In this article, I am going to give you a detailed overview of the factory how the power banks are being made. Such as the assembly process and the quality control.
- Checking all the components.
Every time before assembling a product, all components must be checked to ensure that the assembly can be completed smoothly. This is the most basic step. Usually, we will check the following parts:
- Checking the PCBA
Workers will check whether the board is damaged and whether all the components on the PCB are complete and soldered, so that they can be attached to the batteries and the process stars from here.
- Checking the battery
Check whether the battery is in good condition and whether the surface is damaged. And also check whether the positive and negative pieces of the battery are flat to ensure that they can be better attached to the PCB.
- Checking the case
Check whether there are scratches on the case, whether the case is defective, whether the edges are smooth, and whether the printing of the LOGO is clear. At last, put it back in the foam pad after inspection to prevent scratches later.
- Checking the accessories
The most common is the charging cable and instruction. Workers will check whether the interface of these cables is in good condition and whether there is any damage on the cable. For the instruction, whether the printing is clear and whether the quantity is sufficient.
- Checking the package
The package of a product usually has at least two or more parts, such as inner packaging and outer packaging. Workers have to check the quantity of each part and check whether is damaged before packing.
- Solder the batteries and PCB
Professional workers will use special tools to solder the battery and PCB evenly with tin. First, tin is added to the positive and negative electrodes of the battery to make the tin point full. Then solder the silicone wire to all the batteries. The red is the positive electrode and the black is the negative electrode. The positive and negative electrodes cannot be connected reversely, otherwise the chips on the PCB will be burned. In addition, it is necessary to pay attention to the edge of the tool to prevent the screen and the battery from being burnt, which will have very serious consequence. Most factories still use manual soldering, but now many large factories are changing their mode and start to use machines to solder, which is more efficient.
- Checking the product whether charging or not
In this stage, all PCBs with soldered batteries are tested for function to see weather each port is charging or discharging normally. And also check whether the PCB and the battery are properly connected. The defective products need to replace the PCB and re-test.
- Preliminary assembly
This stage is to install the PCB with soldered battery to the bottom case. This step needs to be very careful. First of all, install the battery in place, and make sure that the battery does not touch any sharp place on the bottom case, and be careful not to scratch the battery. If you accidentally scratch the battery, you must replace it, because this can cause serious problems. Then install the PCBA.
- Aging testing
Put all the semi-finished products in the aging cabinet, then plug in the Micro-USB port and USB-A port for aging. The aging process is to first discharge the battery, then charge it again, and then discharge it to 60%-70% (this is regarded as a cycle); if it is required to do it twice, then discharge it again, recharge it, and then discharge it to 60 %-70%. In this process, it is necessary to pay attention to put the semi-finished product to the bubble bag to prevent scratching the bottom case. In addition, be careful not to over discharge, you need to ensure that there is still 60%-70% of the electricity.
- Gluing and covering
In this stage, they will use the hot glue machine to put the hot glue on the edge of the bottom case and cover the top piece of the power bank, in order to make sure the top part is properly fixed on the bottom case. But for some styles, there is no need to glue, just directly lock mechanism to the snap the top case to the bottom case. For this step, pay special attention to not clamp the battery in the buckle position to prevent battery damage.
- Checking again
In this step, you need to press the switch to see if the power is between 60% and 70% or not. If the power is too low, you need to pick it out and recharge it. In addition, they will also check the power bank charging and discharging is functioning.
- Packaging
In the packaging stage, workers first prepare all the accessories. Such as outer packaging, inner packaging, charging cable, as well as instructions, stickers and so on. Then the outer packaging and inner packaging will be pre-folded, and then the packaging will begin. First put the charging cable and the instruction in the inter packaging, and then check the appearance of the power bank, the surface is being cleaned by a solution. Secondly, put the power bank in the inter packaging and then pack in the outer packaging. Last seal with the sticker.
The above is the process of assembling the power bank for your reference. Of course, with the continuous reform of technology, the assembly process will gradually towards to the direction of automation, which will greatly improve the efficiency.
