How to control EMC consistency in mass production of motion controllers (MC)

EMC consistency in mass production of motion controllers (MCs) requires a continuous process across design, materials, and manufacturing. The design phase should consider manufacturability, using standard packages and automated soldering processes. Critical EMC components, such as common-mode inductors, filters, and TVS diodes, must have specified brand and model numbers and undergo rigorous incoming material inspection. The PCB's layer stack-up, board material, and copper thickness must be standardized. Manufacturing process parameters, such as reflow profiles and conformal coating thickness, should be standardized.

Establish rapid screening stations on the production line, such as simplified conducted emission pre-scanning or port EFT injection testing for each product. Regularly sample complete units for full EMC testing. Any material or process changes require a reassessment of their EMC impact. Statistical process control methods should be used to monitor key test data. These measures ensure that the EMC performance of mass-produced products is consistent with certified samples, mitigating market risks.