High and Low Voltage Power Measurement Board

High & Low Voltage Power Measurement Board (IPM Solution) | Power Industry

Customer Needs and Core Challenges

• Industry-Specific Needs: Focusing on energy measurement scenarios in the power industry, the customer requires a high & low voltage power measurement board that meets the "Reliability Requirements for Power Electronic Equipment". Core requirements include high-voltage isolation protection (supporting 10kV voltage measurement), strong electromagnetic interference resistance, long-term stable operation (adapting to a wide temperature range of -40℃ to 85℃), and accurate metering requirements for energy measurement PCB solutions.

• Core Challenges:

  • Material Level: The PCBA-specific BOM lacks standard component specifications, and the parameters of non-standard components (such as high-voltage sampling modules) are vaguely defined, leading to difficulties in material selection;
  • Supply Chain Level: Incompatibility of non-standard components is not guaranteed, and the supply cycle of core materials fluctuates greatly, posing a risk of supply disruption;
  • Production Level: Due to unclear material specifications, high rework rates, uncontrollable delivery cycles, and difficulty in controlling procurement costs.

IPM One-Stop Solution (Integrating Power Electronics PCB Design Core Capabilities)

Based on the core IPM business of the IPDM system, integrating three major technology platforms—KBOM, PCBA, and EES—it provides a full-chain solution:

• Deep Empowerment with KBOM Technology:

  • Intelligent matching of multi-source alternative materials through a library of 3.27 million certified materials, conducting original manufacturer specification traceability and sample verification for non-standard high-voltage sampling modules;
  • Providing domestic alternative solutions, balancing cost and performance, and establishing a full lifecycle BOM risk warning mechanism to proactively avoid material shortage risks;
  • Incorporating verified non-standard components into the KINGBROTHER-PLM product lifecycle management system to achieve compliant material control.

• PCBA Process-Specific Support:

  • Employs double-sided mixed assembly and 3D assembly processes, coupled with conformal coating, to enhance the product's resistance to corrosion and moisture in power environments;
  • Manufactured according to IPC-A-610G Ⅲ standards, using flying probe testing to ensure 100% circuit connectivity, and optimizing the SCH isolation layout for mixed strong and weak current designs;
  • Utilizes a high-reliability nitrogen reflow soldering process to improve soldering yield and connection stability under high-voltage conditions.

• EES Full-Process Validation Support:

  • Conducts DFM manufacturability analysis to proactively avoid manufacturing process defects and reduce assembly defect rates;
  • Utilizes CNAS/CMA accredited laboratories for environmental reliability testing (salt spray, high and low temperature cycling) and electrical reliability testing (withstand voltage, insulation resistance);
  • Establishes a 24-hour failure analysis closed-loop mechanism to quickly locate and resolve material or process issues.

Core Technical Parameter Table

Implementation Results

• Significantly improved production efficiency: Mass production cycle reduced by 28%, production rework rate decreased from 12% to 3%, and delivery efficiency improved by 30%;
• Enhanced supply chain resilience: Supply chain risk incidence rate reduced by 45%, core material supply stability improved to 99%, and non-standard component compatibility issues completely resolved;
• Precise cost control: Through domestic substitution and BOM optimization, material procurement costs decreased by 18%, and overall machine maintenance costs decreased by 40%;
• Full lifecycle management implemented: Achieved full-process material traceability from material selection, procurement, production to operation and maintenance, with 100% management coverage;
• Doubled product reliability: Product failure rate reduced by 50%, fully meeting the core requirements of the power industry for high-voltage isolation, electromagnetic interference resistance (EMI/EMC PCB Design), and long-term stable operation.