Industrial Automation Servo Drive PCBA Solution Case
1. Background Overview
Under the accelerating global trend of industrial automation, a client from Europe aimed to develop a servo drive product with high dynamic response, high-precision control, and high integration for their next-generation industrial automation equipment. After evaluating multiple suppliers, the client ultimately chose to collaborate with KKPCB, seeking a one-stop customized service from PCB manufacturing to PCBA assembly in order to achieve fast delivery and reliable mass production.
2. Application Scenarios
This PCBA solution for servo drives is primarily used in:
- High-speed motion control systems in automated production lines
- Servo systems for CNC machines
- Joint drive modules in industrial robots
- Control units for high-precision machinery like packaging and printing equipment
- Motion control components in smart warehousing and logistics systems
As the core control unit in automation systems, servo drives must offer stable, fast signal processing and precise motion control to ensure efficient, high-accuracy operations.
3. Product Specifications
| Item | Specification |
|---|---|
| Input Voltage | AC 220V / 380V (Three-phase) |
| Output Current | 2.5A – 50A (Customizable) |
| Control Modes | Current / Speed / Position Loop Control |
| Encoder Interfaces | Incremental & Absolute Encoder Support |
| Communication Protocols | CANopen / Modbus / EtherCAT (Customizable) |
| Cooling Method | Forced Air / Natural Cooling |
| Overload Protection | 150% overload for 10 seconds |
| PCB Layers | 6–8 Layer High-Density Multilayer Board |
| Size Customization | Fully Supported |
| Assembly Process | SMT + DIP |
4. Application Results
The client’s original servo system suffered from signal interference and heat buildup during extended operation. KKPCB’s PCBA solution featured optimized layout, enhanced power-layer isolation, and improved thermal design. After 72 hours of continuous high-load testing, the system exhibited stable signal transmission with no packet loss. Heat levels remained within safe thresholds, and anti-interference performance improved by approximately 45%. The PCBA passed all in-house EMC and thermal tests and is now in stable production. The client expressed high satisfaction with the performance and delivery speed.
5. KKPCB Advantages Demonstrated in This Case
- Advanced PCB Fabrication Capabilities: 6–14 layer high-density boards for complex servo circuitry.
- Strict Quality Control: Full AOI and X-ray inspection to ensure soldering reliability.
- Flexible Customization: Rapid prototyping with tailored dimensions, materials, copper thickness, and layout.
- One-Stop Manufacturing Service: Covering PCB fabrication, components sourcing, SMT, DIP, and functional testing.
- International Quality Certifications: ISO 9001, IATF 16949 (automotive), ISO 13485 (medical), ensuring consistent product quality.
6. KKPCB’s Custom Manufacturing Solution for Servo Drive Projects
To meet the client’s requirements, KKPCB provided the following manufacturing-focused solutions:
- High-TG & ENIG PCB Technology: Ensures excellent conductivity and corrosion resistance under high temperatures.
- Thermal Management Enhancements: Embedded copper blocks and thermal vias to improve heat dissipation.
- High-Speed Signal Routing: Controlled impedance and differential pair design to maintain signal integrity.
- Optimized Through-Hole Soldering: Strengthened pad layout and dual-process soldering for high-power components like IGBT/MOSFETs.
- Automated PCBA Testing Platform: Based on test points and functional specs provided by the client, ensuring full inspection before delivery.
7. Real-World Outcomes of the Solution
Six months after implementation, the servo drive PCBA solution achieved remarkable results:
- 30%+ improvement in system uptime, with virtually zero board-level failures
- Repair rate below 0.2%, significantly outperforming industry averages
- Approx. 18% faster response time, resulting in more agile system performance
- 12% cost reduction achieved via BOM optimization and streamlined manufacturing
- Excellent consistency, enabling smooth batch deployment and easy future upgrades
If you’re also working on servo or motion control solutions, KKPCB is your trusted partner. With our zero-defect commitment, full-process quality control, and extensive industry experience, we help industrial automation projects come to life efficiently and reliably.
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