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Industrial automation equipment tends to be installed in locations a long way from the warm confines of your clean office or lab. Electronic equipment used in factories, power plants, transportation centers, outdoors on industrial sites, etc. is subjected to severe temperature and humidity, vibration, dust, and corrosive chemicals, as well as electrical noise. In that case, the dependability of the control system rests heavily on one key element - industrial control PCB assembly. A good industrial control PCB design and its accurate assembly at the base engenders the sequestered stable long term operation even in the extremely severe environment.
Understanding the Challenges of Harsh Industrial Environments
Before we discuss how industrial control PCB assembly ensures stability, we want to make sure you understand the problems these PCBs must endure:
Temperature Extremes: Industrial machinery can run in extreme heat or cold causing thermal fatigue.
Vibration and mechanical shock: Motors, compressors, heavy machinery vibrate incessantly.
Humidity and moisture: Condensation and moisture can cause rust and/or short circuiting.
Dust and chemical contaminants: Industrial air may be laden with conductive dust, oil mist, or corrosive gasses.
Electrical Interference: Electromagnetic interference (EMI) which can be a product of running high-power equipment can actually interfere with sensitive signals.
Industrial control PCB assembly needs to be designed to address all of these hazards at once.
Robust PCB Design as the First Line of Defense
Stable operation is a result of a design developed specifically for the industrial control application. Industrial control pcb assembly has stricter requirements on the layout design of the pcb,making choice of components and ensuring signal integrity.
Higher quality designs utilize larger copper traces to dissipate more current and heat less. Critical signal paths are separated to reduce EMI and grounding schemes and shielding configurations are developed.
Multilayer PCB stack-ups are commonly used to enhance the electrical and mechanical performance. At King Field, industrial control pcb assembly projects undergo scrutiny by experienced engineers who consider not only circuit functionality, but environmental survivability at the beginning of design.
Industrial-Grade Component Selection
The parts in consumer electronics will not endure the same conditions as the parts in industrial systems. A key feature of industrial control system PCB assembly is the availability of industrial-grade or extended temperature range components.
These components are designed for broader temperature ranges typically from -40°C to +85°C or more. Long life capacitors, reinforced connectors and vibration resistant elements are selected for reliable operation. Such careful selection of components leads to greatly reduced failure rates in long term industrial use.
Precision Assembly Processes for Reliability
Even the best design can be compromised by poor quality assembly. Industrial control PCB assembly involves high-tech, tightly regulated production processes.
The combination SMT-THT assembly gives compactness and mechanical strength.
The optimized soldering profiles eliminate cold joints and over-thermal.
A number of hidden solder defects can be detected by automated optical inspection (AOI) and X-ray inspection, more effectively for BGA and fine-pitch components.
Solder joints strengthened by Over-Molding exhibit greater resistance to vibration and thermal cycling.
Every step of the process King Field exercises rigid process control to maintain consistency, repeatability, and long-term reliability in industrial control PCB assembly.
Protection Against Moisture, Dust, and Corrosion
Industrial control PCBs are known to operate in very challenging environments such as extreme temperatures, high humidity, corrosive, or dusty air and so on, and they need be protected for application, sometimes the protection is more then PCB standard assembly. Conformal coating is a standard treatment in the assembly of industrial control PCBs.
These protective coatings form a thin film that protects the PCB from moisture, dust, chemicals, and corrosion while maintaining electrical performance. In severe cases, potting or enclosure protection is applied to further boost ruggedness.
Thermal Management for Continuous Operation
Heat is a leading cause of electronic failure. Industrial control PCB assembly incorporates the techniques of thermal management to ensure that the performance remains stable when running without stop.
These incorporate thermal vias and heat sinks, optimized component placement, and thicker copper layers for efficient heat dissipation. Good thermal design eliminates hot spots and allows components to run at normal temperatures even when heavily loaded.
Comprehensive Testing Under Simulated Harsh Conditions
Dependable industrial control PCB assembly is not just about manufacturing. Validation of robustness requires stringent testing.
Functional testing, thermal cycling, vibration testing and burn-in imitate the severe environment conditions of reality. These evaluations can reveal possible failures before they are put into service. At King Field, PCBA for industrial control is equipped with full testing procedures to meet the industrial requirements and custom customers' needs.
Long-Term Stability Through Quality Management
Predictability is essential in industrial applications, and failure interruptions are very expensive. Industrial control pcb assembly operates under quality system management, to guarantee that all batches are at the same quality level.
Material traceability, process documentation and continuous improvement systems enable manufacturers such as King Field to provide consistent, repeatable results for industrial customers around the world.
Industrial environments are no place for basic electronics. They need systems that can run under continuous load and in harsh environments. With rugged design, industrial grade components, precise assembly, shielding, thermal management and testing, industrial control pcb assembly guarantees a stable performance in which it can not fail.
King Field offers industrial control pcb assembly solutions for critical industrial applications with the highest reliability to endure aggressive environments and to provide unparalleled long term, stable operation due to our vast experience and commitment to quality.
