Toshewar tashar sukurori ta J-GUANG PCB - Jerin firam na 5.0mm don oda mai yawa
Lokacin da ƙungiyar sayayya ta yi odar babban bulogin tashoshi—misali guda 50,000 na nau'in sukurori na PCB mai girman 5.0mm—ba wai kawai suna amincewa da takardar bayanai ba. Suna aika masu binciken kayayyaki, suna neman samfura, kuma suna gudanar da gwaje-gwaje waɗanda suka wuce binciken gani mai sauƙi. A J-GUANG, mun ɗauki nauyin binciken masana'antu da dama a cikin shekaru goma da suka gabata, kuma mun ga irin waɗannan tsare-tsaren dubawa masu tsauri sun bayyana a cikin masana'antu: daga masu siyan injinan sarrafa kansa na masana'antu a Jamus zuwa OEMs na rarraba wutar lantarki a Arewacin Amurka. Wannan labarin ya bayyana ainihin wuraren binciken da ƙungiyoyin sayayya ke amfani da su kafin bayar da izinin masana'anta don odar babban bulogin tashoshi, bisa ga ƙwarewarmu ta kai tsaye da ƙa'idodin masana'antu kamar IEC 60998 da kuma UL 1059.
Ko kai ƙwararre ne a fannin siyayya da ke neman inganta jerin bincikenka ko kuma masana'anta da ke da niyyar cin jarrabawar a gwaji na farko, waɗannan sassa bakwai sun haɗa da takardar shaidar kayan aiki, bin ƙa'idodi, gwajin lantarki, ingancin plating, tabbatar da marufi, bitar takardu, da kuma iya samar da kayayyaki a wurin. Za mu haɗa da ainihin bayanai daga layin samarwa namu - kamar Tashar tashar sukurori ta PCB 301-5.0—don kwatanta abin da ya wuce da abin da ya gaza. Bari mu fara da tushe: tabbatar da kayan aiki.
1. Takaddun Shaidar Kayan Aiki Duba-bincike: Bayan Katin Rawaya na UL
Ƙungiyoyin sayayya ba sa karɓar katin rawaya na UL a farashin fuska. Suna buƙatar rahotannin gwajin kayan aiki na musamman (MTRs) ga kowane yanki na resin da aka yi amfani da shi a cikin gidan bututun tashar. Ga gidajenmu na PA66, wannan yana nufin tabbatar da ƙimar ƙonewa ta UL 94 V-0 tare da ainihin bayanan gwajin ƙonewa: lokacin ƙonewa dole ne ya kasance ƙasa da daƙiƙa 10 a kowane samfuri, kuma babu wani digo na ƙonewa da zai iya kunna alamar auduga. Mun ga masu binciken sun ƙi wani rukuni saboda MTR ya nuna ƙonewa ta bayan daƙiƙa 12 a kan samfurin ɗaya - duk da cewa matsakaicin daƙiƙa 8 ne. Ma'aunin kowane samfurin ne, ba matsakaici ba.
Bayan ƙonewa, suna duba yawan zare na gilashi a cikin PA66. Matsakaicin ƙayyadaddun bayanai shine cika gilashin 30% ± 2% don daidaiton girma. Masu duba suna amfani da nazarin thermogravimetric (TGA) don tabbatar da wannan. Idan abun cikin gilashin ya faɗi zuwa 27%, gidan na iya karkacewa yayin haɗa raƙuman ruwa, wanda ke haifar da rashin daidaiton fil. Muna da ikon TGA a cikin gida don tabbatar da kowane tsari kafin jigilar kaya. Ga ƙarfe na ƙarshe, ƙungiyoyin sayayya suna buƙatar nazarin spectrographic don tabbatar da abun da ke cikin tagulla (yawanci C36000 ko C37700) tare da abun cikin tagulla sama da 57% da abun cikin gubar tsakanin 1.5% da 3.5% don injin. Muna ba da wannan bayanan a cikin namu Takardun samfur ga kowane oda mai yawa.
Dakunan gwaje-gwaje na waje kamar Ayyukan gwajin kayan UL Sau da yawa ana amfani da su don tabbatar da wasu kamfanoni. Ƙungiyoyin sayayya kuma suna iya neman rahoton gwaji mai amincewa da ISO 17025 daga dakin gwaje-gwajen mai samar da kayayyaki. A J-GUANG, muna da takardar shaidar ISO 9001:2015 kuma muna kula da bayanan daidaitawa ga duk kayan aikin gwaji, wanda masu binciken kaya ke dubawa yayin nazarin masana'anta.
