Quality & Reliability – 热泵控制板、无刷直流电机控制器 | 10 年研发、设计与制造经验

End-to-End ISO 9001 Quality System

Anchored by ISO 9001 certification, we implement a full-cycle quality management mechanism covering design review, Incoming Quality Control (IQC), In-Process Quality Control (IPQC), Outgoing Quality Control (OQC), and customer feedback closure. Leveraging the Kingdee K3 system for quality data traceability, we drive continuous improvement to achieve "zero-defect" delivery.

IQC Incoming Quality Control Stage

1. PCB Key Inspection

Rigorously verify incoming PCBs’ copper thickness, dielectric strength, and appearance to ensure downstream reliability.


Test Item	Test Standard	Test Equipment	Inspection Ratio (Frequency / Record Method)
Copper Thickness Cross‑Section	2 oz copper; high‑current paths ≥ 3 oz (ΔL ≤ ±5%)	Metallographic section microscopy system	First piece of each lot / Micrographs + Report
Dielectric Strength Test	500 V DC, 60 s no breakdown (per IEC 60112)	High‑voltage insulation dielectric tester	100% inspection / Strength curve + Pass label
PCB Visual AOI Inspection	100% defect‑free solder joints and traces	Automated optical inspection system	100% inspection / AOI report

2. Precision Screening of Power Devices  Verify MOSFETs, IGBTs, and electrolytic

capacitors’ parameters and leakage to ensure stable performance of critical components.


Test Item	Test Standard	Test Equipment	Inspection Ratio (Frequency / Record Method)
MOSFET Rds(on)/Vgs(th)	Rds(on) ± 0.5% @ 100 A; Vgs(th) consistency ± 0.1 V	Power device parameter analyzer	5% sampling per lot / Parameter summary table
IGBT Switching Loss Test	Dual pulse test over 0–3 kV; switching loss ≤ design spec	Dynamic parameter tester	3% sampling per lot / Waveform capture
Capacitor Leakage Current Test	≤ 1 nA resolution, 0–500 V range	Capacitance & leakage tester	100% inspection / Data logging

3. PMagnetic Component Reliability Verification

Verify inductors and transformers under saturation and high voltage conditions to guard against overload and insulation failures.


Test Item	Test Standard	Test Equipment	Inspection Ratio (Frequency / Record Method)
Inductor Saturation Current Test	ΔL ≤ 10% @ rated current; temperature rise ≤ 40 ℃	LCR meter + DC bias source	5% sampling per lot / Test report
Transformer Dielectric Strength Test	AC 3 kV, 1 min no breakdown; leakage ≤ 2 mA	Safety standard dielectric tester	5% sampling per lot / Result log

IPQC In Process Quality Control Stage

1. SMT High Precision Process Monitoring

Continuously monitor solder paste, placement, and reflow quality to ensure solder joint consistency and placement accuracy.


Test Item	Test Standard	Test Equipment	Inspection Ratio (Frequency / Record Method)
Solder Paste Thickness	75 ± 15 μm; Cpk ≥ 1.67	3D solder paste inspection system	Every 2 hours / Thickness distribution + Cpk trend
Reflow Profile	Peak 245 ± 5 ℃ (lead free)	Reflow profile recording system	Each lot / 9 point thermal profile (signed)
Component Placement Offset	BGA offset ≤ 25 μm	Online placement offset detection system	100% online / Offset coordinates export

2. Wave Solder / Post Solder Process Control

Use microscopic and torque testing to strictly control solder fill and heatsink assembly quality, and verify conformal coating coverage.


Test Item	Test Standard	Test Equipment	Inspection Ratio (Frequency / Record Method)
Wave Solder Through Solder Rate	≥ 75% (IPC 610 Class 3)	Metallographic microscope	Once per shift / Micrographs + depth annotation
Heatsink Assembly Torque	0.6 ± 0.1 N·m (audible/visible alert)	Digital torque wrench	Every unit / Torque value capture
Conformal Coating Coverage	Thickness 50 ± 10 μm; 100% hole avoidance	Dry film thickness/UV fluorescence system	3 points per station per day / Thickness log

OQC Final Inspection & Reliability Stage

1. Functional Test (FCT)

Simulate real world conditions to verify dynamic performance and protection functions, ensuring reliable end product functionality.


Test Item	Test Standard	Test Equipment	Inspection Ratio (Frequency / Record Method)
Motor Control Board Dynamic Test	Stall response ≤ 10 ms; phase current imbalance ≤ 5%	Real time simulation platform + load simulator	100% testing / Waveform + current profile capture
PFC Power Efficiency Test	Efficiency ≥ 95% @ 230 VAC; PF ≥ 0.98	Power analyzer	Each lot / Efficiency report + temperature chart
Fault Injection Test	Over voltage/over current protection trigger accuracy ± 3%	Fault injection test system	100% testing / Fault log

2. Reliability Testing

Accelerate screening of potential weak points through thermal cycling, vibration testing, and HALT, validating design robustness.


Test Item	Test Standard	Test Equipment	Inspection Ratio (Frequency / Record Method)
Safety Compliance Test	Withstand voltage: AC 3000 V/5 mA/3 s no breakdown; Insulation resistance ≥ 100 MΩ @ 500 V DC	High voltage insulation tester; Safety compliance analyzer	100% full inspection / Withstand curve + Insulation report
EMC Pre Scan	Conducted disturbance: EN 55032 Class B limit; ESD immunity: ± 8 kV contact discharge	EMI receiver; ESD simulator	First piece + 5% sampling per lot / EMI spectrum + ESD video
Temperature Cycling Test	–40 ℃ ↔ +125 ℃, 5 cycles (15 ℃/min); Efficiency degradation ≤ 1%	Climatic temperature & humidity chamber	5% sample units / Profile comparison report
Vibration Test	5–500 Hz; 22 g; crossed rod support platform; 30 min per axis	Vibration test system	5% sample units / Monitoring video + Report

Testing Equipment

Comprehensive Testing Systems & Reliability Validation Platform

Equipped with specialized In-Circuit Test (ICT), Functional Circuit Test (FCT), Automated Optical Inspection (AOI), and a full suite of Reliability Lab equipment, we conduct rigorous burn-in testing, temperature cycling tests, vibration tests, and failure analysis. This ensures every smart controller meets customer performance standards and industry safety compliance requirements.

Automatic key testing

Capacitance durability test

Voltage drop generator

Constant temperature and humidity test

Testing instruments

Salt spray test

Combined interference generator

EMI

Te rohs halogen free environmental protection testing instrument

EMS

RoHS halogen-free environmental tester

Global Leader in Intelligent Control Solutions

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