Specialize in the Manufacture of Reliable Power Quality Products For 30 YearsSpecialize in the Manufacture of Reliable Power Quality Products For 30 Years
How Active Harmonic Filter Static Var Generators are Made
A Deep Dive Into iKonMac's World-Class Manufacturing Process
Welcome to Our Factory
At iKonMac, quality isn't just an outcome - it's a process. From the moment raw materials enter our doors to the final moment a fully assembled Active Harmonic Filter (AHF) or Static Var Generator (SVG) is sealed and shipped, every detail is meticulously planned, executed, and monitored.
We are proud to give you an insider's look at how our advanced power quality solutions are made. This tour will walk you through our production, assembly, testing, and quality control workflows - showcasing how we achieve reliability, durability, and performance excellence with every unit.
1. Electrostatic Protection & Safe Assembly
The safety of electronic components starts with electrostatic protection. iKonMac applies strict ESD control throughout the production workflow to prevent hidden damage to sensitive chips, circuit boards and power electronic modules.
Anti-static tiles are laid across key production and assembly areas.
Every worker wears anti-static caps, protective clothing and anti-static shoes.
ESD wrist straps are used during module and circuit board assembly.
Military-grade anti-static turnstiles control access to the production line.
Air shower dust removal is required before entering the clean production area.
All personnel are required to wear anti-static caps, clothing, and shoes to prevent electrostatic discharge (ESD) from damaging sensitive electronic chips. Even the slightest static charge can cause product failures, affecting stability and lifespan.
To ensure the highest quality standards, everyone must pass through military-grade anti-static turnstiles and undergo air shower dust removal before entering the production line. Every step is controlled to guarantee the reliability of each product.
2. Production Workshop Layout
We don't just build power quality equipment - we build them in one of the most advanced facilities in the industry.
Cleanroom Classification: Class 100,000
iKonMac is the only manufacturer in the power quality industry with a Class 100,000 cleanroom. This controlled environment reduces dust, particles and hidden contamination risks during module production.
Production Capacity & Infrastructure:
30,000 modules per year.
$30 Million USD annual output value.
Automated and expandable assembly lines are ready for rapid scale-up as demand grows.
3. High-Precision Production & Assembly
Precision, cleanliness and standard operating procedures are maintained throughout the production and assembly process. From module handling to wiring and fastening, each stage follows documented process requirements.
4. Testing & Quality Control:
Seven-Stage Full Process Inspection is used to make sure each product is checked before, during and after assembly. This process reduces hidden risks and ensures reliable operation after delivery.
1
Incoming Inspection
All incoming components and raw materials are rigorously checked for quality and compliance before entering the production line. This step eliminates defects at the source and ensures consistent baseline quality.
2
ICT Test (In-Circuit Test)
This stage verifies the electrical performance of the PCB and its individual components. Our ICT process checks circuit continuity, soldering reliability and component accuracy before module assembly.
3
FCT Test (Functional Circuit Test)
Functional circuit testing validates the control logic, signal response and real operating behavior of the circuit board under simulated application conditions.
4
Assembly Inspection
After assembly, technicians inspect wiring, fastening, structure and safety details against process standards to prevent hidden assembly defects.
5
LV-HV Testing
Low-voltage and high-voltage tests verify insulation, withstand voltage and operating reliability before products enter the aging process.
6
Aging Test
Modules run through aging and load tests to confirm long-term stability under continuous industrial working conditions.
7
Final Factory Test
Final automated and manual tests confirm every unit is ready for delivery before packaging and shipment.
5. Protective Coating & Environmental Durability
Industrial sites can include dust, humidity, corrosive gases and large temperature changes. iKonMac uses protective coating processes to improve environmental durability for demanding installations.
Standard module protection supports industrial environments, and customized protection levels can be configured for stricter project conditions.
6. Burn-in Aging & Stress Verification
Before shipment, modules go through aging and stress verification to confirm stable operation under continuous working conditions. This step helps identify abnormal behavior before products leave the factory.
7. Final Testing & Packaging, Ready to Ship
Our final factory testing includes both manual inspection and automated computer-driven testing. To ensure modules arrive as perfect as they left the factory, finished products are protected with moisture-proof packaging, corner protection and durable wrapping for long-term storage and global shipping.
Sealed in moisture-proof bags.
Eight-corner protection for cabinet and module edges.
Double plastic wrap for long-distance transport.
Final inspection records before shipment.
Get In Touch
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Factory Address
Building 3, Shanghai Tiandi Innovation Park, 879 Zhongjiang Road, Putuo District, Shanghai, China
Head Office
Eastern Area, First Floor, Block 1, No.508, Chuanhong Road, Pudong New Area, Shanghai, China