2. Bin Ka'idojin Girma A Ƙarƙashin Na'urar Microscope: Dokar 0.1mm
Binciken girma shine inda yawancin binciken oda na girma ke zama mai girma. Ƙungiyoyin sayayya suna amfani da injinan aunawa masu daidaitawa (CMM) ko masu kwatanta gani don duba ma'auni masu mahimmanci akan girman samfurin guda 125 a kowace fili (bisa ga IEC 60512-1). Ga toshewar tashar pitch 5.0mm, mahimmin ma'auni sune: tazara tsakanin firam (5.0mm ±0.2mm), diamita na fil (1.0mm ±0.05mm), tsawon gaba ɗaya (10.0mm ±0.3mm), da kuma daidaita tsakiyar rami (≤0.1mm). Mun ga masu binciken sun ƙi wani tsari saboda diamita na fil akan samfuran 3 daga cikin 125 sun auna 0.94mm—kawai 0.01mm ƙasa da ƙayyadadden ƙayyadaddun bayanai. Haƙurin ya cika.
Amma ainihin binciken ya ta'allaka ne akan hanyar haɗin gwiwa: zurfin zaren sukurori da buɗewar maƙallin waya. Ga samfurinmu na 301-5.0, zaren sukurori na M2.5 dole ne ya kasance yana da zurfin 4.0mm ±0.1mm, kuma buɗewar wayar dole ne ya zama 2.5mm ±0.15mm. Masu duba suna amfani da ma'aunin go/no-go don waɗannan duba. Idan zurfin zaren ya yi ƙasa sosai, sukurori ba zai samar da isasshen ƙarfin matsewa ga waya 14 AWG ba; idan ya yi zurfi sosai, sukurori na iya ƙasa ya yanke. Mun tattara teburin kwatantawa daga bayanan bincikenmu wanda ke nuna ƙimar wucewa/faɗuwa ta yau da kullun:
| Girma | Iyakar Takamaiman | Yawan Shiga (Samar da Mu) | Ƙimar ƙin amincewa da masana'antu |
|---|---|---|---|
| Tazarar filin wasa | 5.0mm ±0.2mm | 99.8% | 2-5% |
| Diamita na fil | 1.0mm ±0.05mm | 99.5% | Kashi 3-7% |
| Zurfin zaren sukurori | 4.0mm ±0.1mm | 99.2% | Kashi 4-8% |
| Buɗewar shiga waya | 2.5mm ±0.15mm | 99.6% | 2-6% |
| Daidaita tsakiyar ramin | ≤0.1mm | 98.9% | 5-10% |
Muna kula da tsarin kula da tsarin kididdiga (SPC) wanda ke bin diddigin waɗannan ma'auni a ainihin lokacin yayin ƙera allura da kuma buga tambari. Masu binciken kuɗi suna son ganin jadawalin SPC - yana nuna cewa muna da ƙarfin hali, ba masu ƙarfin hali ba. Don ƙarin bayani game da tsarin ingancinmu, duba namu Bayanin layin samfur.
3. Gwajin Wutar Lantarki a Ƙarƙashin Load: Juriya ga Dielectric da Juriya ga Hulɗa
Ƙungiyoyin sayayya ba wai kawai suna gwada tubalan tashar a zafin ɗaki ba. Suna gwaji a yanayin zafi mai yawa (85°C na awanni 1000 a kowace IEC 60998-2-1) da kuma bayan fallasa danshi (95% RH na awanni 48). Mahimman sigogin lantarki guda biyu sune ƙarfin lantarki mai jure wa dielectric da juriyar hulɗa. Ga tubalan tashar da aka kimanta 300V, gwajin dielectric shine 1500V AC na minti 1 ba tare da lalacewa ko kwararar iska da ta wuce 5mA ba. Mun ga masu binciken sun yi amfani da 1800V na tsawon daƙiƙa 5 a matsayin gwajin gefe - idan ya gaza, an keɓe dukkan yankin.
Ana auna juriyar hulɗa ta amfani da hanyar Kelvin mai waya huɗu. Matsakaicin yawanci shine farkon ≤5 milliohms, kuma ≤10 milliohms bayan zagayowar saka/fitarwa 50. Amma ga abin da ya faru: ƙungiyoyin sayayya galibi suna gwadawa da ainihin waya (tagulla mai ɗaure 14 AWG) maimakon fil na gwaji, saboda hanyar haɗin waya zuwa tashar ita ce abin da ke da mahimmanci a fagen. Idan ƙarfin mannewar sukurori bai isa ba, juriyar hulɗa na iya ƙaruwa zuwa milliohms 20 bayan zagayowar zafi. Muna gwada kowane rukuni da wutar lantarki 10A don zagayowar 1000 don tabbatar da kwanciyar hankali. Dakunan gwaje-gwaje na waje kamar TÜV sabis na gwajin lantarki na Rheinland samar da tabbaci mai zaman kansa ga masu siye waɗanda ke buƙatar sa.
