How do network filters
Line filter - a device that is in the house almost everyone. Except that we do not always reflect what kind of a filter, calling the special equipment banal "extension" or "pilot". Splitter for five or six outlets with a separate button "on / off", that is for sure you have on the floor in an apartment or office can be both an extension and thus a surge protector. From the extension line filter is different "stuffing": inside there are different elements, such as varistors, capacitors, coils, etc., and the outside of the housing there is also a fuse with the button..
Surge - thing is really necessary. He removes the problem with high-frequency and impulse noise, which can be a lot of power in the home, protects your equipment from overload or short-circuit.
The bulk of the power strips sold in Russia is produced in China. Now almost all produced in China. All save, the Chinese too. If the customer in control of their well, they will do well, but if quality control was careful not save wherever possible and impossible. And it turns out that it is written on one package, but in fact the product has very different characteristics. So instead of a filter in the package is a banal extension cord.
And Russian companies that require the Chinese minimum price, simply push the latter to save on on what you can not save. Further product can be of unknown quality in large quantities to sell to the consumer at a reasonable price and have a good profit. And what I am actually purchased the buyer - it is a problem of the buyer. But there was a man in Russia, which produces a surge in Russian. Eugene humpback controls a group of companies that are just engaged in the production of network filters under the brand name Power Cube (or "Strength in Cuba"). Initially filters called Power Cube, because the company was called Cube. In 2009 we introduced the name "Power of Cuba", the "Cube" - it got accustomed simplified product names.
Having been in production, I confess, I was at first very surprised why these guys do everything ourselves, from the mold before the cord is easier both in the world to give most of the work is outsourced? After speaking with clarity Eugene on this issue has increased. They earn money and obtain the necessary stability.
Let's see, how do surge.
The filter consists of a body to be cast in the injection molding machine of plastic. What are the mold.
The instrumental section for the manufacture of molds.
The machine, which makes the body. Into a surge protector Power Cube, in contrast to a large part of Chinese products, non-flammable plastics used for housing, it fades when ignited, will not burn.
The resulting body line filters do not require additional treatment.
And to make the cord with plug, you must first make the cable itself. Here make wires for power strips, and other devices.
At the bottom of the extruder of the cable line
The shop receives raw materials - copper stranded conductor and flexible PVC in granules. From here these granules make insulation.
The application of insulation on the wire.
The output of the line wire is wound on the drums, which are then fed to the twisting machine lived.
Twisted strands ready for application of external insulation.
From Business Wire cords into a power strip.
The cable you need to cut, attach it fitting.
Now, this structure is necessary to fill in the other thermoplastic compound. And the product - ready cord with plug:
In order to make the filter needs contact the tire and the ground bus, still need to find good quality and cheaply - screws, switches, fuses, connection cables, make individual packaging, general packaging, normal solder, etc...
All collected, go to the filter assembly.
In general, the assembly - work laborious and requires attention. Perhaps that is why on the assembly of filters work primarily by women. The quality of the assembly depends largely on the quality of the finished product.
Soldering contact group, cord, switch, electronic components
Each workstation on the shop floor is equipped with a personal stretch, so the air in the room is clean, contrary to expectations, overheated and overheated rosin tin solder here does not smell
Each collected specimens are censored and only then enters into the packaging.
Now you can shop!
Yes, the thing is generally simple, but even to her to do, you need to work hard.
And all began to Eugene. In the early 90's bought in China are the same Chinese filters, sold in Russia. Sales grew, but tired of the Chinese problem: the quality is not satisfied with Chinese constantly disrupted delivery times, for long periods had to be frozen current assets. In 1998, these troubles added another - the price. The dollar rose sharply and the same Chinese goods began in rubles cost significantly more. The idea of starting to produce a surge in Russian logically from the existing premises. "His production, a" candle factory "- is not a dream of a lifetime, but it is interesting. But there is no experience - Education programmer. On which side to approach - not very clear. Come to the main, from the staff. Was invited to the team who had experience in the production in Russia on the subject of the necessary us ", - said Eugene.
Then, the first task was to make the mold. "Well, I think it's no problem - the plants are now them come, pay the money, they will do us all. After several months of unsuccessful searches realized that things are not so rosy: the people in the factories there, all left to trade on the market, work managers, security guards, sit in the secretary's office. Those who are willing to work, asking for his job so much money, that the product turns out very expensive. No one will buy. That had to step by step all the work to organize themselves, one after another production process. And in Russia is still destroyed many production chains, the normal sub-contractors are hard to find "- says Eugene.
In the beginning, to get the filter housings for Lada with a trailer drove the mold of the plant, which remained operational injection molding. And in one of those factories mold spoiled so that it cracked across. Imagine: an assembly plant already staffed, they are ready to collect filters - give work, and there is no packages, the mold is cracked! Miraculously managed to fix it.
Drawings for that mold made then the designer of the old school, it is the old-fashioned drew them on paper. I must admit that the designer knew that designed, that the mold is considerably longer fulfilled its intended service life. We were still in Russian engineering traditions. Following mold bought in China, in Russia at that time it was quite bad with the manufacturers of molds, but are unhappy with the quality. A mold also need constant maintenance, so once all the prerequisites to, to organize their production tool.
The same story was with a cord and plug. We ordered a large batch of the Chinese, and those detained for three months delivery! Again, all production costs. "I had to buy cords wherever they may have held. Cord for our filters is critical, so the production of cord with a plug need to control themselves. First cords only made to fit your needs, and now the production has to fit your needs is not more than 15% of the total volume produced. Now we have the cord with different types of plugs and other processing all buy all manufacturers who make at least some equipment, which is powered from the mains. "
So, as Eugene admits the full cycle of production of filters in Russia - compulsory, although justified in the Russian context step. Want to get a quality product and stability - do it all himself. Now the production of a few hundred employees.
"Of course, it is easier to bring finished goods from China, the more we can and have extensive experience working with the Chinese. Now China is already doing very good equipment, we use it at home. They have a lot to learn. But when we come to our Chinese friends, they are also being taken away from us some idea of engineering. Yet we are important quality of our products manufactured and stability. It can only be obtained on its production ", - says Eugene. Here's more on the difference between the approaches to the production of first-hand. "We do not save where it can not be done accurately. We want to do well, not to be ashamed, first of all, to themselves. Our cords, unlike Chinese, contain copper and copper not coated with aluminum (aluminum fragile and of a material in soft cable cords used simply dangerous). self-extinguishing plastic housing only, components from trusted manufacturers. Power Cube products are constantly tested to confirm our certificates, we serve certified filter available commercially.
But Chinese goods seller sold it, and more of it is not responding. He can apply for certification of a quality product, and then to sell more expensive, which is guaranteed not to pass certification.