The process of inverters from production to after-sales service

Here is a comprehensive overview of the inverter lifecycle process from production to after-sales service, based on industry standards and manufacturing practices:

1. Production & Manufacturing

• Design & Planning: Technical specifications are finalized based on market requirements and regulatory standards (e.g., IEC, UL)
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• Component Procurement: Sourcing critical parts (capacitors, IGBTs, PCBs) with strict quality control
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• PCB Assembly:
  • SMT (Surface Mount Technology): Automated placement of micro-components
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  • DIP (Dual In-line Package): Manual insertion of larger components.
• Module Assembly: Integration of power modules, control boards, and heat sinks
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• Casing & Wiring: Installation of enclosures, cooling systems, and electrical connections
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2. Quality Control & Testing

• In-process Checks: Real-time monitoring at assembly stages (e.g., solder quality, component alignment)
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• Functional Testing:
  • Electrical Safety: Insulation resistance, dielectric strength (e.g., 1,500V startup voltage)
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  • Performance: Efficiency, output waveform, harmonic distortion.
• Reliability Testing:
  • Environmental Simulation: Temperature cycling (-30°C to 60°C), humidity, and vibration tests
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  • Aging Test: 48-hour stress testing under extreme conditions.
• Safety Certification: Compliance with VDE, TÜV Rheinland, or UL standards.

3. Packaging & Logistics

• Final Inspection: Cosmetic review and electrical retesting
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• Packaging: Anti-static wrapping, protective padding, and IP65-rated boxing for moisture resistance
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• Labeling: Barcodes for traceability and compliance markings (CE, RoHS).

4. Installation & Commissioning

• Site Preparation: Ensuring ventilation, shade avoidance, and clearance (≥30 cm around inverter)
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• Electrical Connections:
  • DC Side: PV string wiring with MC4 connectors; polarity checks.
  • AC Side: Grid connection via circuit breakers; grounding verification.
• Grid Synchronization: Testing grid compatibility (voltage/frequency ranges).
• Commissioning: Activating via monitoring apps (e.g., Solar Go).

5. Operation & Maintenance

• Routine Checks:
  • Physical: Dust removal from fans, cable integrity, and thermal inspection (using IR cameras)
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  • Electrical: Monitoring leakage current, insulation resistance, and efficiency drops
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• Predictive Maintenance:
  • Replacing cooling fans every 3–5 years
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  • Exercising DC switches annually to prevent contact degradation.
• Fault Handling:
  • Common issues: Grid overvoltage, insulation faults, or communication errors
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  • Solutions: Adjusting grid settings, rewiring damaged cables, or firmware updates
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6. After-Sales Service

• Warranty Support: 5–10 years coverage for manufacturing defects; onsite technician dispatch
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• Remote Diagnostics: Monitoring platforms (e.g., Growatt, SMA) for real-time alerts
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• Spare Parts Management: Stocking critical components (fans, PCBs) for rapid replacement.
• End-of-Life: Recycling programs for electronic waste; carbon footprint offset analysis (e.g., SMA’s 1.4-year CO2 payback).