Follow us :

Switching power adapter production process

time2006/05/18

Switching power adapters, also called power adapters, are also called chargers; they are an external power conversion device that can be converted from alternating current to direct current and can be converted at the same time.
Switching power adapter, also called power adapter, also called charger; what is the power adapter? It is an external power conversion device that can be converted from AC to DC and can be converted at the same time. Switching power adapters are closely related to everyone's life. Because everyone needs to use this electronic accessory, such as mobile phone / tablet charger, or home broadband cat, router need to use the switching power adapter. What is the production process of the switching power adapter that is used every day? Let me introduce it to you today. From development to formal mass production, there are two stages.

development process:
First of all, according to the needs of use, design, after the determination. Open the mold and produce the outer casing.

Secondly, according to the performance requirements, the electronic engineer develops the electronic circuit part, selects the appropriate scheme, designs the electronic schematic diagram, and draws the drawing of the circuit board (PCB), and gives the PCB board manufacturer a sample of the PCB.

Next, the electronics engineer makes a manual sample and then performs various tests such as performance testing, assembly testing, and aging testing on the sample.

Then, the sample is tested after ok. Develop PCB production molds. Conduct small batch trial production. Testing will have some problems in the production process. Then make the appropriate adjustments.

Finally, the circuit board (PCB) is finalized, and if the PCB changes, the mold needs to be reopened. Produce corresponding documents such as specifications, work instructions, and inspection instructions.

Mass production process:
1.Patch (SMT): After the materials are ready, after the inspection is passed, the PCB is first passed through the SMT machine for the placement process;

2. Plug-in (DIP): A piece of PCB is attached, and the plug-in process is performed on the plug-in. DIP will be subdivided into: inserts, press parts, immersion tin, cutting electronic feet and other processes;

3. After welding (supplement welding): After the plug is pulled, the circuit board after immersion in tin, some electronic components have not been soldered, and then need to be welded to solve. The post-welding process is subdivided into:
Over-wave soldering: After the plug is pulled again by the machine, there is no good tin metal material when immersed in tin;
Kanban repair welding: usually a PCB sub-area, many people carry out manual kanban, no good tin, manual repair, there are few electronic components, not inserted, also marked;
Replacing electronic materials: electronic materials are inserted in reverse, and fewer parts are corrected;
QC Test 1: By making a companion test tool. The bare board is tested, the test is OK, and the next process is given. If the test fails, the repairman is repaired;

4. Assembly: This process is the most complex and the most advanced process in the production process.

a. Bonding wire: Solder the DC wire to the bare board. Weld the AC wire to the lower case metal part of the case.

b. Gluing: Gluing components that are easy to fall off or break during transportation. It has solder joints such as transformers, filters, AC lines and DC lines.

c. Enclosure: Close the outer casing of the switching power adapter.

d.QC Test 2: Test the performance of each output through the computer integrated tester. If it does not pass, it will be handed over to the repairman for repair. Test again until you pass the test.

e. Repair: Repair the switching power adapter that failed the test.

f. Screw: Fix the outer casing. Some housings use ultrasonic waves. Just put it behind the i.QC test 3 process;

h. Aging test: Transfer the screwed product to the aging workshop for aging test. The aging test is after a certain period of time. Then transfer back to the assembly to do the final full inspection QC test.

i.QC Test 3: The last full inspection, the product after the aging test is fully inspected, if not passed, it is returned to e. Repair. Pass the test to the next step.

j. Ultrasonic: If the outer casing is fixed with screws, this process is not required.

k. Appearance QC: Here you need to pick out the appearance of the problem. Replace the casing.

l. Post nameplate: After the appearance inspection ok. Label the product with the appropriate label.

m. Packing: After the product passes the layer inspection. Finish the packaging.

5.Quality sampling: The finished products that have been completed shall be inspected according to the relevant national quality inspection standards. The sampling contents include functionality, appearance, and the like. After passing the sampling inspection of the quality department, it can be shipped.