Case Study: PCBA Solution for Voltage Regulator in Industrial Automation
1. Background Overview
A European customer in the industrial automation sector required a stable and efficient PCBA solution for a voltage regulator module. Their challenge was ensuring voltage output consistency, thermal stability, and cost efficiency across high-volume production.
2. Application Scenario
The voltage regulator is used in industrial control cabinets and automation systems, delivering stable DC power to PLCs, sensors, and motion controllers. It must operate reliably in environments with variable input power and elevated temperatures, particularly in high-demand production lines or distributed control systems.
3. Product Specifications
| Parameter | Value |
|---|---|
| Input Voltage | 85–265V AC |
| Output Voltage | 24V DC ±1% |
| Rated Output Power | 100W |
| Output Ripple | ≤50mVp-p |
| Efficiency | ≥88% |
| Operating Temp. | -20°C to +70°C |
| Cooling Method | Natural air convection |
| Protections | OVP, OCP, Short circuit |
4. Application Results
- ✅ First-pass yield (FPY): Achieved 99.3% at SMT and DIP stages
- 💰 Cost reduction: Reduced overall unit cost by 15.8% via design-for-manufacturing (DFM) and local sourcing
- 🔧 Thermal optimization: Cut hotspot temperature by 21% by redesigning copper distribution and improving via layout
- 🚚 Lead time: Shortened from 4.5 weeks to 3.2 weeks, including material procurement and assembly
- 📉 Defect rate: Field failure rate dropped from 0.9% to 0.2% over six months of deployment
5. KKPCB Strengths Demonstrated in This Case
KKPCB showcased its full-range capabilities in PCB fabrication and PCBA assembly, backed by ISO9001, IATF16949, and ISO13485 certifications. The customer benefited from our:
- Advanced AOI, ICT, and X-ray testing
- IPC-A-610 certified soldering and inspection teams
- Bilingual engineering support that ensures fast and accurate design feedback
- Flexible production lines that handle both prototyping and volume orders
- Strong supplier network to secure component availability and control cost
6. Custom Manufacturing Solution from KKPCB
To address the client’s strict requirements for power stability and thermal performance, KKPCB implemented the following in the manufacturing stage:
- Used high-Tg FR4 materials with 2 oz copper for improved current handling and thermal dissipation
- Optimized PCB stack-up with shorter signal paths to reduce EMI
- Re-engineered solder pad layout to improve solder joint strength and reduce rework
- Applied selective conformal coating to protect sensitive areas from dust and humidity
- Conducted pre-production NPI review and implemented traceability at each process step
7. Real-World Impact of the Solution
- ⚙️ Reliability: Improved long-term operational stability by 24%, based on thermal shock and lifecycle tests
- 💡 Energy efficiency: Improved power conversion efficiency led to lower system energy loss
- 📦 Time-to-market: Accelerated product launch by 30% through rapid prototyping + volume transition
- 📉 Total cost of ownership (TCO): Lowered through-life costs by 18% by reducing field maintenance, returns, and component aging issues
