channel： Technical

Recently, the No. 6 Changlongshan Pumped Storage Power Station was put into trial operation and put into production. LKK, together with Dongfang Electric Group, jointly built the generator top cover for the Changlongshan Pumped Storage Power Station.

 

As early as 2019, LKK was involved in the project of the generator top cover of the Changlongshan Pumped Storage Power Station. In the past three years, LKK has provided a series of services such as brand strategy, industrial design, mechanical design, prototype production, and machine maintenance in strict accordance with technical standards to ensure high-quality products.

Technological innovation and design innovation are the two major factors that affect the development of the times. After the Changlongshan pumped-storage power station is fully put into operation, it is expected to reduce carbon dioxide emissions by about 420,000 tons, nitrogen oxides by about 1,050 tons, and sulfur dioxide by about 2,800 tons each year. When scientific and technological strength is developing rapidly and upward, of course, design cannot be left behind. Therefore, in order to break away from the simple impression that the hydropower station has always brought to people, a more beautiful and modern top cover has become the rigid need of the Changlongshan Pumped Storage Power Station.

In terms of industrial design, LKK used futuristic paint to enhance the quality of the power station. The detailed processing of sheet metal brings a strong, safe and reliable visual experience. A neon light strip is placed on the upper part of the top cover to intelligently monitor the working status of the generator, and more beautiful colors are presented through the interaction of lights, which is convenient for the staff to monitor the running status of the generator.

In order to avoid the waste of materials and personnel, LKK regards strong operability and rapid construction as the first purpose of mechanical design. Through the modular design, the internal structure is optimized to make the whole installation process simpler and smoother. The setting of openable and closable inspection doors and ventilation windows reduces the difficulty and cost of later maintenance of the generator.

As the leader in generator cover solutions for large-scale hydropower stations, LKK has 12 years of relevant experience in product design, development, and manufacturing. LKK has experience in Xianju power station top cover, Baihetan generator top cover, Fengman Hydropower Station generator top cover, Changlongshan generator top cover, Fengning generator top cover. LKK has also been using independent innovation to provide strong design support for the high-quality development in other fields such as C919 aircraft, Tianhe rocket core cabin (photo as below), and Olympics2008 subway gates.

Over the past 18 years, LKK has adhered to the user experience as the core, adhered to “Chinese design”, and is committed to providing more companies with overall innovative solutions in the industry, achieving symbiosis and win-win results, and finally letting the world see more of the beauty of China.

 

Defective 5. Electroplating semi-transparent

Description:

The translucent and pinhole light transmission properties are similar, and they also occur on PC transparent or translucent materials that require cover mold plating. When illuminated with light, the light passes through the coating position.

Analysis of the causes:

1. The amount of aluminum wire in the plating furnace is too small to form semi-permeability

2. The current through the tungsten wire is set too small in the plating furnace

3. The vacuum pressure in the electroplating furnace is too high

4. Air leakage in a vacuum furnace

5. Insufficient coating time

Key points of quality control:

1. The amount of aluminum wire in the plating furnace is too small to form semi-permeability 2. The current through the tungsten wire is set too small in the plating furnace
3. The vacuum pressure in the electroplating furnace is too high
4. Air leakage in the vacuum furnace
5. Insufficient coating time

Defective 6. Plating Burnt/Black Plating

Description:

The yellowing or whitening of the surface of the coating is obviously different from that of the standard plate.

Analysis of the causes:

1. There is air leakage in the vacuum furnace

2. The coating time is too long

3. The vacuum pressure of the vacuum furnace is too high

4. The current passing through the tungsten wire is too strong

5. There is a fault during the operation of the equipment

Key points of quality control:

1. Confirm whether the pressure gauge can reach the set standard pressure during the operation of the vacuum furnace.

2. Confirm whether the actual current parameters are consistent with the “Operation Instructions”, and require adjustment if they do not match.

3. Confirm whether the pressure gauge parameters are consistent with the “Operation Instructions”, and require adjustment if they do not match

4. Confirm whether the parameters in the benchmark book are consistent with the actual parameters, and require adjustment if they do not match.

5. Regularly check whether the equipment is inspected and maintained as required, and confirm the maintenance records

Defective 7. Accumulated oil

Description:

Oil deposits generally appear in the product； Edge or angular position, commonly known as runny oil. target； Depending on the hypertrophy, there is a feel.

Analysis of the causes:

1. Improper spraying technique, too thick spray film

2. Not drying in time after spraying, too long standing time

3. The viscosity of paint spraying is too low

4. The oil volume and air pressure of the spray gun are too high

Key points of quality control:

1. In the production process, confirm whether the spraying times and the distance of the spray gun are consistent with the “Operation Instructions”, and compare and confirm with the sample during the production process

2. Supervise the spraying of UV primer, and it needs to pass UV within 6 minutes after spraying

3. Confirm the paint before production, and deal with the bad paint in time

4. During the process inspection, confirm whether the spray pressure is within the standard range of the “Working Instructions”

Defective 8. Thin-oil

Description:

Contrary to oil accumulation, it is mainly caused by uneven local spraying, showing orange peel, dense pinholes and other phenomena.

Analysis of the causes:

1. Improper spraying technique, too thin spraying film thickness

2. Too high spraying viscosity, which is not conducive to operation

3. The fuel volume of the spray gun is too small / the air pressure is too small

Key points of quality control:

1. In the production process, confirm whether the spraying times and the distance of the spray gun are consistent with the “Operation Instructions”, and compare and confirm with the sample during the production process.
2. Confirm the paint test spray before production, and deal with the bad paint in time
3. During the production process, confirm whether the oil quantity and air pressure of the spray gun are within the standard range of the “Working Instructions”

Defective 9. Chromatic Aberration

Description:

Produces local or overall color differences on the surface of the coating. Generally, the overall color difference needs to take the standard sample as a reference, and the overall color is darker or lighter than the standard plate.

