In the development of industrial design electronic solutions, ensuring the safety and stability of products requires systematic planning from the whole process of hardware design, software research and development, testing and verification, and production control. Here are the specific key measures and implementation points:

一. Hardware design: build a secure and stable foundation from the architecture layer
1. Power system reliability design
Multiple protection mechanisms

Surge suppressors (e.g., TVS transistors, varistors) are added to the input side to prevent transient high voltages such as lightning strikes and grid fluctuations from damaging the circuit.

Multi-level filtering (EMI filtering, LC filtering) is used to suppress the interference of power supply noise on sensitive chips.

Design over-voltage/over-current/under-voltage protection circuits (such as fuses, MOS tube current limiting, voltage monitoring chips) to avoid device damage under abnormal working conditions.

Redundant power supply design

Critical equipment is backed up by dual power supplies (such as mains battery backup or dual mains inputs), and seamless switching is achieved through diodes or power switching chips to ensure continuous system operation in the event of a power failure.

Example: The power modules of industrial PLC controllers are often equipped with redundancy to keep the production line running.

2. Anti-interference and electromagnetic compatibility (EMC) design
Circuit partition isolation

Tightly distinguish areas between digital and analog circuits to avoid coupling high-frequency digital signals to analog links (e.g., AD/DA conversion circuits).

Power circuits (e.g., motor drives, power modules) are physically isolated from low-power signal circuits to reduce magnetic field coupling interference.

Grounding strategy optimization

"Single-point grounding" or "layered grounding": analog and digital connections are connected by 0Ω resistance or inductance to suppress ground loop currents; The power ground is led out separately to avoid the large current backflow affecting the signal ground.

The metal enclosure is securely grounded and acts as an electrostatic discharge path, reducing the risk of ESD (electrostatic discharge).

Shielding and filtering

Impedance matching (e.g., series termination resistors) for high-speed signals (e.g., USB, Ethernet) to reduce signal reflections; Differential signal transmission (e.g., RS485, CAN bus) is used to improve the ability to resist common-mode interference.

Magnetic beads and common-mode inductors are installed on external interfaces (such as USB and Ethernet ports) to suppress electromagnetic interference (EMI) radiated by cables.

3. Thermal management and mechanical protection design
Thermal design

Heat-generating devices (such as power chips and power modules) are equipped with heat sinks or thermal grease to export heat through PCB copper foil and metal shells. If necessary, design air ducts and use fans to force heat dissipation.

Example: IGBT modules for industrial drives are typically dissipated by a combination of a large-area aluminum heat sink and fan.

Mechanical structure strengthening

The component layout avoids overhanging or cantilever structures, and is reinforced by glue fixing or metal brackets to prevent vibration from causing solder joint fracture (e.g., automotive electronic equipment needs to pass vibration testing).

The housing is made of high-strength materials (such as aluminum alloy, stainless steel), which meets IP67 and other protection levels, and is dustproof, waterproof and shockproof.

二. Software design: the whole life cycle ensures the robustness of the system
1. Real-time and fault-tolerant mechanism
Task priority scheduling

Real-time operating systems (RTOS, e.g., FreeRTOS, VxWorks) are used to assign the highest priority to safety-critical tasks (e.g., emergency stop signal processing) and ensure response times are less than critical values (e.g., < 10ms).

Exception handling and reset mechanisms

The "Watchdog" timer is embedded in the program, which automatically triggers the system reset if the main program runs off or crashes; Critical data, such as parameter configuration, is stored in non-volatile memory (EEPROM/Flash) to prevent loss due to power failure.

Example: Industrial robot control software needs to respond to an emergency stop signal within 1ms to avoid machinery runaway.

2. Data security and communication reliability
Communication protocol verification

When customizing the communication protocol, add CRC check and sequence frame number to prevent data transmission errors. Permission verification (such as passwords and digital signatures) is added to key commands (such as device start/stop) to avoid misoperation or malicious attacks.

Cyber security

Connected devices are integrated with firewalls and encrypted transmissions (such as SSL/TLS) to prevent hacker intrusion. Regularly update firmware to fix security vulnerabilities (e.g., OTA update mechanism for IIoT devices).

