1. Background Overview

In industrial automation systems, sensors play a vital role in enabling intelligent monitoring and equipment interaction. A European client recently sought to develop a PIR-based motion sensor module for use in equipment activity detection and control systems. The module required high sensitivity, strong anti-interference capability, low power consumption, and stable performance in harsh industrial environments. KKPCB provided a one-stop solution covering both PCB fabrication and PCBA assembly, ensuring fast, reliable, and cost-effective manufacturing.

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2. Application Scenarios

This motion sensor module is designed for various industrial applications:

• Smart Lighting Control: Activates/deactivates lighting based on human or machine movement;
• Security Monitoring: Detects unauthorized motion in unmanned zones;
• Equipment Status Detection: Monitors robotic arms or AGV activity for logic control;
• Energy Management Systems: Optimizes HVAC and other utilities based on occupancy detection.

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3. Product Specifications (Table Format)

Parameter Category	Specification
Sensing Technology	Passive Infrared (PIR)
Operating Voltage	DC 3V–5.5V
Operating Current	< 45μA @3V
Detection Range	Up to 8 meters (typical)
Detection Angle	Horizontal 110°
Response Time	< 2 seconds
Output Format	Digital Output (High/Low)
Operating Temperature	-20°C to +60°C
Module Dimensions	22.7mm × 10.5mm

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4. Application Results

Optimization Area	Results
Performance	Detection sensitivity improved by 15%; better anti-interference in noisy environments
Cost Reduction	~12% cost savings by optimizing BOM and using locally sourced components
Delivery Time	Prototype-to-small batch delivery in just 12 working days (5 days faster than previous supplier)
Quality	100% functional test pass rate; failure rate < 300 DPPM in pilot batch

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5. KKPCB Advantages Highlighted in This Project

KKPCB demonstrated its strength as a trusted, zero-defect PCBA manufacturer through:

• Advanced SMT & DIP production lines supporting 01005, QFN, BGA, and more;
• Flexible prototyping to small/medium batch delivery, covering R&D to pilot runs;
• Bilingual engineering support (English/Chinese) for efficient communication;
• Comprehensive AOI, X-ray, and functional testing to ensure zero-defect delivery;
• Value-added component localization service to reduce sourcing risks and costs.

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6. KKPCB’s Custom Manufacturing Solution (Focused on PCB & PCBA Execution)

For this client, KKPCB’s tailored manufacturing solution included:

• PCB Design Optimization Suggestions: Recommended high CTI base material for high-impedance input circuits and enhanced grounding layout to reduce noise;
• Refined PCBA Process: Adopted low-temperature solder paste and tight reflow temperature control to protect sensitive components;
• Customized AOI + Functional Test Jig: Ensured digital output logic worked reliably across all units;
• Fast Prototyping & Split Delivery: First prototype completed in 5 days; 1,000 pcs delivered within 10 days after confirmation;
• Component Replacement Service: Helped the client replace high-cost imported components (e.g., MCU, LDO) with equivalent domestic options, ensuring consistent performance at a lower cost.

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7. Real-World Outcome of the Solution

The delivered PCBA solution brought measurable improvements:

• Quality: Passed 72-hour aging and temperature cycling tests at client site; 100% acceptance rate, no returns;
• Performance: 15% improvement in sensitivity; false trigger rate reduced by approx. 30%;
• Cost Efficiency: 12% cost savings thanks to localized sourcing and manufacturing optimization;
• Lead Time: Reduced delivery cycle to 12 working days, ~30% faster than previous supplier;
• Supply Chain Reliability: All key components are now sourced in China, avoiding EU supplier shortages and delivery uncertainties.