The process of manufacturing a power adapter involves a variety of steps. It begins with power adapter development. We will talk about the details in this article, hope it will help you at the factory inspection.
Development processing of power adapters
There are many aspects to consider when developing a power adapter, it should be energy efficient, needs to meet the proper EMI standards, power adapters must be safe for use, and make sure that the power source does not interfere with other electronics.
First of all, design circuits for the power adapter according to the needed parameter and requirements.
During this process, the engineers need to consider that the power adapter should be able to isolate the user from lethal AC mains voltage, and they must not cause any damage to the environment by emitting electromagnetic emissions. There are several international standards that power adapters must meet, some of which are mandatory, and some are voluntary. It is also important to consider the country where the adapter will be used, as there are often differences in these standards.
Secondly, prototyping PCB and assembling components for testing the function, parameter, and efficiency, and debugging, if needed modifying the design, after confirming all electronic functions working well, we go to the next step.
Thirdly, according to the needs of use, finish the appearance design, and make the suitable module for the outside casing. Casing sample and testing after the module is manufactured.
Fourthly, assemble the sample casing and electronic parts(including PCB and components, dc, ac cables), make the first power adapter sample, and test it, including function, ageing, and comprehensive testing……
The final step, make the datasheet, manufacture the second sample and save them, and prepare the BOM list according to the sample and datasheet.
In order to make a power adapter more energy efficient, the manufacturer must consider the size of the adapter’s input and output voltages. This will determine the amount of power it can convert and output. Ideally, the adapter will be 100% energy efficient. However, power conversion systems use many discrete components, some of which create energy losses. In addition, switching-mode power supplies have a large number of small losses in different parts, including inductors and semiconductors.
Production processing of power adapters
Step 1: Production processing begins with the selection of the right components.
Step 2 SMT & DIP: The next step involves placing these components on the board to meet customer specifications. This process also involves consideration of electrical characteristics, safety distance, and thermal convection.
Step 3: After components are placed on the board, QC for components assembly and voltage and current testing is required to make sure all materials are assembled well, and the PCB board working well. After all the testing passes, go to the next steps.
Step 4: Casing installation, and assembly of outside casing and cables with PCB board, by ultrasonic soldering machine.
Step 5: After the Casing assembly, the QC team will check the casing is installed well by pull and drop testing.
Step 6: Aging testing, to check the function and efficiency during and after the ageing testing.
Step 7: Final comprehensive testing to make sure power adapters with good preference.
The reliability of power adapters is highly dependent on the design and manufacturing processes. So, let’s follow the steps of Development and Production Processing of Power Adapters for manufacturing.
