PCBA Solution Case Study for Motor Driver
— High-Performance Drive Control Board Empowering Industrial Control Systems
1. Background Overview
A customer from the Middle Eastern region, engaged in industrial control system integration, planned to develop a two-phase open-loop stepper motor driver for use in precision mechanical control applications. The project required a control board (PCBA) with high stability, strong interference resistance, precise microstepping control, and support for high-voltage input, compact size, high-speed output, and auto-parameter optimization.
After evaluating multiple suppliers, the customer chose KKPCB to provide a customized PCBA solution specifically tailored for motor driver applications, aiming for both fast R&D and stable mass production.
2. Application Scenarios
This stepper motor driver is widely applied in the following industrial control fields:
- Automated production lines and CNC machine systems
- Precision position control in packaging and logistics systems
- Motor control for robotic end effectors
- Electric actuator drivers in energy and oil & gas sectors
- Multi-stage pump speed control in water treatment systems
Whether deployed in high-temperature regions like the Middle East or in high-safety-demand environments in Europe, the product must ensure excellent stability and environmental adaptability.
3. Product Parameters
| Item | Specification |
|---|---|
| Operating Voltage Range | DC 24V–70V / AC 20V–80V |
| Max Output Current | Peak 7.0A, effective current auto-regulated |
| Current Control Algorithm | PID control |
| Microstepping Settings | 16-level DIP switch configuration |
| Max Rotational Speed | Up to 3000rpm (depending on motor used) |
| Anti-Vibration Design | Built-in auto-resonance detection & damping |
| Signal Filtering | 2MHz digital signal filtering |
| Input Signal Mode | DIR & PUL, CW/CCW dual-pulse supported |
| Idle Current Control | Auto half-current when motor is idle |
| Protection Mechanisms | Over/under-voltage, overcurrent, opto-isolation |
4. Application Results
With KKPCB’s customized PCBA solution, the customer successfully developed and mass-produced the two-phase open-loop stepper driver. The board performed excellently in various industrial environments, passing both anti-interference and high-temperature aging tests. It maintained high torque at high speeds, and the compact board design helped minimize enclosure space while simplifying wiring. The customer’s technical team was highly satisfied with the board’s overall performance.
5. KKPCB’s Advantages Demonstrated in This Case
In this project, KKPCB demonstrated several key strengths:
- Fast engineering support: We finalized the initial design solution within a week of the customer’s request.
- One-stop manufacturing service: From PCB prototyping and small-batch testing to mass PCBA production, we streamlined the full process to accelerate time-to-market.
- High-reliability standards: We adopted full SMT automation, AOI optical inspection, and X-ray solder verification to ensure zero-defect delivery.
- Flexible customization: We supported low MOQ and fast design iteration for different product versions.
- Strict quality control: Our factory is certified under ISO 9001 and IATF 16949, ensuring that our products meet high industrial reliability requirements.
6. KKPCB’s Custom Manufacturing Solution
To meet the customer’s demands for a high-performance stepper driver board, we proposed the following manufacturing-centered solution:
- PCB Fabrication: We used high-TG, high-voltage FR4 material to improve dielectric strength and heat dissipation. A 4-layer PCB layout was adopted to optimize power and signal layer routing for better signal integrity.
- PCBA Assembly: We selected compact components (e.g., 0201 packages, high-efficiency MOSFETs, digital isolators) and ensured tight layout integration. Our reflow/wave soldering processes maintained high consistency and quality.
- Modular and Compatible Design: We reserved flexible signal input options (pulse/voltage control) to support future function expansions.
7. Real-World Impact of the Solution
The delivered PCBA solution significantly improved the customer’s product performance and shortened the development-to-delivery timeline to just five weeks. During field testing, the driver remained stable even under heavy load and in environments with strong electromagnetic interference. The product’s after-sales failure rate dropped by nearly 40%. The customer has since expressed interest in continuing cooperation with KKPCB for next-generation smart driver projects.
