Posts Tagged ‘PCBA’

PCB vs CCA: What is a Circuit Card Assembly?

星期一, 22 7 月, 2024

Hey there! If you’re curious about circuit card assembly (CCAs) and what makes them tick, you’ve come to the right place. CCAs are the unsung heroes behind many of the electronic devices we use every day. Let’s dive into what they are, their essential parts, how they’re made, and why they’re so important.

What is a circuit card assembly?

Circuit card assembly or CCA is the process of producing printed circuit boards. In essence, it is the same as PCBA (PCB assembly), just in different name. CCA is a manufacturing technology that converts raw materials into printed circuit boards. It is used in many industries, including the military and aerospace sectors. This type of manufacturing requires skilled professionals to lay out the design and then assemble it. If you are planning to buy a batch of circuit card components, here are some things you should know about CCA.

A circuit card is a thin, flat dielectric material on which conductive paths or traces are etched. These paths connect various electronic components. They are also used to connect components to sockets on printed circuit boards. Circuit card assy is the process of manufacturing circuit card components. The process involves adding electronic components to the substrate.

Key components of a circuit card assembly (CCA)

Circuit card assembly have several key components to make the circuit function properly. These can be divided into three basic components.

Printed Circuit Board (PCB)
Electronic component
Solder paste

Printed Circuit Board (PCB)

This is the backbone of the CCA. The printed circuit board provides the structural foundation on which all other components are mounted. A PCB is typically made of a flat, insulating material such as FR4 fiberglass, which is layered with conductive tracks made of copper. These tracks form the circuit pathways that connect various electronic components. The PCB board can be single-sided, with components and conductive tracks on one side only, or double-sided, with tracks and components on both sides. For more complex applications, multi-layer PCBs are used, which consist of multiple layers of insulating material and conductive pathways stacked together. These printed circuit boards are essential in ensuring that electrical signals are routed efficiently and reliably across the assembly.

Electronic Components

These include resistors, capacitors, integrated circuits, transistors, and more passive and positive components. Each part plays a specific role in the circuit, like pieces of a puzzle fitting together to make a complete picture. Resistors control the flow of electrical current, capacitors store and release energy, integrated circuits (ICs) perform various functions like processing and memory storage, and transistors act as switches or amplifiers. These components are carefully placed on the PCB in positions that allow them to connect and interact as designed.

Solder paste

Solder paste is like the glue that holds everything together, but it’s electrically conductive. It’s used to attach the electronic components to the PCB, so that they can stay put and work properly. Soldering creates a strong, conductive bond between the component leads and the PCB’s copper tracks. There are different types of soldering, such as lead-based and lead-free solders, each with its specific properties and applications. The soldering process can be done manually or using automated printing machines, depending on the complexity and volume of the assembly. Please noticed that solder paste should used in a very short time, otherwise, it will become dry solder paste.

What is the Difference Between a PCB and a CCA?

You might wonder, what’s the difference between a PCB and a CCA? Well, here’s a quick rundown:

Aspect	PCB (Printed Circuit Board)	CCA (Circuit Card Assembly)
Definition	A blank board with conductive pathways	A PCB populated with electronic components
Components	No electronic components	Includes electronic components like resistors, capacitors, ICs
Functionality	Serves as the foundation for electronic circuits	A functional electronic circuit ready for use in devices
Manufacturing Steps	Involves design, etching, and printing of conductive paths	Involves PCB manufacturing plus component placement and soldering
Usage Stage	Intermediate stage in manufacturing	Final stage, ready for integration into electronic devices
Complexity	Less complex, involves fewer manufacturing steps	More complex, involves multiple stages of assembly and testing

What is the circuit card assembly manufacturing process?

Making a CCA is a multi-step process:

Design

First, the PCB layout is designed using computer software. It includes numerous steps, like schematic drawing, layout design, SI, PI analysis, DFM. This can ensure the PCB board can fit all the necessary components and function correctly.

Fabrication

The PCB is then fabricated, which involves creating the physical board with layers of insulating and conductive materials. This is where the board gets its pathways. In this step, proceed strict quality control process to make sure the bare boards are qualified.

