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Design.Production.Quality Control

Production ( Including Video )

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Our company has advanced production equipment , and first - class designer and production technician ; pay great attention to the quality control of the products , follow the production technological process to operate strictly , strictly control the gate of the quality monitoring , while associating in every business , abide by business ethics , handle affairs according to the regulation of the contract strictly , trusting by travelling trader and favorable comment.

Production ( Including Video )

BACK

    Ultrasonic Welding of Speaker Grill

    Since the design of the plastic trim ring is relatively narrow, we cannot use the glue to mount. If we try to use the glue to mount, the glue will spill over from the side because there is too much of glue, and will make the poor appearance; however if we use less glue, it cannot mount together effectively. Therefore we use the ultrasound to mount the grill. The ultrasound makes the iron net and the plastic surface vibration and friction 200 times per second, this will heat up the plastic and makes it liquefaction to mount it with the iron net.

    Mount Speaker Cone with Rubber Surround

    On the rubber surround’s adhesive surface we fill glue perfectly first, then put the rubber surround into the laminating machine mold. This mold’s size and angle match perfectly with the product. We heat up the laminating machine mold to 60 degree, when the mold presses down will fully fit the cone with the rubber surround.

    Speaker P.P. Cone Cutting

    We put the completed P.P. cone into the semiautomatic mold, the mold’s size and angle will have to match perfectly with the processed cone. Then we press the two start bottoms on the left and right hand side, to make the mold punches down. The mold was designed by pressing two bottoms with two hands in order to avoid injuries if the worker is pressing down the bottom by one hand while the other hand is still under the machine.

    Put Glue on Speaker Rubber Surround

    Before boding the rubber surround with the cone, we will have to fill it with glue first. We can only heat up to stick them together when the glue is dry. In the video, the product is 6x9 car speaker rubber surround.

    Pad Printing Logo in Speaker Cone Paper

    This machine is the pad printing machine, to print on the spherical or surface products. In the video we can see the cone paper is cone-shaped, we cannot use the screen printing.

    Tampo Printing Logo In Speaker Panel

    On the left hand side is the ink ditch, the scrapper will push the ink forward to the plate, and the ink will remain on the text printed pattern surface. Last, we use pad printing machine to print on the product. Please briefly watch the video again to be clear.

    Production Speaker Voice Coil

    We put the kepton bobbin into aluminum form machine, and then leave it into the coiler. We have already set the length and number of turns, so the machine will stop automatically when it reaches the designated. The finished voice coil will have to be washed directly by hand, clean up and remove the bobbin, and in the end will have to put it into the baking machine

    300 Line Silk Printing

    The silk-printing’s plate is made by the cloth with extremely tiny holes (300 lines). We leave the printed pattern or text blank, the rest parts we sealed with glue in order to block the ink by passing through. We can see in the video that now printing the black ink onto the translucent plastic light guide sheet, the rest part can be transparent. To make sure it’s opacity, we will have to re-print with black ink one more time.

    Screen Printing

    The way silk-printing works, if there is large quantity we use the machine to produce; but if it’s small quantity we use by artificial.

    Plastic Injection Dust Cap

    We put the mold in plastic injection, after the plastic material is melted by high temperature we inject it into the mold. When the plastic cools down, we open the mold and take the product out.

    Dust Cap Cut Off

    After the plastic injection, most of times there will be some extra parts on the plastic product. Usually we made the product bigger, and then use the machine to cut off those parts we do not need, and only keep the correct size.

    Dust Cap Cut Off 2

    This is the plating dust cap. The process production of this project is after we finished injecting the plastic, the second we do electroplate and then the last step is to cut the side off. The cutting machine needs to use hydraulic to pressure up, and the pressuring speed is quite slow. Also we need to heat up the mold of the cutting machine, in order to avoid damage on electroplate.

    Plastic Injection Cone Paper

    This is the semi-finished product of P.P. injection cone which has not stick with the rubber surround. To make the product this bright and smooth, the mold has to be very meticulous, and the surface has to be very smooth in order to product the perfect product.

    Electroplating Products

    There are some adornments on the car speaker, such as on the grill, nameplate, or the magnet cover. All these adornments will be using the electroplating, and there can be tons of different looks and colors on designs

    Electroplating Speaker Dust Cap

    Now we are producing the bullet type post cap. First, we product the Mylar flake by vacuum molding; second, we put the Mylar flake on the round scroll bracket, and clean the dust by using the blowing machine. The whole work environmental must be close to the clean room, and when people passing in and out there are three filtration processes. Last, we put the round scroll bracket on the oven rack. When the oven rack is spinning, the bracket will spin as well, in order to attach the plating on the product averagely. Now we take the finished product out from the boiler, and put another product which is going to electroplate. We can see in the video, the completed perfect appearance. However, the product has not finished yet. It needs to cut the side off, and then QC one more time.

