Three-Phase Three-Wire Power Filter PCBA Solution
1. Background Overview
A European client in the industrial automation sector was facing challenges related to electromagnetic interference (EMI) suppression, long lead times, and cost control in their power filter modules. They required a reliable manufacturing partner to deliver high-quality PCBA with strong EMI performance and timely delivery. KKPCB was selected for its advanced PCB fabrication and PCBA assembly capabilities.
2. Application Scenario
The three-phase three-wire power filter is primarily used to suppress EMI in industrial equipment and ensure system stability. Typical applications include:
- Industrial automation equipment
- Three-phase motor drives
- Inverters and converters
- UPS and switch-mode power supplies (SMPS)
3. Product Specifications
| Specification | Value / Description |
|---|---|
| Rated Voltage | 250/440VAC |
| Operating Frequency | 50/60Hz |
| Rated Current | 6A~10A |
| Dielectric Withstand | L-L: 1450VDC; L-G: 2700VDC |
| Leakage Current | ≤1.5mA |
| Climatic Category | HPF25/085/21 |
4. Application Results
By partnering with KKPCB, the customer achieved significant improvements:
- Quality: Passed IEC61000-4-4 EMC testing; EMI suppression improved by 20%
- Cost: Total BOM and production cost reduced by 15%
- Lead Time: Delivery cycle shortened from 18 days to 12 days (33% improvement)
- Performance: Stable operation under high temperature and humidity conditions
5. KKPCB’s Strengths in This Case
KKPCB demonstrated the following advantages:
- One-stop service covering both PCB fabrication and PCBA assembly, minimizing coordination efforts
- High-precision production, using state-of-the-art SMT lines, AOI, and X-ray inspection
- Rapid response and agile scheduling for urgent projects
- Engineering support, including DFM analysis to improve manufacturability and reliability
6. KKPCB’s Customized Manufacturing Solution
To address the customer’s needs, KKPCB provided a manufacturing-focused solution aligned with its positioning:
- PCB design optimization: Recommended a 4-layer high-TG FR4 stack-up to enhance EMI shielding
- Process enhancement: Applied protective conformal coating to key components for better vibration resistance
- Custom functional testing: Designed and implemented dedicated test jigs for 100% testing coverage
- Component localization: Suggested cost-effective alternatives for passive components to shorten procurement time
- Packaging upgrade: Used anti-static foam packaging to ensure product integrity during shipment
7. Real-World Outcomes
As a result of this customized solution, the client achieved:
- 99.5% pass rate in mass production—well above industry norms
- 15% reduction in total production cost, boosting product competitiveness
- Delivery cycle reduced to 12 days, supporting the client’s go-to-market speed
- High satisfaction, with the client planning to extend future projects to KKPCB
