In this series, we’ll take a look at how products get made at SANYO DENKI.
Here, we’ll examine the manufacturing process for UPS (uninterruptible power supply) at a Fujiyama Works, located in Ueda, Nagano Prefecture. This second section will introduce the assembly process for printed circuit boards (PCBs).
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Location: |
4016, Fujiyama, Ueda-shi, Nagano |
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Property Area: |
95,632 m2 |
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Main Products: |
Fans, UPSs (uninterruptible power supplies), PV inverters, servo amplifiers, stepping drivers, system controllers, etc. |
Making an Uninterruptible Power Supply
Assembly Processes highlighted in yellow is what is covered in this page.
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1. Acceptance Warehousing |
2. Unloading & Setting |
3. Parts Assembly |
Small Capacity UPS |
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A. Wire Processing
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4. Final Assembly Assembly & Wiring |
5. Final Inspection Inspection Aging |
6. Shipping Preparation Packaging |
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B. PCB assembly Component Mounting Soldering |
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Mid & Large Capacity UPS |
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4′. Final Assembly Unit Assembly Assembly & Wiring |
5′. Final Inspection Inspection Aging |
6′. Shipping Preparation Packaging |
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3: Parts Assembly
B. PCB assembly Component Mounting
(1) Inserter Process
While maintaining high-accuracy, electronic components are automatically mounted to substrates at rates up to one per 0.12 seconds.
Inserter Line and Component Mounting
POINT
The first finished piece of a lot is compared against diagrams and checked to make sure the right component is mounted in the right orientation.
(2) Manual insertion
Electronic components that cannot be mounted automatically are mounted by hand.
Manual Insertion and a production guide system
POINT
The production guidance system and digitization of work order sheets contribute to the establishment of a work environment which limits the possibility of human error.
(3) Soldering
After flux is applied in the automatic fluxer, soldering is applied in the automatic soldering tank.
Spray Fluxer & Automatic wave soldering machine
The inverter before loaded into the soldering machine/ and after soldering
POINT
Depending on the type of PCB, a wave solder pallet may be used to protect thermally sensitive components. Temperature, speed, and nozzle height are managed in shift-start and periodic inspections to ensure solder quality.
(4) Finishing
Finishing processes include adjusting solder, mounting nonstandard parts, affixing the lot number, and applying coatings. Soldering work may only be performed by those who have passed a hand soldering certification exam.
Final Adjustment by hand/ Applying Coating
Finished PBC top
Finished PBC bottom
POINT
Treating all PCBs with a transparent coating known as HumiSeal results in improved moisture and corrosion resistance and overall-reliability. Two layers of coating can be applied to further increase reliability, especially for harsh environments.
(5) Inspection
And lastly, various inspections are performed to complete the PCB assembly process.
Left: Component mount condition inspection by an automated optical inspection
Right: Electrical characteristics and circuit check by an in-circuit tester (ICT)
Visually inspects the state of mounted components, soldering, and coating
POINT
The outflow of defective goods can be prevented through double and triple inspections. All inspections are carried out by certified workers. Visual inspectors also must have been certified for soldering work.
VOICE
“To build a high-quality product, we gather and discuss ways we can make improvements.”