Component Placement

Next, printing solder paste and preparing components, then place them onto the PCB board according to the BOM file (bill of material). After setting up the pick and place machine, automated machines can precisely position each component based on the design.

Soldering

The components are soldered to the PCB. This can be done using methods like wave soldering or reflow soldering to ensure everything is securely attached and electrically connected. You must know, different products require different parameters, please make sure all the parameters like temperatures, time are suitable.

Inspection and Testing

The assembled CCA goes through rigorous inspection and testing to ensure it works as intended. This includes visual inspections, automated optical inspections (AOI), in-circuit testing (ICT), aging testing and functional testing.

Final Assembly

If the CCA passes all tests, it moves on to final assembly, where it’s integrated into the larger electronic system or device. That is we say the box building assembly.

What are the types of circuit card assembly?

CCAs can be divided into various types according to the different manufacturing technology.

Through-Hole Technology (THT) Assembly

Here, components have leads or pins inserted into holes drilled through the PCB and soldered on the other side. This method provides strong mechanical bonds, making it great for components that experience mechanical stress. It’s often used in aerospace, military, and industrial equipment.

Surface Mount Technology (SMT) Assembly

In SMT, components are mounted directly onto the PCB surface using solder paste. No drilling required, which allows for higher component density and smaller PCBs. This method is commonly used in consumer electronics, telecommunications, and automotive industries.

Box Building Assembly

Box building assembly involves the complete assembly of electronic systems, including CCAs, into enclosures or boxes. This process includes not only the assembly of the PCB but also the integration of cables, connectors, and other components into a final product. Box building is ideal for producing complete electronic devices ready for end-use.

Advanced materials for CCAs

Advanced materials help CCAs perform better and last longer:

High-Temperature Laminates (e.g., FR-4, Polyimide)

High temperature laminate like FR4 or polyimide. These materials can handle extreme conditions without breaking down. FR-4 is popular for its excellent thermal and mechanical properties, while polyimide is great for high-temperature stability.

Flexible Substrates (e.g., Kapton, PET)

Kapton and PET are the most common flexible substrate. These materials allow CCAs to bend and flex. Kapton, a type of polyimide, is known for its high thermal resistance and flexibility, making it perfect for wearable electronics and medical devices. PET (polyethylene terephthalate) is another flexible material with good electrical insulation properties.

Advanced Solder Compounds

SAC305 (a lead-free alloy of tin, silver, and copper) is favored for its mechanical and thermal properties. Whatever you want to mount a ceramic PCB or the flexible PCB, it is the best choice. Sn63Pb37, a traditional tin-lead solder, is still used for its ease of use and excellent performance.

Reliable circuit card assembly manufacturers

Choosing the right manufacturer for your CCAs is key to getting quality products. PCBonline and Best Technology are go-to-choice reliable circuit card assembly manufacturers. Both of them has advanced pick and place machine, full-auto SPI, AOI equipment, ensuring a good quality.

As a leading manufacturer in the circuit card assembly, Best Technology prides full turn-key service, ranging from the PCB design, PCB fabricating, electronic component sourcing, circuit card assembly and box build assembly. We handle complex and high-volume orders efficiently, ensuring timely and fast delivery without sacrificing quality. In 2023 alone, we completed over 5000 high-complexity projects with a client satisfaction rate of over 98%.

It is crucial for anyone to fullly understand the circuit card assembly in the electronics industry. From their basic components and manufacturing process to the advanced materials used, CCAs are the backbone of modern electronic devices.

What is a Bill of Materials (BOM)?

A Bill of Materials (BOM) is a detailed list of all the parts, components, and materials needed to manufacture a product. In PCB manufacturing, a BOM outlines every item required to assemble a PCB, including quantities, part numbers, and descriptions. It serves as a guide to ensure that the manufacturing process runs smoothly and that no crucial components are missing.

Types of Bill of Materials

There are several types of BOMs used in different stages of production. Each type serves a specific purpose and provides unique details to streamline processes and ensure accuracy. Here are the primary types of BOMs:

Engineering BOM

This type of BOM is creating during the design phase. It lists all the parts and components designed by the engineering team, including specifications and relationships as intended in the final product. And of course, it mainly used by design engineers to communicate the product structure and details to manufacturing teams.

