In many electronic manufacturing facilities, anti-static products are widely used. However, despite these efforts, electrostatic damage still occurs frequently. This article explores the common issues in factory anti-static practices and how they can be improved.
One of the most common mistakes is the lack of anti-static testing equipment. Many companies purchase a lot of anti-static products but neglect to invest in basic testing tools. Over time, these products may degrade or become damaged, and without proper testing, their effectiveness cannot be confirmed. This leads to a false sense of security and fails to prevent static damage.
Another critical issue is poor grounding. A reliable and independent grounding system is essential for effective static control. The grounding resistance should typically be below 10Ω, and the installation must meet specific standards like GBJ97. It's important to avoid connecting the anti-static ground wire to the power supply neutral line or lightning protection system, as this can create dangerous loops. In three-phase five-wire systems, the ground wire can serve as an anti-static ground, but the neutral and ground lines must not be mixed.
The size of the grounding wires also matters. The main grounding line should have a cross-sectional area of at least 100mm², while branch lines should be no less than 6mm². Anti-static wrist straps and workbench grounding should use multi-strand plastic conductors with a minimum of 1.25mm². Yellow-green is the standard color for grounding wires. All connections should be properly soldered to ensure good conductivity.
Additionally, some companies treat anti-static products as regular items, assuming that if they look fine, they are still functional. For example, anti-static wristbands have a limited lifespan. Even if they appear undamaged, internal faults may exist, which can be detected through testing. Regular checks are essential to maintain their effectiveness.
Another overlooked factor is the use of socks and insoles. Anti-static shoes work best when paired with appropriate socks or insoles. If the feet are sweaty, the socks may generate static instead of dissipating it. In summer, it's recommended to wear anti-static slippers rather than regular shoes. In winter, cotton socks are preferred over nylon ones to reduce static buildup.
Some workers only wear anti-static shoes but skip the anti-static clothing. This is a mistake, as clothing—especially synthetic fabrics—can generate significant static electricity. Wearing anti-static overalls helps to minimize this risk.
Conversely, wearing anti-static clothing alone without proper footwear is also ineffective. Studies show that even with anti-static clothes, if the shoes are not grounded, the static charge cannot be properly discharged. Both clothing and footwear are necessary components of a complete anti-static system.
Some facilities fail to install anti-static floors or wrist straps, relying only on clothing and shoes. This is insufficient, as static electricity must be directed to the ground through either the floor or a wrist strap. Ideally, both should be present in well-equipped facilities.
Lastly, improper use of wrist straps is another common problem. Wrist straps can easily wear out, so daily testing is crucial. If a wrist strap is too loose, it won't make proper contact. Using a real-time monitoring system ensures continuous functionality. Unfortunately, many companies don’t even have a simple wrist strap tester, leading to ineffective static control.
In conclusion, effective static control requires more than just purchasing anti-static products. It involves proper testing, correct grounding, the right combination of clothing and footwear, and regular maintenance of all components. Only then can factories truly minimize the risk of electrostatic damage.
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