Management of Raw Material Suppliers

1. Enclosure Color (Semi-Annual Sealing Sample):

· Sealing Sample Management: Suppliers provide enclosure samples, which are confirmed and sealed by both parties as the standard for subsequent production colors.

· Regular Review: Re-seal samples every six months to ensure consistency in the supplier's production process.

· Standardized Inspection: Use a colorimeter for periodic detection of color differences between batch products and the sealed sample to ensure compliance with color requirements.

2. MOV (Metal Oxide Varistor):

· Supplier Inspection Report: Require suppliers to provide factory inspection reports for each batch, including key parameters such as surge current capacity, residual voltage characteristics, and leakage current.

· Destructive Testing:

o Conduct regular sampling and internal testing using specialized lightning surge equipment, such as overload surge tests and durability tests, to verify performance compliance with design requirements.

o Compare test results with the supplier's inspection reports to evaluate data accuracy and consistency.

· Review of Production Processes: Regularly dispatch quality teams or third-party agencies to audit the suppliers' production processes, ensuring process stability and compliance.

3. GDT (Gas Discharge Tube):

· Testing and Certification: Require suppliers to provide certification documents and test reports compliant with industry standards (e.g., CE, UL 1449).

· Performance Verification:

o Focus on testing parameters such as breakdown voltage, insulation resistance, and surge current capacity.

o Conduct high-voltage surge and aging tests quarterly to ensure the product performance meets design requirements.

· Batch Consistency Testing: Perform small sample inspections for each batch to verify the stability of key parameters.

4. SMD (Surface-Mounted Device) Suppliers:

Quality Management System Audit:
Evaluate the supplier's quality management system (e.g., ISO 9001 certification) to ensure their production processes are well-controlled.

Sample Inspection:

o Initial Stage: Conduct comprehensive testing of the SMDs' electrical properties (e.g., capacitance, inductance) and mechanical properties (e.g., pad flatness, dimensions).

o Mass Production Stage: Use Automated Optical Inspection (AOI) and X-ray inspection equipment to verify product consistency.

Unscheduled On-Site Reviews:

o Inspect the supplier's production workshops and laboratories to check raw material control, production environments, and maintenance of key equipment.

o Confirm strict implementation of moisture control and ESD (Electrostatic Discharge) protection measures.

Incoming Material Inspection for Raw Materials

I. MOV (Metal Oxide Varistor) Inspection and Control

1.Key Inspection Items

1. Surge Current Capacity Test: Verify whether the MOV's maximum surge current capacity meets design requirements.

2. Residual Voltage Test: Measure the MOV's voltage drop performance under lightning or surge conditions.

3. Leakage Current Detection: Assess the MOV's leakage current level to evaluate its insulation performance.

4. Aging Performance Test: Simulate actual working conditions to validate the long-term reliability of the MOV.

2.Laboratory Equipment

Surge Generator:

1. Function: Simulates 8/20μs and 10/350μs waveform surge current tests to assess the MOV's surge current capacity.

2. Purpose: By applying standard surge currents, it tests whether the MOV can withstand predetermined current surges.

3. Testing Standard: In compliance with IEC 61643-11 and other standards.

DC Parameter Tester (Lab Validation):

1. Function: Tests the MOV's leakage current and breakdown voltage.

2. Purpose: Precisely measures the MOV's volt-ampere characteristics to ensure key parameters meet specifications.

High-Temperature Aging Chamber:

1. Function: Subjects the MOV to a prolonged high-temperature environment for aging.

2. Purpose: Simulates long-term usage conditions to verify stability and performance degradation over time.

3. Manual Inspection and Operation (Lab to Confirm Availability of Magnifying Glass)

· Visual Inspection: Use a magnifying glass to check the MOV's appearance for cracks, bubbles, or encapsulation defects.

· Manual Sample Testing: Select a specific proportion of products from each batch for manual testing, with special attention to performance edge-case samples.

· Destructive Testing: Gradually apply increasing surge currents to the sample until the MOV is damaged to ensure the design has sufficient safety margins.

II. GDT (Gas Discharge Tube) Inspection and Control

1.Key Inspection Items (Lab to Confirm Equipment):

1. Breakdown Voltage Test: Verify whether the GDT's breakdown voltage under specified conditions meets the requirements.

2. Insulation Resistance Test: Assess the insulation performance in a non-breakdown state.

3. Surge Current Capability Test: Validate the GDT's ability to handle surge or lightning current.

4. Lifetime Test: Simulate multiple surge conditions to assess performance changes and ensure product longevity.

2.Laboratory Equipment

High-Voltage DC/AC Tester:

1. Function: Tests the GDT's breakdown voltage and insulation resistance.

2. Purpose: Ensures key parameters comply with IEC standards, such as IEC 61643-311.

Surge Impulse Generator:

1. Function: Applies an 8/20μs surge waveform to test current-handling capability.

2. Purpose: Verifies whether the GDT can function normally under surge conditions and effectively conduct surge currents.

3. Manual Inspection and Operation (Lab to Confirm Equipment):

· Individual Parameter Verification: Use a high-voltage tester to test each product in small batches, focusing on breakdown voltage and insulation resistance.

· Manual Re-Inspection: Manually verify the abnormal products identified by the testing equipment to rule out false positives from equipment errors.

· Destructive Testing: Select samples for extreme current-handling tests to ensure the product has sufficient tolerance margins.

Our Incoming Material Inspection Equipment and Instruments

Lightning Surge Equipment:

· Limiting Voltage Measurement Test

· Activation Load Test

· Voltage Protection Level Determination

· Grade Limiting Voltage Test

· Lightning Current Surge Test to Ensure Component Performance

Hardness Tester:

· Measures the hardness level of metal components.

Salt Spray Chamber:

· Simulates environmental conditions for metal components to verify their corrosion resistance, including resistance to environmental factors such as saltwater exposure.

RoHS Tester:

· Ensures that materials used in the manufacturing process comply with RoHS (Restriction of Hazardous Substances) regulations.

Lightning Protection Component Tester:

· Tests the U1mA value of MOV (Metal Oxide Varistor) and the trigger voltage of GDT (Gas Discharge Tube).