Quality Process
The company has 14 advanced flexible production lines, 2 straight lines, and 2 automatic assembly and testing lines. It is capable of producing different specifications and models of SPDs (Surge Protective Devices), SSDs (Backup Protectors), and electronic (lightning protection system) products in small batches, multiple varieties, or mass production. Through the ISO9001 quality management system, the company carefully selects high-quality raw materials and auxiliary materials, strictly controls the quality throughout the manufacturing process, and ensures 100% quality inspection of key processes to deliver high-quality products.
Automatic assembly and testing production line for surge protective devices (SPDs) and backup protectors (SSDs).
Features:
1. First In, First Out Material Management (E-Kanban):
- Full visual management ensures materials and semi-finished products are used in sequence.
- The system automatically calls the corresponding materials based on the production plan, reducing waste.
2. Fully Automated Process:
- Automation equipment completes welding, assembly, and testing, improving efficiency and reducing human errors.
3. Real-Time Quality Control:
- Online quality inspection devices are installed at each process node, with data monitored in real-time via the MES system, ensuring closed-loop quality management.
4. Finished Product Traceability System:
- Enables full lifecycle traceability from raw materials to finished products, quickly identifying problematic products and supporting precise recalls.
Our Equipment
SPD Automatic Assembly and Testing Equipment：
It enables automatic product assembly, dry contact, MOV, and GDT testing functions, and supports traceability of original test data.
SSD Fully Automatic Assembly and Testing Equipment:
It enables product assembly, riveting, automatic testing of power-frequency tripping, and dielectric strength.
Production Equipment and Cloud Testing Equipment – Traceability of Original Test Records
Fully Automated Welding Equipment with Visual Inspection Function
Reflow Soldering Machine
Laser Welding Machine:
Process Inspection
1. Comprehensive Process Inspection and Key Performance Monitoring
(1) Thermal Trip Detection
Importance:
Simulate and verify the product's performance during field use, ensuring that the MOV degradation causes leakage current and triggers normal protection tripping, preventing fire hazards.
Process Control Method:
Apply a voltage greater than the MOV's U1mA value to simulate the product's degraded state by generating heat, ensuring that the product trips normally and provides effective protection.
(2) Pull-Out Force Testing
Importance:
Evaluate the welding strength or the reliability of connecting components to ensure the assembly process meets product design requirements.
Process Control Method:
Use a pull-out force testing machine for dynamic loading to assess the pull-out strength of welds, terminals, or connections.
Integrate SPC analysis with pull-out force test data to promptly identify abnormal welds or weak connecting components.
(3) SSD Over-travel, End Pressure, and Opening Distance Detection
Importance:
Verify the internal component contact reliability and ensure the product meets the rated surge withstand voltage.
Process Control Method:
· Analyze the structure and convert it into measurement standards for dimensions and force values.
· Implement an automatic alarm mechanism: If the detection data exceeds the specifications, an immediate notification is sent to the operator to remove defective products.
(4) Silk Screen Adhesion Testing
Importance:
Monitor the silk screen adhesion during the production process to ensure that the model parameters remain clearly distinguishable throughout the product's service life.
Process Control Method:
Simulate real-world transportation and working environments (such as humidity, temperature, and load) to dynamically test the silk screen adhesion performance.
2.Automated Quality Management and Early Warning
Process Abnormality Early Warning:
AI algorithms analyze inspection data to predict potential quality issues (such as reduced pull-out force or welding defects) and trigger alarms before the problems occur.
Closed-Loop Quality Improvement:
All inspection data is automatically uploaded to the MES system to generate inspection reports, which are then integrated with FMEA analysis to develop preventive improvement plans.
Defective Product Traceability Management:
The traceability system is used to trace quality issues (such as non-compliant thermal tripping or low pull-out force) discovered during the production process, identifying the problematic batches or suppliers.