Manufacturing BOM (Formal)

It is a formal BOM files that used in the assembly phase. Different with engineering BOM, it includes additional details necessary for manufacturing, such as packaging, handling instructions and assembly details. And some special instructions.

Sales BOM

Sales BOM is used by sales teams and includes information relevant to the sales process, such as pricing and availability. It helps in providing accurate quotes, managing customer expectations, and handling sales orders efficiently.

What Should Include in an Effective Bill of Materials?

An effective BOM should be detailed, accurate, and easy to understand. It should include all the details of components and indicated revisions. As a 18 years expertise in PCBA production, we summarized the key elements that should be included in the BOM.

Component details

It should include all the components and their detailed information, such as names, part numbers (PN), and descriptions for each part.

Quantity (QTY)

The exact quantity of each component required for the product. Accurate quantities can prevent shortages and overstocking.

Foot print

It is the package of each component, helping to ensure the correction of part.

Reference Designators

Unique identifiers that match each component to its specific location on the product layout. These are essential for assembly and troubleshooting.

Manufacturer Information

Manufacturer information, including the manufacturer name of components and manufacturer part number. It helps to ensure correct parts are sourced. And convenient for alternative part sourcing if it is shortage.

Supplier information (Optional)

It means the name of the supplier or distributor. The part number used by the supplier, which may differ from the manufacturer’s part number.

Assembly instructions

Any special notes for assembly such as DNF remark, and version control to track revisions should also be included. Additionally, cost information helps in budgeting, and lifecycle status information helps plan for component availability and avoid discontinued parts.

How to Make a PCB Bill of Materials (BOM)?

Creating a PCB BOM is a systematic process that involves compiling all the necessary information about each component required for the assembly of the PCB. Here’s a detailed guide on how to create a PCB BOM:

Open a Blank Spreadsheet

Use software like Microsoft Excel or Google Sheets to start with a blank spreadsheet. They are common to use, offering flexibility and ease of use for creating and managing BOMs.

Define Columns

Set up your spreadsheet with appropriate column headers. Common headers include:

Part Number
Component Name
Quantity
Reference Designator
Manufacturer
Manufacturer Part Number
Supplier
Supplier Part Number
Description
Package Type
Cost
Notes

Input Data

Enter the required details for each component under the appropriate headers. Please be make sure that all information is accurate and complete. This may involve referencing design files, datasheets, and supplier catalogs. If it is incorrect, then it needs a lot of time to find out and revise the errors, resulting in schedule delay.

Use Formulas

Utilize Excel formulas to automate calculations, such as summing total quantities or calculating costs. This helps in reducing manual errors and saves time.

Format for Clarity

Use cell formatting options to highlight important information and ensure the spreadsheet is easy to read. For example, you can use bold text for column headers, color coding for different component types, and borders to separate sections.

Include Version Control

Add a version control section to your BOM to track revisions and updates. This can be a simple row at the top or bottom of the spreadsheet, indicating the version number, date of revision, and a brief description of changes.

How to Make a BOM? — (BOM file reference)

Save and Update

Save your BOM and update it regularly to reflect any changes in the design or component availability. Regular updates ensure that the BOM remains accurate and up-to-date, preventing issues during production.

Review and Verify

Have multiple team members review the BOM for accuracy. Cross-check all component details, quantities, and part numbers against the design files. Verification helps catch errors early and ensures the BOM is reliable.

Communicate with Suppliers:

Maintain open communication with suppliers to confirm component details and availability. This ensures that you can source the correct parts and avoid delays in the production process.

How Can I Optimize My BOM for PCB Assembly?

Sometimes, a simple BOM is not good to process PCB assembly process, and manufacturers may need to spend a lot of time to optimize it, make into convenient for manufacturing. If you are a layman, here are some steps to help you in optimizing your BOM file.