Analysis of the causes:

1. Improper spraying technique, a too thick or too thin topcoat

2. Too little or too much air pressure on the spray gun

3. Too little or too much fuel in the gun

4. The color difference of the paint itself

5. Color difference of electroplating coating

6. High humidity and moisture absorption

Key points of quality control:

1. In the production process, confirm whether the spraying times and the distance of the spray gun are consistent with the “Operation Instructions”, and compare and confirm with the sample during the production process

2. During the production process, confirm whether the air pressure of the spray gun is consistent with the parameters of the “Operation Instructions”

3. During the production process, confirm whether the oil quantity of the spray gun is consistent with the parameters of the “Operation Instruction”

4. After the paint is toned, the color of the first piece is the same as the standard sample when confirmed

5. Confirm that the parameters of the electroplating furnace are consistent with the parameters of the “Operation Instructions”

6. Regularly confirm and record the temperature and humidity of the workshop (standard: relative humidity 65%±10)

Defective 10. Crack

Description:

Linear cracks on the UV primer or on the surface of the material are more obvious under the reflection of light or through light transmission. Cracks tend to worsen over time.

Analysis of the causes:

1. The UV energy is too strong

2. The UV primer is sprayed too thickly

3. Degreasing solvent is too strong

4. The UV primer is too strong, and the solvent penetrates into the material, causing cracking

5. The internal stress of the material is too large, and it is cracked by normal UV irradiation or solvent degreasing

Key points of quality control:

1. Confirm whether the number of strong and weak lamps in the UV furnace and the light energy are consistent with the “Operation Instructions”

2. In the production process, confirm whether the spraying times and the distance of the spray gun are consistent with the “Operation Instructions”, and compare and confirm with the sample during the production process.

3. Before using different batches of flux, make a trial to confirm, and then put into production

4. Different batches of primer should be tried and confirmed before use, and then put into production

5. When the material is inspected, it will be confirmed as a trial production according to the standard process

More in the next chapter. Follow LKKER SCM Linkedin Page for chapter updates. 

The design of the medical equipment has put forward higher requirements regarding process efficiency, information accuracy, and service convenience. A comprehensive automated data analysis and management platform that improves medical service experience and resource utilization through aggregation and integration have also emerged under this demand trend in the experiment laboratory field.

The laboratory of Beijing Genomics Institute (BGI Genomics Co., Ltd) jointly works with LKK Design to launch HALOS – an all-in-one gene data information analysis platform and gene sequencing equipment. The product integrates full automation and multi-function algorithms, effectively saving the testing delivery cycle, a lot of costs, materials, and manpower. The product won the 2022iF Design Award.

Affected by the office environment of the hospital, most of the sequencing tests of patients need to be carried out in other hospitals, and the process is very cumbersome and complicated. At the same time, due to the large number of analysis and calculation peripheral equipment required by the laboratory gene sequencer, the line connection between the various equipment is complicated and messy. The laboratory space is generally tight for hosting all types of equipment.

In order to solve the various problems of the current all-in-one machine, the LKK Design project team has provided a set of overall solutions for the hospital testing environment after sorting out the relationship between the various equipment and having in-depth interviews with experimental researchers and equipment maintenance personnel. The design effectively realizes the effective use of laboratory space, and at the same time, through a series of appearance optimization designs, it shows the aesthetic pursuit of BGI in the field of gene sequencing.

In terms of equipment space optimization, different from the gene sequencing equipment on the market, the all-in-one HALOS can be customized and assembled according to the hospital’s requirements for data storage or computing performance. Front-end computers and servers can be flexibly combined or split to adapt to various environmental needs and greatly improve the utilization of laboratory space.

For large products, excellent design can often endow products with strong vitality and expressiveness. In addition to optimizing the functional layout of the product, LKK Design also strives to conform to the brand design language of BGI at the visual level. The design team hopes to create a comfortable, convenient, safe intelligent working method for experimental researchers through a simple and natural design language.

In terms of appearance, the LKK design team integrated the product design with the concept of modularization, and redefines the compatibility of basic elements such as product placement and size according to the limitations of different experimental spaces, and strives to achieve the optimal size. Make the product more smooth and comfortable in the overall look and feel.

The overall shape adopts a streamlined design, which is expressed in a stable, balanced, and soft design, which weakens the cold feeling commonly present in medical equipment, and realizes the visual effect of the integration of the screen, the operating table, and the fuselage, which is effectively different from the appearance of other gene sequencing equipments on the market.

HALOS, the all-in-one gene data information analysis platform, and gene sequencing equipment is mainly used in experiment laboratories. It is equipped with fully independent research and development of core analysis algorithm and can be automated sequencing data for clinical test sample analysis, annotation, and interpretation, at the same time to provide professional services to artificial data interpretation, enhance the report accuracy, shorten patients genetic testing cycle. The reasonable function layout of the All-in-one HALOS gene data analysis platform can effectively reduce the enterprise cost in the later production and operation. It also outstands for its combination of human thinking design and flexible design language appearance. 

As the designer of the HALOS, the all-in-one gene data information analysis platform, LKK Design provides product planning, industrial design, and mechanical design service for our client – BGI. 

The EV car industry has developed rapidly worldwide. China, as a leader in the EV car industry, comes up with a lot of EV car brands such as Xpeng, Nio, Hiphi, etc. EV charger, as an accessory product for electric vehicles, is also becoming popular with the rise of the EV car industry.

EV chargers are a product between industrial products and consumer products. While pursuing the ultimate product design, LKKdesign (LKKER SCM mother company) is also thinking about how to make a transition from technical design to concept design, from function design to emotional design, giving the EV chargers a new form of consumer goods, and setting off a cost management change through a product design change in the EV charger industry.

ABB Evinn 7kW AC EV Charger

ABB is a pioneering technology leader that works closely with utility, industry, transportation, and infrastructure. In 2010, ABB started involving in the EV charger industry. ABB provides a one-stop charging solution for EV cars and EV buses. 

The ABB Evinn 7kW AC EV Charger jointly designed and built by ABB and LKKdesign can be used in all-weather indoor and outdoor parking charging scenarios, with high safety and reliability. The product design is injected with the blood of new design aesthetics.

In terms of functional design, the ABB Evinn 7kW AC EV Charger has multiple design ingenuities such as flexible networking, Bluetooth connection, scheduled charging, voice and breathing light prompts, double-layer front cover design, and easy maintenance. And its double-layer front cover design not only ensures the overall beauty of the product design but also provides convenience for the follow-up maintenance of the product. The innovative functional design breakthrough and the round and full appearance design have been favored by users as soon as they are listed, and are widely covered in public places such as residential areas, offices, shopping malls, parks, parking lots, and so on.

