Zhangjiagang Electronics Plant
Located in Zhangjiagang, Jiangsu Province, covering an area of 22,000 ㎡.
The factory is equipped with SMT, DIP, assembly and testing production lines.
PCBA - SMT
Highly Automated and Intelligent
- Automated Production: Full-process automation from PCB loading to finished goods, using automatic chip mounters, printers and reflow ovens.
- Intelligent Control: Real-time monitoring and process optimization via MES & IoT.
- AI & Machine Learning: AI-driven defect detection, predictive maintenance and process optimization.
High Precision & High Mounting Speed
- Placement Accuracy: Advanced mounters (Siemens SX series) achieve ±25μm accuracy, supporting 01005 and smaller components.
- High Speed: Multi-gantry mounters exceed 200,000 CPH. Dual-track lines double efficiency.
- Fine-Pitch Capability: Supports QFN, BGA, CSP for high-density PCBs in 5G and automotive electronics.
Flexibility & Quick Changeover
- Quick Changeover: Intelligent programming & modular design reduce changeover time within 10 mins, ideal for multi-variety, small-batch production.
- Compatibility: Supports PCBs from 50×50mm to 510×460mm for LED, consumer electronics & medical applications.
Reliability Enhancement Technology
- In-line Inspection: AOI, AXI & flying probe testing ensure real-time defect rejection, with FPY over 99%.
- Environment Control: Constant temperature & humidity, ESD protection safeguard precision components.
PCBA - DIP
Soldering Line
Selective soldering: Local soldering for THT & SMT+THT PCBs, avoiding thermal shock to sensitive components.
- High precision: Multi-nozzle design, 2 mm minimum pitch, ±50 μm accuracy via laser/visual positioning.
- Intelligent & reliable: Independent temperature control (up to 300℃), nitrogen atmosphere for 20%+ better wettability.
- Flexible production: Changeover<5 min, supports 50×50 to 500×450 mm PCBs and odd-shaped components.
- In-line traceability: Integrated AOI/3D inspection, MES-based full-process parameter recording.
Pin Insertion Line
Pin insertion for THT components: pin headers, terminals, relays, etc.
- High Precision & Speed: Servo + vision positioning, ±0.05mm accuracy, 0.5mm pitch, >10,000 pins/hour.
- Smart Error Prevention: Force feedback avoids bending/missing pins, defect rate <0.1%. AI optimizes insertion sequence.
- Flexible & Quick Change: Modular fixtures, changeover <3 mins. Supports THT and Press-fit.
Coating Line
Conformal coating for PCBs to enhance moisture, corrosion and dust resistance.
- High Precision Selective Spraying: Non-contact spraying, 10-50μm (±5μm) thickness, vision positioning to avoid no-spray areas.
- Smart Process Control: Auto-adjust pressure/flow for various coatings. UV/hot air curing <30s.
- Environmental & Safe: Closed spraying + VOC treatment, RoHS/REACH compliant. Coating utilization >90%.
- In-line Inspection & Traceability: IR/3D inspection, MES records parameters for quality traceability.
Highly Automated Assembly
Complete machine assembly involves processes such as structural part assembly, screw locking, gluing, wire harness connection and shell packaging.
Robotic Assembly
Collaborative robots / 6-axis arms for precision assembly.
Automatic Screw Locking
Servo + vision, torque accuracy ±1%, prevents missing/loose screws.
Auto Dispensing & Bonding
High-precision jet dispensing with ±0.02mm tolerance.
Final Product - Testing
The testing process includes fully automated testing, intelligent data analysis, a high-compatibility test system, radio frequency calibration, etc.
Fully Automated Testing
- Robot Automatic Loading & Unloading: Robotic arms (e.g., EPSON SCARA robots) feed products to be tested into test stations, minimizing manual intervention.
- Parallel Testing: Multi-station simultaneous testing (e.g., 4 mobile phones undergoing 5G RF calibration at the same time), improving efficiency by 300%.
- AI Visual Inspection: Deep learning algorithms identify appearance defects (scratches, color differences) with an accuracy of >99.9% (e.g., Cognex ViDi).
Intelligent Data Analysis
- Real-time monitoring and early warning: SPC (Statistical Process Control) analyzes test data and automatically triggers alarms (e.g., out-of-tolerance parameters).
- Predictive maintenance: Predict test equipment failures through data such as vibration and temperature to reduce downtime.
Highly Compatible Test System
- Modular test architecture: Supports quick change of test fixtures (e.g., shared test platform for mobile phones, TWS earbuds and smart watches).
- OTA (Over-the-Air) test: Automated RF testing for 5G / Wi-Fi 6E / Bluetooth (e.g., Keysight UXM5G tester).