First, it’s a good idea to standardize components where possible. Using standard parts that are readily available from multiple suppliers can simplify procurement and reduce costs. This approach minimizes the risk of shortages and ensures you can get parts quickly and affordably. Also, make sure all entries in your BOM are clear and concise to avoid confusion during assembly. Double-checking part numbers and quantities against design files is crucial to prevent errors that could lead to rework or delays.

Building strong relationships with your suppliers is another key factor. Good communication with suppliers helps ensure reliable component availability and keeps you informed about any changes in lead times or part availability. Regularly updating your BOM to reflect any design changes or component availability issues is essential. Keeping your BOM current and accurate prevents last-minute surprises during assembly.

What Common Mistakes Should I Avoid When Creating a PCB BOM?

Avoiding common mistakes in BOM creation can save time and reduce errors. Here are some pitfalls to watch out for:

Incomplete information – ensure all necessary details are included for each component.
Incorrect quantities – double-check quantities to avoid shortages or excess inventory.
Outdated data – keep the BOM updated with the latest design changes and component information.
Ambiguous descriptions – provide clear and precise descriptions to prevent confusion.
Lack of version information – implement version control to track changes and ensure the correct BOM version is used.

Creating an effective and accurate PCB BOM is essential for smooth manufacturing and assembly. By following best practices and using the right tools, you can ensure your BOM is comprehensive, clear, and up-to-date, ultimately leading to a successful PCB production process.

Best Technology is an expert in SMT and PCB assembly, we have more than 18 years in this industry, that can offer you a best experience of PCBA solution. In our facotry, we have advanced equipment like full auto pick and place machine, online dual AOI, X-ray, 3D SPI, nitride reflow oven and three-proof paint machine. So that we can ensure the fast lead time and high quality of your PCBA products. Reach us to get a instant quote!

What are active and passive components meaning?

Active and passive components, simply say, the device that needs an energy (electrical) source is called an active device, and the device that does not need an energy source is a passive device. Active components, such as transistors and diodes, require external power to function. They can control the flow of electricity. Passive components, like resistors and capacitors, do not need external power. They cannot control electrical flow but can store, resist, or filter energy. Both passive and active components are common useful in PCB assembly and SMT technology.

Active components play a dynamic role in circuits. They can amplify signals, switch currents, and perform various complex functions. These components rely on an external power source to operate and influence the behavior of the circuit. For instance, a transistor can amplify a weak signal, making it stronger and more useful for further processing.

What Are the Differences Between Active and Passive Components?

Passive components, on the other hand, are more static in nature. They cannot amplify signals or control current flow but are essential for other functions like energy storage and signal filtering. Resistors, capacitors, inductors, and transformers are common examples. Each of these components has a specific role in maintaining the stability and functionality of an electronic circuit.

What are the key differences between active and passive components?

The main difference between active and passive components is their ability to control electricity. Active components can amplify signals and perform complex tasks. Passive components can only store, resist, or filter energy. They cannot amplify signals or control current.

Active components are energy-dependent. They require an external source of power to function and can influence the flow of electricity within the circuit. For example, an integrated circuit (IC) can perform multiple functions like amplification, switching, and signal modulation, all of which require external power.

Passive components, in contrast, do not require an external power source. They can only perform their functions passively. For instance, a resistor can limit the current flowing through a circuit without needing additional power. Similarly, a capacitor can store electrical energy and release it when needed, all without external energy input.

Common active components in electronics

Active devices are the main components of electronic circuits. From the physical structure, circuit function and engineering parameters, active devices can be divided into discrete devices and integrated circuits.

1. Discrete devices

Bipolar transistor, generally referred to as transistor or BJT
Field effective transistor
Thyristor
Semiconductor resistors and capacitors – resistors and capacitors manufactured by integrated technology are used in integrated circuits.

2. Integrated circuit

Integrated circuit can be divided into analog IC and digital IC. Analog integrated circuits mainly deal with continuous analog signals, such as sound, light, temperature, etc., and retain the continuity and accuracy of the signal through amplification, filtering, mixing and other operations. In contrast, digital integrated circuits are used to process discrete time digital signals, convert the signal into binary digital form, and then perform logical operations and processing.