    Powder Painting

    We hang the aluminum die-cast materials on the conveyor, and enter the studio after we clean up all the dust and powder by airbrush. We use the robot to spray powder, now is working we cannot enter. After spray the materials will enter the oven aisle, and when it’s finished we still need to inspect is there any spot or defect, and use sandpaper to polish everything, and do the spray once more

    Paint of Amplifier Case

    This is aluminum amplifier case, we have already used the liquid spray to spray once. After the first inspection and polish, we will do the liquid spray for the second time. Before spraying, the work will press the switch first to spray only the air out but not the paint. This is one little step of cleaning, and when we re-press the switch then the paint will spray out. After finished painting, we put the case into the oven conveyor to dry the paint.

    Speaker Frame Forming

    We put the iron tablets on the conveyor, and set the mold ready. This production is forming the frame and cut out. Then we start the next production stage.

    Speaker Frame Punch Press Windows

    We put the finished frame in the mold and PRESS WINDOWS PUNCH. Because the angle is too wide and big, it cannot punch out in once. We will have to do it separately.

    Speaker Frame Side Cutting

    We put the finished frame on the punch machine, and while cutting off the unnecessary edge also make screw holes.

    Speaker Top Plate Tapping

    We make 4 screw holes on the finished forming top-plate, so we can use screws to lock the frame on.

    Speaker Frame Punch Press Terminal Hole

    After we finished windows on the frame, we make another terminal hole.

    Speaker Factory, Metal Department

    Our hardware department is producing frame, top plate, and accessories etc., totally 34 machines.

    Speaker Frame Mold Replacement

    If we are going to product different models, we will have to change at least more than 3 molds. Every time when we change the mold it takes 30 minutes, after that we have to adjust spacing, pressuring force, and in the end we have to send some samples to the QC department to test is the product qualified or not.

    Speaker Top Plate Production

    We cut the iron tablet to the size we want, and put in on the machine then punches out the top plate. We have set the point on the punch mold, so workers can be working in the same space.

    Speaker Frame Production

    Some bigger size frames, these iron tablets have to smooth and straighten by the machine first then produce. In the video we can see that some higher frames need to reform for the second time. Every window needs an additional work. Of course we have set the fixed point on the mold when we are making windows on the frame, otherwise the space between every window will be different.

    Speaker Plane Spray Painting

    This is the front plastic panel of speaker box, according to the customer’s request of color painting. After the paint the panel still needs the second step of baking, and after that there is one last step of inspection by the worker. If there is spot or defect, the worker has to clean it by hand, and then reprint the paint once again.

    Speaker Case Plastic Injection

    Big size plastic materials need to use big size plastic injection to produce. Because the size is bigger, so the production speed is slower. Overall costs of electricity, material costs, and labor costs will be higher than normal.

    Ceiling Speaker, Panel Plastic Injection

    This is the panel for ceiling speaker, it needs the special plastic material which is UV-resistant. When we take the panel out from the mold, worker will cut off the unnecessary parts immediately, and inspect if there is any defect.

    Speaker Parts Plastic Injection Department

    Here is the plastic injection department, there are different size of injection machines. The bigger size machines are 1300 tons and 1500 tons. In the video we can see the scale of human and the machine.

    Speaker Case Plastic Injection Mold

    This is the bigger size mold, and workers are building it up right now.

    Speaker Factory Tweeter Production Line

    The magnet is already in the plastic frame. We put the capacitor onto terminals, and weld, cut line, then gluing. This is the automatic gluing machine, it will glue the parts with the diaphragm. To maintain the quality, we have to keep clean to avoid the glue overflow, and then we stick the diaphragm on and magnetizing it. After all these we weld the coil wire onto terminals, and cut off the unnecessary solder and wire. Last, we have to check has it welded perfectly, does the positive and negative wire connected correctly, is the capacitor stick stable enough, and wait for the glue to dry.

    6-1/2” 2-Way Coaxial Production Line

    We put the speaker on the production line, and test does the speaker energize and does the coil rub. Then we put AB glue on the tweeter’s bottom bracket, and the electricity will pass through the center point. We spin the bracket to mix the AB glue completely, and then use the fixture to adjust, move tweeter to the center area. After this, we adjust the direction, sort out the tweeter’s wire, weld the tweeter’s wire to the woofer’s terminal and cut off the extra wires. At the end, we sort the wires out and put the tape on to stabilize it, composition, and wait the tweeter bracket’s glue to dry.

    6x9” 3-Way Coaxial Production Line

    We put the completed alt bracket and woofer combination speaker onto the production line, and test the speaker’s frequency & sensitivity. We can only move on to the next step when the speaker passes the test. The worker will check the appearance, clean it up, and do the same thing once again. We can see in the video that the microphone is testing does the positive and negative connect correctly. Before do the packing, we will do one more test of the quality test. After the quality test, workers will start post stickers, fixed cable, put gasket, and start packing.

    Monitor Speaker Production Line - 1

    In this video we can see how the monitor speaker builds up. We put the plastic panel which has already finished painting on the production line, and put the EVA FOAM to prevent leak first, then start assemble the woofer and tweeter with the panel. Last, connect the wire on, and set the position of the wire.

    Monitor Speaker Production Line - 2

    In the video we can see that we have used 14 screws to lock the plastic panel to the speaker. Now the worker is gluing around the air hose, to make sure the air hose can stick hard enough. When we put the air hose on, and then lock two more screws on the left and right to make it steadier.

