Hardware Redesign for a Smart Building Access Control System

Redesigning the hardware architecture (electronics and mechanical design) of a modern access control system utilizing the NXP i.MX8M-Plus Quad processor to optimize manufacturing, reduce assembly complexity, and improve overall product quality.

A client, based in Oslo, Norway, is a leader in digital access control, providing cloud-managed intercom solutions for the modern PropTech market. Their ecosystem replaces physical keys and traditional panels with high-definition video entry and centralized web administration. To prepare for mass production, the client required comprehensive hardware design services to rethink their internal architecture and optimize their electronic design services for global scaling.

Case Highlights

Hardware redesign of two key devices: Display Unit and Control Unit
Complete PCB redesign from scratch
Mechanical enclosure redesign for both devices
Transition to the NXP i.MX8M-Plus Quad processor platform
Integration of modern cellular connectivity with LTE support and a 5G-ready architecture
Significant reduction of manual assembly operations
Improved camera performance for day and night conditions
Increased vandal resistance of the entrance device

Problem

The client approached Softeq to optimize the design of their access control hardware and prepare it for future mass production.

The system includes two main devices:

Display Unit - a smart video intercom panel installed at the building entrance that allows visitors to call residents and communicate via video.
Control Unit - an indoor device responsible for managing door locks and access control decisions.

While the original hardware design was functional, it presented several challenges for manufacturing.

The internal structure relied heavily on manual assembly processes. The devices contained numerous wires, connectors, and components that required soldering, gluing, and complex manual installation. This significantly increased production time and cost.

Also, manual assembly was particularly problematic due to the high labor costs in the client’s region. As a result, scaling production with the existing hardware design would have been inefficient and expensive.

At the same time, the redesign had to preserve the existing functionality of the system and maintain compatibility with the client’s platform while fundamentally rethinking the internal electronics architecture to reduce assembly complexity.

Additionally, the client wanted to modernize the platform by adopting more powerful processing hardware, improving connectivity, and increasing the durability of the entrance device.

The client needed an engineering partner capable of redesigning the devices' electronics and mechanical structure to reduce manufacturing complexity and improve overall product quality.

Solution

Softeq performed a complete hardware redesign of the client’s devices while preserving their original functionality.

The Softeq team redesigned the electronic architecture, optimized the devices' internal structure, and introduced a modern processing platform.

Upgrading the System Architecture with NXP i.MX8M-Plus Quad

To meet the client’s requirement for a high-performance product, Softeq strategically chose the NXP i.MX8M-Plus Quad processor for integration. There were several reasons this processor model was selected:

Superior Vision: The processor features a built-in Image Signal Processor (ISP). This allows the camera to see clearly in complete darkness or bright sunlight, ensuring the resident always knows who is at the door.
Edge Intelligence: It's built-in NPU (Neural Processing Unit) enables local processing of visual data without relying on cloud processing.
Rugged Reliability: It is designed for industrial use, so it won't freeze or overheat, even in extreme weather.

Selecting this platform ensured that the client’s hardware would remain scalable and relevant for years to come.

Optimized PCB Design and Assembly

Softeq hardware engineers developed new PCB designs from scratch for both the Display Unit and Control Unit. The redesigned architecture consolidated components and improved the internal layout, significantly reducing the number of separate assembly elements.

To further enhance manufacturability, Softeq streamlined the assembly process: manual wiring and complex connectors were replaced with board-to-board interfaces, reducing the required assembly steps to just a few straightforward actions. This approach significantly lowers production complexity and manufacturing costs while ensuring a robust and reliable hardware platform.

Modern Connectivity and Video Capabilities

The redesigned Display Unit integrates a cellular modem with LTE support and a 5G-ready architecture, enabling reliable video communication between visitors and residents via the client's platform.

Softeq also optimized antenna placement and tuning to ensure stable connectivity.

To improve video communication, the system integrates a high-sensitivity camera that delivers clear images in both daylight and low-light environments.

Mechanical Redesign and Durability Improvements

The Softeq team also redesigned the device enclosures to support the new hardware architecture and simplify the final assembly and installation process.

The Display Unit enclosure was strengthened with more robust materials and improved mounting mechanisms, making it significantly more resistant to vandalism and unauthorized removal.

The device was also upgraded to include a security feature that can trigger an SOS alert and transmit its GPS location if the unit is forcibly removed while still powered.

Connectivity and Mechanical Durability

5G-Ready Architecture: We integrated a cellular modem with LTE support and optimized antenna placement for reliable video communication.
Vandal Resistance: The enclosure was redesigned with robust materials and a "Security SOS" feature that triggers an alert and GPS location transmission if the unit is forcibly removed.

Result

A Scalable, High-Performance PropTech

The collaboration transformed the client's hardware into a production-ready solution, delivering clear business advantages:

Lower Manufacturing Costs: The PCB redesign and transition to board-to-board interfaces slashed manual labor requirements, making mass production financially viable.
Market-Leading Performance: The NXP-based architecture provided a competitive edge in video quality and processing power.
Comprehensive Documentation: Softeq delivered full schematics, PCB layouts, and a refined Bill of Materials (BOM), providing the client with a turnkey package for their manufacturing partners.

By leveraging Softeq’s hardware design services, the client successfully bypassed the prototype phase's limitations, securing a clear path to global market expansion with a robust, vandal-resistant, and cost-effective product.