1️⃣ Background Overview

With the tightening of global environmental regulations and the upgrading of industrial water resource management needs, sewage treatment plants of customers in Europe, America and the Middle East are in urgent need of highly reliable and extreme environment resistant automation control systems. Traditional PLC modules have pain points such as frequent signal interference, poor stability under high temperature conditions and high maintenance costs in complex sewage treatment scenarios. KKPCB has designed a set of customized PCBA solutions based on highly reliable programmable logic controllers, focusing on the process upgrades of PCB manufacturing and PCBA assembly to achieve full coverage of environmental adaptability, long-term stability and intelligent control capabilities of hardware equipment.

2️⃣ Application Scenarios

This solution focuses on two typical scenarios:

❶High temperature and high dust environment in the Middle East: pump station control of sewage treatment plants in desert areas, and stability issues of sensor signal transmission in sand and dust environments.

❷High humidity and corrosive environment in Europe: corrosion and salt spray protection requirements for sewage treatment equipment in coastal or high humidity areas.

Core control requirements include:

Real-time monitoring of sewage flow, pH value, turbidity and other parameters;

Precise control of the start, stop and adjustment of aerators, centrifuges and dosing pumps;

Remote central control room data interaction and fault warning.

3️⃣ Product application results

✅In a sewage treatment project in the Middle East, the PCBA control module equipped with TRICONEX PLC card has been running continuously for 18 months without failure under high temperature and dust conditions of 55℃, and the equipment maintenance cycle has been extended to 3 times that of the original system.

✅European customers have reported that the double-layer three-proof paint process PCB board designed by KKPCB has a 50% increase in corrosion resistance in a humid environment, and the average annual operation and maintenance cost has been reduced by 32%.

✅By integrating Ethernet communication modules, centralized data control of cross-regional sewage treatment stations is achieved, and the frequency of manual inspections is reduced by 75%

4️⃣ KKPCB’s core advantages in manufacturing

Precision PCB manufacturing capabilities:

Supports 12-layer high-density interconnect (HDI) PCBs to meet the layout and signal integrity requirements of PLC card multi-interfaces (Ethernet/RS485).

Adopt RO4350B high-frequency substrate to ensure zero attenuation of signal transmission in high temperature environment.

Harsh environment adaptation process:

Customized solution for Middle East customers: PCB surface covered with dust-proof nano-coating + thick copper paving design for key components, supporting -40℃~85℃ wide temperature operation.

Customized solution for European customers: Through immersion gold process + three-proof paint (moisture-proof, salt spray-proof, mildew-proof), it complies with CE/UL dual certification.

Intelligent PCBA assembly:

8 fully automatic SMT production lines (accuracy ±0.025mm) realize 01005 micro-component mounting, ensuring the compactness of modular design.

X-RAY/AOI full inspection ensures welding quality, and the pass rate exceeds 99.5%.

5️⃣ Manufacturing solutions for Europe, America and the Middle East

📊Solution 1: Middle East customers-anti-high temperature and dust PCBA manufacturing

PCB design:

Adopt 4-layer rigid-flexible board (FR4+PI substrate) to avoid line breakage caused by vibration;

Add a shielding layer to the key signal layer to reduce electromagnetic interference in a dusty environment.

PCBA process:

Coating dustproof epoxy resin glue, passed IP67 protection certification;

Design copper-based heat dissipation hole array in high-power component area, reducing temperature rise by 15℃.

📊Scheme 2: European customers – high corrosion resistance PCBA manufacturing

PCB design:

Select corrosion-resistant aluminum substrate, surface gold immersion process (plating thickness ≥ 1μm);

The board edge adopts stamp hole + V-cut design to facilitate later module replacement.

PCBA assembly:

Fully automatic selective coating of three-proof paint, coverage rate reaches 100%;

Integrated industrial-grade Ethernet isolation transformer, anti-common mode interference ability increased by 40%.

6️⃣ 🌾🌾Actual application effect

Improved manufacturing efficiency: KKPCB compressed the delivery cycle of the first 100 sets of PCBA for Middle Eastern customers to 7 days (industry average 15 days) through MES system + intelligent production scheduling.

Customer cost optimization: Modular design reduces spare parts inventory for European customers by 60%, and faulty boards can be partially replaced instead of scrapping the entire board.

Long-term stability verification:

Middle Eastern customers’ PCBAs only require one preventive cleaning and maintenance within 5 years;

European customers report zero oxidation on gold-plated PCB contacts, and a communication bit error rate as low as 0.001%.