Production Capabilities
Highly Accurate And Efficient Automated Production Lines
To maintain high production capacity, miniaturization and high precision of product, ABC ATEC has invested in building an intelligent technology factory, focusing on the introduction of automatic production in winding, welding, assembling, bending process, as well as automatic optical inspection (AOI) and automated inspection systems, so as to achieve quality and capacity control, which can not only shorten the manufacturing process and delivery time, but also ensure the product performance is not affected.
Automatic Winding & Welding Station
The winding process is a critical step in the manufacturing of inductors, the process involves winding a conductive wire, typically copper or aluminum, around a core to create the desired inductance. The winding process is crucial in inductor manufacturing because it directly determines inductance value by the number of turns in the winding, the spacing between the turns, and the core material. ABC ATEC introduce automatic equipment with different winding methods according to the characteristics of the product, with digital tension control, real-time dynamic tension control and monitoring of spot welding temperature output guarantee the stability of product quality and efficiency.
Automatic Assembly Station
The assembly process in inductor manufacturing is a vital step that involves integrating all the componentsāsuch as the wound coil, core, terminals, and housingāinto a finished inductor. ABC ATEC automatic assembly process begins with preparing the core, which is the magnetic material around which the coil is wound, followed by gluing which use adhesives to secure different components of the inductor such as the coil and housing, with camera to control gluing position and area. After applying the adhesive, the components are positioned and aligned correctly to ensure proper functionality. The assembly must remain stable during this stage to prevent misalignment or movement until the adhesive cures. The curing process involves allowing the adhesive to harden and form a strong bond and the curing time is critical, as it directly affects the bond strength and, consequently, the inductor's mechanical stability.
Automated Optical Inspection (AOI) Station
AOI is a critical quality control process in inductor manufacturing that uses cameras and sophisticated imaging software to inspect inductors for defects and ensure they meet stringent quality standards. After curing, the product is inspected via seven sides AOI camera to ensure that all components are securely bonded and that there are no gaps, voids, or misalignments, as well as to detect defects in product dimensions, crack and breakage of product appearance, analyzing the defect rate in real time and export the production report.
Testing & Packing Station
Testing and packing are the final stages in inductor manufacturing, crucial for ensuring the inductors meet quality standards and are ready for shipment. The product is first marked by Laser, and then the 100% electrical characteristics are tested, including RDC, L and SDS value with data collrction, and finally packaged through carrier tape.