PMAC PEVC2107 AC EV Charger

PMAC is an enterprise involved in the operation of electricity systems in the field of public buildings.

PMAC PEVC2107 AC EV charger is an innovative and economical public AC EV charger jointly created by PMAC and LKKdesign. It has won the successful product design award with its excellent product design and functional experience.

Traditional public EV chargers do not consider product design at an early stage. PMAC PEVC2107 AC EV charger’s minimalist curved surface design breaks out of the previous shell mechanical design and breaks the previous traditional public EV charger’s rigid impression.

The organic curved surface design creates a natural sunshade for the product, and the display interface that conforms to the human-machine angle ingeniously combines the product form and the product function, which is highly personalized and improves user convenience.

Different from the traditional custom independent charger seat and cable storage device, the round charger seat is integrated into the shape of the host, and the charging cable can be wrapped around the body, which greatly reduces the production cost. At the same time, the circular aperture indicator light integrated into the charging gun storage seat can visually display the running status of the machine, bringing dual feelings of vision and experience.

PMAC PEVC2107 AC EV charger can be widely used in private parking spaces, large-scale matching of electric vehicle manufacturers, and real estate development enterprises. 

PMAC PILOT 180KW DC EV Charger

Good product design should not only give the product a good shape but also create a brand value through innovative product design and realize the empowerment and transformation of commercial value.

PILOT 180KW DC EV Charger jointly created by PMAC LKKdesign focuses on conveying the minimalism of product design and the ease of use of products and integrates the brand corporate identity into the product design. It is used on the product operation panel, and at the same time, it is embellished with brand colors to create products that fit the brand genes of PMAC, form product differentiation, and create DC EV Chargers that fit the brand image.

While the appearance design is innovative, the LKKdesign team also considers the user experience of the product, integrates the interactive area in the operation panel, and centrally sets the progress light, status light, and card swipe area in the middle area, so that users can use the EV charger more smoothly.

At the same time, the strengthened use of brand symbols allows users to identify the charger status from a distance in one second, greatly improving user efficiency and effectively improving user stickiness!

Chilye Smart EV Charger

With the rapid market growth of electric vehicles, users have also put forward higher requirements for the convenience and safety of electric vehicle home chargers.

In response to this situation, Chilye together with LKKdesign has launched a product portfolio of fixed charging piles that can be carried on the vehicle and can be installed in a portable manner – Chilye Smart EV Charger.

Through innovation, the Chilye smart EV charger can monitor the temperature change during the charging process, adjust the current in a timely and effective manner, automatically control the fire problem, cut off the current thermal runaway, solve the fire problem in a timely manner, and realize a major safety detection that the EV Charger itself is prone to fire!

At the same time, the product is universally adaptable and can provide household and mobile charging solutions for electric and hybrid vehicles, and expand various applications through intelligent systems.

The product can accept commands remotely through the APP, and realize remote operations such as timed charging, fault detection, and remote upgrade, creating a good user experience for users. Private users can quickly complete the charging work in 10 seconds, realizing plug and play.

At the same time, the product has a high degree of freedom for customization in product design. Enterprises can customize the scope of functions, color matching, appearance patterns, and LOGO changes. Create design aesthetics on top of functions, use a simplified design language, and show the modern sense of technology of products for individual and corporate users.

If you have energy storage or EV charger design, development, sourcing, and manufacturing project, please contact lkkerscm@lkkdesign.com.

About LKKER SCM

LKKER SCM Co., Ltd is a member company of LKKdesign Group, 100% owned by LKKdesign Group which is founded in 2004. LKKER SCM is a one-stop product development and customized supply chain solution provider. We offer services from design to manufacturing covering industrial design, mechanical design, electronics engineering, rapid prototype, tooling, pilot production, and mass production. LKKER SCM has been recognized as Indiegogo Recommended Prototyping & Manufacturing Expert since 2019.

LKKdesign Group is a regular product design award winner worldwide. Being the largest and top-tier design house in China, LKK has won 521 design awards since company establishment. LKKdesign is recognized as the National Industrial Design Center by The Ministry of Technology since 2013. Key investors of LKKdesign include Fortune Capital, China Culture Industrial Investment Fund, and Green Pine Capital Partners.

LKKER SCM partners with you to develop your product and get it to market quickly, efficiently, and economically. We have the design expertise, engineering knowledge, and manufacturing know-how to tailor solutions that work for you and your product in these sectors:

 

 

Due to the rapid expansion and development of the industrial Internet industry, the demand for clean energy storage equipment and clean energy applications is growing. The energy storage product market has become highly homogeneous and nowadays industry players have to pay higher attention to product design.

LKKER SCM (below called LKK), which is under the LKKdesign group, has always provided forward-looking market insights, continuous product design breakthroughs, and supply chain resources to help more energy storage new products to successfully launch and scale up in the market. We continuously promote the development of the energy storage industry by fulfilling increasingly iterative function development needs and improving products through human-centered design thinking that meets various usage scenarios in the market. What’s more, LKK is excel in changing the stereotype of the previous energy storage product and making innovative design breakthroughs to make clean energy storage new products look more technological and fashionable.

Storion Energy SMILE5

Storion Energy is a U.S.-based company that operates in the technology industry. It is a spinoff of R&D innovator, ITN Energy Systems. Storion Energy is committed to changing the future of household energy supply and usage. It is growing to become world-class energy storage and industrial internet company to realize the goal of “energy creation, energy storage, energy-saving, energy intelligence”, so that clean energy can benefit the world to the greatest extent.

SMILE5 is one of the contracted product design projects between Storion Energy and LKK Shenzhen Team. It has achieved great success in the energy storage market. SMILE5 is a human-computer interaction interactive system and energy management system, allowing users to easily grasp energy information.

The LKK design team participated in the product design of SMILE5, breaking the traditional rigid design of home energy storage in appearance, adopting a modern and simple style design, integrating it into the home environment, and redefining clean energy application in the new era. The product won the 2018 Red Dot Design Awards and iF Design Awards for its outstanding appearance and innovative functional design.

In addition to showing design aesthetics, SMILE5 adopts a modular design in the product mechanical design. It is assembled by expanding battery modules like Tetris, which not only facilitates manual disassembly and assembly but also reduces transportation costs, greatly improving work efficiency and reducing labor costs. At the same time, the intelligence of SMILE5 is that it can not only provide power support for household consumption but also monitor the system through the app, which is convenient for users to master the electricity consumption of the home outdoors.

