Due to the development of robotics and similar technologies, many different remote control devices are used in numerous fields. The assembly of printed circuit boards is essential for smooth movement and solid electrical connections between controllers and industrial machinery.

Electronics must be rugged and able to withstand the harshest environments of industrial use. In addition, industrial control PCBs must meet stringent industrial SIL and IEC requirements and provide unique design features and form factors for any industrial environment.

PCB Applications in Industry

The following are just a few examples of our industrial PCBs applications:

Units that provide electrical power
Robotics
Electronic control gearboxes
Drives and inverters for industrial applications
Electronic test and measurement instruments
Energy consumption regulation systems
Smart meters for use in industrial environments
Smart tags for computers and other electronic devices
Lighting systems

How to Make Industrial PCBs?

A printed circuit board (PCB) consists of an insulating board on which copper layers and signal lines are etched or printed. The number of layers on an industrial PCBs can range from one to eight or more as the complexity of the circuit increases. The PCB manufacturing process includes the following steps:

PCB Layout
When considering the industrial control PCB manufacturing process, design and layout are the first considerations.

You need to understand what you want and then choose a designer who can turn your vision into reality (virtual). Understanding PCB design and layout is the most critical step in producing industrial circuit boards.

PCB Design
The design will determine how the product will look and operate. A successful PCB design supports the operation of the device it is built on. Not all devices have the same pricing, so PCB designs can vary on many parameters. The type of user and their access to resources also determines the style of the PCB.

Today, design is done using specialized tools that can be used online and offline; they can be free or expensive.

PCB Prototyping

Once the design and layout are authorized for production, you can prototype and test the product to confirm that its functions and features are as expected. If the industrial PCBs is very complex, prototyping may take longer than usual.

Once the PCB prototype is completed, a third party will usually conduct further testing before it can be put into production. Therefore, the functionality and other characteristics of the final product are completely dependent on this component.

Assembling PCBs in an Industrial Setting
All the components and parts required for the PCB are etched onto the board in this manner. At this point the board is complete and ready to be sent to you or your client. Now, various organizations offer top-quality PCB assembly services.

Number of Layers in Industrial PCBs

Substrate or Base Material
The base material for industrial PCBs is called the substrate, which is usually made up of a durable fiberglass substance. PCB substrates are usually made of FR4 fiberglass. It must be remembered that the substrate acts as the structural core of the board.

In this case, the rigidity and thickness of the PCB is provided by the fiberglass. On the other hand, flexible PCBs may come with an adjustable plastic base.

The thickness of the PCB varies. Generally speaking, the thickness ranges from 0.8 mm to 1.6 mm. However, you may find some that are much thinner. As you pointed out, most PCBs have a fiberglass base. As an alternative, epoxy or phenolic resins can also be used.

However, this type of PCB requires a strong and durable base. Fiberglass and aluminum are the best materials in this case.

Copper Coating
The copper layer is laminated to the substrate using heat and glue. PCBs with two or more layers of copper on each side of the substrate are called “double-sided” boards. Some PCBs have only one layer of copper on the substrate. Similar to the substrate, the thickness of the copper layer varies, expressed in ounces per square foot.

The typical amount of copper used for most PCBs is one ounce per square foot. In addition, high-power industrial control PCBs are also common. As a result, they rely on copper weighing between two and three ounces. The thickness of copper required to make one ounce is about 35 microns.

Solder Mask
Put on the masking layer and start soldering. Two-layer and multi-layer PCBs use this layer as the bottom and top layers. The green color of the PCB may be attributed to this layer, which is often seen on copper foil.

Copper traces are designed to prevent accidental contact with other metals, solder, or conductive bits by a layer placed above the copper layer. This layer often helps ensure soldering is done in the proper locations and avoid solder skipping.

Silkscreen
Remove the solder mask and place the silkscreen layer on top. On this layer, the PCB has more letters, numbers, and symbols on it. These components make it simple to assemble the board and provide visual cues that help understand the board. Identifying the purpose of each pin or LED is usually done with silkscreen labels. As a reminder, silkscreen is usually white, but you can choose any color.

Industrial PCB Types Based on Layers
There are three main types of industrial PCBs in this category.

Single-layer PCBs
The most common printed circuit boards (PCBs) are single-layer. They are constructed with just one layer of base material. Copper-based conductors are applied to a single layer, and on top of the copper layer, they may have a silkscreen coating or protective solder mask.

The low manufacturing cost of this form of PCB is one of its major advantages. However, it may be used in applications that require simple circuits, which is not common in industrial environments.

Double-layer PCBs
Double-layer PCBs can have more complex circuits installed on them than single-layer PCBs. They are similar to single-layer boards, except that the conductive material is present on both sides instead of one.

Double-sided boards have advantages for more complex household circuits. In addition to increased freedom of operation, this type of board is also a practical choice for creating higher density circuits.

Double-sided boards are useful in many ways, but they are not a practical alternative for very complex circuits. To reduce electromagnetic interference, they cannot function with existing technology.

Multilayer PCBs
Multilayer industrial PCBs are best suited for complex circuit systems. These boards have multiple layers of substrate sandwiched between insulating layers.

The number of layers in a printed circuit board (PCB) may vary from 2 to 8, depending on the complexity of the circuit. The most advanced designs use boards with up to 42 layers.

Rigidity or flexibility of industrial PCBs
The rigidity of these PCBs is also a notable feature. Based on the rigidity, PCBs are divided into three categories:

Rigid printed circuit boards
The layers of these boards are made of hard, non-flexible materials. The material of the board prevents it from bending beyond a certain point, otherwise it will crack or break. This PCB is a solid board.

Solid PCBs
PCBs made of rigid materials tend to be smaller and can handle complex circuit designs. Furthermore, the signal lines of rigid PCBs are easy to organize, and their maintenance and repair are simple.

PCBs with flexibility
Flexible PCBs are another form of PCBs, and their circuits are built on flexible insulating materials that can be bent and twisted. Flexible PCBs are characterized by their adaptability. In addition to being available in single-layer, double-layer, or multi-layer boards, they can also be bent.

These boards are an excellent choice for saving weight and space when manufacturing specific equipment. Their excellent flexibility and low volume also make them popular. However, due to the flexibility of the board, it can be challenging to use.

Rigid-Flex Board
This is an industrial PCBs with a flexible but rigid structure, which comes with rigid and flexible components. Both flexible and rigid PCBs are used in this design. These circuits are mainly used in aerospace and military applications that require extremely thick wiring. A significant advantage of rigid-flex PCBs is that they can significantly reduce the weight of electronic products.

Every electrical device relies on printed circuit boards (PCBs). PCBs are essential to many current technologies. In addition, PCBs are essential to the smooth and efficient operation of any industrial electronic equipment.

In addition, industrial control PCBs come in many forms to meet the needs of different industries. Therefore, you need to choose the PCB that best suits your industrial equipment. If you are not sure which type is best for your application, please consult KKPCB for advice.