Industrial PCBA Solution for High-Performance Data Storage Modules in Automation Systems
1. Background Overview
With the rising demand for data processing and real-time analysis in industrial automation systems, high-speed and reliable data storage devices have become essential. A European industrial equipment manufacturer approached KKPCB for a customized PCBA solution for their new-generation data storage modules. The goal was to ensure high performance, reliability, and cost-efficiency under long-term 24/7 operating conditions. KKPCB leveraged its extensive experience in industrial PCBA manufacturing to deliver a tailored solution.
2. Application Scenarios
The data storage module is widely used in industrial settings such as:
- Edge computing units in automated production lines
- Energy management and logging systems
- PLC/Industrial server data cache units
- Sensor gateway data hubs
Its core functions include fast read/write operations, data caching, and reliable storage for continuous system uptime.
3. Product Parameters (Table)
| Parameter Category | Key Specification |
|---|---|
| Storage Protocols | NVMe, SAS, SATA |
| Max Bandwidth | ≥1.5 GB/s (sustained R/W) |
| IOPS | ≥300K |
| Interface Compatibility | PCIe Gen3/4, SFP+, RJ45 |
| Operating Temperature | -10°C to 60°C |
| Operating Voltage | 12V / 3.3V DC |
| EMC Compliance | EN 55032, EN 55035 |
| Board Size Limit | ≤ 180mm x 130mm |
4. Results Achieved
After implementation, the customer achieved:
- Improved Quality: First-pass yield rate reached 99.8%, zero failures in 1000-hour burn-in test.
- Cost Savings: Manufacturing cost reduced by 15% through BOM optimization and process efficiency.
- Faster Lead Time: Prototyping within 7 working days, mass production lead time shortened to 14 days.
- Enhanced Performance: Storage performance improved by approx. 20%, meeting high-speed caching demands.
5. KKPCB Strengths Demonstrated
KKPCB showcased its strengths in high-reliability industrial PCBA manufacturing. With 100K-class cleanrooms and fully automated SMT lines, we excel in complex multilayer boards, impedance control, EMI suppression, and high-speed layout processing.
Our engineering team supports clients with BOM reviews, DFM feedback, rapid prototyping, and strong coordination with R&D, helping customers reduce design cycles and accelerate product launches.
6. Manufacturing-Oriented Custom Solution (with image suggestion)
KKPCB provided a customized manufacturing solution including:
- HDI board capability for high-speed signal integrity
- Precision reflow soldering profiles to ensure BGA quality
- Differential impedance control and testing
- Dual-layer inspection (AOI + X-Ray) for critical components
- Custom labeling and pre-programming for product traceability
7. Real-World Outcome
The custom PCBA solution enabled:
- Zero failure rate in EMC and power interruption tests
- Lead time reduction of 44% compared to prior vendors (from 25 to 14 days)
- 15% lower cost than previous local EMS providers
- Over 1,000 units shipped to the European market with highly positive feedback on performance and reliability
