Tips for Component Selection When Designing an Embedded Carrier Board
Designing a customer carrier board, what will provide you with the optimal solution, can be straightforward if you are aware of the key considerations. Begin with the fundamentals, particularly the appropriate choice of components.
Since many embedded customers design systems meant to last over a decade, choosing the right components for the carrier board is essential for long-term reliability. ADLINK’s I-Pi team experts offer tips on selecting components to lower the overall failure rate and increase robustness.
1. Power input
When designing system power input, it is essential to determine whether you need to use a single voltage DC input or a wide range voltage DC input. This decision can significantly impact the overall reliability and efficiency of your system. A wide range voltage input can offer more flexibility and adaptability, especially in environments where power sources may vary. However, it must be carefully matched to the specific requirements and tolerances of your components to avoid potential issues. Ensuring that the power input design aligns with the long-term goals and operational conditions of your system can help enhance performance and longevity.
2. Address overheating components
It's well-known that components operating near or beyond their thermal limits are more likely to fail. For switched power transistors, selecting parts with lower RDS(on) can help manage heat dissipation effectively. Voltage-regulator ICs with high Vin–Vout differentials tend to experience considerable self-heating, particularly at increased output currents. It is also essential to verify the design margin of resistors' power ratings. As a contingency measure, a heatsink can be attached to an overheating device, though minimizing heat generation remains the best option.
3. Ensure that components have ample design margins
It's crucial to check power dissipation, maximum current, maximum voltage, and operating temperature range for all components. Generally, when power transistors operate near their specified limits, their lifespan shortens. This applies to current, temperature, and voltage extremes. Capacitors should remain well below their maximum voltage rating.
4. Thermal solution design
Thermal solution design is another critical aspect to consider. Ensuring adequate airflow and effective heat dissipation, particularly for components such as CPUs, GPUs and connectivity modules, is essential for maintaining performance and longevity. Proper thermal management can prevent overheating and reduce the risk of component failure, thus extending the lifespan of the entire system. Passive heatsinks or coolers, which do not rely on moving parts, are generally more reliable and require less maintenance compared to active cooling solutions.
5. Remove electrolytic capacitors whenever possible
Although ECs are inexpensive and frequently used, they often cause component failures. It's important to remember that ECs have a limited lifespan, influenced by the device's characteristics and the temperatures they encounter.
Opting for surface-mount (SMT) multilayer ceramic capacitors (MLCCs) is a significantly more dependable choice, with availability extending up to 100 µF. While higher capacitance values are accessible in non-SMT-MLCC formats, it remains crucial to rigorously qualify all components prior to deployment.
6. Check lifetime of all components in use
Opt for components that will be available for a long time and steer clear of those nearing the end of their lifecycle. This proactive approach minimizes the risk of future obsolescence, ensuring that replacements and support will remain accessible. Furthermore, by selecting long-lasting, reliable components, you foster a more sustainable and cost-effective system, reducing the frequency of maintenance and the need for costly extensive redesigns. Evaluating the supply chain for each component can also provide insight into their long-term availability, helping you make informed decisions that bolster the robustness and longevity of your system.
Still having questions? We are happy to help! Contact us by email: ipi.wiki@adlinktech.com