Designing electronic devices is a complex process that requires careful selection of the appropriate components. These choices directly influence the functionality, performance, and reliability of the final product. Below are the key aspects to consider when selecting electronic components.
Key criteria for component selection
The analysis of the technical specifications of components is crucial. It is important to pay attention to parameters such as voltage, current, capacitance, resistance, operating frequency, signal gain for transistors, switching time, and output current. These values must align with the requirements of the designed device. Additionally, the operating conditions of the components, such as temperature and humidity, compatibility with other circuit components, and compliance with the relevant standards and norms, should also be considered..
High reliability of components is essential, especially in applications where failures can have serious consequences. It is recommended to review MTBF (Mean Time Between Failures) and FIT (Failure in Time) data, along with the manufacturer’s track record of product reliability, as well as conduct FMEA (Failure Mode and Effects Analysis).
The availability of an adequate supply of components is crucial; without it, even the best components will be rendered useless. It is crucial to verify whether components are consistently available from suppliers and if there are alternative sources of supply. It is also important to consider the reliability of supply (lead times) and the impact of global trends and risks on availability, such as pandemics or semiconductor shortages. Strong relationships with suppliers can also significantly enhance supply reliability.
The cost of components is also a significant factor that can influence the final manufacturing cost of the device. It is crucial to strike a balance between quality and cost to ensure the project remains profitable. One should also take into account the Total Cost of Ownership, which includes expenses related to purchasing, maintenance, and potential component failures and replacements.
Understanding the project requirements
The first step in the component selection process is to thoroughly understand the project requirements. This includes:
- Technical specifications
What are the requirements for voltage, current, operating frequency, capacitance, and resistance? What are the requirements for response time, compatibility with other systems, and specific regulations and standards that must be met? - Functionality
What functions should the device perform? What are the key features that should be considered? What are the user interface and ergonomic requirements? What are the specific requirements for different types of devices, such as medical, industrial, or consumer? - Operating environment
Under what conditions will the device operate? Will it be exposed to extreme temperatures, humidity, shock, or vibration? Consideration should also be given to corrosion and radiation resistance. What are the requirements for power supply, electromagnetic interference, protection against dust and water (IP protection classes), and safety (compliance with UL, CE standards)?
Electrical and mechanical properties
Each component has specific electrical and mechanical properties that must align with the project requirements. The most important ones include:
Operating voltage
Components must withstand the operating voltage. It is also important to consider the maximum voltage a component can endure, as well as the breakdown voltage that can occur under certain conditions. Exceeding this voltage can lead to component damage, system failure, or even a safety hazard.
Rated current
The rated current is the maximum current that can flow through a component without risking overheating. This is crucial because excess current can cause overheating, which reduces the component’s lifespan and may lead to failures.
Tolerance
Refers to the precision of the values of components such as resistors and capacitors. The smaller the tolerance, the more accurate the component. This is important in high-precision applications because a small tolerance minimizes deviations from the intended parameters.
Mechanical durability
Mechanical durability refers to the resistance of components to physical forces, vibration, and shock. It is crucial in applications where components are exposed to demanding operating conditions, as it ensures device reliability and longevity.
Modern technologies and innovations
- Miniaturization
Modern technologies enable further miniaturization of components, making it possible to design even more compact and efficient devices. Examples include microcontrollers integrated with various functionalities that take up less space on the circuit board. Technologies such as systems-on-a-chip (SoCs) are finding applications in IoT, medicine, and wearables, enabling the creation of advanced yet compact devices. - Energy-efficient components
It is advisable to choose components with low power consumption, especially in mobile and IoT (Internet of Things) devices, as well as in large data centers. This can extend battery life and reduce operating costs. Additionally, using energy-efficient components helps reduce CO2 emissions and significantly benefits the environment. - Compatibility with new standards
It is advisable to consider components that are compatible with the latest communication standards, such as Wi-Fi 6, Bluetooth 5.0, and USB-C. This ensures better performance and facilitates easier integration with other devices. In addition, future technologies such as 5G or Wi-Fi 7 may become standard, therefore, it is recommended to follow the latest solutions to ensure the long-term viability of the project.
