Factory Tour

How Active Harmonic Filter Static Var Generators are Made

A Deep Dive Into Elcosine Energia World-Class Manufacturing Process

Introduction

At Elcosine Energia , 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

Sensitive electronics are highly vulnerable to static electricity, which can cause hidden damage or immediate failure. That’s why electrostatic discharge (ESD) prevention is a cornerstone of our production process.

Our workshop floor is equipped with anti-static tiles that ground static charges from personnel, carts, and materials.
Every technician wears ESD wrist straps, connected via wires to deeply embedded grounding rods (2–3 meters underground). This ensures a complete discharge path for any static buildup.
A green indicator light constantly monitors the grounding system. If there’s any fault — whether in the wrist strap, ground wire, or rod — an alarm is immediately triggered.
Before entering the clean production area, all personnel pass through air shower systems and must wear anti-static clothing and footwear.
The workshop’s temperature and humidity are tightly controlled, as dry air can increase electrostatic buildup.

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 meticulously 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

As the only manufacturer in the power quality sector operating a Class 100,000 cleanroom, iKonMac sets a new benchmark for cleanliness and precision in production. This environment minimizes airborne particles, ensuring the highest quality during module assembly.

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 and cleanliness go hand in hand. Our automated production lines use advanced tools and robotics to ensure every weld, cable, and screw meets strict tolerances.

Robotic welding stations ensure uniformity and reduce human error.
Every cable is routed and terminated according to a strict wiring protocol, and all conductive elements are grounded to our electrostatic discharge pathway on the first floor.
Materials are transferred through pass-through windows — workers never enter the cleanroom with external materials. This minimizes dust, grease, or external contamination.

These production standards not only improve reliability but also extend the lifespan of our devices.

4. Testing & Quality Control:

We believe that world-class power quality solutions begin with uncompromising quality control. Our Seven-Stage Full Process Inspection framework ensures that every Active Harmonic Filter (AHF) and Static Var Generator (SVG) that leaves our facility performs with the reliability and precision our customers expect.

1Incoming 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.

2ICT Test (In-Circuit Test)

This stage verifies the electrical performance of the PCB and its individual components. Our ICT systems detect issues such as open circuits, shorts, and faulty solder joints at an early stage of assembly.

3FCT (Functional Circuit Test)

We simulate real working conditions to test whether the assembled circuits function properly. This step is critical to validate actual performance rather than just electrical integrity.

4Assembly Inspection

Our technicians perform manual visual inspections during assembly to ensure correct component placement, soldering accuracy, and overall workmanship. This hands-on quality control step prevents downstream defects.

5LV-HV Testing (Low & High Voltage)

Modules are tested at both low (30V) and high (400V) voltages to check for insulation integrity, leakage current, and reliable performance under operational stress.

6Aging Test

7Final Factory Test

Before packaging, every product is subjected to a final test under simulated field conditions. This confirms that the entire system — hardware and software — is ready for deployment and meets all technical parameters.

5. Protective Coating & Environmental Durability

Power quality products often work in industrial, high-dust, or humid environments. To ensure long-term operation, we apply protective conformal coatings to key components, preventing conductive dust or moisture from causing electrical failures.

IP Protection Rating Options:

IP20: For ventilated cabinet installations where airflow is essential
IP42 Electronic Layer (Customizable IP54 or IP65): For sealed environments requiring conductive dust and splash protection