1.Background Overview A client from Europe, engaged in the development of industrial automation systems, required integration of a high-precision pressure sensor module in their next-generation process control system. The module needed to detect subtle changes in gas or liquid pressure in real time to enable dynamic control and safety alerts. Given the complex environment in...
Client Industry: European Industrial Equipment Manufacturer Applications: Particle Accelerator RF Systems / Industrial Microwave Heating 1. Industry Manufacturing Challenges Critical Requirements: Sustain 100A+ high-frequency current (13.56MHz) Maintain MOSFET junction temperature <135°C in 85°C ambient Achieve 10-year maintenance-free operation Previous Supplier Issues: ▶ CTE mismatch in traditional aluminum substrates caused copper layer delamination ▶ Manual MOSFET soldering led...
Client Industry: European EMC Testing Equipment Manufacturer Applications: ISO 17025-Certified Probe Calibration / High-Frequency Field Measurement 1. Manufacturing Challenges Critical Requirements: Maintain dielectric thickness tolerance ±2% across 150mm×150mm panels (18GHz applications) Control Dk temperature drift within ±0.02 (-40°C to +85°C) Achieve 100% electrical parameter consistency for laboratory-grade calibration Previous Supplier Limitations: ▶ Manual thickness compensation caused ±8% dielectric variation ▶ PTFE delamination during lamination...
— 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,...
Client: A Leading Metro System Operator (Asia) Application: Underground Tunnel Communication Systems 1. Operational Challenges Environmental Conditions: 24/7 high humidity: 95% RH (Relative Humidity) Condensation cycles with temperature fluctuations (15°C–45°C) Continuous vibration from passing trains Critical Failures Observed: ▶ Insulation resistance (IR) dropped to <1GΩ within 6 months ▶ Bit Error Rate (BER) surged to 10⁻⁴ (vs....
—Ultra-High-Density Design & Thermal Management for Compact Servo Systems 1. Customer Requirements Application: Industrial robotic joint drive control Key Challenges: Integrate 16-channel PWM control + current sampling within 80mm × 60mm Excessive MOSFET temperature rise (>30°C @20A), causing throttling Compliance with IEC 61000-6-4 (Industrial EMC Standard) 2. KKPCB Innovative Solution （1）Ultra-High-Density Interconnect Design 10-layer any-layer HDI (1+N+1 stackup), 0.1mm laser microvias, enabling 5μm trace/space Hybrid...
Discover how KKPCB delivered a high-reliability servo drive PCBA for a European industrial automation client. Featuring 6–8 layer HDI PCB fabrication, high-TG materials, ENIG finish, optimized thermal design, controlled impedance routing, copper-block heat management, and full SMT + DIP assembly. Achieved 45% EMI improvement, 30%+ uptime increase, <0.2% repair rate, and 12% cost reduction.
——High-Efficiency Design Solving Thermal Challenges in RF Applications 1. Customer Challenge Application: 5G Base Station/Radar Power Amplifier Pain Points: Low Efficiency: Only 35% at 6GHz, causing excessive heat Unstable Performance: Return loss > -15dB, signal reflection issues Material Limitations: FR4-only PCB led to dielectric loss (Df > 0.02 @10GHz) 2. KKPCB Breakthrough Solution （1）Hybrid Material Stackup Rogers RO4350B (top/bottom)...
——12-Channel Isolation & High Reliability for Mission-Critical RF Systems 1. Customer Challenge Application: Military/5G Base Station SDR Backplane Critical Requirements: Support 12 independent RF channels without interference Achieve cross-channel isolation >65dB @2.4GHz Pass FCC Part 90 certification for industrial radio equipment Withstand harsh environments (85°C/85%RH for 1,000+ hours) 2. KKPCB’s Innovative Solution (1) Ultra-High Isolation Design EBG (Electromagnetic Bandgap) Structures:...
1. Background A European industrial automation customer was developing a power supply module for control systems, requiring high stability, conversion efficiency, and EMC compliance to ensure performance in demanding industrial environments. After evaluating several suppliers, the customer sought a reliable PCBA manufacturer with proven quality control and customization capabilities. 2. Application Scenario The power supply...
KKPCB is a leading electronic solutions provider specializing in PCB design, fabrication, assembly, and testing for Flex, Rigid-Flex, RF/Microwave, HDI, rigid multilayer, and ATE test boards. We offer comprehensive end-to-end services, including prototyping, component sourcing, SMT/THT assembly, functional testing, enclosure assembly, and final product packaging. With our one-stop, in-house capabilities, KKPCB delivers OEM and ODM solutions with fast turnaround, high quality, and cost-effective results, serving clients worldwide.
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