3. Condition monitoring and redundancy design
Monitoring of key parameters

The software collects voltage, current, temperature and other data in real time, and sets threshold alarms (such as triggering frequency reduction protection when exceeding 85°C); The sensor signal is filtered (e.g., Kalman filter) to eliminate noise interference.

Functional redundancy design

Dual MCU hot standby (such as master-slave mode) for important functions, which automatically switches to the slave controller when the master controller fails; Sensor redundancy, such as dual temperature sensors, ensures data reliability.

三. Testing and verification: multi-dimensional exposure of potential risks
1. Security compliance testing
Electrical safety testing

Withstand voltage test (e.g. AC 1500V/1min) to verify dielectric strength and prevent the risk of electric shock; Ground continuity testing ensures that the enclosure ground resistance is < 0.1Ω.

Complies with safety standards such as IEC 60950 (information technology equipment) and IEC 61010 (measurement equipment), and obtains CE, UL certifications, etc.

Environmental Suitability Testing

High and low temperature cycle (e.g. -40°C~85°C), humidity (95% RH non-condensing), vibration (e.g. sine sweep 5~500Hz), impact (50g/11ms) test, simulating the extreme environment of the industrial site.

Example: Oil platform equipment needs to pass the salt spray corrosion test (ISO 9227) to ensure long-term operation in a high humidity and high salt spray environment.

2. Reliability and fault tolerance testing
Fault injection testing

Humans simulate faults such as sensor failures, communication interruptions, power fluctuations, etc., to verify whether the system can trigger protection mechanisms (e.g., automatically switch to a backup sensor, enter safe mode).

Long-term aging test

The whole machine runs continuously for more than 72 hours, monitors the temperature rise, power consumption, and functional stability, and exposes early failure problems such as leakage of electrolytic capacitors and poor contact of connectors.

四. Production and operation and maintenance: whole-process quality control

1. Supply chain and process control
Component screening

Industrial grade (-40°C~85°C) or automotive grade (AEC-Q100) devices are selected to avoid the failure of consumer devices in harsh environments; Key components (e.g., MCU, power chip) are subjected to secondary inspection (e.g., X-ray flaw detection to check soldering quality).

Production process optimization

PCBA welding adopts SPI (solder paste inspection), AOI (automatic optical inspection), ICT (online test) to ensure that the solder joints are free of false soldering and short circuits; After the whole machine is assembled, the function is fully inspected to avoid short circuit caused by wrong wiring harness.

2. O&M and upgrade mechanism
Remote monitoring and early warning

IoT Platform collects device status data in real time to provide early warning of abnormalities (such as abnormal bearing temperature increases indicate mechanical failures) to avoid downtime accidents.

Maintainability by design

Modular design is convenient for fault location and replacement (such as independent power supply module, communication module); Reserved debugging interfaces (such as JTAG, UART) support on-site or remote firmware upgrades.

五. Industry standards and best practices
Follow functional safety standards

Equipment involved in personal safety (e.g. industrial machinery, medical equipment) is required to comply with ISO 13849 (PL class), IEC 62061 (SIL class), and risk points are identified through fault tree analysis (FTA) and failure mode and effects analysis (FMEA).

Case Reference

In the field of industrial automation: Siemens PLC adopts a "dual-channel redundancy" design, and the CPU module has a built-in independent safety core to ensure the reliability of logic control.

New energy field: Lithium battery management system (BMS) prevents safety accidents caused by overcharge and overdischarge through multiple voltage/temperature sampling and equalization control.

Summary: Systems thinking drives security and stability
The safety and stability of industrial electronic products are the result of the collaboration of the whole chain of "design-testing-production-operation and maintenance":

At the hardware layer, a physical security baseline is built through power protection, anti-interference design, and thermal management.

The software layer is based on real-time, fault-tolerant mechanism, and data encryption to ensure reliable logic;

The process layer relies on standardized testing, supply chain control, and operation and maintenance systems to reduce risks throughout the life cycle.
Through the above measures, the anti-risk ability of the product in industrial scenarios can be significantly improved and the high reliability requirements can be met.