For some occasional emergencies, such as power outages, the integrated UPS (uninterruptible power supply) of this management system successfully ensures the normal operation and continuous power supply of household consumption, realizes a true 24-hour uninterrupted power supply, provides clean energy available at any time, and promotes low carbon sustainable lifestyle.

The product is manufactured by one of LKK suppliers – Alpha ESS Co., Ltd.

YOSHOPO Portable Power Station

YOSHOPO is a portfolio company invested by world-leading battery company Contemporary Amperex Technology Co., Limited (CATL). YOSHOPO adheres to the firm belief of “becoming the world’s leading smart energy solution provider”.

At present, large-capacity energy storage power stations on the market generally have problems such as large size, heavy-weight, inconvenient storage, carrying, low power, low capacity, short battery life, and insufficient battery safety. At the same time, consumer groups are increasingly showing family-oriented and all ages related features. YOSHOPO cooperates with the LKK design team to create the YOSHOPO portable power station, which integrates high safety, high power, long life, and long battery life features. It is a product suitable for self-driving travel, outdoor camping, emergency rescue, and other scenarios, which effectively solves a variety of outdoor power supply needs.

YOSHOPO portable power station, equipped with CATL (Contemporary Amperex Technology Co. Limited) lithium iron phosphate battery in compliance with electric vehicles industry standard, supports 3000W high power continuous output t and adopts the human-centered design of splitting the “electric” module and “control” module, allowing users to do stack products or change two modules according to their needs. The positional relationship between these two modules can match various transport spaces and storage scenarios, effectively realizing the lightweight of energy storage products and the improvement of portability.

In terms of appearance, the LKK design team adopts the ultimate and simple cube design, which is not only convenient for users to store, but also has a rounded chamfer design, which greatly increases the affinity of the product; at the same time, different surface treatment processes are used to visually layer the appearance of the product, effectively highlight the product texture and sense of stability, and the configuration of the long handle will provide a better experience for users of all ages and genders.

CHOCOLATE Modular External Battery Pack

CHOCOLATE Modular External Battery Pack designed by LKK has a chocolate-like appearance and size, magnet-adsorbing splicing, magic rotation, and free-combination sharing and charging, giving the battery pack new aesthetic connotations and usage scenarios.

CHOCOLATE Modular External Battery Pack adopts the world’s first patented combined design. The product uses magnet adsorption, just like chocolate, to supply energy for users, and users can freely choose the amount according to charging needs. This breakthrough innovation is convenient for users to use and store.

In order to ensure the perfect realization of the “combined” product structure and meet the requirements of the safety standard of 3 series batteries, the design team has undergone various processes such as mold stretching, polishing, sandblasting, and anodizing to realize the combination of product design.

At the same time, through the continuous discussion and experimentation with the LKK design team, the risks that may arise in the use of the product have been avoided, and the product has successfully launched in the market.

The products are manufactured by one of LKK ‘s suppliers –  Hong Kong Mricetechnology Co., Ltd, and won Red Dot Design Award 2013. It becomes a pioneer product design in the battery industry and a lot of industry players also borrow the idea of modular and swappable battery packs in their product lines.

LKK GaN 65W Fast Charger

LKK GaN 65W Fast Charger is a product designed, developed, and manufactured by LKK and directly branded under the name of LKK. 

In the process of product design, the LKK design team starts from the user value, fully considers the user’s usage needs and usage habits, and conducts a human-centered design on how to use it and the user experience.

As new technology in charging energy, the gallium nitride charger came into being in recent 3 years. From strategy to design, from design to mass production, the LKK design team created an exclusive gallium nitride fast charging charger for mobile game players—— LKK GaN 65W GaN Fast Charger.

First of all, the LKK design team fully considers the multi-faceted needs of mobile game players in terms of function fulfillment. Starting from the user’s experience, a lot of thought has been spent on design and craftsmanship, using 8-sided unique silk screen printing, 4-sided row mold design, PC raw material for pellet injection, slot design, etc., all just for the sake of good hand-held texture.

At the same time, the 90-degree pin design saves space for storage, and can also protect the plug from twists and turns; The design of 3 power inputs and multi-port synchronous output perfectly realizes one machine for multiple purposes and supports fast charging from mobile phones to tablet computers.

The dual cooling design of intelligent temperature control and high thermal conductivity silicon can completely avoid the overheating phenomenon when charging for too long.

If you have an energy storage or charger design, development, sourcing, and manufacturing project, please contact lkkerscm@lkkdesign.com.

About LKKER SCM

LKKER SCM Co., Ltd is a member company of LKKdesign Group, 100% owned by LKKdesign Group which is founded in 2004. LKKER SCM is a one-stop product development and customized supply chain solution provider. We offer services from design to manufacturing covering industrial design, mechanical design, electronics engineering, rapid prototype, tooling, pilot production, and mass production. LKKER SCM has been recognized as Indiegogo Recommended Prototyping & Manufacturing Expert since 2019.

LKKdesign Group is a regular product design award winner worldwide. Being the largest and top-tier design house in China, LKK has won 521 design awards since company establishment. LKKdesign is recognized as the National Industrial Design Center by The Ministry of Technology since 2013. Key investors of LKKdesign include Fortune Capital, China Culture Industrial Investment Fund, and Green Pine Capital Partners.

LKKER SCM partners with you to develop your product and get it to market quickly, efficiently, and economically. We have the design expertise, engineering knowledge, and manufacturing know-how to tailor solutions that work for you and your product in these sectors:

Turnkey designs Electronic Design Mechanical Design Assembly Process Design Metal & Plastic Enclosure DFM Certification Support Prototypes Builds NPI Project Management

Supply Chain Development Cost Down Solution Alternatives Solution QC, QA, and Delivery Manufacturing Operation Supplier Management Presence in China Transfer to High Volume Manufacturing Ship Direct to Customers

 

Introduction to Vacuum Plating:

Vacuum plating mainly includes vacuum evaporation, sputtering, and ion plating. They are all used to form various metal and non-metal films on the surface of the product by distillation or sputtering under vacuum conditions, so as to achieve the effect of electroplating.

