PCBA Solution Case Study for Voltage Sensor in Industrial Automation
1. Background Overview
A European customer specializing in voltage regulators was seeking to integrate a new high-performance voltage sensor module into their next-generation products. The client faced challenges such as unstable temperature drift, inefficient component layout, and long delivery cycles. They were looking for a reliable manufacturing partner with strong customization capabilities and ultimately chose KKPCB for its extensive experience in high-reliability PCBA solutions.
2. Application Scenarios
This voltage sensor PCBA solution is widely used in:
- High-voltage DC system voltage monitoring
- Voltage regulator control and feedback units
- Power supervision in industrial automation platforms
- Electrical isolation modules in smart manufacturing equipment
3. Product Parameters
| Item | Specification |
|---|---|
| Voltage Measurement | Up to 1500V DC |
| Response Time | < 3 µs |
| Accuracy | ±0.8% FS |
| Output Type | Analog voltage (±5V or ±10V) |
| Mounting Method | PCB-mounted |
| Insulation Rating | 6400V |
| Operating Temperature | -40°C to +85°C |
| Standards & Compliance | IEC 61010-1, UL 94-V0 compliant |
4. Application Results
- Quality: First-pass yield rate reached 99.85%; long-term burn-in tests showed exceptional stability.
- Cost Optimization: BOM cost was reduced by approximately 7% by replacing non-critical components with cost-effective equivalents.
- Performance Upgrade: Electromagnetic isolation redesign reduced signal interference by over 30%, increasing accuracy to ±0.5%.
- Delivery Time: Lead time shortened from 20 days to 13 days through streamlined SMT and inventory integration.
5. KKPCB Advantages Demonstrated in This Case
As a manufacturer committed to “Zero Defect and Trusted Delivery,” KKPCB provides significant advantages for industrial-grade PCBA projects:
- 15+ years of experience in producing high-voltage, high-reliability control boards
- ISO 9001 and ISO 13485 certifications, ensuring strict quality standards
- Advanced MES system & inline SPI/AOI inspections, reducing defects and inconsistencies
- One-stop service from PCB fabrication to SMT assembly and functional testing
- Dedicated international project team for effective English communication and technical support
6. Custom Manufacturing Solution
In this case, KKPCB provided a customized manufacturing solution tailored to the product’s industrial and high-voltage needs:
- PCB Material Customization: High CTI FR4 material was used to improve voltage insulation, with clearances ≥8mm
- Optimized Circuit Layout: Clear zoning between analog input, isolation, and output sections to minimize interference
- Mixed Assembly Process: Combined SMT and THT to ensure consistency for hybrid module components
- Error-Proof Design: Key components featured customized pad shapes to prevent misplacement during manual insertion
- Full Traceability: Each PCBA was labeled with a unique QR code for full traceability of materials, process, and testing
7. Actual Results Achieved
Following batch delivery, the customer reported:
- Excellent product reliability, with a 99.85% pass rate across 500 units tested
- 6–8% cost reduction per unit, attributed to optimized BOM and local sourcing
- Performance enhancement, with accuracy improved to within ±0.5%, ideal for precision voltage control feedback
- Flexible lead time, with regular orders shipped in 14 days and expedited builds completed within 10 days