Wani bincike da muka gudanar a bara ya shafi ƙungiyar sayayya daga wani kamfanin kera inverter na hasken rana. Sun kawo nasu na'urar gwajin kuma suka gudanar da gwajin dielectric na 2000V akan samfura 50. Duk sun yi nasara, amma sun lura cewa nisan da ke rarrafe akan samfurinmu na 301-5.0 ya auna 6.2mm—sama da mafi ƙarancin 5.5mm don digiri na gurɓataccen 300V 2. Wannan ƙarin ribar ya sa muka sami matsayin mai samar da kayayyaki da aka fi so. Gwajin lantarki ba wai kawai game da wucewa/faɗuwa ba ne; yana game da nuna ƙarfin ƙira.
4. Ingancin Rufewa da Juriyar Tsatsa: Gaskiyar Fesa Gishiri
Tashoshin tubalan ƙarshe galibi tagulla ne da aka yi da nickel, tare da kauri na plating na microns 2-5. Ƙungiyoyin sayayya suna tabbatar da hakan ta amfani da na'urorin nazarin hasken X-ray (XRF). Idan layin nickel ya ƙasa da microns 2, tashar na iya lalacewa a cikin yanayin zafi mai yawa, wanda ke haifar da ƙaruwar juriya ga hulɗa. Mun ga masu binciken sun ƙi wani tsari inda matsakaicin kauri na nickel ya kasance microns 1.8 - duk da cewa ƙayyadaddun ya ce microns 2-5. Iyakar ƙasa cikakke ce.
Amma ainihin gwajin shine feshin gishiri bisa ga ASTM B117. Ga tubalan tashar masana'antu, awanni 48 na fallasa feshin gishiri ba tare da ja tsatsa a saman tashar ba abu ne da aka saba gani. Wasu ƙayyadaddun bayanai na motoci suna buƙatar awanni 96. Muna gudanar da gwaje-gwajen feshin gishiri a kowane wurin samarwa kuma muna ba da rahoton. A lokacin wani bincike, ƙungiyar sayayya daga kamfanin kayan lantarki na teku ta nemi feshin gishiri na awanni 120 - mun wuce ba tare da tsatsa ba, amma saboda tsarin facinmu ya haɗa da ƙaramin layin nickel na microns 3 kafin ƙarewar nickel na ƙarshe. Wannan ƙarin kauri yana kashe mu kimanin $0.002 a kowace tashar, amma ya cancanci amincewa.
Masu duba kaya kuma suna duba mannewa na plating ta amfani da gwajin tef (ASTM D3359). Idan wani plating ya fashe, za a ƙi tashar. Mun inganta sinadaran plating ɗinmu don tabbatar da mannewa, kuma muna yin rikodin abun da ke cikin baho da zafin jiki na kowane aiki. Don ƙarin bayani kan tsarin plating ɗinmu, duba ƙayyadaddun fasaha akan namu shafin samfur.
5. Tabbatar da Marufi: Ba Akwati Kawai Ba
Oda mai yawa na tubalan tashoshi 50,000 suna buƙatar marufi wanda ke hana lalacewa yayin jigilar kaya da ajiya. Ƙungiyoyin sayayya suna duba marufi don abubuwa uku: kariyar hana tsayawa, shingen danshi, da kuma matashin kai na injiniya. Tubalan tashoshi masu gidajen PA66 suna da hygroscopic - idan an fallasa su da fiye da kashi 60% RH na fiye da awanni 48, suna iya sha danshi kuma suna haifar da lahani na solder (popcorning) yayin soldering na raƙuman ruwa. Masu duba suna duba cewa marufi ya haɗa da jakar shingen danshi tare da busarwa da katin nuna danshi. Idan katin ya nuna ruwan hoda (wanda ke nuna sama da kashi 60% RH), za a ƙi dukkan filin.
