Advanced Industrial Control PCB Design

I need a production-ready PCB that will sit at the heart of an advanced industrial automation and control system. The board must coordinate multiple high-speed sensor inputs, drive several actuator channels, and communicate reliably with a PLC over both Ethernet and RS-485. Because the application environment is electrically noisy, careful attention to EMI/EMC, differential pair routing, and galvanic isolation is essential.

Scope of work
• Translate my functional block diagram into a complete multi-layer schematic
• Lay out the board for compact, high-integration placement while respecting creepage/clearance and thermal restraints
• Provide a clean power architecture that supports 24 V industrial rails and generates the regulated logic rails with minimal ripple
• Include protection features—TVS, fuses, reverse-polarity diodes—appropriate for factory floors
• Deliver manufacturing-ready files: Gerbers, drill, pick-and-place, full BOM with manufacturer part numbers, and an annotated PDF schematic

Acceptance criteria
1. Gerbers load in KiCad and Altium without errors
2. All differential pairs meet 100 Ω ±10 % impedance on the proposed stack-up
3. Power plane simulation shows