LKKER SCM currently uses mainly vacuum evaporation. Vacuum evaporation (vacuum evaporation coating) is a technology in which the evaporated material is heated by an evaporator to vaporize it under vacuum conditions, and the evaporated particle stream is directly shot to the product and deposited to form a solid film on the product.

The film material (aluminum wire) is placed in the evaporation source (tungsten wire) in the vacuum chamber. Under high vacuum conditions, the evaporation source heats up to make it evaporate. After the atoms and molecules of the film material vapor escape from the surface of the evaporation source, they are directly When it reaches the surface of the product to be plated, due to the low temperature of the product, it condenses to form a film.

In terms of the production process, LKKER SCM has expanded from a single manual electroplating line in the original Shenzhen Guanlan factory to a vacuum electroplating department integrating automatic and manual lines in the current Tangxia factory.

Introduction to Electroplating process:

Material degreasing → cover mold → clamping → dust removal → UV spraying

→UV Curing → Coating → Finishing → Baking → Inspection → Packaging

A sketch of the effect of vacuum plating:

Vacuum plating process (1): manual production line process

Vacuum plating process (2): automate production line process

Defective 1. Lines/dust spots

Description: The raised granules or lines on the surface of the product are bad, and the distribution is irregular.

Analysis of the causes:

1. The surface of the material is not cleaned or cleaned in place
2. Invisible wool (plastic wire) produced at the corners of the product during the molding process
3. Too much dust in the air or on the floor
4. Dust from the workshop vents
5. Flying dust inside the equipment (such as UV machine, etc.)
6. Paint pollution or poor paint
7. Flying dust or fibers/hair on the human body falls on the product during operation

Key points of quality control:

1. When pre-processing materials, confirm whether the operator’s dust removal method is in accordance with the requirements of the “Operation Instructions”
2. When the materials are received, refer to the standard template and “Inspection Benchmarks” for confirmation
3. Regularly confirm the workshop “3S” during the inspection process
4. Confirm the use of the ventilation system during the process inspection, and confirm whether the ventilation equipment is regularly inspected and maintained
5. Regularly check the equipment maintenance records and “3S” to confirm whether the equipment is regularly inspected and maintained.
6. Before using the paint, test spray to confirm, and replace the bad paint in time.
7. Check whether the workshop workers wear electrostatic clothes/caps as required Wait

Defective 2. Oil stains/oil spots

Description: The concave shape on the surface of the product is not good, the shape is generally round or oval, and it is diffuse. Neat edges generally appear in the groove position of the product

Analysis of the causes:

1. The oil on the surface of the material has not been treated.
2. The material itself has too much oil and cannot be removed by normal degreasing.
3. There is water or oil in the air pipe of the spray gun. 4. The paint is bad or polluted.

Key points of quality control:

1. Confirm whether the operation method is consistent with the “Operation Instructions” during pre-processing
2. Regularly confirm the use of mold release agents at the molding site
3. Check whether there is water in the spray gun every day before production
4. Confirm the paint before production, and deal with the expired paint in time

Defective 3. Explosive tungsten wire

Description: The light transmission of tungsten filaments generally occurs on transparent or translucent PC materials that require cover mold plating. Light is irradiated, and the light passes through the coating position.

Analysis of the causes:

The electroplating tungsten wire is aging, and the undissolved part of the aluminum wire falls on the product after evaporation to form light transmission

Key points of quality control:

Check the appearance of the tungsten wire before going online, if there is obvious nodule or oxidation, it cannot be used, and regularly confirm the replacement record of the tungsten wire

Defective 4. Electroplating pinhole light transmission

Description: Pinhole light transmission generally occurs on PC transparent or translucent materials that require cover mold plating, illuminated with light, and the light passes through the coating position.

Analysis of the causes:

1. 1. The electroplating tungsten wire is aging, and the undissolved part of the aluminum wire falls on the product after evaporation to form pinhole-shaped light transmission
2. After the primer is cured, flying dust adheres to the surface, resulting in pinhole light transmission after electroplating
3. The purity of electroplated aluminum wire is too low and contains impurities
4. The thickness of the coating is too thick
5. Before the topcoat is sprayed, the dust removal pressure is too high
6. The spray pressure of the topcoat is too high

More in the next chapter. Follow LKKER SCM Linkedin Page for chapter updates. 

01 Mold appearance

1. The content of the mold nameplate is complete, the characters are clear, and the arrangement is neat.

2. The nameplate should be fixed on the mold foot near the template and the reference angle. The nameplate is reliable and not easy to peel off.

3. The cooling water nozzle should be made of plastic block water nozzle, if the customer requires otherwise, please follow the requirements.

4. The cooling water nozzle should not protrude from the surface of the mold base.

5. The cooling water nozzle needs to be processed with a counterbore. The counterbore diameter is 25mm, 30mm, and 35mm. The orifice is chamfered and the chamfering should be the same.

6. The cooling water nozzle should be marked for entry and exit.

7. Mark English characters and numbers should be greater than 5/6, and the position should be 10mm directly below the tap. The handwriting should be clear, beautiful, neat, and evenly spaced.

8. Mold accessories should not affect the hoisting and storage of the mold. During installation, there are exposed oil cylinders, faucets, pre-reset mechanisms, etc., which should be protected by supporting legs.

9. The mounting of the support leg should be fixed on the mold base with screws passing through the support leg, and the excessively long support leg can be fastened to the mold base with a machined external threaded column.

10. The size of the ejector hole of the mold should meet the requirements of the specified injection molding machine. Except for small molds, one center cannot be used for ejection.

11. The positioning ring should be fixed and reliable. The diameter of the ring is 100mm and 250mm. The positioning ring is 10-20mm higher than the bottom plate. Unless otherwise requested by customers.

12. The overall dimensions of the mold should meet the requirements of the designated injection molding machine.

13. For molds with orientation requirements, an arrow should be used to indicate the installation directly on the front template or the rear template, and there should be “UP” next to the arrow. The arrow and text are both yellow and the height of the font is 50mm.

14. The surface of the mold base should not have pits, rust marks, redundant rings, water vapor in and out, oil holes, etc., and defects that affect the appearance.

15. Moulds should be easy to hoist and transport. Mold parts must not be disassembled during hoisting. Lifting rings must not interfere with faucets, cylinders, pre-reset rods, etc.