Ana tabbatar da gyaran matashin kai ta hanyar amfani da gwaje-gwajen faɗuwa: ana sauke akwatin tubalan ƙarshe daga mita 1.2 zuwa bene na siminti. Idan fiye da kashi 1% na na'urorin sun nuna gidaje masu fashe ko fil masu lanƙwasa, ƙirar marufi ta gaza. Muna amfani da kayan saka kumfa na musamman tare da yankewa don kowane layin tubalan ƙarshe, kuma mun ci nasara a kowace gwajin faɗuwa a cikin shekaru uku da suka gabata. Ƙungiyoyin sayayya kuma suna duba marufi mai aminci ga ESD (juriyar saman ƙasa
Lakabi wani abu ne da ake dubawa: kowane akwati dole ne ya kasance yana da lakabin da ke ɗauke da lambar sashe, adadi, lambar kwanan wata, da lambar fili. Dole ne Barcodes su kasance masu dacewa da tsarin rumbun ajiya mai sarrafa kansa na GS1-128. Mun ga masu binciken sun ƙi jigilar kaya saboda an yi wa barcode ɗin ɓarna kuma ba za a iya duba shi ba. Ƙaramin bayani ne, amma yana da mahimmanci a cikin manyan kayan aiki.
6. Takardu Zurfi: Canzawa daga Resin zuwa Jigilar kaya
Ƙungiyoyin sayayya suna son bin diddigin kowane shingen tashar zuwa ga tsarin kayan aikinsu. Wannan yana nufin binciken ya haɗa da bita na dukkan sarkar takardu: takardar shaidar bincike ta mai samar da resin (CoA), sigogin injin ƙira (zafin jiki, matsin lamba, lokacin zagayowar), bayanan kula da manne, rajistan shara na wanka, da rahotannin dubawa na ƙarshe. Muna kula da tsarin bin diddigin dijital inda kowace lambar fili ke haɗuwa da duk waɗannan bayanan. Masu binciken kuɗi suna zaɓar lambar fili bazuwar kuma suna roƙonmu mu cire takardun cikin mintuna 15. Ba mu taɓa cin wannan gwajin ba.
Wani bincike da aka saba yi game da binciken shine rashin rikodin daidaitawa na maƙullan ƙarfin juyi da aka yi amfani da su don saita ƙarfin matse sukurori. Idan ba a daidaita maƙullan ƙarfin juyi ba cikin watanni 12 da suka gabata, ana zargin cewa dukkan aikin samarwa yana kan aiki. Muna daidaita kowane maƙullan ƙarfin juyi duk bayan watanni 6 kuma muna ajiye takaddun shaida a fayil. Hakazalika, CMM da ake amfani da shi don duba girma dole ne ya sami takardar shaidar daidaitawa ta yanzu da za a iya gano ta zuwa NIST ko makamancin haka. Muna ba da kwafi yayin binciken.
Ƙungiyoyin sayayya kuma suna duba rahotannin rashin bin ƙa'ida (NCRs) na shekarar da ta gabata. Suna son ganin mun gano tushen musabbabin kuma mu aiwatar da matakan gyara. Misali, mun sami NCR a bara inda diamita na fil ya koma 0.96mm saboda tambarin da aka yi wa manne. Mun rubuta tushen musabbabin (saka manne bayan zagayowar 500,000), matakin gyara (saka manne da ƙara yawan dubawa zuwa kowane zagaye 10,000), da kuma tabbatarwa (guda 10,000 na gaba duk a cikin takamaiman bayani). Wannan matakin cikakkun bayanai yana gina aminci. Albarkatun waje kamar ISO 9001: Tsarin Gudanar da Inganci na 2015 samar da tsarin wannan takardar.
7. Ikon Samarwa a Wurin Aiki: Tafiyar Masana'antu
Matakin duba na ƙarshe shine duba yanayin aikin samarwa. Ƙungiyoyin sayayya suna neman abubuwa biyar: tsafta, kula da kayan aiki, horar da masu aiki, tsarin aiki, da aminci. Yankin datti na ƙera allurar da ke zubar da mai a ƙasa alama ce ta gaggawa - yana nuna rashin kyawun tsarin sarrafawa. Muna kula da tsarin 5S (Rarraba, Saita a Tsarin, Haske, Daidaita Daidaita, Ci gaba) kuma masu binciken sau da yawa suna ɗaukar hotuna don kwatantawa da hanyoyin da muka rubuta.
Ana duba rajistan ayyukan gyaran kayan aiki: shin injinan gyaran suna kan jadawalin gyaran kariya? Shin ana duba diga-digan tambari bayan kowace zagaye 100,000? Muna nuna musu bayanan gyaranmu, waɗanda suka haɗa da duba man shafawa na yau da kullun da kuma auna lalacewar ma'aikata na mako-mako. Haka kuma ana duba bayanan horar da masu aiki - kowane ma'aikaci dole ne ya sami takardar shaida ta yanzu don nau'in injinsa. Muna ba da horo na shekara-shekara kuma muna kula da ma'aunin ƙwarewa.
