The production of electric fly swatters

The production of electric fly swatters is a systematic process that integrates precision manufacturing and strict quality control. Every link, from component processing to finished product assembly, affects the performance and safety of the product. As a manufacturer with more than ten years of experience in producing electric fly swatters, today we will take you through the detailed production process:

I. Production of Core Components

Manufacturing of Circuit Components

Electronic components such as transistors, capacitors, and resistors in the high-frequency oscillation circuit are mass-produced by professional electronic manufacturers in accordance with specifications to ensure stable parameters. As the core component for voltage boosting, the transformer needs to be precisely wound with enameled wires using a winding machine. The turns ratio between the primary coil and the secondary coil is strictly implemented in accordance with the design requirements. After winding, it undergoes paint dipping and curing treatment to enhance insulation and stability.

Processing of Power Grids

Stainless steel wires or galvanized iron wires with a diameter of 0.3-0.5mm are used and processed into a three-layer mesh structure through stamping dies. The outer layer of the mesh has larger apertures (about 10-15mm) to play a protective role, while the inner layer has smaller apertures (about 3-5mm) for electric shock. The distance between adjacent layers is controlled at 5-8mm, which not only ensures that mosquitoes can easily enter but also prevents accidental contact by the human body. After processing, it needs to go through rust removal, polishing, and plating treatments to improve rust resistance.

Injection Molding of Plastic Parts

The handle and frame are made of ABS or PP engineering plastics and are formed in one go through an injection molding machine. The mold needs to be precisely polished to ensure a smooth surface without burrs. The handle is designed with grooves according to ergonomics to enhance the grip feeling. After injection molding, deburring treatment is carried out to remove gate residues and ensure a neat appearance.

Battery Assembly

Rechargeable battery packs (such as lithium batteries) are formed by welding battery cells, protection boards, and wires. The protection board must have overcharge, over-discharge, and short-circuit protection functions. For dry battery models, a battery compartment is reserved with built-in metal contact pieces to ensure good contact with the battery.

II. Pretreatment and Inspection of Components

All components must undergo strict screening before entering the assembly process:

III. Assembly Line Assembly

Circuit Welding

On the PCB circuit board, components of the oscillation circuit and rectifier circuit are fixed through wave soldering or reflow soldering, and the solder joints must be full without cold soldering. Manual assistance is required for welding large components such as transformers and wires to ensure correct circuit connections. At this point, a preliminary power-on test can be conducted to check whether the oscillation frequency meets the design standards (usually 10-20kHz).

Mesh Placement and Assembly

The three-layer power grid is embedded into the frame in sequence and fixed with clips or screws to ensure that the grids are aligned and there are no protrusions on the edges. Then, the wires connecting the power grid and the circuit board are connected, and the joints are wrapped with insulating sleeves to prevent short circuits.

Handle Assembly

First, install components such as the battery compartment, switch buttons, and indicator lights into the handle shell, then embed the welded circuit board, connect the wires, and fix them. The upper and lower shells of the handle are sealed with screws or ultrasonic welding to ensure waterproofing and dustproofing. At this point, install the power plug (for rechargeable models) or the battery cover (for dry battery models).

Overall Integration

Connect the frame and the handle through a rotating shaft or fixed clips, test the firmness of the connection. For models that can rotate 360 degrees, it is necessary to ensure smooth rotation without jamming. Finally, install a protective cover (for some models) to prevent the power grid from being exposed.

IV. Finished Product Inspection and Packaging

Performance Testing

Appearance and Durability Inspection

Check whether the plastic parts have scratches, whether the power grid is flat, and whether the switch is pressed smoothly. Conduct a drop test (free fall from a height of 1.2 meters to the concrete ground), and after the test, the function should be normal without component falling off.

Packaging and Storage

Qualified products are put into dust bags and packed into packaging boxes printed with instructions and warning signs, with built-in charging cables (for rechargeable models) or instructions. Finally, they are stored in batches. Thermometers and humidity detectors should be placed in the warehouse, and the appropriate temperature and humidity in the warehouse should be ensured daily. The storage environment needs to be dry and ventilated, avoiding high temperature and direct sunlight.