Views: 81 Author: Site Editor Publish Time: 2024-04-07 Origin: Site
In simple terms, the production process of frequency converters can be divided into two main parts: PCB board manufacturing process and complete machine production process.
Because each stage of the production process undergoes rigorous quality inspection, the frequency converter manufacturer ensures that the entire production process is a controlled process, guaranteeing the quality of the products. This article introduces the production process of Hars frequency converters, providing technical colleagues with an opportunity for exchange and learning.
[a.]Board processing → [b.]Initial board testing → [c.]Aging → [d.]Secondary board testing (PQC)
Currently, Chinese frequency converter manufacturers employ two main methods for PCB board fabrication:
In this method, the frequency converter manufacturer provides the PCB layout, materials, and relevant lists to external manufacturers. These external manufacturers utilize Surface Mount Technology (SMT) for the majority of component soldering. This approach is cost-effective and technologically advanced. As of now, many frequency converter manufacturers complete the majority of their PCB boards through outsourced manufacturing.
In contrast, in-house manufacturing involves electronic assembly by personnel within the frequency converter manufacturer's facility. This method involves supplementing the outsourced PCBs with additional components, parameters, and certain ICs. While this approach offers more control, it tends to be less efficient and more costly compared to outsourced manufacturing.
Since both plug-in and surface mount components coexist on the PCB boards of frequency converter manufacturers, the operating procedures follow the principle of soldering surface mount components before plug-in components. According to the component list, the required surface mount components and ICs are soldered onto the board. By standardizing the operation process, it ensures the correctness of the plug-in and surface mount components and the quality of tin plating on the PCB board, thus improving the PCB fabrication process.
The processing methods are as follows: 1) Component shaping; 2) Layout; 3) Plugin; 4) Inspection; 5) Tinning; 6) Trimming; 7) Adjustment; 8) Solder joint inspection; 9) Short circuit inspection; 10) Comprehensive cleaning of all solder residues and solder balls on both sides of the PCB board.
It is important to pay attention to the use of tools and the use of soldering irons during the process to prevent phenomena such as virtual soldering, missed soldering, solder bridging, pinholes, and incomplete solder penetration.
Through testing, ensure that all circuits work normally and that the keyboard displays and functions properly. The main objects of inspection are the main control board, power board, keyboard, etc.
By subjecting the PCB board to aging, test the stability performance of its components. The general aging time is 24 hours.
Using the same method as the first board testing, retest the PCB board after aging to ensure the reliability and high-temperature aging resistance of each component.
①Assembly process → ②PQC inspection process → ③Debugging → ④Aging → ⑤FQC inspection process → ⑥Packaging process → ⑦OQC inspection process
Processing of Small Components
Processing of small components is a preparatory work for complete machine assembly. Some small components need to be processed before complete machine assembly can take place.
Small component processing mainly includes the following aspects:
- Fan processing
- Capacitor board or capacitor assembly processing
- IGBT interposer board processing
- Relay processing
- Transformer processing
- Surge board processing
- Assembly of charging resistors
- Connection of cement resistors
- Processing of various wire materials, etc.
During the assembly process, PQC is responsible for on-site patrol inspections, specialized inspections, and random inspections. It is essential to master the timing and methods of inspection to conduct strict checks on the produced products, including inspections of small component processing, semi-finished product checks, and complete machine inspections.
The inspection items are divided into:
Inspection of fan assembly and soldering
Inspection of capacitor board soldering or capacitor assembly
Inspection of IGBT interposer board soldering
Inspection of relay wiring
Inspection of transformer soldering
Inspection of surge board soldering
Inspection of assembly of charging resistors
Inspection of connection of cement resistors
Inspection of processing of various wire materials, etc.
The purpose of whole machine debugging is to adjust various testing circuit parameters to match the displayed values or protections with the actual values.
General Inspection: Check if there are any foreign objects inside the chassis, whether the physical objects, material lists, and "Product Records" are consistent, and whether the connections of main components are correct.
No-load Test: Adjust the displayed value of input voltage to match the actual value.
Load Test: Adjust the output current value and "OC" value to correspond to the protection parameters of different machine models and series. The output current value belongs to general overload, and the "OC" value belongs to overcurrent. Refer to the corresponding documents for specific operating procedures.
Other Tests: Power failure tracking test, energy consumption braking test, and some internal and external keyboard tests, etc.
Whole Machine Aging Process After the machine passes the debugging, it is aged by professional personnel.
FQC is responsible for the final inspection to verify whether the adjustments made by the debugging personnel to various parameters meet the requirements. Correspondingly, the internal parameters are set according to the factory requirements to ensure the normal performance and protection functions of the whole machine.
General Inspection, appearance, and nameplate labels.
No-load test: verification of voltage display value.
Load test: verification of output current value and "OC" value.
Other inspections: verification of power failure tracking, energy consumption braking, etc.
After verifying the above parameters, reset the cumulative time to zero and select the control mode.
Attach the certificate and anti-counterfeiting label, and organize and record relevant parameters.
Select the corresponding packaging box according to the model and appearance size. After passing the FQC inspection, pack it and check whether there is an FQC inspection mark.
Special packaging for some special shipments (such as overseas orders or orders with special instructions from customers).
OQC is the final link in the whole machine production, which checks whether all the documents in each link are filled in correctly, so that the product documents can play a substantive role and facilitate traceability in future work.
If you want to know more about the production process of frequency converter manufacturers, you can visit the Hars frequency converter manufacturer. The email address of Hars frequency converter manufacturer is: sales@vfdspread.com