Tsarin gudanar da aiki yana da mahimmanci: ya kamata a sanya wa kayan aiki alama a sarari kuma a raba su da kayan da aka gama. Muna amfani da kwandon shara masu launi: kore don dubawa da amincewa, rawaya don keɓewa, ja don ƙin amincewa. Masu binciken kaya suna tabbatar da cewa yankin keɓewa yana kulle kuma ma'aikata masu izini ne kawai ke da damar shiga. Tsaro ba za a iya yin shawarwari ba: tsayawar gaggawa a kan dukkan injuna, na'urorin kashe gobara masu alamun dubawa na wata-wata, da kuma bin ƙa'idodin PPE. Mun wuce kowace binciken tsaro saboda muna ɗaukar ta a matsayin babban ƙima, ba akwati ba.
Wata ƙungiyar sayayya daga wani kamfanin sarrafa kansa na Turai ta yi kwana ɗaya a kan benenmu, tana tsara kowane mataki na aiki kuma tana kwatanta shi da lokutan zagayowar da aka rubuta. Sun gano cewa ainihin lokacin zagayowarmu don ƙera gidan 301-5.0 shine daƙiƙa 28, idan aka kwatanta da daƙiƙa 30 da aka rubuta. Wannan iyaka ta daƙiƙa 2 ta ba su kwarin gwiwa kan iyawarmu na cika odar raka'a 100,000 a cikin makonni 4. Tsarin ba wai kawai game da gano matsaloli ba ne—yana game da tabbatar da cewa mai samar da kayayyaki zai iya cika alkawuran da aka yi.
Tambayoyin da ake yawan yi: Tambayoyin Binciken Oda Mai Yawa na Tashar Terminal Block
Menene mafi ƙarancin girman samfurin da ƙungiyoyin sayayya ke buƙata don binciken odar babban bulo na tashar?
Ma'aunin masana'antu shine guda 125 a kowace kuri'a a bisa ga IEC 60512-1, amma ƙungiyoyin sayayya da yawa suna buƙatar samfura sama da 200 don oda mai yawa sama da raka'a 100,000 don cimma matakin amincewa da kashi 95% tare da gefen kuskure na 5%.
Ta yaya ƙungiyoyin sayayya ke tabbatar da ƙimar UL 94 V-0 mai ƙonewa a kan gidajen tubalan tashar?
Suna buƙatar rahoton gwajin kayan aiki daga mai samar da kayayyaki wanda ke nuna sakamakon gwajin ƙonewa a tsaye a kowace UL 94, tare da lokacin ƙonewa bayan wuta ƙasa da daƙiƙa 10 a kowace samfuri kuma babu digowar ƙonewa. Muna samar da wannan ga kowane rukunin oda mai yawa.
Wadanne jurewar girma ne ake karɓa don tubalan tashar sukurori a cikin oda mai yawa?
Ka'idojin karɓuwa na yau da kullun: tazara tsakanin ramin ±0.2mm, diamita na fil ±0.05mm, tsawon gaba ɗaya ±0.3mm, da kuma tsakiyar ramin da ke cikin 0.1mm. Samfurinmu yana ɗaukar ±0.1mm akan ma'auni masu mahimmanci.
Shin ƙungiyoyin sayayya suna buƙatar gwajin dakin gwaje-gwaje na ɓangare na uku don odar manyan bulo na tashoshi?
Eh, ga oda da ta wuce raka'a 50,000 ko kuma don aikace-aikacen da suka shafi aminci (misali, allunan kula da masana'antu), masu siye galibi suna ba da umarnin gwajin UL ko TÜV Rheinland. Muna kula da fayil ɗin UL E kuma muna iya shirya binciken dakin gwaje-gwaje.
Menene lokacin jagorancin da aka saba amfani da shi don binciken masana'antar yin odar babban bututun bututun?
Binciken da ake yi a wurin yana ɗaukar kwana 1-2, tare da isar da rahoto cikin kwanakin kasuwanci 5. Ana iya kammala binciken daga nesa ta hanyar duba bidiyo cikin kwana 1. Muna tsara binciken cikin makonni 2 bayan buƙatar.
Ta yaya ƙungiyoyin sayayya ke bincika tubalan tashar jabu a cikin oda mai yawa?
Suna tabbatar da takardar shaidar ISO 9001 ta mai samar da kayayyaki, lambobin sassan da aka yi amfani da su tare da takaddun bayanai na masana'anta, suna duba ingancin alamar laser, kuma suna yin nazarin kayan XRF don tabbatar da abun ciki na tagulla da ƙarfe a cikin tashoshi.