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From Production to Connection: ZION COMMUNICATION’s Keystone Jacks Quality Control

High-Quality Keystone Jacks From ZION COMMUNICATION

ZION COMMUNICATION not only upholds the philosophy of providing customers with high-quality keystone jacks but is also able to implement and enforce methods in its production & purchasing.

Quality Control System

1. ZION’S Keystone Jack list

UTP CAT5E keystone jacks

 

 

 

 

Include 90 degree ,180 degree,Toolless keystone jacks

FTP CAT5E keystone jacks
UTP CAT6 keystone jacks
FTP CAT6 keystone jacks
UTP CAT6A keystone jacks
FTP CAT6A keystone jacks

 

2. Refer Standards:

IEC 60603-7-1 standard

3. Construction of Keystone Jack:

Construction of Keystone Jack

4. IQC (Incoming quality control) of raw material:

4.1 All-in-one PCB circuit board:

In order to ensure the quality on the multi-in-one PCB circuit board of the KEYSTONE JACK, our company chooses high-quality materials used for PCB substrates, such as FR-4 (flame retardant 4) or other good electrical performance and size stability Appropriate materials. The PCB manufacturing process, including material treatment, manufacturing, welding and assembly strictly following the IPC (connected to the electronics industry) industry standards and guidelines. Make sure you are accurate on PCB, accurately place components to achieve correct electrical connection and minimize signal interference. Use the automatic assembly process to maintain consistent and reliable components. Reliable welding technology, such as reflux welding or wave welding, to achieve strong and consistent welding joints. Ensure appropriate welded adhesion applications, and use automated optical inspection (AOI) or X -ray inspection to detect and solve any welding defects.

4.2 IDC terminal blocks

In order to ensure the quality of the terminal block of the IDC (insulation displacement connector) in the keystone jack, our company chooses the durable and reliable plastic of the good electrical insulation characteristics as the high -quality material of the IDC terminal block. The recognized industry standards and guidelines for designing and manufacturing. These standards include the compatibility of the wires and the requirements of the performance requirements. Our IDC terminal block uses materials with appropriate conductivity and corrosion resistance. It has a carefully designed contact and can effectively pierce the insulating layer of the wire. Our terminal block is easy to install and efficiently installed, with sufficient tensile resistance, and the wire insertion point is compatible with different types of color codes of different wire types.

4.3 Thickened dust cover

In order to ensure that the dust cover in Keystone Jacks is good, our company chooses durable and flexible plastic or rubber compounds for high -quality materials for dust cover. These standards include specifications related to size, material characteristics, assembly and protection functions. We ensure that the design of the dust cover aims to firmly install it on the top of the Keystone Jack to effectively prevent dust, dirt and debris. Verify the size, shape, and characteristics of the dust cover are compatible with the models they expected.

5. Keystone jack's production process

The production process of Keystone Jacks involves several key steps:

Design and Engineering: The process begins with the design and engineering of the Keystone Jacks. This includes designing the physical dimensions, electrical specifications, and other features based on the intended application and industry standards.

 

Material Procurement: The required materials for Keystone Jacks, such as plastic housings, contacts, PCBs (Printed Circuit Boards), shielding components (if applicable), and other necessary parts, are procured from approved suppliers. The materials should meet the required quality standards and specifications.

 

Injection Molding: The plastic housing for the Keystone Jacks is typically produced through injection molding. This involves melting the plastic material and injecting it into a mold cavity to form the desired shape of the housing. The molding process ensures consistent and precise dimensions of the housing.

 

Contact Manufacturing: The electrical contacts, which provide connectivity between the Keystone Jack and the plug, are manufactured separately. These contacts may be stamped, formed, or machined from suitable materials like copper alloy or phosphor bronze. Surface treatment processes like gold plating or tin plating may be applied to enhance conductivity and corrosion resistance.

 

Assembly: The assembly of the Keystone Jacks involves inserting the contacts into the plastic housing and securing them in place. The PCBs, if applicable, are also mounted and soldered onto the contacts. Additional components like shielding, LEDs, or latch mechanisms are incorporated into the assembly as per the design requirements.

 

Quality Control: Throughout the production process, various quality control measures are implemented to ensure the Keystone Jacks meet the required standards. This includes visual inspections, dimensional checks, functional testing, and electrical performance testing. Any non-conformities or defects identified during quality control are addressed and resolved.

 

Packaging and Labeling: Once the Keystone Jacks pass the quality control checks, they are packaged and labeled appropriately. This includes placing the Keystone Jacks in suitable packaging materials, such as trays or blister packs, and affixing labels with product information, part numbers, and compliance markings.

 

Storage and Distribution: The finished Keystone Jacks are stored in a controlled environment to maintain their quality until they are ready for distribution. They are then distributed to customers, distributors, or assembly facilities for integration into network infrastructure systems.

Plastic Injection Molding Machine 2

Plastic Injection Molding Machine

Plastic injection molding machines are used to inject molten plastic into a mold to form the plastic shell of Keystone Jack

Metal Stamping Machine

Metal Stamping Machine

Metal die casting machines are used to manufacture metal parts in Keystone Jack, such as connecting pins, contact pieces, etc.

