BEOK Thermostat Production Process – Precision Manufacturing from Start to Finish
Introduction:
At Beok Controls, every thermostat undergoes a meticulously designed 5-stage production process: Incoming Quality Control (IQC) → Core Component Processing → Assembly → Finished Product Testing → Packaging & Warehousing. From the moment raw materials arrive at our factory to the final packaged product ready for global shipment, quality is monitored and controlled at every single step. Below is a detailed look at our complete manufacturing workflow.
Stage 1: Incoming Quality Control (ICQ)
Before any component enters our production line, it must pass rigorous incoming inspection.
01
Material Receiving
02
Electronic Component Inspection
03
Structural Part Inspection
04
Qualified Warehousing
| Step | Operation Details | Inspection Standard |
| ① Material Receiving | Verify purchase orders, confirm material model, quantity, and batch number | Match BOM exactly |
| ② Electronic Component Inspection |
Resistors/capacitors/chips: verify specifications (resistance, capacitance, voltage rating); Sensors: test sensitivity (output signal at 25°C); PCBs: no warping, short circuits, or pad oxidation |
Component defect rate ≤0 |
| ③ Structural Part Inspection |
Enclosures (ABS material): no burrs, color difference, or deformation; Buttons: consistent rebound force; Screws: correct specifications, no thread damage |
Dimensional tolerance ±0.2mm |
| ④ Qualified Warehousing | Affix "PASS" labels to qualified materials; store separately (ESD area for electronics, moisture-proof area for structural parts) | FIFO (First-In-First-Out) |
Stage 2: Core Component Processing
This stage transforms raw PCBs and components into functional circuit board assemblies through SMT, DIP, and pre-assembly processes.
2.1 PCB SMT (Surface Mount Technology) Process
| Step | Operation Details | Standard/Control Point |
|---|---|---|
|
① PCB Pre-treatment |
Clean PCB surface of oil, dust, and oxidation layer | ESD dust removal equipment, alcohol wipe |
|
② Solder Paste Printing |
Position stencil, print solder paste onto PCB pads | Solder paste thickness: 0.15-0.2mm; no missing or bridging |
| ③ Component Placement | Use pick-and-place machine to precisely mount chips, resistors, capacitors, sensors, etc. onto pads |
Placement accuracy: ±0.05mm; no misalignment or missing components |
| ④ Reflow Soldering | Pass PCB through reflow oven following temperature profile: Pre-heat (80-120°C) → Soak (150-170°C) → Reflow (230-250°C) → Cooling | No cold joints, false soldering, or solder bridging |
| ⑤ SMT First-Article Inspection | Inspect first PCB with AOI; proceed to mass production only after approval | First-article sign-off; random sampling every hour thereafter |
| ⑥ Rework | Manually rework defective boards with soldering iron; touch up or replace components | ESD wrist strap required; re-inspect after rework |
| ⑦ QC Inspection | Passed boards go to ESD-safe storage | PCBA must be placed on ESD racks or in ESD bins |
2.2 DIP (Dual In-line Package) Soldering Process
| Step | Operation Details | Standard/Control Point |
|---|---|---|
| ① Through-Hole Preparation | Insert connectors, power interfaces, fuses, and other odd-form components into corresponding PCB holes | Correct component polarity; no reverse insertion |
| ② Wave Soldering | Pass PCB through wave soldering machine; solder wave wets component leads | Soldering temperature: 260±5°C; duration: 3-5 seconds |
| ③ Lead Trimming | Trim excess leads (leave 0.5-1mm); clean residual solder and flux from PCB surface | No lead scratches on PCB |
| ④ Solder Bridging Correction | Use soldering iron to separate bridged solder joints | Soldering iron temperature: 380°C |
| ⑤ Cleaning | Use brush with cleaning solution to clean PCB surface | No solder residue or water marks |
| ⑥ QC Inspection | 100% inspection; passed boards go to ESD-safe storage | PCBA on ESD racks or in ESD bins |
2.3 Panel PCB Pre-Processing
| Step | Operation Details | Standard/Control Point |
|---|---|---|
| ① Sensor Soldering | Solder temperature sensor (thermistor/NTC) to main control PCB | Soldering iron temperature: 260°C |
| ② Coin Cell Battery Soldering | Solder 3V coin cell battery; ensure correct polarity | No reverse polarity; soldering iron temperature: 260°C |
Stage 3: Assembly
3.1 Panel Assembly
| Step | Operation Details | Standard/Control Point |
|---|---|---|
| ① Display Module Installation | Solder LCD display and backlight to main control PCB | No solder bridging on LCD pins; soldering iron temperature: 260°C |
| ② Touch Conductive Sponge Installation | Attach touch conductive sponge to designated button frame on the upper board | Sponge must not be misaligned |
| ③ PCB Securing | Use electric screwdriver to secure main control PCB with screws into the bezel | Torque: 0.8-1.0 N·m; no stripped screws or damaged heads |
| ④ Firmware Programming | Use dedicated tool to flash specified firmware into the main control chip | Verify correct program per order requirements |
3.2 Power Base Laser Engraving
Laser Engraving
Confirm engraving content per order requirements; proceed after sample approval.