02 Mold material and hardness

1. The mold base should be a standard mold base that meets the standard.

2. The material of mold forming parts and gating system (core, movable and fixed mold insert, movable insert, diversion cone, pushrod, sprue sleeve) shall be made of materials with performance higher than 40Cr.
3. When molding plastics that are corrosive to the mold, the molded parts should be made of corrosion-resistant materials, or the molding surface should take anti-corrosion measures.
4. The hardness of the molded parts should not be lower than 50HRC, or the hardness of the surface hardening treatment should be higher than 600HV.

03 Eject, reset, pull out the core, take out

1. The ejection should be smooth, free of jamming, and no abnormal sound.

2. The inclined top surface should be polished, and the inclined top surface is lower than the core surface.

3. The sliding parts should be provided with an oil groove, and the surface needs to be nitrided, and the surface hardness after treatment is HV700 or higher.

4. All ejector rods should have stop-rotation positioning, and each ejector rod should be numbered.

5. The ejection distance should be limited by a limit block

6. Standard parts should be used for the return spring, and both ends of the spring should not be polished or cut off.

7. Slider and core-pulling should have stroke limit, small slide is limited by spring, if spring is inconvenient to install, corrugated screw can be used; cylinder core-pulling must have a stroke switch.

8. Generally, inclined guide posts are used for core pulling of the slider, and the angle of the inclined guide post should be 2°~3° smaller than the angle of the locking surface of the slider. If the stroke of the slider is too long, the oil cylinder should be used for drawing.

9. When the end surface of the core-pulling forming part of the cylinder is covered, the cylinder should be equipped with a self-locking mechanism.

10. There should be a wear plate under the large sliding block with a width of more than 150 mm. The material of the wear plate should be T8A. The hardness after heat treatment is HRC50~55. The wear plate is 0.05~0.1 mm higher than the large surface. Open the oil tank.

11. The ejector rod should not move up and down.

12. Add barbs to the top rod, and the direction of the barbs should be consistent, so that the barbs are easy to remove from the product.

13. The clearance between the ejector pin hole and the ejector pin, the length of the sealing section, and the surface roughness of the ejector pin hole should be in accordance with the requirements of the relevant enterprise standards.

14. The product should be convenient for the operator to remove it.

15. When the product is ejected, it is easy to follow the inclined top, and the top rod should be grooved or etched.

16. The top block fixed on the top rod should be firm and reliable, the non-formed parts around the circumference should be processed with a 3°~5° slope, and the lower periphery should be chamfered.

17. There should be no iron filings in the oil passage hole on the mold base.

18. The end face of the return rod is flat and there is no spot welding. No gasket at the bottom of the embryo head, spot welding.

19. The gate plate of the three-plate mold slides smoothly, and the gate plate is easy to open.

20. Three-plate mold limit rods should be arranged on both sides of the mold installation direction, or pull plates should be added to the mold base to prevent the limit rods from interfering with the operator.

21. The oil circuit and air passage should be smooth, and the hydraulic ejector reset should be in place.

22. An exhaust port should be opened at the bottom of the guide sleeve.

23. There should be no clearance for the positioning pin installation.

04 Cooling and heating system

1. The cooling or heating system should be fully unblocked.

2. The seal should be reliable, the system should not leak under the pressure of 0.5MPa, and it is easy to check and repair.

3. The size and shape of the sealing groove opened on the mold base should meet the requirements of relevant standards.

4. Grease should be applied to the sealing ring when it is placed, and it should be higher than the surface of the mold base after it is placed.

5. Water and oil flow channel separators should be made of materials that are not easily corroded.

6. The front and back molds should use a centralized water supply.

05 Gating system

1. The gate setting should not affect the appearance of the product and satisfy the product assembly.

2. The runner section and length should be reasonably designed, and the process should be shortened as much as possible under the premise of ensuring the forming quality, and the cross-sectional area should be reduced to shorten the filling and cooling time. At the same time, the plastic loss of the pouring system should be the least.

3. The partial cross-section of the three-plate mold runner at the back of the front mold plate should be trapezoidal or semicircular.

4. The three-plate mold has a material breaker on the gate plate, the diameter of the gate entrance should be less than 3 mm, and the ball head has a 3 mm deep step recessed into the gate plate.

5. The ball end pull rod should be reliably fixed, can be pressed under the positioning ring, can be fixed with headless screws, or can be pressed with a pressure plate.

6. Gates and runners should be machined according to the size requirements of the drawings, and manual grinding and polishing machines are not allowed.

7. The pointed gate should be in accordance with the requirements of the specification.

8. There should be an extension at the front end of the runner as a cold slug hole.

9. The Z-shaped inverted buckle of the pulling rod should have a smooth transition.

10. The runner on the parting surface should be round, and the front and rear molds cannot be misaligned.

11. The latent gate on the ejector rod should have no surface shrinkage.

12. The diameter and depth of the cold slug hole for transparent products should meet the design standards.

13. The handle is easy to remove, there is no gate mark on the appearance of the product, and there is no residual handle at the product assembly.

14. For the curved hook latent gate, the two parts of the insert should be nitrided, and the surface hardness can reach HV700.

06 Hot runner system

1. The wiring layout of the hot runner should be reasonable for easy maintenance, and the wiring numbers should be a one-to-one correspondence.

2. The hot runner should be tested for safety, and the insulation resistance to the ground should be greater than 2MW.

3. Standard parts should be adopted for temperature control cabinets, hot nozzle, and hot runner.

4. The main flow port sleeve is connected with the hot runner with threads, and the bottom surface is in contact with the hot runner for sealing.

5. The hot runner is in good contact with the heating plate or heating rod, and the heating plate is fixed with screws or studs, and the surface fits well.

6. The J-type thermocouple should be used and matched with the temperature control meter.

7. Each group of heating elements should be controlled by thermocouples, and the position of the thermocouples should be reasonably arranged.

8. The nozzle should meet the design requirements.

9. The hot runner should be reliably positioned, at least two positioning pins, or fixed with screws.

10. There should be an insulation pad between the hot runner and the template.

11. The error between the set temperature of the temperature control meter and the actual display temperature should be less than ±5°C, and the temperature control should be sensitive.

