Shenzhen Keysun Technology Limited

Shenzhen Keysun Technology Limited

KSPOWER accept OEM/ODM customization, including AC/DC Cable length, special connector, power adapter label, PCB solution, logo print and package and so on.

Power Adapter Manufacturing Process

1. Design & Prototyping
- Circuit design: Engineers create schematics and PCB layouts using CAD tools, ensuring compliance with safety standards (e.g., UL/IEC).
- Prototype testing: Functional verification, thermal analysis, and EMI/EMC testing are conducted.

2. Component Sourcing
- Procurement of key components:
• Transformer cores and copper windings
• Power ICs and MOSFETs
• Capacitors (electrolytic/X7R)
• Connectors (USB-C, barrel jacks, etc.)
- Incoming quality control (IQC) checks for component specifications.

3. PCB Assembly (SMT & THT)
- SMT Phase:
• Stencil printing of solder paste
• Pick-and-place machine mounts SMD components
• Reflow soldering (typically 220-250°C peak temperature)
- Through-Hole Phase:
• Manual/auto insertion of larger components
• Wave soldering for THT connections
- AOI (Automated Optical Inspection) verifies solder quality.

4. Transformer Production
- Bobbin winding with enameled copper wire
- Core assembly (EE/EI/ferrite types)
- Varnish dipping for insulation and vibration resistance
- Inductance and turns ratio testing

5. Assembly & Integration
- Housing assembly: Injection-molded plastic cases with UL94-V0 flame rating
- Potting (for industrial units): Filling with thermally conductive epoxy
- Final assembly: Integrating PCB, transformer, and cooling components (heat sinks/thermal pads)
- Strain relief installation for cables

6. Testing & Quality Assurance
- Electrical Tests:
• Load regulation (±5% typical)
• Ripple/noise measurement (<150mVpp)
• Short-circuit/overcurrent protection
- Safety Tests:
• Hi-pot test (3kV AC or equivalent)
• Insulation resistance (>10MΩ)
- Burn-in testing (2-4 hours at full load)

7. Packaging & Shipping
- Laser marking for certifications (UL, CE, FCC, RoHS)
- Anti-static packaging with protective foam
- Palletization according to shipping requirements

Key Process Controls:
- IPC-A-610 Class II/III standards for PCB assembly
- 100% electrical testing before packaging
- Traceability system for batch tracking

This end-to-end process typically takes 15-30 days depending on order complexity, with automated lines achieving >95% first-pass yield in modern facilities.

R&D Capabilities of a Power Adapter Manufacturer

KSPOWER possesses strong "Research & Development (R&D)" capabilities, enabling us to design and produce high-performance, reliable, and innovative power adapters for various applications. Our R&D strengths include:

1. Advanced Power Electronics Design
- Expertise in "high-efficiency topologies" (Flyback, LLC Resonant, PFC + PWM)
- Custom solutions for low standby power (<0.1W)
- Optimization for energy efficiency (DoE Level VI, CoC Tier 2, ErP)

2. EMI/EMC Optimization
- EMI/EMC compliance design (FCC, CE, CISPR32 Class B) with minimized noise
- Use of GaN (Gallium Nitride) and SiC (Silicon Carbide) for high-frequency, low-loss designs

3. Mechanical & Safety Engineering
- Compact and rugged enclosure design (IP68 waterproof, shock-resistant)
- Compliance with global safety standards (UL, TUV, CCC, KC, PSE)

4. Customization & OEM/ODM Support
- Tailored solutions for consumer electronics, medical, industrial, and automotive applications
- Firmware customization for intelligent power management
- Global certification support (ENERGY STAR, ErP, RoHS, REACH)

Why Choose Our R&D Team?
✅ Innovation-driven – Continuous development of next-gen power solutions
✅ Cost-optimized designs – Balancing performance and manufacturability
✅ Full compliance– Meeting international regulatory requirements

Our R&D team collaborates closely with clients to deliver cutting-edge, reliable, and efficient power adapters for diverse market needs.

Shenzhen Keysun Technology Limited was founded in 2008 with a vision to deliver "high-performance, reliable power supply solutions" for the global electronics industry. Over these years, we have grown from a "small workshop" into a "fully integrated manufacturing and trading enterprise", combining "innovative R&D, precision engineering, and customer-centric service".

Key Milestones

- 2008: Established Shenzhenshi Zhenhuan Electronic CO., LTD.

The first designed power adapter was launched into market.

- 2009: The LED driver was launched into market.

The factory was expanded to be 2,500㎡ and moved to Baoan District, Shenzhen.

- 2010: Implemented Total Quality Management(TQM)

Acquired CCC certification.

- 2011: Acquired ISO-9001 certification(TUV)

Certified by ISO 14001:2004 environment management system and ISO9001:2000 quality system

- 2012: Implemented products CE、UL declaration

Implement Green Product / ROHS compliance / Lead free manufacturing

- 2013: Equipped the automatic wave-soldering production lines

Acquired CQC and KC certifications

评定为深圳市高新技术企业 Evaluated as Shenzhen High-tech Enterprise

- 2015: Recognized by CNAS Lab

KSPOWER was certified by ISO9001:2008 quality system management system

The industry leading DOE VI power adapter was launched into market

- 2017: a group of self-confident, passionate and brave guys from the KSPOWER team started to the Hong Kong exhibition.

After the perfect appearance of last year's exhibition, we met again. Meanwhile, our power supply production workshop also added a variety of new machines.

- 2019: relocated and expanded the scale of the production workshop; a series of standard certificates for power adapters were upgraded, and applied ISO9001:2015 QUALITY MANAGEMENT SYSTEM CERTIFICATE. Launched the latest H series Dimmable LED driver firstly.

- 2020: Have own brand, continues to improve and launch power adapter and LED driver’s lineup of higher wattage, replaced the aging test equipments and so on.

- 2022: Officially launched the L series ultra thin led driver, and five series led driver power supplies collected.

- 2023: Strictly implemented and completed the 7S sorting and rectification and regional division of the production workshop.

- 2024: Upgraded 5W-120W series power supplies solution with latest IEC/EN 62368/61558 safety certifications for Home application.

Today & Future

With "17+ years of expertise", we serve clients across USA, Canada, Europe, Japan and South Korea countries and so on, offering "end-to-end solutions" from design to logistics. As technology evolves, we continue to invest in "green energy, compatible adapters, and miniaturized designs", striving to power the world "smarter and safer".

KSPOWER is committed to being a leading manufacturer, specializing in development and production of ac dc power supplies and LED drivers. With ISO9001:2015, KSPOWER offers total quality, from in-house design through to manufacturing facilities around the world. It has provided the opportunity to not only sell but also manufacture high quality, energy efficient power supplies to internationally recognised standards as it is environmentally friendly manufacturing facility.

KSPOWER has developed technologies that further reduce energy wastage, resulting in products which are up to 93% efficient. Our goal is to continue to develop such products and sell the benefits to our customers.