The Grit Behind Circuit Boards
Bob Wettermann from Best discusses why PCB rework is crucial for the automotive industry.
Modern cars are packed with electronics that are key to various safety, entertainment, and navigation functions. You’ll find microprocessors, sensors, and other electronic components throughout the car—from inside the cabin and under the hood, to even within the tires.
On average, today’s cars are equipped with over 50 CPUs and more than 100 million lines of code managing different systems. For example, the BMW SUV iDrive includes advanced features like gesture recognition. Similarly, the 2017 Honda CR-V offers road departure mitigation, adaptive cruise control, rear cross traffic monitor, a blind spot information system, and automatic high-beam control, among other features. The main dashboard has a 17.9cm touchscreen display with Apple CarPlay and Android Auto, enabling smartphone integration. Additionally, it has an automatic door locking system that activates when the key moves more than two meters away from the vehicle. All these high-tech gadgets rely on electronic hardware and subsystems that can sometimes malfunction.
A challenge arises because car manufacturers are introducing new features faster than these systems can be miniaturized and reliability-tested. This pace results in a higher need for rework, repair, or replacement of these electronic components.
In the automotive sector, the task of miniaturization and associated rework doesn’t progress as quickly as it does in other markets. According to Susie Inouye, research director and principal analyst at Databeans, it’s challenging to deploy technology that remains viable for a car’s typical ten-plus-year lifespan. Vehicle environments can range from -40 to +250°C, which further complicates device maintenance. The devices also need to endure significant shocks, necessitating very durable mechanical designs.
Given these harsh conditions, automotive electronics must be incredibly reliable. Cars are expected to operate in extreme temperatures and last up to ten years, covering over 100,000 miles, says David Alexander, principal automotive technology analyst at ABI Research. Components need to pass rigorous vibration and quality tests and are often embedded in epoxy or conformally coated to protect against these conditions. These coatings can make rework particularly challenging.
PCB rework in the automotive industry faces stringent requirements, such as absolute traceability of parts, guaranteed correct part placement, and flawless soldering operations. These high standards add pressure and complexity to the rework services market.
Since many rework tasks are performed manually, tracking parts is also manual—requiring meticulous documentation of serial numbers and transcription accuracy. Automated Optical Inspection (AOI) equipment can ensure correct part placement, although for single rework locations, the time to set up and inspect can outweigh the rework time itself. Hand soldering, common in rework projects, complicates achieving consistent soldering quality.
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