12. The cavity and nozzle installation hole should pass through.

13. The hot runner wiring should be bundled and covered with a pressure plate.

14. There are two sockets of the same specification, which should be clearly marked.

15. The control line should be sheathed and not damaged.

16. The structure of the temperature control cabinet is reliable, and the screws are not loose.

17. The socket is installed on the bakelite and cannot exceed the maximum size of the template.

18. The wires must not be exposed outside the mold.

19. There should be rounded transitions at all the places where the hot runner or template is in contact with the wires.

20. Before the template is assembled, there is no open circuit or short circuit in all circuits.

21. All wiring should be connected correctly, with good insulation performance.

22. After the template is installed and clamped, all circuits should be checked again with a multimeter.

08 Injection molding production process

1. The mold should have the stability of injection molding production and the repeatability of process parameter adjustment within the range of normal injection molding process conditions.

2. The injection pressure during mold injection production should generally be less than 85% of the injection molding machine’s rated maximum injection pressure.

3. The injection speed during the injection molding production of the mold, the injection speed of the three-quarter stroke is not less than 10% of the rated maximum injection speed or more than 90% of the rated maximum injection speed.

4. The holding pressure during mold injection production should generally be less than 85% of the actual maximum injection pressure.

5. The clamping force of the mold during injection molding production should be less than 90% of the rated clamping force of the applicable model.

6. During the injection molding production process, the product and nozzle material should be taken out easily and safely (the time is generally not more than 2 seconds each).

7. For molds with inserts, the inserts are easy to install and the inserts are fixed reliably during production.

09 Packing and shipping

1. The mold cavity should be cleaned and sprayed with anti-rust oil.

2. The sliding parts should be lubricated.

3. The inlet of the sprue bushing should be sealed with grease.

4. The mold should be equipped with a clamping piece, and the specifications meet the design requirements.

5. Spare parts and wearing parts should be complete, with a detailed list and the name of the supplier.

6. Sealing measures should be taken to prevent foreign matter from entering the mold water, liquid, gas, and electrical inlets and outlets.

7. Spray paint on the outer surface of the mold, as required by the customer.

8. Molds should be packaged in moisture-proof, waterproof, and bump-proof packaging, as required by customers.

9. Mold product drawings, structural drawings, cooling, and heating system drawings, hot runner drawings, spare parts, and mold material supplier details, operating instructions, mold test report, factory inspection certificate, and electronic documents should all be complete.

Learn More:

1.  LKK Mold Making Service

2.  Mold Assembly Process Video

3.  Mold Making Process Video 

4.  Mold T0 Sample, T1 Sample Video -Sweeping Robot

On October 18-21, the four-day “2018 Hong Kong Autumn Mobile Electronics Show” came to a successful conclusion. The LKKER R&D SCM team brought more than 30 innovative products to Hong Kong’s largest pavilion – Hong Kong AsiaWorld-Expo along with nearly 3,700 domestic and foreign manufacturers.

Exquisite and special space

 During the four days of the exhibition, there was a large amount of people.

The booth attracted buyers from all over the world

The flow of people at the booth of the LKKER SCM was always endless. More than 30 products with exquisite appearance, unique functions and high sales volume attracted the audience at home and abroad.

For the innovative companies around the globe, in the process of product incubation, there will be countless difficulties. Who can help them? The factory does not have the ability to innovate and integrate. The design company does not have production management capabilities. The traditional supply chain companies do not have the ability to develop and control products. The LKKER SCM is a one-stop innovative product integration service platform integrating product design, R&D, prototyping, tooling, production, packaging and transportation, e-commerce channel and supply chain finance. It is a product production management company that truly has technology, team, resources and experience.

Therefore, a large number of customers from Europe, America, and Asia in the exhibition found that in the country of manufacturing – China, there is such a supply chain management company that can realize the complete incubation of a product. It is a treasure. A large number of customers came one after another, and even many customers came to our booth several times in the exhibition several days to communicate product cooperation ideas. And all that we have seen and gained makes us more confident in the development of “globalization, integrated management, innovative R&D.”

Xiaoya AI Speaker disassembly diagram

Hong Kong Mobile Electronics Show, as Asia’s largest consumer electronics show, is not difficult to see from its exhibiting products over the past few years, it is also facing a major problem as the domestic product market – “product homogenization”, various industries’ electronic products are developing towards extreme market maturity, and the competition in the industry is becoming more and more fierce. This is also the dilemma of product-oriented enterprises. The global smart electronic products are in urgent need of transformation.

LKKER SCM is committed to building a world’s largest ecosystem of innovative products, providing supply chain management services centered around product development, helping companies to bring their ideas to life. Over the years, we have been deeply involved in the five major product areas of smart hardware, medical & health, new retail, new entertainment, and small household appliances. Through the integration of product flow, information flow and capital flow, we provide design assurance, product quality assurance and delivery cycle guarantee, cost control guarantee, production fund guarantee, and sales channel guarantee. It is the best choice to truly solve product innovation and creative landing.

Then, next, let’s take everyone to see the exhibition site.

What are the good products that attract countless customers domestically and internationally?

Self-developed Smart Mouse Sikitime

At the exhibition site, everyone showed great interest in the smart mouse independently developed by the LKKER SCM. This collapsible mouse named Sikitime is the world’s first mouse that provides users with two distinct modes of operation. The clicker and mouse are integrated into one, and the appearance is simple and generous. It is the best assistant for business people.

MagicPen Food Painting Robot “Little Ma Liang”

In addition, “Little Ma Liang” also attracted frequent visitors to the scene. It’s a robot that can customize painting on food, which can help catering merchants print patterns on the surface of more than 20 kinds of ingredients, WeChat upload, 15 seconds of customization, it turns coffee, yogurt, bread, cakes, macarons, biscuits, etc. into a custom food.

Uface Ubisoft Smart Front Desk

Uface is a face recognition system. The biggest feature of this product is that it can realize the functions of attendance registration, visitor registration and access control under face recognition mode by pre-recording personal name, image and other information. The recognition speed is shortened from 3-5s to 0.01s, and the recognition rate can be 97%, which is much higher than other similar products. You can view and modify user data at any time through the APP and cloud background, generate attendance and visitor lists. Achieve smart experiences in new office scenarios.

