Improving Manufacturing Logic and Process to Motor Controller Logic Board

Problem

A leading manufacturer of motor controls presented TT Electronics with this challenge. The original PCB layout had significant manufacturing and cost issues. Not only were the surface mount technology headers on the bottom side of the printed circuit board causing difficulty in assembly, but the jumper wires and two Digital Signal Processors (DSPs) were dated and not necessary.

Solution

TT Electronics eliminated the unneeded jumper wires and updated the layout with a single DSP to lower costs. The bottom side headers were converted to through hole technology for easier alignment and fast hand soldering. The assembly and component cost savings were 53%.