motorola QIP2500 (standard-definition non-DVR QAM/IPTV) and a step below the Motorola QIP6416 (high-definition with DVR QAM/IPTV). The QIP6200 is not a DVR box, but is HD capable, and features embedded IP networking over coaxial using MoCA technology (two-way IP data comm.) and features a single 64/256 QAM tuner (supporting MPEG-2 high-definition formats).

This box is high-definition and features composite output and HDMI, however it also features a host of other interconnect and output options including S-video, SPDIF (digital audio optical output), coaxial cable out, standard RCA video out, and two sets of RCA stereo jacks. It also features an Ethernet connection, USB (x2), IEEE1394 (Firewire), IR blaster and has a smart card reader for conditional access control.

This box is part of Motorola's IP Set-Tops group of devices. It seems that the "QIP series references to the fact that these boxes are both QAM tuner-equipped and IPTV-enabled. The QIP boxes we have analyzed includes two non-DVR versions (HD (QIP6200 - this model) and SD (QIP2500)) and an HD/DVR version with 160GB HDD (QIP6416).

Per Motorola: ""The QIP6200 delivers superior all-digital video and sound quality for a true home theater experience. It decodes standard- and high-definition programs and processes both QAM and IP video transports. With embedded IP networking supporting high bandwidth data applications it can operate as part of a multi-room DVR home network via MoCA™ (Multimedia over Coaxial Alliance standard). The QIP6200 advanced hardware platform supports feature-rich applications and graphics and typical digital TV functionality, including the interactive program guide (IPG), video on demand (VoD), and commercial-free, CD-quality music."

Motorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box Main ImageMotorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box Main Image

Target Market

Captive customer base of 'cable alternative' service providers - ie telco service providers. Whether VDSL, FiOS or other high-speed delivery system, IPTV will gain popularity as a cost-effective competitor of cable and satellite, as the pipeline required to deliver IPTV will also provide coincidental improvement in broadband service and facilitate the quality and quantity of VoIP devices.

Released

January 2006 assumed per date of press release at this time. Verizon was the first service provider to offer the Motorola QIP series of set-top boxes.

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 US (via Verizon). It may be available more broadly - but evidence of this was not found in Motorola literature and press releases.

Motorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box - Main PCB TopMotorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box - Main PCB Top

Volume Estimations

For the purposes of this teardown analysis, we have assumed that Motorola will produce 5 million units of this STB during the product lifetime, which may, depending on the acceptance and penetration of IPTV may be more.

As a reminder, volume production assumptions are not meant to be necessarily 'market accurate', and our meant primarily to be 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).

Function / Performance

No performance testing was performed.

Motorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box Cost AnalysisMotorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box Cost Analysis

Cost Notes

The QIP6200 and QIP6416 are more expensive than the most comparable recently analyzed IPTV STBs from Motorola - the VIP1200 and VIP1216. This is for several reasons: the chipsets used (Broadcom and Entropic primarily), and the QAM tuning circuitry (dual tuners too!) which is functionally different from the VIP boxes. We also looked at a hybrid box HD from Philips last year based on a Sigma Designs core - and the costs were only slightly lower than in this design.

Despite this differentiator, in both analyses Motorola is assumed to have a great deal of market presence and are assumed to leverage their purchasing power to the best of their ability, making their prices very competitive for all purchased components. So cost differentials in this case are design-related and structural in nature.

Main Cost Drivers

Silicon (Main PCB)

Broadcom - BCM7038KPB3 - Dual Channel HD Video/Audio/Graphics System on Chip - 300MHz, 64-Bit MIPS CPU - Qty(1)

World Wiser Electronics Inc. (WWEI) - Main PCB - 6-Layer - FR4 - Qty(1)

Broadcom - BCM3250KPB - Front End - Single-Chip QAMLINK Advanced Set-Top Box - Qty(1)

Entropic Communications - EN2010 - c.LINK Controller - For Coaxial Networks - Qty(1)

Alps - TDER5-501A - Tuner Module Value Line Item - Qty(2)

Texas Instruments - TSB43DA42GHC - Microcontroller - Single Chip Solution for IEEE1394a Link-Layer, w/ Integrated 2-Port PHY - Qty(1)