2nd Generation Carrobot Lite

“Carrobot” is a smart on-board robot based on HUD+ voice control man-machine dialogue, which can greatly improve the safety of driving. After successfully launching the smart Carrobot, the LKKER SCM team perfectly improved the second generation Carrobot – compass-type smart navigation system. The HUD transparent projection screen placed on the instrument panel directly in front of the steering wheel displays information, and realizes functions such as voice navigation, making a call, sending and receiving WeChat, and listening to music through voice control.

Onecup Smart Drinking Machine

Onecup is the world’s first smart drink machine. Of course, it is more than just a smart drink machine, it is an innovative solution to the Chinese hot drink culture. Its emergence will liberate people from the tediousness of homemade drinks on the basis of satisfying people’s preferences for hot drinks and ensuring food safety, providing a simpler, more efficient and more convenient experience.

Smart Companion Robot ZIB

This product is the celebrity of the children’s robotics industry, released in the Silicon Valley, becoming the industry’s number one brand. It solved the problem of the lack of companionship with the children, becomes lonely, and hopes to provide more care, fun, novelty, education, and efficient learning environment. Let the children feel the emotional care of their parents no matter time and location.

Peapad Children’s Robot

Peapad is a children’s robot that integrates teaching and entertainment. LKKER SCM provided structural design, supply chain management, pilot production, 3C certification and other services. Its exterior is made of food-grade raw materials. When the distance between the child and the screen is less than 20cm, the Peapad will open the eye protection mode and automatically adjust the brightness of the screen according to the brightness of the ambient light to achieve the eye protection effect.

In addition to the above mentioned products

Also exhibited more than 20 other models

Innovative products designed and developed by us

It is through so many truly valuable products that customers saw the accumulation and value of the LKKER SCM in the field of innovative products, so we obtained a lot of business opportunities and orders.

In addition to good products, LKKER SCM’s planning for the globalization is one of the reasons for the success of the exhibition. Its excellent overseas business opportunity, technology, marketing team, a professional team of being proficient in English and a deep understanding of LKKER SCM capture the favor of so many overseas customers.

Our team answered questions for customers in fluent english.

The success of this Hong Kong Mobile Electronics Show

Brought us more confidence

In the future, we

will participate more in overseas exhibitions

We will always follow

“Innovation-based” values

Always work hard to bring more Good design, good product

to everyone

See you next time!

 

As the core task of supplier management, the maintenance of customer relationship brings direct or potential advantages to sourcing enterprises by promoting open exchanges between the two sides and avoiding many potential problems.

For example, when an enterprise makes an urgent request of increased quantity of supply or early deliveries to the supplier, its demands can easily be met with a solid purchaser-supplier relationship that shortens the negotiation between the parties, simplifies the problems and settles disputes with little hindrance.

Based on LKKER SCM’s years of experience in managing 3,000+ supplier partners, we would like to share with you the following key approaches in building favorable purchaser-supplier relationship.

1. Build mutual trust and maintain business confidentiality

The purchaser must maintain strict confidentiality of all costs, techniques and performance of the supplier. Any disclosure of a supplier’s information to another supplier will soon be learnt by the supplier, which will undermine the long-term relationship between the supplier and the supply management company.

It is of great importance to enter into a mutual confidentiality agreement with the supplier in the early stage of establishing a partnership.

2. Conduct strategic cooperation and consultation with supplier executives

The executives of the purchaser should meet with its counterparts in the key suppliers on a regular basis to discuss the strategic cooperation objectives in the long run.

Many Fortune 500 companies such as Caterpillar, Intel, and Toyota regularly hold such meetings with key suppliers, during which managers of both sides discuss market trends, potential expansion plans, long-term technical issues and future investment plans.

3. Focus on end user

Each party in the supply chain should be aware that they are serving the common end consumer, which leads to a common core.

Honda told all its suppliers of parts and raw materials that they are contributing to the manufacturing of each Honda. All suppliers, regardless of where they are in the supply chain, have the same core.

4. Carry out satisfaction surveys on suppliers on a regular basis

To collect feedback from suppliers and inquire about the communication with the purchaser, the attitude towards purchaser-supplier relationship, the accuracy of information communication, the punctuality of payment, the equality of status and the possibility of exposure to new opportunities, especially in terms of payment through a questionnaire.

Late payment will undoubtedly give the supplier a bad impression and may cause financial problems to the supplier, which will affect its ability to pay the downstream supplier or fulfill a contract, and ultimately influence the entire supply chain of the enterprise.

5. Deliver pertinent training for suppliers

Some supply management companies provide training opportunities for their suppliers to improve their quality of products and processes. This is an investment in supplier performance and also in the relationship between the two sides.

For example, some of the largest Korean companies, such as LG Electronics and Samsung, offer their suppliers training courses covering leadership, solutions and computer aided conceptual design (CACD).

Case Sharing: How does Caterpillar build a good relationship with suppliers?

Caterpillar regards suppliers as a key part in its business operation and value chain. It has set up a global sourcing center dedicated to the formulation and development of supplier strategies, as well as selection of suppliers, demonstrating the great importance it has attached to the selection and development of suppliers. Caterpillar has developed a set of selection criteria for suppliers, namely the QCLDM, where Q stands for Quality, C stands for cost, L stands for logistics, D stands for development, i.e., the ability to develop, and M stands for management. Caterpillar evaluates its suppliers from the five aspects of QCLDM.

Caterpillar not only selects, but also helps and supports its suppliers. In Caterpillar, whether a Chinese supplier is to be selected as China-based matching supplier or a global supplier is determined by a variety of factors such as the products, management and cost and quality of the supplier. At present, Caterpillar has 300+ suppliers in China, most of whom are local suppliers, and some are foreign suppliers drawn to China with the expansion of Caterpillar. For example, some Japanese suppliers have invested and developed in China after following Caterpillar into China.

No company has invested such a large amount of resources to support and develop suppliers in China like Caterpillar. Such support has also earned Caterpillar the highest praise among suppliers. With the help of Caterpillar, many suppliers have grown into global suppliers of Caterpillar from scratch, and some are even included into the Harvard Business School Cases.

 

Caterpillar has established a Caterpillar Supplier Park specialized in excavators in Xuzhou to construct a comprehensive supporting network. A competitive and efficient supply chain system will be an indispensable part of the future competitiveness of an enterprise. The building of an efficient and integrated supplier system, including information flow, logistics and integration is vital to enterprises, especially if their production capacity reaches a certain extent.