KKPCB Success Case:Industrial Network Router PCBA Solution
1. Background Overview
A European customer in the industrial automation sector required a high-performance and reliable industrial network router for device-to-device communication in their automated systems. The router needed to support high-speed data transfer, strong anti-interference capabilities, remote control functionality, and stable operation in harsh environments. The customer was looking for a supplier with expertise in customized PCB design and PCBA assembly to meet their strict quality and performance requirements.
2. Application Scenario
The industrial network router is widely used in smart factories and industrial automation systems to connect various automation devices (such as PLCs, sensors, controllers, etc.), enabling real-time data exchange and remote monitoring. The router’s high-performance network connectivity ensures smooth operation across the production line, reducing downtime and improving production efficiency.
3. Product Parameters
| Item | Parameter |
|---|---|
| Processor | ARM Cortex-A9, 1.2GHz |
| Interfaces | 2x Gigabit Ethernet, 1x Serial RS232/RS485 |
| Wireless Support | Wi-Fi, LTE/4G |
| Power Supply | 12VDC, PoE Support |
| Operating Temperature Range | -20°C to +60°C |
| Supported Protocols | MQTT, Modbus TCP, HTTP, VPN |
| Mounting Method | DIN Rail Mount |
| EMC Certification | EN55032, EN61000-6-2 compliant |
4. Application Results
Through KKPCB’s PCBA solution, the industrial network router successfully addressed multiple customer needs. In terms of quality, the product’s stability was significantly enhanced, with a system failure rate of less than 0.1%. By optimizing PCB design and precision PCBA assembly, the router’s anti-interference performance was greatly improved. The customer reported a 15% increase in production efficiency thanks to the router’s remote control capabilities. In terms of cost, KKPCB’s customized solution helped reduce the production cost per unit by approximately 12%. Moreover, KKPCB’s quick response and short production lead times allowed the customer to receive the first samples in just 4 weeks, meeting their time-sensitive requirements.
5. KKPCB’s Advantages Demonstrated in this Case
- High-Precision PCB Manufacturing: KKPCB has advanced multi-layer PCB design and manufacturing capabilities to meet the demands of high-density, complex layouts, ensuring stable operation for the industrial network router.
- Custom PCBA Assembly: KKPCB uses precision SMT placement technology and efficient reflow soldering processes to ensure accurate component assembly and long-term reliability.
- Comprehensive Testing Capabilities: KKPCB conducts thorough functional, environmental, and EMC testing for every product batch, ensuring they meet industrial standards and perform reliably under harsh conditions.
- Flexible Production and Delivery: KKPCB’s ability to adjust production schedules based on customer requirements allows for on-time delivery of high-quality products even within tight timelines.
6. KKPCB’s Customized Manufacturing Solution for the Customer
For this industrial network router project, KKPCB provided the following customized manufacturing solution:
- PCB Design Optimization: KKPCB designed multi-layer PCBs suitable for high-frequency transmission and anti-interference, ensuring stable performance even under high-speed data transfer conditions.
- Precision PCBA Assembly: Using precision SMT technology and stringent soldering controls, KKPCB ensured the accuracy of component assembly and product long-term reliability.
- Environmental Testing: To ensure the product operates in extreme temperatures, humidity, and vibration conditions, KKPCB provided thermal, humidity, and vibration testing for each batch of products, ensuring compliance with industrial application standards.
- Quick Response and Delivery: With flexible production capabilities and efficient supply chain management, KKPCB responded quickly to customer needs, ensuring timely delivery of both samples and mass production.
7. Actual Results of the Solution
KKPCB’s PCBA solution significantly enhanced the performance and reliability of the industrial network router. The product not only passed rigorous environmental testing but also showed improved anti-interference performance. In terms of production efficiency, the customer reported a 0.1% decrease in production line failures and a 15% increase in production efficiency. Additionally, the overall production cost per unit was reduced by 12%, allowing the customer to optimize their production budget while maintaining product quality. Moreover, KKPCB’s quick delivery capability ensured that the customer could meet their market deadlines.
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