/ made in Germany

Electronic assembly

EA Elektro-Automatik manufactures its power supply systems and electronic loads at a ca. 6000m² site in Viersen, Niederrhein. We have a high level of vertical integration. Thus, we produce all our electronic components for our core products in-house. In our circuit board production, we use both SMT (Surface Mounted Technology) and THT (Through Hole Technology) in modern assembly and soldering stations. Our products undergo numerous test phases both during the manufacturing process and at final inspection. The first test phase, the component test, follows directly after the initial assembly: computer aided systems test the functional capability of the circuit boards.

Subsequently our technicians mount the individual components together to build the complete device. From cable fabrication to our own fitting shop, we are well equipped to meet any demands: whether serial production, prototypes or individual customisation – our technical staff do everything themselves and are therefore rapidly responsive.

Standardised processes across all phases make for a lean and efficient production. Even so, before our devices are dispatched they pass through various automated test systems for quality assurance. And all that under full ESD protection across the whole process chain.

Automated production lines

We have three automated production lines equipped with automatic placing machines. These automated circuit board assemblers guarantee a high quality electronic manufacture. These automatic placing machines use a collect-and-place system and save significant time in the manufacturing process.

Component miniaturisation

The SMD technology enables the components to occupy significantly less space, enabling us to use the smallest circuit boards and achieve a high component density. In this way the SMD assembly miniaturises the circuit boards, saving costs. Every circuit board is identified with a unique serial number allowing material tracing. Quality is assured by a final testing of all boards using automatic optical inspection (AOI).

Moisture sensitive components (MSL – Moisture Sensitivity Level) are stored after assembly in evacuated Dry-Shield Bags. Thus, we can guarantee that the quality of the components used in a later production charge remains to our standards.

Cost advantage of SMD assembly

  • Rapid device manufacture using Collect-and-Place
  • High quality through automated circuit board assembly
  • No contamination
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In our THT (Through Hole Technology) assembly a team of about 35 employees assemble modules with leaded components. Soldering is made using a wave soldering station, lead-free under nitrogen. Thus, we achieve high quality soldered connections as well as conforming to RoHS.

High grade soldered connections

Where necessary other components can be added using the selective soldering station, also lead-free and under nitrogen. Finally, primary and secondary sides of our systems are mounted together to make a complete controller.

Intelligent screwing system

Intelligent screwing systems with monitored entry angle and torque connect the power semi-conductor with the heat sink. The technicians also work here in air-conditioned rooms, ensuring the cleanliness needed for controller assembly.

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Following assembly, the circuit boards and modules are tested: automated, computer-controlled systems test the boards for functional integrity. The boards are connected via a needle bed adaptor. The test system collects data automatically from the test procedures, generates a test report and stores this. This information can subsequently be used for statistical analysis or for article history.

Quality from circuit board to controller modules

The controllers are also tested: our technicians test the individual switching functions of each module to ensure subsequent functional conformity.

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At the start of the assembly process all the parts and modules required for the order are collected. Our fitters assemble these according to instructions. The modular construction of our power supplies enables us to standardise the assembly processes, making production lean and efficient.

Our own fitting shop in-house

Required mechanical changes to the modules as well as prototypes are done quickly ourselves: whether drilling, turning, milling or bending, our internal fitting shop is fully equipped for all sheet metal works.

Cable manufacture

After the testing process the modules to be used in our products are connected together. The leads and cable looms required are produced in our own cable manufacture, from cutting to length through crimping of cable shoes to bundling of multiple leads.
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Before a device leaves us, it is extensively tested: firstly, a calibration, before all functions are tested. Included, for instance, are output ripple, stability and accuracy of current and voltage and control setting time. For verification of the safety features every device undergoes a safety check. In a stress test the device must demonstrate that it can maintain its parameters at load limits. If required by the customer a recorded calibration needed for the application is carried out. Prior to dispatch a final test ensures that the values have not changed since the stress test and that all parameters are still within specification.

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