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PCB Assembly FAQ

Common Problems And Avoidance Strategies In Industrial Control PCBA Manufacturing

2023-12-21

PCB refers to the printing board that connects and prints components according to the predetermined substrate on the general substrate. The main function is to make various electronic components form the connection Essence PCB applications are very wide, and almost all electronic products need to use PCB, so PCB is also called "the mother of electronic products".

In the fields of 5G communication, consumer electronics, automotive electronics, industrial control, and medical care, which are the rapid development of PCB assembly. The corresponding multi-layer board, HDI, soft board, packaging substrate, and other types of product demand will be more prominent, so PCBA is also called the "Mother of the Electronic Industry".

1. Understand PCB

● Basic Structure

PCB is usually made of insulating material, such as epoxy resin enhanced by glass fiber. By printing or etching, a copper layer is formed on the board to form a conductive path and connection point.

● Types of PCB

According to different application and design requirements, there are many types of PCB, including single-layer boards, double-layer boards, multi-layer boards, high-density interconnect boards (HDI), etc.

● Technical Development Trend

With the continuous development of electronic devices, the design of printed circuit boards has continued to evolve. High-density, high-performance, light, and light short (Miniaturization) is one of the main trends of the current PCB design.

Application Field

In the fields of 5G communication, consumer electronics, automotive electronics, industrial control, and medical care, PCB demand has ushered in rapid development. Different application areas may have higher requirements for specific types of PCB, such as considering signal integrity in high-frequency applications. The demand for high-performance and high-density PCB assembly has further increased.

● Product Type

Multi-layer boards, HDI (high-density interconnection), soft boards, packaging substrates, etc. are some special types of PCB. They have promoted the continuous innovation of PCB assembly technology while meeting different application needs.

Printed Circuit Board is used to support electronic components and connect them

2. Common problems in PCBA manufacturing  

In the field of industrial control, various technical problems may be encountered during the PCBA manufacturing process. Here are some common problems:

● Welding Quality Problem  

The problems of Poor welding may not be completely wet, welded, and broken welding. Welded welded welds may cause short circuits.

● Component installation problem

The component is installed in the reverse position, causing abnormal circuits. The component is not installed in the specified position correctly, which may affect signal transmission and circuit performance.

● Component damage

During the assembly process, components may be damaged due to inappropriate anti-static measures. In the process of installation or processing, components may be damaged due to mechanical stress.

● Circuit board design problem

Unreasonable PCBA wiring may cause signal integrity, such as string disturbance and timing problems. Poor power supply layout may cause voltage unstable in some parts.

● Quality Control Problem

The lack of real-time process monitoring may cause problems to be tested in time on the production line. Inadequate testing also may lead to the flow of defective products into the market.

● Environmental Factor

Inappropriate temperature and humidity conditions may affect the performance of welding and components.

Dust and foreign bodies in the production environment may hurt the performance of the circuit board.

Suitable and high-quality components protect PCB circuit boards

3. Solution  

● Solve welding quality problems

Introduce advanced soldering technologies, such as reflow soldering and wave soldering, to ensure accurate control of soldering temperature and time. Use high-quality solder and implement strict quality control during production, including visual inspection and automated testing.

● Solve component installation problems

Implement an automated component installation system that uses vision guidance and precise mechanical positioning to ensure components are installed correctly. Strict inspection procedures are implemented during the manufacturing process, including manual and automated inspections, to ensure correct component location and polarity.

● Solve component damage:

Implement anti-static measures, including using anti-static floors, wearing anti-static clothing, and providing appropriate storage conditions. Use automated processing equipment to reduce the possibility of human damage, and strengthen employee training to increase protection awareness.

● Solve circuit board design problems

Conduct a thorough board design review to ensure proper routing and power distribution. Use advanced design tools and simulation techniques to identify and resolve potential issues before they happen. Optimize layout with simulation and analysis tools to improve circuit performance.

● Solve quality control issues

Solution: Introduce a real-time process monitoring system to monitor process parameters and adjust them in real-time. Strengthen testing procedures, including automated testing and manual inspection, to ensure product quality meets specified standards. Establish quality control standards and train employees to improve their quality awareness.

● Address environmental factors

Control the temperature and humidity of the production environment and use appropriate filtration systems to reduce dust. Implement appropriate dust protection measures such as sealed production lines and clean rooms. Ensure employees follow best practices for environmental controls.


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