Power Supply PCBA Solution Case Study
1. Background
A European industrial automation customer was developing a power supply module for control systems, requiring high stability, conversion efficiency, and EMC compliance to ensure performance in demanding industrial environments. After evaluating several suppliers, the customer sought a reliable PCBA manufacturer with proven quality control and customization capabilities.
2. Application Scenario
The power supply unit is used in PLC systems, motor drives, and automated production lines. It converts AC input into multiple stable DC outputs for control cores and peripheral sensors, supporting 24/7 reliable operation.
3. Product Specifications
| Item | Specification |
|---|---|
| Input Voltage Range | 90 |
| Output Voltage / Current | 24VDC / 2.5A |
| Power Rating | 60W |
| Conversion Efficiency | 88% (typical) |
| Operating Temperature | -20°C to +70°C |
| Cooling Method | Natural air cooling |
| Safety Certifications | Complies with EN62368, UL, etc. |
| EMC Performance | Meets EN55032 Class B |
4. Application Outcome
With KKPCB’s high-reliability PCBA solution, the power supply performed with exceptional stability in the customer’s industrial system. It passed EMC testing on the first attempt and showed strong performance during long-term operation in temperature- and humidity-intensive environments. The customer’s time-to-market was significantly shortened, and the PCBA exceeded expectations in MTBF (Mean Time Between Failures), securing confidence for mass production.
5. KKPCB Advantages Demonstrated in This Case
- Certified Quality Systems: ISO 9001, ISO 13485, and IATF 16949 certified manufacturing ensures international-level product quality.
- Advanced SMT Capabilities: Supports high-precision mounting of 0201 components for compact and efficient board layout.
- Comprehensive Testing: ICT, FCT, AOI, and X-ray inspections ensure reliability for mission-critical industrial power modules.
- Responsive Engineering Support: Fast prototyping to mass production transition, with dedicated project tracking for every step.
6. KKPCB’s Custom Manufacturing Solution
To meet the customer’s requirements, KKPCB implemented the following tailored strategies:
- PCB Design Optimization: Customized multi-layer PCB with reinforced copper and widened clearance to meet high-voltage safety requirements.
- Precision PCBA Assembly: Lead-free reflow soldering with full AOI inspection ensured consistent soldering quality of power components.
- Functional Test Development: Designed a custom load test platform for 100% burn-in testing under simulated operation.
- Protection and Coating: ESD-safe process and optional conformal coating enhanced durability in harsh environments.
7. Actual Results of the Solution
The solution led to a production yield increase to over 99.8%. EMC compliance was achieved within 3 days, compared to the previous two-week timeline. Delivery time for PCBA boards was reduced from 6 weeks to 4 weeks. The customer has now moved into full production and is considering KKPCB for additional industrial modules.
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