As a manufacturer of solar water pumps, DIFFUL not only have our own production workshop for water pumps but also possess a dedicated controller workshop. In this workshop, we manufacture high-quality controller circuit boards that are crucial for the functioning of our solar water pumps. Let's take a closer look at the process of creating these high-quality controller circuit boards.

Plugin Process and ESD Protection

The plugin process is the initial step in the production of high-quality controller circuit boards. During this process, the risk of touching the electronic components is relatively high. To mitigate any potential damage caused by electrostatic discharge (ESD), our workers are required to wear antistatic wristbands. These wristbands help prevent any quality issues resulting from human-generated static electricity. By implementing ESD protection measures, we ensure that the sensitive electronic components remain unaffected during the plugin process.

Quality Inspection after Plugin Process

Following the plugin process, we have dedicated quality personnel who thoroughly inspect the previous step. This inspection ensures that all components have been properly inserted and connected without any defects or issues. By conducting comprehensive quality checks, we maintain high standards throughout the production of the controller circuit boards.

Wave Soldering

After passing the quality inspection, the controller circuit boards enter the wave soldering process. Wave soldering is a highly efficient and reliable method used to solder the components onto the circuit boards. In this process, the boards are passed over a wave of molten solder, allowing the solder to create secure connections between the components and the board. Wave soldering ensures accurate and uniform soldering, providing reliable electrical connections for optimal performance.

Trimming, Visual Inspection, and Rework

Once wave soldering is completed, various subsequent processes are carried out to further enhance the quality of the controller circuit boards. Trimming involves removing any excess solder or protruding component leads, resulting in a neat and tidy appearance. Visual inspection is then performed to identify any visible defects, ensuring the quality and accuracy of the soldering joints. If any issues are detected, necessary rework is undertaken to rectify the problems and guarantee the reliability of each connection.

ICT Testing

ICT (In-Circuit Testing) is a vital step in the production of high-quality controller circuit boards. During ICT testing, the circuit boards undergo comprehensive testing to detect open circuits, short circuits, and the quality of soldering joints for all components. This process allows us to precisely identify any faults or open circuits, ensuring accurate troubleshooting and prompt resolution. ICT testing is critical in achieving high-quality controller circuit boards that meet the required standards.

FCT Testing

FCT (Functional Circuit Testing) is the final testing process before the assembly of the controller circuit boards. It involves subjecting the boards to low-voltage testing to evaluate their functionalities. Through FCT testing, we verify various parameters such as voltage, current, power, and rotational speed to ensure that the boards perform as intended. By conducting thorough functional testing, we ensure that our products meet the necessary specifications and are in perfect working condition before assembly.

Circuit Board Assembly and Aging

After passing the ICT and FCT testing, the high-quality controller circuit boards proceed to the final assembly stage. In this stage, the boards are integrated with other components to form the complete controller units. Once assembled, the products undergo an extended aging process to evaluate their stability and reliability over an extended period. The aging process ensures that the controller units can withstand different environmental conditions and maintain optimal performance throughout their lifespan.

By following these meticulous processes, including the plugin process, wave soldering, trimming, visual inspection, ICT testing, assembly, and aging, we successfully manufacture high-quality controller circuit boards for our DIFFUL solar water pumps. These boards play a vital role in the efficient operation of our pumps, ensuring reliable performance and longevity.

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