I use JIO TV and my JIO Set Top Box remote gone bad recently and had to order a new one in 499 INR that’s when I came to know that these are manufactured in India. This was also a good opportunity to see what is inside, electronics, plastics, packaging.
Such remotes can de designed and manufactured at around 100 INR or less in high volumes like above 100K units per months types.
These type of remotes can easily be designed and manufactured in India. If you are building a product and want to manufacture in India, contact our team at info@capuf.in, we help companies build products in India and within competitive BOM cost so you can compete with Chinese products.
JIO Set Top Box Remote Packaging
Lets get to the internals of Jio Set Top Box Remote, will show you all the details like packaging, electronics, carbon pads for keys, Microphone, plastics.
It comes with a simple package. MRP is 799 INR. Manufactured by Bhagwati Products Limited.
Remote is packed in a simple poly bag manufactured in Faridabad, wow.
That’s my native place.
JIO Set Top Box Remote Front and Back
JIO Set Top Box Remote Internal Hardware
Opening the enclosure is quite easy as there are no screws, both top and bottom cover are press fitted.
Top side of the PCB you can see color pads and tracks.
See the zoomed image for details. The hole you see is a through hole connection for connecting the carbon pads and tracks to the other side PCB copper layer.
Having a good microscope in your development lab is really help in these kind of analysis. I suggest all engineers to have a good lab with useful tool, they will help you be productive and doesn’t cost much.
In the images below you see the other side of the PCB where all the components are placed. Left side you see the battery connector terminal, a capacitor on the battery input rail to stabilize the power supply.
On the right had side you have a Realtek (TAIWAN) controller which does the job, Key scan, IR LED driving, capturing audio from the microphone and sending data to set top box via RF connectivity.
You see a lot of large side 0 ohm resistance, they are nothing but jumpers as designer have only one layer for the design.
Large package also allows traces to go under the components.
I like how a single MCU is able to handle everything required from power supply to IR LED driver to indication LED to keys scanning to microphone capture and sending data over RF.
Zoomed in image of the controller
In my remote, this crystal came off along with the PCB pad, that’s why it has gone bad. May be due to falling to many times on the floor 🙂
this inductor capacitor is for the DC DC converter inside ethe MCU
This is the close up of IR LED and LED indication (you see the hole below it for light to pass on the other side) and microphone.
this is the microphone close up image
In the image below you see the Mic opening on the other side of the PCB, on the left side you see the LED peeping out as well.
Some test points are available for debug and testing in the production.
These test points are carefully placed at the location where they can be accessed even after enclosure is fitted, near the cell opening. This is an important decision.
JIO Set Top Box Remote Plastic Details
Some more images of the plastics if you want to see the details.
Crazy part is to build something like this in <100 INR in volume production, it may sound easy but it takes a lot of effort, careful decision making and lot of experience in building consumer electronics price sensitive products.
That’s all in this teardown, I hope you have learned something new today.
Help our country design and manufacture products in India. It is our collective responsibility to make it happen.
I am running an Embedded Design House, CAPUF Embedded Pvt. Ltd, located in Bangalore, India. At CAPUF, we help companies build embedded products end-to-end from concept to mass manufacturable product with our hardware, firmware and software development services.
We help companies who are currently buying product from China, design and manufacture in India. We have helped several companies in past for their products.
We also help in design optimizations for power consumption, cost, mass manufacturing, and performance.