Motorola DVI3120 Set-Top Box Teardown

Overview / Main Features

The Motorola DVI3120 set-top box appears to be a digital [standard definition] cable set top box (STB) for the continental Europe market. Little is known about the device other than a reference in a press release on the 1 millionth digital STB shipped to Ono (see feature links). The digital STB is primarily a Broadcom design (BCM7115KPBG) with a Cirrus Logic ethernet controller.

Motorola DVI3120 Set-Top Box Main Image

European Cable Television Service Providers

Released

unknown

Motorola DVI3120 Set-Top Box - Main PCB Top

Pricing for this kind of product (at the consumer level) is typically meaningless as it is a completely subsidized part of a service package. Cable set-top boxes are typically rented out to subscribers on a monthly schedule in accordance with the service contract which varies region to region and market to market. Since the device cannot function without being properly set-up by a service provider, after-market product and prices have no validity.

Availability - Continental Europe

Volume Estimations

For the purposes of this teardown analysis, we have assumed a lifetime production volume of 2.5M 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.

Motorola DVI3120 Set-Top Box - Main PCB Bottom

Main Cost Drivers Representing ~64% of total materials cost

Broadcom - BCM7115KPBG - Set-Top Box Device - Single-Chip, w/ Personal Video Recording (PVR)

Tai Hong Circuit - 4-Layer - FR4

Delta Electronics - EADP-18GB - AC Adapter - Input: 220-230V~, 50Hz, 0.5A, Output: 12V, 1.5A (18W)

Numonyx - JS28F128J3D-75 - Flash - NOR, 128Mb, 75ns, 0.13um, 2.7 to 3.6V

Cirrus Logic - CS8900A-CQ3Z - Ethernet Controller - Single-Chip, 10BASE-T

Enclosure, Main, Top - Stamped / Formed Electro-Galvanized Steel (SECC), Silver Painted

Teridian Semiconductor - AVPro5002R-CGT - Audio / Video Switch Matrix - Include Multiplexers, Support Dual SCART, w/ Integrated Output Drivers

Enclosure, Main, Bottom - Stamped / Formed Electro-Galvanized Steel (SECC), Printed

Sanyo - LA7784 - RF / IF Downconverter - Digital CATV, Consists of AGC Amplifier & Mixer

Chi Mei Corporation - Enclosure, Main, Front Panel - Injection Molded ABS, Silver Painted, Printed

Anadigics - AIT1051R - Tuner - Digital Video, 78dB Gain, 1.6mA

Epcos - B39361-X6966-M100 - IF SAW Filter - Bandpass, 36.125MHz

Micron Technology - MT46V16M16P-6TF - SDRAM - DDR, 256Mb (16M x 16), CL=2.5, 2.5V

Cypress Semiconductor - CY62137FV30LL-45BVXI - SRAM - 2Mb (128K x 16), 45ns, 3.0V

Freescale Semiconductor - SCF80003AE - Microcontroller

Taiwan Semiconductor - TS2596CMRN - DC-DC Converter - Step-Down, Adjustable, 3A, 150KHz

SCART Socket - Right Angle, w/ Metal Housing & Screw Lock (Qty:2)

Freescale Semiconductor - MC44BS373CAEF - Audio / Video Modulator - Multi-standard, PAL/SECAM/NTSC

Flat Flex Ribbon Cable - 3000V,105C, 24 28AWG Conductor, w/ 1 TV Pass Card Socket & 1 24-Position Pin Socket Connector

Total BOM Cost $58.90

Motorola DVI3120 Set-Top Box 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 assembled in Taiwan. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in Taiwan.

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 hard disk drive), 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 DVI3120 has an overall component count of 799, of which, only 44 are mechanical in nature. This complexity metric is on par with other non-DVR set-top boxes we have previously analyzed.

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 Taiwan.

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 Motorola DVI3120 Set-Top design:

Main PCB

Logic

• Broadcom - BCM7115KPBG - Set-Top Box Device
• Cirrus Logic - CS8900A-CQ3Z - Ethernet Controller
• Freescale Semiconductor - SCF80003AE - Microcontroller

Memory

• Micron Technology - MT46V16M16P-6TF - SDRAM
• Numonyx - JS28F128J3D-75 - Flash

Analog

• Teridian Semiconductor - AVPro5002R-CGT - Audio / Video Switch Matrix

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Motorola DVI3120 Set-Top Box - Enclosure Disassembly