how to make power supplies

Today we would like to record the processing of manufacturing switch power supply in our factory.
When every component is ready, we need get the PCB SMT first.
This is the PCB (Printed Circuit Board)

power supply pcb

Surface-mount technology (SMT) is a method for producing electronic circuits in which the components are mounted or placed directly onto the surface of printed circuit boards (PCBs)

power supply smt

After the SMT, the next step is Reflow soldering.
Reflow soldering is a process in which a solder paste (a sticky mixture of powdered solder and flux) is used to temporarily attach one or several electrical components to their contact pads, after which the entire assembly is subjected to controlled heat, which melts the solder, permanently connecting the joint.
Here is the photo of reflow soldering.

power supply reflow soldering

We got the PCBs that are finish reflow soldering like this:

power supply pcb finish smt

Next, plug-in the electronic components such as capacitor, resistor etc.

power supply plunin process

power supply plun-in process

Next step is Wave soldering.
Wave soldering is a bulk soldering process used in the manufacture of printed circuit boards. The circuit board is passed over a pan of molten solder in which a pump produces an upwelling of solder that looks like a standing wave. As the circuit board makes contact with this wave, the components become soldered to the board.

power supply wave soldering

power supply wave soldering machine

power supply finish wave soldering

Next step is welding repair.

power supply welding repair soldering

Then Semi-Finished Product Test.

power supply semi-finished test

Next is assembly.

power supply assembly

After that, the Semi-Finished Product will be suffering burn-in test, Users of power supply products demand increasingly higher levels of reliability and performance. Although the suppliers of individual components can confidently provide impressive life and reliability data, the compound effect on overall reliability when a large number of individual components are combined in a module such as a power supply can be significant. Perhaps more important for product reliability is the quality and repeatability of the assembly process. Solder joints, connectors and mechanical fixings are all potential origins for product failure. In use, operating temperature and other environmental factors also affect the life and reliability of a power supply.

power supply burn-in test

After burn-in test, products will be do hi-pot test, also called isolation test.
Electrical isolation test is a direct current (DC) resistance test that is performed between subcircuit common and subsystem chassis to verify that a specified level of isolation resistance is met.

power supply hi-pot test

Last step is final finished test and packing.

power supply packing

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