The production process of automotive pcb relay is the key to ensure its reliable performance and stable quality. It covers multiple links from raw material preparation to finished product testing. Each step has an important impact on the quality of the final product. The first is the selection and processing of raw materials, which is the basic link of production. The core components of the relay include contact materials, electromagnetic coil materials and PCB boards. The quality of these materials directly determines the performance of the relay. The contact material must have good conductivity and wear resistance. Common precious metal alloy materials must be strictly screened to ensure purity and physical properties meet the standards; the wire material and insulation layer quality of the electromagnetic coil are also very important. It is necessary to ensure that there is no short circuit or aging during long-term power-on; the PCB board requires a flat surface and strong copper foil adhesion. It must be cleaned to remove impurities and oxides on the surface to prepare for subsequent processing.
Next is the processing process of the PCB board. As the carrier of the relay circuit, the manufacturing accuracy of the PCB board affects the electrical performance of the relay. First, the circuit design and plate making must be carried out. The circuit schematic is converted into a PCB layout through professional design software, and then the circuit pattern is transferred to the copper clad board using photolithography technology. Then etching is performed to remove the unnecessary copper foil parts, leaving the precise circuit lines. The etching process requires strict control of parameters to ensure that the line width and spacing meet the design requirements and avoid the hidden dangers of short circuit or open circuit. After the etching is completed, drilling, copper deposition and other operations are also required to make the PCB board have complete electrical connection functions. At the same time, the solder mask and character layer are coated on the surface to protect the circuit and mark the component installation information.
The welding assembly of components is a key step in the production process. The processed PCB board is sent to the mounting equipment, and various electronic components such as resistors, capacitors, transistors, etc. are accurately mounted to the designated positions of the PCB board through the automatic mounting machine. This process requires extremely high mounting accuracy, and the position deviation of the components may cause the circuit function to fail. Reflow soldering is then performed to melt the solder between the component pins and the pads on the PCB board by heating to achieve a firm electrical connection. For the core components of the relay, such as the electromagnetic coil and the contact assembly, special welding processes and equipment are required for installation to ensure reliable connection without affecting its mechanical and electrical properties. During the welding process, the temperature curve and welding time must be strictly controlled to prevent damage to components due to overheating or problems such as cold welding and false welding.
After assembly, the relay needs to be encapsulated in the shell. The shell not only protects the internal components, but also prevents the external environment from affecting the performance of the relay. The shell material is usually made of plastic or composite materials with good insulation and mechanical strength, and is made by injection molding. During the encapsulation process, the assembled PCB board and internal components must be accurately placed in the shell mold to ensure that the positions of each component are correct, and then the molten plastic material is injected to form a complete shell after cooling and solidification. The encapsulation process must ensure the sealing of the shell to prevent moisture, dust, etc. from entering the interior and affecting the normal operation of the relay. At the same time, the design of the shell must take into account the heat dissipation requirements, and reasonably set the heat dissipation holes or heat dissipation structures to avoid the performance degradation of the relay due to heat accumulation during long-term operation.
The detection link in the production process is indispensable and it is an important means to ensure product quality. First, an appearance inspection should be carried out to check whether the shell of the relay is complete, whether there are scratches or defects on the surface, whether the components are installed neatly, and whether the solder joints are full and smooth. Then, the electrical performance test is carried out, and professional testing equipment is used to measure the coil resistance, contact resistance, insulation resistance and other parameters of the relay to ensure that all indicators meet the design requirements. It is also necessary to simulate the actual working environment and perform functional tests on the relay to check whether its pull-in and release actions under different voltage and current conditions are normal, and whether the contact is reliable. Through these tests, defective products in the production process can be discovered in time to avoid entering the market and causing safety hazards.
Throughout the entire production process, quality control runs through. Establish a strict quality management system to monitor and record every production link. From raw material warehousing inspection to finished product factory inspection, operations must be carried out in accordance with standard procedures to ensure the stability of the quality of each batch of products. During the production process, the equipment must be regularly maintained and calibrated to ensure processing accuracy and production stability. At the same time, professional training is provided to operators to improve their operating skills and quality awareness to ensure that each production step can be carried out in a standardized manner. Through comprehensive quality control measures, the production level and product quality of automotive pcb relay are continuously improved.
The production process of automotive PCB relay is a complex and rigorous process, involving multiple key steps such as raw material processing, PCB board processing, component assembly, shell packaging, product testing and quality control. Only by strictly controlling each link can we produce automotive PCB relays with reliable performance and excellent quality to meet the high requirements of automotive electronic systems for safety and stability.