Standard: Verify correct content; clear and legible engraving.
3.3 Power Module Assembly
Install power supply into power base; secure with screws; attach isolation sponge.
Standard: Verify correct power type per order; torque: 0.8-1.0 N·m
3.4 Final Assembly
Step: Panel-Power Engagement
Operation Details: Insert power ribbon cable into panel header; snap front panel to power base; check gap uniformity.
Standard: Gap uniformity: ≤0.3mm; no looseness
Stage 4: Finished Product Testing
tSETING pROCESS
At BEOK, we place the utmost importance on product inspection and testing. Every single thermostat undergoes a comprehensive series of rigorous tests - from power-on functional testing to 24-hour aging and final quality control. Our commitment to 100% inspection, combined with advanced testing equipment and skilled quality engineers, ensures that only products meeting our strict standards leave the factory. This dedication results in an exceptionally low defect rate and guarantees reliable performance for our customers worldwide.
Power-On & Functional Testing
All functions are tested at 100%
Aging Testing
100% on High-Temperature Aging test
Final Quality Control (FQC)
All products are tested at 100%
4.1 Power-On & Functional Testing
| Test Item | Details | Standard/Control Point |
|---|---|---|
| Initial Power-On Test | Apply rated voltage (AC220V) via test fixture; check display illumination, dead pixels, touch sensitivity, buzzer clarity, and full-screen content | No short circuits or tripping; responsive touch; complete display; clear buzzer |
| Temperature Setting | Verify temperature setpoint range accuracy | Within specified range |
| Temperature Control Test | Simulate heating/cooling; verify thermostat activates/deactivates output at setpoint | Accurate switching |
| Mode Switching | Test Manual/Auto/Temporary modes for proper operation | All modes functional |
| Network Connectivity | Activate network function; verify APP connection and control | Stable connection |
| Fault Simulation | Simulate sensor open circuit; verify fault alarm function | Alarm triggers correctly |
| Appearance Inspection | Verify laser engraving meets order requirements; check for scratches | Clear engraving; no surface scratches |
4.2 Aging Testing
| Test Item | Details | Standard/Control Point |
|---|---|---|
| High-Temperature Aging | Place finished thermostats in aging room at 40°C; power on for 24 hours | No system crashes or reboots during aging |
| Low-Temperature Test | Power on for 2 hours at -10°C (sampling test) | Display functions normally at low temperature |
4.3 Final Quality Control (FQC) – 100% Inspection
| Test Item | Details | Standard/Control Point |
|---|---|---|
| Appearance Inspection | Visual check of enclosure, button printing - no scratches, stains, or deformation | Pass/Fail |
| Functional Retest | Repeat functional test steps; record data; generate inspection report | All functions pass |
| Hi-Pot Test | Apply AC 1500V for 3 seconds; no breakdown or leakage | Hi-Pot Tester |
| Pass/Fail Decision | Passed units get "QUALIFIED" label; failed units marked by defect type and sent to rework area | Clear labeling |
Stage 5: Packaging & Warehousing
1
Inner Packaging
Place finished product in ESD bag; include user manual, warranty card, and installation accessories (screws, expansion tubes)
2
Outer Packaging
Load into carton; affix shipping label (product model, quantity); seal with carton sealer; apply strapping
3
Warehouse Sampling
Warehouse conducts 5% random sampling inspection; verify quantity and model
Quality Is Built In, Not Inspected In.
At BEOK, quality control is not a single step - it is embedded throughout the entire production process. From IQC with a target component defect rate of ≤0.1%, to SMT placement accuracy of ±0.05mm, to 100% functional testing and 24-hour aging tests, every thermostat that leaves our factory has been verified at dozens of quality checkpoints. This commitment to quality is why BEOK thermostats are trusted in over 120 countries worldwide.
Our production process is the backbone of BEOK's reliability, and we are proud to share it with you. If you have any questions about our manufacturing steps, testing procedures, or would like to discuss a custom solution, we are here to help.
You are also welcome to schedule a factory tour to see our precision assembly lines and quality control systems in action. Reach out to our team – we look forward to partnering with you.
Our address
Head office: Room 301, Block A, No.5 Shenwang Road, Minhang District, Shanghai, China
Phone Number
(021)-33880317-808
shine.wang@beok-controls.com
Your Reliable HVAC Controls Manufacturing Partner
Benefit You Can Get By Partnering With Us
- Certified Quality
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- Professional R&D Team
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Get in Touch with BEOK Controls