Automatic Assembly Equipment 1

Automatic Assembly Equipment

Automated assembly equipment is used to automate the assembly of Keystone Jack's components

6. IPQC(In-process quality control) of Keystone Jack

Our company will implement quality control measures for KEYSTONE JACKS during the manufacturing process to ensure that Keystone Jacks meets the required quality standards before entering the next production stage. The following is some of the key aspects of IPQC’s Keystone Jacks:

Visual Inspection: Conduct visual inspections at various stages of the manufacturing process to identify any visible defects or irregularities in the Keystone Jacks. This includes checking for proper alignment, cleanliness, labeling, and overall appearance.

 

Dimensional Check: Verify the dimensions of the Keystone Jacks, ensuring they adhere to the specified requirements. This can be done using measurement tools such as calipers, micrometers, or gauges to check critical dimensions such as length, width, height, and hole spacing.

 

Contact Testing: Test the electrical contacts of the Keystone Jacks to ensure proper connectivity and conductivity. This can be done using specialized test probes or equipment to check for continuity, resistance, and signal integrity.

 

Functionality Testing: Verify the functional performance of the Keystone Jacks. This can include testing the insertion and extraction forces of the connector, ensuring smooth and secure plug insertion and removal. Functionality testing may also involve verifying the latch mechanism, LED indicators (if present), and other features specific to the Keystone Jack model.

 

Interoperability Testing: Ensure that the Keystone Jacks are compatible with standard plugs or connectors. Test the connectivity and proper mating of the Keystone Jacks with compatible plugs to ensure reliable data transmission.

 

 

Insulation Resistance Testing: Perform insulation resistance tests to ensure that the Keystone Jacks maintain adequate electrical isolation between contacts and prevent leakage or short circuits.

 

Labeling and Marking Check: Verify that the Keystone Jacks are correctly labeled and marked with the required information, including part numbers, specifications, and compliance markings (such as CE, RoHS, etc.).

 

Documentation Review: Review and verify that all relevant manufacturing documentation, including work instructions, assembly drawings, and quality control records, are completed accurately and in compliance with the specified requirements.

 

Non-Conformance Handling: Implement processes to address any non-conformities or deviations identified during IPQC, including documenting the issues, investigating root causes, implementing corrective actions, and ensuring proper disposition of non-conforming products.

Physical Inspection Scope

Physical Inspection Scope

The physical visual inspection instrument is used to inspect the appearance of Keystone Jack

Return Loss Tester

Return Loss Tester

The reflection loss tester is used to measure the reflection loss at the Keystone Jack connection

High Frequency Tester

High-Frequency Tester

The high-frequency tester is used to test the transmission performance of Keystone Jack in the high-frequency range

Continuity Tester

Continuity Tester

The connectivity tester is used to check if Keystone Jack's connection is working.

Signal Tester

Signal Tester

The signal tester is used to evaluate the performance of Keystone Jack when transmitting signals

Strength Testing Equipment

Strength Testing Equipment

The strength tester is used to evaluate the housing strength of the Keystone Jack

7. Packing and Delivery For Fiber Optic Splice Closure

Packing of ,100 PCS/Inner box, Several Inner boxes /outer Carton (depending on the size of the product);

Several Cartons/Pallet.

Keystone Jacks Packing2​
Keystone Jacks packing​ 1

Here is the customized content we can do for your orders:

1.Printing on the carton

2.Label design 

3.Flexible quantities

4.Sample confirmation before order

8. Application of Keystone Jack

Keystone Jacks are widely used in various applications for establishing reliable and standardized connections in network infrastructure. Here are some common applications of Keystone Jacks:

 

Networking and Data Communication: Keystone Jacks are extensively used in structured cabling systems for networking and data communication. They are commonly used in Ethernet installations, including Cat5e, Cat6, Cat6a, and Cat7 networks. Keystone Jacks provide a modular and flexible solution for connecting Ethernet cables to wall outlets, patch panels, and network switches.

 

Telecommunications: Keystone Jacks find applications in telecommunications systems for voice and data transmission. They are used to establish connections in telephone systems, VoIP (Voice over Internet Protocol) systems, and other telecommunication infrastructures. Keystone Jacks provide a standardized interface for connecting telephone lines or other communication cables.

 

Audio and Video Distribution: Keystone Jacks are used in audio and video distribution systems, allowing for the transmission of audio and video signals. They are commonly used in multimedia rooms, home theater setups, and commercial AV installations. Keystone Jacks provide a convenient and organized way to connect audio and video cables, including HDMI, RCA, and speaker cables.

 

Security Systems: Keystone Jacks play a role in security system installations, particularly for connecting cameras, access control devices, and other security equipment. They provide a secure and standardized connection for transmitting data, power, and control signals in CCTV (Closed-Circuit Television) systems, access control systems, and security networks.

 

Home Automation: Keystone Jacks are used in home automation applications for connecting various smart home devices and systems. They enable the integration of devices such as smart switches, sensors, and control panels into a centralized home automation network. Keystone Jacks provide a convenient and modular solution for expanding and customizing smart home setups.

 

Industrial and Commercial Applications: Keystone Jacks find applications in industrial and commercial environments where reliable and standardized connections are required. They are used in control systems, factory automation, building management systems, and other industrial networking applications.

Applicable equipment
Michael Hsu

Michael Hsu

Hello, I'm Michael Hsu, a sales representative at Hello Signal. I specialize in Active Optical Components and Copper Cabling Infrastructure. I can recommend the most suitable products at competitive prices, ensuring worry-free service. Feel free to contact me with any questions.

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