SUNS落地式工装一体机

Overview

The SUNS Floor-Standing Integrated Fixture System is an industrial-grade, dual-station direct-pressure air-tightness tester engineered for high-throughput, repeatable IP68 waterproof integrity verification of smartphone frames and other precision enclosures. Operating on the principle of pressure decay measurement under controlled pneumatic conditions, the system applies a regulated test pressure of 22 kPa to sealed components and monitors pressure stability over a user-defined dwell time. This method conforms to the fundamental physical basis of ISO 16250 (hermeticity testing), ASTM F2096 (bubble emission test correlation), and IEC 60529 (IP code validation protocols). Designed as a turnkey solution, the unit integrates mechanical fixture architecture, pneumatic control manifold, sensor electronics, and operator interface into a single floor-standing enclosure—eliminating external racks, air compressors, or auxiliary PLC cabinets typically required in legacy leak-test setups.

Key Features

• Floor-standing monolithic design with integrated pneumatic manifold, pressure transducers (0.1% FS accuracy), and solenoid valve array—reducing footprint and installation complexity.
• Dual independent test stations enabling concurrent evaluation of two identical or asymmetric parts, increasing line throughput by up to 100% versus single-station systems.
• Modular tooling interface supporting rapid changeover of custom fixtures for varying smartphone frame geometries (e.g., aluminum alloy, stainless steel, or polymer composite housings).
• Real-time pressure monitoring with ±0.1 kPa resolution and automatic pass/fail decision logic based on user-configurable decay thresholds and stabilization criteria.
• Ruggedized industrial enclosure rated IP54, compliant with CE machinery directive (2006/42/EC) and RoHS 3 (EU Directive 2015/863) for factory-floor deployment.

Sample Compatibility & Compliance

The system accommodates smartphone frames with external dimensions ranging from 120 mm × 60 mm × 8 mm to 170 mm × 80 mm × 12 mm, including chamfered edges, internal gasket grooves, and multi-port sealing surfaces. Fixturing utilizes vacuum-assisted clamping with elastomeric seals (EPDM or FKM) compatible with common anodized, PVD-coated, and matte-finished substrates. All test protocols support traceable compliance reporting aligned with ISO 9001:2015 production control requirements and customer-specific quality gates (e.g., Apple IQA, Samsung QCP). Calibration documentation follows ISO/IEC 17025 principles, with annual verification intervals recommended per internal metrology SOPs.

Software & Data Management

Embedded firmware runs on a deterministic real-time OS, synchronized with optional Windows-based host software via Ethernet (TCP/IP) or USB-C. The software enables full test parameter configuration (dwell time, pressure ramp rate, pass limits), barcode-triggered test initiation using integrated scanner input, and structured data export in CSV/Excel format. Audit trail functionality records operator ID, timestamp, serial number (scanned), test result, and environmental temperature/humidity (via optional external sensor input)—meeting baseline requirements for GLP-aligned environments and supporting FDA 21 CFR Part 11 readiness when deployed with electronic signature modules and role-based access controls.

Applications

• Final QA verification of IP68-rated smartphone midframes prior to camera module and battery assembly.
• In-process leak screening of water-resistant wearable device housings (e.g., smartwatches, TWS earbud cases).
• Supplier qualification testing for ODM partners manufacturing metal or ceramic enclosures for consumer electronics OEMs.
• Engineering validation of gasket compression force vs. seal integrity across thermal cycling profiles (when paired with environmental chamber integration).
• Root cause analysis of seal failure modes—including micro-leak detection down to ~0.1 sccm equivalent helium leak rate (correlated via empirical calibration curves).

FAQ

What standards does this system comply with for IP68 validation?
It supports test execution consistent with IEC 60529 Annex B (pressure application methodology) and ISO 20699 (pneumatic leak testing for electronic enclosures); full certification requires site-specific protocol validation.
Can the system be integrated into an existing MES without custom development?
Yes—standard OPC UA and Modbus TCP interfaces are available; pre-built drivers for Siemens Opcenter, Rockwell FactoryTalk, and PTC ThingWorx are offered as optional add-ons.
Is calibration traceable to national standards?
Transducer calibration certificates include NIST-traceable references; on-site calibration services with accredited third-party labs (e.g., SGS, TÜV Rheinland) are available upon request.
What maintenance is required for long-term reliability?
Annual verification of pressure sensors and valve response time; quarterly inspection of sealing surfaces and vacuum lines; no consumables beyond standard industrial air filter elements.