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Industrial Control PCB Assembly And Industrial Instrument PCBA Case Analysis


Industrial control has special circuit boards and general control boards, which are increasingly widely used in industrial automation equipment. Industrial control equipment includes industrial computers, laser systems, industrial instruments, smart meters, special controllers, etc. Industrial equipment is becoming more and more automated and intelligent, especially with the development of Internet technology, smart network equipment is becoming more and more popular, and the demand for industrial equipment is growing. Therefore, the urgent demand for industrial control automation PCB and PCB assembly is also growing.

1. Requirements of Industrial Control PCB Assembly

Due to the special importance of industrial control, the quality standard of industrial control PCB assembly is higher than that of circuit board assembly in other industries. High performance, reliability, and stability are the most critical requirements of industrial control PCB assembly manufacturing. Only PCBA manufacturers with higher production levels can meet the requirements.

PCB assembly plays an important role in the circuit manufacturing process of Industrial control equipment. To ensure high-quality manufacturing, here are some key assembly requirements:

● Advanced Automation Equipment  

Using advanced automation equipment can improve production efficiency and quality. These devices enable precise assembly and soldering of PCB components, reducing the possibility of human error.

● Professional Engineers and Operators

In addition to high-end machines, professional employees are also the key to high-quality PCBA manufacturing. Because PCB and PCBA are very professional and have complex processes in production. Production links from PCB design, PCB fabrication, PCB testing, and other steps require experienced engineers and operators to ensure correct assembly and debugging processes, and timely resolution of possible problems.

● Good Manufacturing Practices

Establishing and adhering to good manufacturing practices is critical to ensuring product quality and production efficiency. Industrial control equipment plays an important role in modern industrial automation production. High-performance industrial control PCBA boards can save the tedious and repetitive work of manual operations, and reduce production costs and improve production efficiency. Therefore, circuit board assembly manufacturers must have good personal hygiene practices to prevent any potential contamination or defects.

● Strict Quality Control System

Establishing strict quality control procedures can ensure actual and accurate quality inspection of PCB assembly. This includes monitoring and inspecting details during the manufacturing process and correcting potential errors on time.

2. Industrial Automation Instrument Case Analysis

Industrial automation instruments require a complex PCB assembly, to be responsible for critical data processing and signal transmission. In addition, it will be equipped with various sensors and actuators to control industrial processes precisely.

PCB Design

Translate the functions and requirements of industrial automation instruments into PCB designs. This includes determining circuit layout, component locations and connections, etc. PCB functional design needs to support a variety of input and output interfaces, including analog and digital signals, as well as communication interfaces such as Ethernet, CAN and Modbus, etc. Consider the layout of components to ensure short signal transmission paths and reduce signal interference. At the same time, industrial instrument heat dissipation and space utilization efficiency should be considered.

● Manufacturing and Assembly

The manufacturing and assembly of industrial automation instrument PCBs require compliance with good production practices and strict quality control systems. For example, in the raw material procurement process, choose high-quality PCB materials, such as FR-4 fiberglass composite materials, to ensure the stability and durability of the instrument PCB. During the manufacturing process, SMT and DIP assembly technology are used to improve instrument production efficiency. During the assembly process, the instrument PCB assembly details are monitored and inspected, including visual inspection, functional testing, automated testing, etc., to ensure that the performance and reliability of each industrial control instrument PCB meet the requirements.

● Testing and Actual Commissioning

Functionally test the assembled instrument PCBA to ensure the normal operation of each component and interface. Electrical testing verifies the electrical performance of the instrument PCB, including connectivity, resistance, capacitance and other parameters.

Industrial automation instrument finished product assembly manufacturing

3. Problems and Solutions Encountered in Industrial Automation Instrument PCBA Manufacturing

● Problem 1: Programming

There are many industrial instruments, and if they are sold worldwide, they need to be programmed with different programs and languages.

Measures: Use programmable devices (such as programmable logic devices, microcontrollers, etc.) and adapt to different regions' language and program needs through software switching. Consider using a software interface that supports multiple languages so that users can switch languages during the use of industrial control automation instruments.

● Problem 2: Welding 

The welding of the display cable of industrial control instruments requires thick tin and high temperature, otherwise the cable part will have tin defects;

Measures: Use appropriate soldering process parameters, including appropriate soldering temperature and time, to ensure that the cable is soldered well. Optimize the welding process when assembling PCBA for industrial control instruments, use thick tin cables or adjust the welding temperature and time to solve the problem of poor tin on the cables.

● Question 3: Finished Product Assembly

When assembling the housing of industrial control instruments, the height of the photoelectric sensor component needs to be controlled. Before soldering, the component needs to have its legs molded to the specified height. Otherwise, the housing cannot be fastened if the height is exceeded.

Measures: Add inspection steps to the PCBA production process to ensure that the height of components complies with regulations, such as using a visual inspection system or laser measurement technology.

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