High frequency transformer production common sense

2019-05-31 11:52:58 JUKE CHINA ODM OEM Transformer factory Read

High frequency transformer production common sense

The quality problems in the production of high-frequency transformers are also the mistakes made in the production of high-frequency transformers. The transformer is a device that converts AC voltage, current and impedance. When an AC current is passed through the primary coil, the core (or core) is in the core. An alternating magnetic flux is generated to induce a voltage (or current) in the secondary coil. The production process of high-frequency transformers is generally divided into two parts: winding, soldering, assembly, impregnation, and testing. There are several common mistakes that are easy to make.
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1. The wire is used incorrectly, which causes the resistance of the transformer to increase and heat.

The main wire of high-frequency transformer is polyester enameled wire and three-layer insulated wire. If it is very demanding (such as power switch transformer), use three layers of insulated wire. If it is required, polyurethane products are no problem! Some specifications have similar wire diameters and are unrecognizable to the naked eye. Measurement instruments such as calipers are required. It is easy to mistake the wire diameter during the feeding process. If the wire diameter is thin, the resistance of the transformer will increase and the heat will be generated. If the wire diameter is too large, the winding ratio will be too large, so that the wire package will become larger as a whole, and the core will be limited due to the limited core window. It is difficult to assemble.

2. The solder is too deep to cause a short circuit

If the temperature of the tin furnace is too low, the product is easy to be welded, the stitches are not bright, and the soldering time should be controlled when the temperature is high. There should be no too deep soldering. Due to the high temperature, the solder may be too deep to melt the insulating tape and cause a short circuit. The flux can be adjusted with half the effort.

3. Assemble the core to cause the winding to penetrate the core and shield

Assembling the transformer is to install the core or core with the coil wound as required. Seemingly simple, in fact, when the line package is full, the core is the easiest to break through the outer tape, causing the enameled wire to bare or touch the core. When the transformer is energized, the winding is on the core and the shield is broken.

4. Impregnation unevenness affects the insulation strength and is fixed

Ordinary impregnation due to insufficient penetration will affect the dielectric strength of high-frequency transformers, fixed, transformers will appear noise and loose core, seriously affecting the quality of high-frequency transformers. Vacuum impregnation can effectively improve the penetration ability of the insulating varnish and increase the filling rate, thereby improving the overall mechanical strength, insulation strength, moisture resistance and mildew resistance of the electrical coil.

5. Test conditions are incorrect and test invalid results

High frequency transformers generally require test items such as turns ratio, inductance, withstand voltage, and leakage inductance. The test is to take the initiative to deal with and prevent, so that the defective product still appears when the finished product is sent to the client for testing. Testing is also the key to ensuring the quality of high-frequency transformers, so operators need to be careful and familiar with the commissioning of test instruments.