Orbit & Skyline partnered with a leading semiconductor OEM facing an urgent controller obsolescence challenge due to the obsolescence of a critical I/O Controller, requiring an end-to-end obsolescence controller solution to ensure continued tool operation. This controller played a vital role in operating semiconductor tools by managing analog, digital, Ethernet (IP/TCP), and fiber optic interfaces. The discontinuation of this component posed a significant risk to ongoing operations, tool availability, and long-term maintenance.
For this semiconductor OEM, the objective was to deliver a fully compatible obsolescence controller solution as a form-fit-function replacement for the legacy controller, capable of supporting four distinct configurations. The replacement had to integrate seamlessly with the existing tool infrastructure while meeting all required functional, electrical, and regulatory compliance standards.
Controller Obsolescence Challenge: The original legacy controller was discontinued, and replacement parts or OEM support were unavailable.
System Complexity: The controller needed to support a mix of analog, digital, Ethernet, and fiberoptic interfaces.
Compliance Requirements: The redesigned controller had to meet industry-standard EMC and safety certifications.
Integration Constraints: The new solution had to retain the mechanical footprint and electrical interface of the original to minimize redesign at the tool level.
The project followed a structured end-to-end obsolescence controller solution roadmap covering reverse engineering, requirements definition, hardware and firmware development, validation, and compliance.
Reviewed obsolete legacy controller board design and its electrical interactions within the system.
Captured detailed functional and interface specifications based on tool-level requirements.
Designed and developed a re-engineered board with firmware and GUI support.
Completed full system-level testing and validated the solution against live tool operations.
Supported external certification tests and initiated ongoing reliability trials.
The new controller was successfully integrated and passed tool-level validation at the customer site.
The controller design accommodates four legacy configurations, ensuring broader applicability.
Enabled continued use of existing semiconductor tools, avoiding costly replacements.
Currently undergoing extended field validation to certify long-term deployment readiness.
Eliminated risks associated with obsolete hardware through a comprehensive obsolescence controller solution.