    Monitor Speaker Production Line - 3

    We connect the speaker output of AMP with the speaker, lock screws on the crate. We have made the fixture to prevent scratches. We test the monitor speaker after we have done the whole assembly processes, and of course when everything is in the required standards then means qualified. After the test, we check is there any scratch during the assembly, and do the cleaning.

    Stick Dust Cap On The Woofer ( Speaker Automatic Gluin Machine)

    We put the woofer speaker which has already pass the inspection on the automatic gluing machine’s spinning table, and control the switch by pedals to drop the glue machine down and gluing. We clean up the lead wire one more time, post the dust cap on, and wait for it to dry.

    Speaker Paper Cone Automatic Production Machine

    We pour the mixed paper pulp into the first horn, and use the computer to control the paper pulp concentration and the water amount. The mold is a copper net, and has been special design the angle. The fiber of the paper pulp will remain on the copper net, and the machine will move it to the second horn. On the bottom of the horn, the mold will absorb the whole water in the horn out. On the top, the mold will heat up to dry the cone paper. All these processes were pre-set at the beginning

    Speaker Cone Paper Production Line

    This is the paper cone production line, and paper dust cap is producing in here as well. Not only press cone, but also semi-press and non-press we are able to adjust and edit the machine to produce.

    Cone Paper Fixed Foam Surround

    - We put the cone paper which has finished quality control on the fixture, and put the sponge edge on. The sponge edge has already put glue on, and the mold will heat up to stick the sponge edge with the cone paper. After that we send the cone paper to the next workstation, use the machine to put glue on the sponge edge and the cone paper. This is for the sponge edge to stick steadier with the cone paper. When the glue is dry, we have to do the quality control and make an inventory.

    Cone Paper Side Cutting

    Both paper cone and P.P. injection cone have side cutting by hand and side cutting by the machine. Usually automatic side cutting and making center hole are used in single species, and the amount will be more than 10000 pcs.

    Speaker Injection Cone Automatic Production Machine

    This production line is producing automatically. There are two sides, one side is cone paper, and another side is dust cap. In the back there are two artificial trimming machines.

    Sub-Woofer Cone Paper Producing

    This is the semi-finished products shelf, and there are rubber edges store next it. The cone of the sub-woofer has to be corresponded the basic requirements of hard and straight. Also, the weight is one requirement in the origin design.

    Speaker PU Surround Producing

    We cut the PU plastic sheet to the size we need, and put it onto the thermoforming machine. We have to adjust the machine temperature, needed time, and then we are able to start the work. When open the mold, we have to put the PU plastic sheet back to the mold again and wait for it to cool down.

    Speaker From Surround Producing

    We cut the sponge to the size we need, and also about the denseness and thickness of the sponge is required. In the video the sponge edge is for producing the sub-woofer, the sub-woofer needs to cut off the whole mid & high frequencies. Therefore the sponge has to be thicker and wider, for big stroke and big power.

    Speaker Cone Paper Mold

    Every cone paper mold was produced by ourselves. Now we can see the paper cone’s drain mold every time when it makes one hole then it has to readjust another time, because of the angle differences.

    Speaker Kevlar Cone

    This is the completed Kevlar cone. Because it is weave material, so we have to put glue on the back of coating to make it unventilated, and then bake it to dry.

    Mount Tweeter Cone & Voice Coil

    This is the automatic gluing machine, we put the voice coil and tweeter cone on the machine. We use the pinhead to put glue on tweeter, and have to be careful about the amount of glue, it cannot be too much.

    Speaker Assembly Production - 1

    We put the completed top plate on the machine, and put the frame with the plate then use the punch machine to punch them as one. We put the AB glue on the surface of T-yoke, and stick the magnet on it and spin it for few seconds. Then we put AB glue on the magnet, and put the completed frame/top-plate on the magnet. To make sure both top-plate and t-yoke’s concentric at the same position, we have to put magnet and blue plastic fixture on. After that, we assemble the terminal, and use airbrush to clean up the dust around voice coil and spider then put it on the automatic gluing machine. The first glue gun should be set on the rivet of top-plate and frame, to make sure it won’t move around; the second glue gun should put glue on the surface of spider. When the voice coil is on position, we put the voice coil and spider into the frame together and send it to the automatic gluing machine. We put the glue on both voice coil and cone paper, and the cone paper has already stuck with the gasket. When putting the glue on the cone paper, the lead wire hole has to target the terminal’s position. On the other side, workers are mounting eyelets for lead wires. We put the glue on the voice coil one more time, to make sure the cone paper sticks together with the voice coil bobbin. Last, we clamp the cone paper, check does the voice coil target the terminal and eyelet correctly, and wait for glue to dry.

    Speaker Assembly Production - 2

    We put the dry speaker on the production line, take the voice coil gauge out, tie the lead wire and voice coil together, solder tin, and cut off the extra voice coil. We weld the lead wire on the terminal, and put the speaker on the magnetizing machine to magnetize it. Next we will test is there any defective product immediately. After that we stick the dust cap on the speaker, and wait for it to dry. In the end, we will do the inspection for the speaker, the appearance, and packing.

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