In the factory of Quankang,we introduced an Automated AI-SMT production line,and this blog will tell you how this line improves power adapter manufacturing consistency.
What is the AI-SMT production line?
For medical equipment, an electric shock may cause misjudgment, and for ITE,POE equipment, high temperature and high load will affect the stability of power supplies then eventually reduce the user’s experience.
Here is our automated AI-SMT line, a precision intelligent manufacturing line that underpins the power supply’s mass production and quality success.
AI (Auto Insertion) line is an automated assembly line specifically designed for “leaded components” (through-hole components). Its core function is to precisely insert components with metal leads, such as resistors, capacitors, and diodes, into the through-holes of the circuit board, and then secure them by subsequent soldering.
SMT (Surface Mount Technology) line is an automated assembly line for “leadless/short-lead components” (surface mount components). Its core function is to mount components onto pads on the surface of the circuit board, rather than inserting them into through-holes.
The core function of automated AI-SMT lines is to achieve high-precision, high-efficiency, and low-defect assembly of electronic components on PCBs through automation and intelligent technologies. It is a core production line for the mass production of modern high quality power supply.
Why is the AI-SMT production line so crucial?
The PCB(Printed Circuit Board) in AC DC power adapter has high density and strong heat sensitivity which means that the circuit boards must be assembled with “zero defects” and mass-produced.
SMT process deviations can cause solder joints to form incorrectly, leading to increased contact resistance, signal distortion, and uneven heat dissipation in power adapters. These small manufacturing variations directly impact electrical performance, thermal behavior, and long-term reliability.
For example,after LED driver ITE Power Adapter UEL060LCP-SPA was completed on the production line,if the power devices or related components in the feedback loop experience contact resistance variations due to surface mount misalignment or high solder joint void ratio during the adapter PCB mounting stage, the output voltage and ripple control of the UEL060LCP-SPA will exhibit slight fluctuations.
When connected to LED lighting fixtures that are highly sensitive to power supply stability, these slight fluctuations will manifest as slight brightness fluctuations or perceptible flickering in the low-brightness dimming range.
But with Auto Insertion and Surface Mount Technology production line, the risk of fluctuation will drop to the minimum.This also applies to medical power supplies and ITE power supplies.
How is the AI-SMT production line brings advantages？
By solder paste printing and high-speed placement.
Solder Paste Printing: The application of electronic adhesives requires precision to ensure optimal results.
Just as the construction of a house necessitates the uniform application of cement, components must be meticulously positioned on a layer of solder paste (the “electronic adhesive”) that has been applied to the power supply circuit board’s pads. In the field of power supplies, the thickness and coverage of solder paste can directly impact solder joint conductivity and stability.
Traditional Manual Application: It is important to note that uneven thickness and misalignment are common issues, which can potentially result in poor contact and abnormal heating during operation.
AI-Powered: Automated printing with AI vision “high-definition photo inspection” is a process that alerts the user instantly if the solder paste is not at the correct thickness, is misaligned by more than 0.01 mm, or is otherwise not correct. This eliminates soldering risks at the source and maximises yield rates.
High-Speed Placement: The process of precision component placement is a key aspect of our business.
This stage is of the utmost importance within the production process: Robotic arms, equipped with specialised grippers, are used to pick up core power components (resistors, capacitors, chips) from feeders and precisely place them on designated PCB locations.
What is its speed? A single line is capable of placing hundreds of thousands of components per hour, equivalent to one person working nonstop for 10 years, thus meeting mass production demands.
How precise is it? Tolerances are guaranteed to be no greater than ±0.02mm, which is thinner than a human hair. Even the slightest misalignment in a power supply component can disrupt current stability, a level of accuracy that is impossible for manual labour to achieve.It is also worth noting that: AI monitors the placement process in real time. If a component is misaligned, the machine instantly corrects it. When a component tray approaches full capacity, the system automatically notifies the user, facilitating the process of replenishment and eliminating the need for manual intervention, which can introduce variability.
Conclusion
When it comes to power supply products, stability doesn’t come from just one design feature. It’s all about how consistent and reliable the manufacturing process is. This is the most important value that automated AI-SMT lines provide for power adapters in mass production.
Contact us to get stable and reliable AC DC power supply solutions.
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