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How Datalink Electronics Delivered a Complete Design-to-Test Solution for High-Power Industrial Control Electronics
Client Profile / Background
A major industrial controls provider — supplying systems for energy management, motion control, and factory automation — partnered with Datalink Electronics to develop a high-power IGBT-based control module for next-generation automation platforms.
Operating globally in sectors similar to Siemens or Schneider Electric , the client required a precision-engineered, high-reliability power electronics solution that could meet the demands of continuous industrial operation, thermal efficiency, and safety compliance.
With extensive experience in industrial control, power switching, and electronic system integration , Datalink was chosen to manage the complete process — design, manufacture, and test — under ISO 9001 standards .
Industrial automation systems demand efficient and robust power switching to drive motors, actuators, and converters safely under variable loads.
The client faced multiple design and production challenges:
- Managing high current and voltage switching using IGBT technology without thermal runaway or performance drift.
- Achieving compact design and efficient heat dissipation within strict enclosure constraints.
- Ensuring EMC/EMI compliance for use within large industrial networks.
- Delivering a repeatable and fully tested product, ready for deployment in mission-critical control systems.
The project required not just circuit design, but a fully integrated process — from simulation through to validated, production-ready hardware.
Datalink provided a turnkey engineering service, combining power electronics design, prototyping, manufacturing, and testing — all within a controlled and certified environment.
Key Differentiators & Capabilities:
- End-to-End Design: Datalink’s engineers designed the complete IGBT drive and protection circuitry, optimising for switching efficiency, fault isolation, and gate control accuracy .
- Thermal & Mechanical Engineering: Thermal simulation and structural design ensured long-term reliability under continuous load. Custom heat-sinking and PCB copper balancing reduced temperature rise across key components.
- High-Reliability Manufacturing: Utilised high-grade power semiconductors and automotive-quality assembly standards , including selective soldering, conformal coating, and automated optical inspection.
- Comprehensive Testing: Every module underwent high-voltage isolation testing, dynamic switching validation, and temperature stress screening , ensuring stable operation across the full load range.
By combining advanced design and in-house testing, Datalink delivered a solution that met stringent performance, safety, and traceability requirements.
- Concept & Simulation:
Datalink developed circuit schematics and ran thermal and electrical simulations to validate switching profiles, gate drive response, and power loss. - Prototype Build:
Rapid prototypes were produced in-house, enabling iterative optimisation of component layout, trace routing, and cooling performance . - Design Validation:
Conducted load, temperature, and endurance testing to benchmark performance against industrial specifications. - Manufacturing Process Setup:
Created a controlled build and inspection process with detailed work instructions, ensuring repeatability and quality control for low- and mid-volume production. - Final Testing & Documentation:
Implemented automated end-of-line testing, capturing full electrical data and traceability records for every unit produced.
The Results / Outcomes
Technical & Operational Achievements:
- Delivered a fully functional, validated IGBT control module meeting the client’s electrical, mechanical, and reliability targets.
- Achieved stable switching and minimal power loss under high-load conditions.
- Improved thermal performance and service life through advanced design techniques.
- Delivered a documented and repeatable production process suitable for ongoing manufacture.
Partnership Outcomes:
- Strengthened the client’s ability to accelerate new product development with a proven, pre-validated control electronics platform.
- Reinforced Datalink’s reputation as a specialist partner for power and industrial control electronics .
- Established a foundation for scalable production and future variants.