Freescale - SCF60004PU - Multi-Stream Conditional Access IC - Qty(1)

Cirrus Logic - CS5331A-KS - ADC - 18Bit, Stereo - Qty(1)

Entropic Communications - EN1010 - Coaxial Network Interface - Qty(1)

Microsemi - LX1671CLQ - PWM Controller - Multi-Phase - Qty(1)

Analog Devices - AD8073JR - Video Amplifier - Triple, Low Cost - Qty(1)

Memory

Micron Technology - MT46V16M16TG-5B - SDRAM - DDR, 256Mb (4 Meg x 16 x 4 Banks), 200MHz@CL3 - Qty(4)

Intel - RC28F128J3D-75 - Flash - NOR, 128Mb, 3V, 75ns, 0.13um - Qty(1)

Internal Power Supply

Lite-On - PB-4360-1Q - Power Supply - 35W, Input AC100-120V, 50-60Hz, 7A, Output +5V/1.8AA, +12V/1.12A, -5V/0.07A, +3.3V/3.78A - Qty(1)

Total w/ Manufacturing $127.76

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 Taiwan. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were sourced in China to take advantage of lower cost structures there.

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 can tuners), 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 tend to 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.

The Motorola QIP6200 has a total component count of 1883 of which 98 are mechanical components (when accounting for the power supply and tuner modules as itemized itemswith complete BOMs). This component count is high, but inline with other hybrid HD STBs.

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

The core design is based on a Broadcom chipset - a BCM7038KPB3 Dual Channel HD Video/Audio/Graphics System on Chip - 300MHz, 64-Bit MIPS CPU, and a BCM3250KPB Front End chip.

The coaxial MoCA™ home-networking (""c.Link") chipset is provided by Entropic, and consists of two chips found in the front-end and I/O interface areas of the devices.

Beyond these 3 core chips, the most significant IC content in this design would include the Texas Instruments - TSB43DA42GHC - Microcontroller - (Single Chip Solution for IEEE1394a Link-Layer, w/ Integrated 2-Port PHY) and the Freescale - SCF60004PU - Multi-Stream Conditional Access IC.

All of the above core devices are common to both the QIP6200 and QIP6416 designs. Also, In terms of design re-use it is interesting to note that the can tuner (Alps - TDER5-501A) is re-used in all QIP boxes, and the power supply used here is common to both HD QIP boxes (Lite-On - PB-4360-1Q - 35W).

Main PCB

Audio/Video Processing

Dual Channel HD Video/Audio/Graphics System on Chip - 300MHz, 64-Bit MIPS CPU - Broadcom - BCM7038KPB3

Interface

c.LINK Controller - For Coaxial Networks - Entropic Communications - EN2010

Texas Instruments - TSB43DA42GHC - Microcontroller - Single Chip Solution for IEEE1394a Link-Layer, w/ Integrated 2-Port PHY

Freescale - SCF60004PU - Multi-Stream Conditional Access IC

Smart Card Interface IC - Teridian Semiconductor - 73S8024R-IL

Front-End

Alps - TDER5-501A - Tuner Module (Can)

Front End - Single-Chip QAMLINK Advanced Set-Top Box - Broadcom - BCM3250KPB

Coaxial Network Interface - Entropic Communications - EN1010

Memory

SDRAM - Micron Technology - MT46V16M16TG-5B - DDR, 256Mb (4 Meg x 16 x 4 Banks), 200MHz@CL3

Flash - NOR - Intel - RC28F128J3D-75 - 128Mb, 3V, 75ns, 0.13um

SDRAM - 16Mb - Hynix - HY57V161610ETP-7 - (2Banks x 512Kb x 16), 143MHz, 3.3V

Other Sub-Assemblies

Power Supply (Internal)

Lite-On - PB-4360-1Q - 35W, Input AC100-120V, 50-60Hz, 7A, Output +5V/1.8AA, +12V/1.12A, -5V/0.07A, +3.3V/3.78A

Motorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box - Enclosure DisassemblyMotorola QIP6200 Hybrid QAM-IPTV HD Set-Top Box - Enclosure Disassembly



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