Research on real-time adaptive adjustment method for HSER stable manufacture and consistent quality

Hermetically sealed electromagnetic relays (HSER) are critical components within aerospace applications, particularly in power supply and communication systems, and thus have stringent reliability requirements. To enhance the quality consistency across different batches, there is a significant need for a production line that is capable of real-time adaptive adjustments. This paper analyzes the manufacturing process of a typical HSER model, identifying the initial pressure of the contact system as the primary control target using single-factor analysis. A dynamic model of the contact system is developed through virtual prototype simulation, and the Taguchi method is utilized to simulate the large-deviation data of the key process. Subsequently, a rapid calculation model is constructed using the Kriging method. A key parameter collection platform for the contact system is also established to enable the real-time acquisition of critical process data. Real-time adjustment strategies based on parameter design and tolerance design methods are provided to address three potential types of deviations in real-time Cpk. These strategies are implemented to analyze and adjust the production line, restoring the Cpk of the initial pressure from 0.60 under extreme conditions back to 1.33, thereby achieving quality stability. The effectiveness of these adjustment methods is thus validated.