Availability and costs
Availability and cost of components are key factors in the design process. Even the best electronic design can run into difficulties if the necessary parts cannot be easily and cost-effectively obtained.
Component delivery time is one of the most important factors in project planning. Components with long lead times can delay the entire project. It is important to anticipate delivery time risks and implement strategies to manage them, such as maintaining safety stock and planning orders in advance.
The unit costs of components should be analyzed in the context of the overall project budget. It is important to consider not only the purchase price, but also additional costs that may arise throughout the entire life cycle of the components, such as maintenance, failure, and replacement costs.
Alternative sources of supply for components reduce supply shortage risks. Maintaining multiple suppliers and building long-term relationships with them can bring benefits such as better contract terms, discounts, and supply stability. Loyalty programs and framework agreements can further secure component availability in the long term.
Compliance with standards and certifications
Electronic components must comply with relevant standards and have the required certifications, especially when the product is intended for international markets. Adhering to standards is important not only from a regulatory standpoint, but also to ensure user safety and environmental protection. Examples of such standards include:
The RoHS (Restriction of Hazardous Substances) standard restricts the use of hazardous substances in electronic equipment. To comply with RoHS, manufacturers must perform thorough analyses of the material compositions used in their products. This requires not only careful selection of raw materials, but also regular testing and auditing to ensure compliance. The compliance process is often time-consuming and costly, but it is crucial for protecting human health and the environment from harmful chemicals.
The CE mark is required within the European Union and confirms that a product meets European safety, health, and environmental standards. To obtain the CE mark, a manufacturer must go through a rigorous conformity assessment process, including laboratory testing, risk analysis, and technical documentation. The process can be complex and requires cooperation with notified bodies authorized to issue CE certificates. The presence of the CE mark facilitates access to European markets and enhances consumer trust in the product.
IPC (Institute for Printed Circuits) standards set quality requirements for the production and reliability of electronic components. To meet IPC standards, manufacturers must implement advanced production processes and quality control systems. This process includes staff training, investment in modern technologies, and regular audits and product testing. Compliance with IPC standards ensures high quality and reliability of components, which is crucial in many advanced technology applications such as aerospace, medicine, and telecommunications. Achieving compliance with IPC standards can be challenging, but it brings significant benefits in terms of increased product reliability and performance.
Testing and reliability
Ensuring the reliability of components is essential for the long-term operation of the device. Therefore, it is crucial to conduct appropriate testing before the final selection to accurately assess how components perform in practice and to ensure they fully meet all design requirements. Regularly conducting quality tests and audits can further increase confidence that components will perform reliably throughout the entire lifecycle of the device.
Laboratory tests enable the verification of the technical performance of components under controlled conditions. They allow you to verify that components are performing as expected and within specifications. These tests include electrical measurements such as voltage, current, capacitance, resistance, and other technical characteristics.
Environmental tests evaluate how components perform in conditions close to real-world scenarios. They include vibration tests, temperature change tests (thermal cycle tests), and long-term tests (burn-in tests). Vibration tests assess components’ resistance to vibration, thermal cycle tests evaluate how components respond to temperature changes, and long-term tests detect potential failures resulting from prolonged operation.
Technical support and documentation
Component suppliers often offer technical support and extensive documentation, which can be extremely helpful in the design process. It is worth choosing components from reputable manufacturers that provide:
Technical documentation, which should include detailed specifications, application instructions and catalog sheets. It is also important that the documentation is regularly updated and available in digital form, including sample designs or CAD models, which can greatly facilitate the work of engineers.
Engineering support includes the ability to consult with technical experts in case of doubts or issues. Reputable vendors also offer additional forms of support, such as webinars, training courses, and online support, facilitating the swift resolution of issues and customization of components to meet specific project requirements.
How can you simplify the selection of components?
Selecting the right components and their suppliers can be a challenge. That’s why at Device Prototype, we offer comprehensive support for device manufacturing. When you decide to manufacture with us, we can order the necessary components and PCBs at your request, at no additional cost. We also have our own warehouse with standard components readily available, which enables rapid project execution. Our services simplify the process of selecting and ordering components, making it more efficient and allowing you to focus on the most important aspects of electronics design.
