Today, we are excited to introduce one of our recent projects produced by JY Company — the Warehouse Shutter Controller PCBA. This project showcases our complete PCB manufacturing and assembly capabilities, from design confirmation to final production and testing. Our goal is always to deliver reliable, cost-effective, and high-quality PCB assembly (PCBA) solutions that meet customer requirements.
PCB Manufacturing Process
Before starting PCB fabrication, we confirm all the PCB production parameters with the customer. For this specific project, the parameters were as follows:
- Single board production
- Board size: 15.51 × 14.63 mm
- Material: Standard FR4
- Solder mask: Green
- Silkscreen: White
- Surface finish: Lead-free HASL (hot air solder leveling)
- Through-hole: Covered with oil
After confirming these details, our engineering team prepares the production draft based on the customer’s Gerber data. This process typically takes one day. Once confirmed by the customer, we begin the PCB production. Since the board design was relatively simple, manufacturing took around five days. We charged the customer 136.8 USD for 100 pieces, providing a highly competitive price in the market.
Component Procurement and Cost Efficiency
The warehouse door controller PCBA contains 41 different components, densely placed on the board. The majority are resistors and capacitors, each costing about 0.001 USD. There are also larger connectors, including:
- KLS2-EDV-5.08-02P-4 + KLS2-EDK-5.08-02P-4S
- KLS2-EDV-5.08-03P-4 + KLS2-EDK-5.08-03P-4S
- KLS1-208Y-5.7-1-08-S
These connectors are critical for the warehouse shutter controller’s stable performance. The PCBA also includes multiple integrated circuits, such as U1–U8 chips, with U8-CY07 v1.1 (433.92 MHz) being the most expensive component. We suggested a local China-made replacement of equivalent quality, significantly reducing the cost — a recommendation that our customer greatly appreciated.
PCBA Assembly Process
SMT Assembly and Inspection
Before assembly begins, our team double-checks all materials and processes. Even a single incorrect component can cause the entire PCBA to fail. During SMT assembly, we perform first article inspection (FAI) and maintain a detailed soldering record. After reflow soldering, we carefully inspect for any short circuits, solder balls, or cold joints. If any defects occur, we analyze the cause — such as excess solder paste, incorrect temperature, or fast heating rate — and fine-tune the reflow oven temperature curve accordingly.
Through-Hole and Wave Soldering
Next comes the through-hole soldering phase. Our operators pay close attention to lead angles and the orientation of each component — especially the U8 chip, which requires precise alignment. Fuse holder soldering is also critical for this design. During wave soldering, engineers continuously monitor and adjust the temperature, remove solder dross regularly, and ensure that every PCBA meets our strict quality standards.
All completed PCBAs are then handled using anti-static transport boxes to prevent any damage from external impact or electrostatic discharge.
Application of the Warehouse Door Controller
The finished Warehouse Shutter Controller PCBA is used in automated warehouse door systems. As shown in the application image, the drum grille structure provides enhanced security while minimizing installation space. This design is especially popular in modern warehouses requiring efficient, compact, and durable control systems.
At JY Company, we are proud that our high-quality PCB and PCBA manufacturing services contribute to our clients’ success in the competitive industrial automation market.
Why Choose JY Company for PCBA Projects?
- Expert engineering support from PCB design to final assembly
- Competitive pricing and cost-reduction recommendations
- Strict quality control and testing procedures
- Fast lead time with reliable logistics
- Full service: PCB fabrication, component sourcing, and assembly
Contact Us
Looking for a reliable PCBA manufacturer for your next project? Whether you need a warehouse shutter controller, industrial automation PCB, or custom electronic control board, we’re ready to assist you.
Contact JY Company today to discuss your project or send us your Gerber files for a free quote!