Basic analog integrated circuit devices generally include:

Integrated operational amplifier (operation amplifier)
Comparator
Logarithmic and exponential amplifiers
Multiplier/divider
Analog switching circuit (analog switch)
Phase lock loop
Integrated voltage regulator
Reference source
Wave-form generator
Power amplifier

Digital integrated circuit including:

Logic gate circuit
Flip-flop
Register
Decoder
Data comparator
Driver
Counter
Shaping circuit
Programmable Logic Device (PLD)
Microprocessor (MPU)
Microcontroller (MCU)
Digital signal processor (DSP)

Common passive components in electronics

Passive devices in electronic systems can be divided into circuit components and connection components according to the circuit functions they play. These components are essential for functions like energy storage, filtering, and impedance matching in electronic circuits. The common passive components are including:

Circuit components

Diode
Resistor
Resistor network
Capacitor
Inductor
Transformer
Relay
Key
Speaker
Switch

Connection components

Connector
Socket
Cable
PCB (printed circuit board)

Why are active components crucial in modern electronics?

The ability of active components to control and manipulate electrical signals makes them indispensable in a wide range of applications.

In computers, for example, active components such as processors and memory chips perform complex calculations and store large amounts of data. In communication systems, active components amplify weak signals, making long-distance transmission possible. Without these amplifiers, the signal would decay with distance, leading to a decline in communication quality. Power electronics, another key area of modern development, relies heavily on active components. Devices like power converters, inverters, and motor controllers use transistors and integrated circuits to efficiently convert and control electrical energy. This efficiency is crucial for applications ranging from renewable energy systems to electric vehicles.

It’s fair to say that without active components, devices like computers, smartphones, and TVS wouldn’t function the way they do today, and our era of big data wouldn’t be moving as fast as it is today.

How do passive components complement active components?

Both active and passive components are indispensable in a circuit. They depend on each other and complement each other. Without active components, the circuit cannot be activated or perform a specific work. Without passive components, the circuit cannot be controlled and adjusted, nor can it achieve a stable operating state. Such a relationship between the two is like the relationship between the “dynamic” and the “static” of a circuit.

For example, in an audio amplifier circuit, the power supply and amplifier are the active components, and the load and resistance are the passive components. The power supply provides energy, the amplifier amplifies the signal, and controls and limits it through load and resistance, and finally realizes the amplification and regulation of the audio signal. In signal processing, inductors filter out high-frequency noise and protect sensitive active components from interference. Transformers, on the other hand, enable efficient power transfer between different parts of the circuit, allowing active components to operate within their optimal voltage range.

Comparing the Energy Requirements of Active and Passive Elements

Active components need an external power source to function. They consume energy during operation. Passive components do not need external power and generally do not consume energy, except for minor resistive losses. This difference impacts the design and efficiency of electronic circuits.

Active components, such as transistors and integrated circuits, rely on external power to operate. This power requirement means that active components consume energy during their operation. The amount of energy consumed depends on the specific component and its application. For instance, a power amplifier consumes more energy than a simple transistor switch.

Passive components, in contrast, do not need external power to function. They operate solely based on the electrical energy present in the circuit. Resistors, capacitors, and inductors do not consume significant energy, except for minor resistive losses in resistors. This low energy requirement makes passive components more efficient in certain applications.

The difference in energy requirements between active and passive components impacts the overall efficiency of electronic circuits. Designers must carefully balance the use of active and passive components to achieve optimal performance and energy efficiency. For example, using passive filters instead of active ones can save energy in low-power applications.

Active and Passive Component Images and Symbols

Recognizing symbols are essential for reading and designing circuit diagrams. They provide a visual representation of the components and their functions, helping designers understand the overall structure and operation of the circuit. Recognizing these symbols is a fundamental skill for anyone involved in electronics. Here is a detailed images and symbols listing of common active and passive components.

Above all is the introduction to passive and active components, hope it is useful for every engineers. Best Technology is a professional PCB and PCBA manufacturer in Asia. We have our own factory in China and Vetnam. Welcome to contact us if you have any questions about components and PCB assembly.