Industrial Router PCB Assembly

Why is it necessary to conduct high and low temperature test during the PCB assembly process of industrial routers?

Industrial routers are widely applied in harsh environments such as power, transportation, and manufacturing. Their operating temperature range typically needs to reach -40℃ to 75℃, far exceeding the 0℃ to 40℃ standard of commercial routers. High and low temperature testing verifies the reliability, performance stability, and service life of the appliance by impersonating extreme temperature conditions. It is a crucial step to ensure the quality of industrial routers.



1.Enhance reliability in extreme environments

According to statistics, approximately 35% of industrial equipment failures are related to temperature stress. High and low temperature tests simulate harsh environments. For example, the -40℃ low-temperature start-up test can verify the operational capability of the equipment in cold regions, while the 75℃ high-temperature test ensures that the equipment can operate stably in high-temperature workshops or outdoor cabinets.
For example, before undergoing high/low temperature tests, the failure rate of the low-temperature startup of a certain brand of industrial router was 12%. After optimization, it dropped to 0.5%, significantly enhancing the adaptability of the equipment.

2. Optimize the performance of key components

The performance of core parts such as CPU, storage chip, and wireless module of industrial router may fluctuate under extreme temperatures. The test data shows that an unoptimized router may experience a 30% decrease in Wi-Fi signal strength at a temperature of 70℃. However, after adjusting the radio frequency circuit and heat dissipation design through high and low temperature tests, the signal attenuation can be controlled within 10%.
In addition, the value of electrolytic capacitors may decrease by 20%-30% in a low temperature environment. Tests can identify solid-state capacitors that are more resistant to low temperatures to ensure power stability.



3. Extend equipment lifespan and reduce downtime

Temperature circuit tests (such as -40℃~85℃ for 100 cycles) can simulate the aging of the simulated device after years of use. Experimental data shows that for routers that failed the test, the cracking rate of PCB solder joints under temperature shock can reach as high as 15%, while the failure rate of the optimized one is less than 1%. In addition, high-temperature and high-humidity testing (such as 85℃/85%RH) can identify components prone to corrosion, thereby increasing the average time between failures (MTBF) of the equipment from 50,000 hours to over 100,000 hours.

4. Meet industry certification and enhance market competitiveness
Industrial routers must be conforming to a number of international standards, such as IEC 60068-2-1 (low temperature test), IEC 60068-2-2 (high temperature test), etc.
According to statistics, products that have undergone rigorous high and low temperature testing experience a 40% reduction in crash recall rate in the Industrial market, while customer satisfaction boosts by 25%. For example, Huawei industrial router, having passed the -40℃~75℃ test, has seen an 18% increase in its market share in the track transportation realm.



Conclusion

High and low temperature tests not only can expose the design flaws of industrial routers in advance, but also can optimize their performance, extend their service life, and meet strict industry standards. Data shows that routers that undergo comprehensive temperature tests can reduce the on-site failure rate by more than 50%, becoming the key guarantee for the reliability of industrial communication equipment.

KingshengPCBA leverages advanced automated production lines and a strict quality control system to ensure efficient and precise production of industrial PCBA projects. With full traceability from material management to delivery, we guarantee high reliability and stability, earning long-term trust from customers.