Project Overview
Recently, our engineering team successfully completed a Rush Door Device System PCB project. The customer required a full solution, not just PCB fabrication and assembly, but also complete product integration including the housing, key lock, and LED indicator. We provided a complete one-stop PCBA service covering design, PCB manufacturing, component sourcing, assembly, testing, and enclosure production.
At the beginning, the customer only supplied a hand-drawn circuit sketch with component placement. Our engineers transformed this into a professional Gerber file design and generated a complete BOM (Bill of Materials). Each component was carefully documented with specifications such as value, package type, quantity, and part number to ensure smooth production.
PCB Specifications
- Type: 2-layer PCB
- Size: 54mm x 58mm
- Material: TG140
- Thickness: 1.0mm
- Copper Thickness: 1oz
- Surface Finish: HASL
- Solder Mask: Green
- Silkscreen: White
- Panelization: With V-CUT for assembly convenience
The PCB panelization allowed efficient SMT & THT assembly. This ensured better yield and faster production while meeting the customer’s delivery requirements.
System Functionality
The Emergency Rush Door System includes a microcontroller-based computerized alarm system. Once the door is opened, after a pre-programmed time delay, the system activates both audible and visual alarms. Key features include:
- Single magnetic switch for alarm activation
- End-of-line protection with a 2.2kΩ resistor
- Neutralizing lock to temporarily shut down the local alarm without affecting the overall security system
- Flexible configuration through JP1 bridge for constant siren engagement or automatic reset when the door is closed
This design ensures reliable emergency door security for applications such as factories, trains, aircraft, and commercial buildings.
Assembly Process & Key Considerations
This project required double-sided assembly with multiple connectors and wire mounting. Since wire soldering was manually performed by skilled workers, our engineers prepared a detailed wire-mounting guide to ensure consistency and avoid cold solder joints. During reflow soldering, particular attention was given to temperature profiles to protect plastic connectors from overheating.
Our 18+ years of experience in the PCB and PCBA industry allowed us to optimize the production process, ensuring both cost efficiency and product reliability. The customer was highly satisfied with our quotation, prototype samples, and production quality.
Testing & Verification
After assembly, every board underwent a full functional test to verify alarm triggering, magnetic switch performance, LED indication, and time-delay operation. The boards performed successfully, and housing production is scheduled for completion next month, finalizing the entire product delivery.
Installation & Operation Guide
- Place the device near the emergency door.
- Ensure the off key on the right side is accessible.
- Connect the magnetic switch to terminal 1, clasps RM and (-).
- Install the 2.2kΩ EOL resistor for proper circuit completion.
- If connecting to an alarm system, wire clasps C1 and NC1.
- Supply 12V DC power to (+) and (-) terminals.
- Connect the lock plug (grey wires) to its connector.
- Close the housing with four screws.
- Set the alarm delay time according to the time chart.
- Mount the LED light to the housing body.
- Turn the key clockwise to activate.
- Test by opening the door to confirm alarm function.
The JP1 jumper allows configuration for either continuous siren mode or auto reset when the door is closed.
Future Development of Rush Door PCBs
Rush door devices play a critical role in safety and emergency systems across various industries. With growing demand in aviation, transportation, manufacturing, and public infrastructure, the need for reliable emergency PCBA solutions will continue to increase. Our proven expertise in custom PCB design, assembly, and enclosure integration makes us a trusted partner for such projects.
Contact Us for PCB & PCBA Projects
If you are looking for a reliable partner for your PCB and PCBA manufacturing needs—including custom design, prototyping, and full assembly services—we are ready to support your next project.
Contact us today to get a competitive quotation and professional engineering support for your custom PCB assembly projects.
