High-Voltage Power Supply Manufacturer Quality Control System

4.1 Quality Control System Framework
A high-voltage power supply quality control system covers the entire product lifecycle, including R&D, component procurement, production, finished product testing, and after-sales service, with the goal of ensuring product reliability (MTBF ≥50,000 hours) and compliance with international standards (IEC 61010-1, UL 61010-1).
4.2 Stage-by-Stage Quality Control Measures
4.2.1 R&D Stage: DFMEA Application
Conduct Design Failure Mode and Effects Analysis (DFMEA) for key components such as high-voltage modules and power devices. For example, for the insulation design of high-voltage modules, identify potential failure modes (insulation breakdown, leakage current exceeding standard), assess risk priority number (RPN), and take improvement measures (using epoxy resin with dielectric strength ≥30kV/mm, increasing insulation thickness to 5mm). Verify the design through prototype testing (high-voltage withstand test, temperature cycle test) to ensure RPN ≤30.
4.2.2 Procurement Stage: Supplier Management
Establish a supplier audit system in accordance with IATF 16949 standards, conducting on-site audits of suppliers' production processes, quality control systems, and testing capabilities. Implement incoming inspection for key components: for high-voltage capacitors, test dielectric loss (tanδ ≤0.001) and insulation resistance (≥1000MΩ); for power semiconductors, test forward voltage drop (deviation ≤5%) and reverse breakdown voltage (deviation ≤3%). Reject non-conforming components and establish a supplier blacklist system.
4.2.3 Production Stage: Process Control
Implement Statistical Process Control (SPC) for key processes such as soldering and high-voltage module assembly. For the soldering process, monitor soldering temperature (240℃±10℃) and soldering time (3s±0.5s), and use a solder joint inspection microscope (magnification 50x) to check for defects (cold joints, solder balls). Conduct online testing for each product: high-voltage withstand test (1.5 times rated voltage for 1 minute, leakage current ≤100μA), output accuracy test (deviation ≤0.2%), and establish a batch traceability system (recording production date, operator, and component batch number).
4.2.4 Finished Product Stage: Reliability Testing
Perform reliability tests on finished products, including:
Temperature cycle test: -40℃ to 85℃, 50 cycles, each cycle 2 hours (1 hour for heating/cooling, 1 hour for soaking), no functional failure after test.
Vibration test: comply with GB/T 2423.10, frequency 10Hz-500Hz, acceleration 50m/s², duration 2 hours per axis (X, Y, Z axes), no structural damage or parameter drift.
MTBF verification: conduct 1000-hour continuous operation test on 50 samples, calculate MTBF using the exponential distribution model, ensuring MTBF ≥50,000 hours.
4.2.5 After-Sales Stage: Feedback and Improvement
Establish a customer complaint handling mechanism, using the 5-Why analysis method to identify the root cause of complaints (e.g., if a customer complains about output voltage drift, analyze whether it is caused by component aging, temperature drift, or improper use). Implement a PDCA (Plan-Do-Check-Act) cycle for continuous improvement: for example, if component aging is the root cause, optimize the component selection standard (extending the component service life by 50%). Establish a product quality file to track quality data throughout the product lifecycle.
4.3 Quality Control Effect
Through the above system, the pass rate of finished products reaches 99.5%, customer complaint rate is ≤0.1%, and the product has obtained CE, UL, and other certifications, meeting the quality requirements of global customers.