Introduction: Inverters are a core component of the photovoltaic power generation and energy storage industry, a technology-intensive industry. The birth of a qualified inverter is based on long-term practice, exploration, and technological accumulation by enterprises in product design, manufacturing processes, and component selection. Many CHISAGE ESS fans are curious about how their inverters are manufactured. Today, let’s take a closer look and delve deeper into the CHISAGE ESS inverter production line, along with the editor’s footsteps.
Production line overview
In May 2023, CHISAGE ESS held its inaugural offline inverter power-on and groundbreaking ceremony, marking the official launch of its inverter production line. Currently, our inverter production line covers an area of over 10,000 square meters and can produce over 3,000 inverters per month, fully capable of mass production and delivery. In the next phase, two new production lines will be gradually introduced to ensure our production capacity meets market demand.
As we turn our gaze, the mysterious gate of the CHISAGE ESS inverter factory appears before us. Stepping through the elevator, an enthusiastic receptionist leads us to the production line area. We pass through 16 areas, including the PCBA and electronics warehouse, assembly workshop, testing area, aging area, finished goods warehouse, packaging workshop, R&D office, and equipment maintenance room. The spacious and bright space, along with the clean and tidy layout, is the result of the inverter factory’s 8S management system, which fully embodies efficiency, aesthetics, and sustainability.
During the initial production line design, we conducted research and gained insight into industry-representative inverter production line design paths and flowcharts. From general planning and design to workflow design for personnel, materials, and equipment, as well as production line, equipment, and testing selection, we benchmarked industry best practices, effectively avoiding potential issues that may arise in similar companies.
The workshop maintains a constant temperature and humidity environment to ensure the safety and reliability of various precision components. Advanced production equipment is also equipped for each process, and employees carry out production work under strict quality control. Each stage is meticulously maintained and rigorously inspected to ensure the high quality of inverter products.
process flow
The CHISAGE ESS inverter production process mainly consists of four main sections: SMT, DIP, assembly testing, and packaging. This time, we will focus on the assembly and packaging testing process, which can be further divided into several stages: pre-processing, assembly, insulation withstand voltage testing, TI testing, aging testing, T2 testing, safety compliance testing, leak testing, packaging, and palletizing for storage.
01 Pre-treatment:
It mainly involves the formation of IGBTs and the soldering of various IGBT plugs, two key processes. IGBT forming must strictly control the IGBT forming pressure angle of 90 ± 3° to ensure the accuracy of the connection point and 100% complete inspection; IGBT soldering must be complete, must not leak welds, false welds, empty welds, false welds, packaging welds, and 100% complete inspection after welding.
02 Assembly:
It mainly involves the assembly and arrangement of the main functional parts inside the inverter, including the high voltage power supply version, low voltage power strip, adapter board, capacitor board, main control board, etc. The assembled inverter takes shape, enabling the basic functions to be commissioned.
03 Insulation and voltage withstand test:
Add the inverter to a certain voltage level for a period of time to check whether the insulation and voltage withstand capacity of the inverter are in compliance with regulations to avoid the danger of electric shock.
04 TI Test:
Test the overall performance of the inverter and calibrate a set of standard parameters. Our company is equipped with four sets of TI testing equipment, which can perform one inverter test every 15 minutes. I asked the production manager and learned that our testing standards are in sync with the European market. I believe this is one of the reasons why CHISAGE ESS, as a new brand, has quickly gained the trust of most users.
05 Aging Test:
A key step in inverter testing is simulating inverter operation under extreme conditions, such as extremely high and low temperatures, to ensure product quality and reliability and provide a baseline for subsequent inverter maintenance. Currently, our company has eight sets of aging equipment, each of which can be connected to 12 inverters simultaneously, allowing for simultaneous testing of 96 inverters.
Moreover, according to my understanding, the aging time for standard products in the industry is 2 hours. As a new brand, we strictly control the aging process, and currently the aging time for each machine is 48 hours. We will then gradually reduce the aging time based on market feedback. However, improving performance does not mean compromising quality. We continue to conduct benchmark tests against the highest industry standards to ensure that users can use each inverter with peace of mind.
06 Testing T2:
Slight changes in the inverter’s internal performance may occur after the aging process. T2 testing is performed to ensure product safety and stability. Our company is equipped with four T2 testing machines, with each inverter test performed every 15 minutes.
07 Security Compliance Testing:
This includes testing electrical safety, material safety, electromagnetic compatibility, environmental safety, and other aspects as required by different countries and regions. It ensures that the inverter complies with relevant safety regulations and standards and does not cause harm or hazard to users, the environment, or other devices under normal operating conditions.
08 Leakage test:
Our inverter products must achieve an IP65 protection level. During the inverter leak test, a device injects a specified air pressure into the inverter for 90 seconds, stabilizes for 3 seconds, and then releases the air for 3 seconds, monitoring the internal pressure changes, which should not exceed the standard leakage range.
09 Packaging:
Using an automatic packaging machine to tie and wrap the package in one line, it can simultaneously complete a large number of production tasks in a short time, while also ensuring a flat, uniform, and beautiful sealing effect.
10 Palletizing for storage:
Currently, our company standardly palletizes 4 boxes of inverters, using stretch film to package and arrange the inverters in an orderly manner in the warehouse, ready for shipment.
After layers of precise and complex processes, CHISAGE ESS inverters were finally successfully delivered to customers. Behind each inverter are the professional skills and hard work of employees, the production strength, and the company’s technological level.
The mystery tour of the inverter production line has ended, but the story of CHISAGE ESS continues. We look forward to more visits and exchanges with our global partners to discover more exciting content together.
