High-frequency transformer manufacturing process and working principle
High-frequency transformer manufacturing process and working principle
High frequency transformer
The high-frequency transformer is a power transformer with a working frequency exceeding the intermediate frequency (10 kHz). It is mainly used for high-frequency switching power supply transformers in high-frequency switching power supplies, and also for high-frequency inverters in high-frequency inverter power supplies and high-frequency inverter welding machines. Variable power transformer. According to the working frequency, it can be divided into several grades: 10kHz- 50kHz, 50kHz-100kHz, 100kHz-500kHz, 500kHz~1MHz, 10MHz or more.
High frequency transformer working principle
A transformer is a device that converts alternating voltage, current, and impedance. When an alternating current is passed through the primary coil, an alternating magnetic flux is generated in the core (or core) to induce a voltage (or current) in the secondary coil.
The transformer consists of a core (or core) and a coil. The coil has two or more windings. The winding connected to the power supply is called the primary coil, and the other winding is called the secondary coil.
High frequency transformer manufacturing process
One of the main points of the manufacturing process of high frequency transformer
A Determine the parameters of BOBBIN
B All winding requirements are flat and do not overlap as a principle
C Single-group winding can be a monochromatic line, and two-group winding must be dip-lined with a two-color line or an open line to avoid misalignment.
D cross-line must be taped
1. The dredging is completely evenly separated
2. The tight winding wire is evenly close
3. Maintain a sufficient safety distance between the two sides of the coil and the edge of the winding groove A, B
4. The length of the casing must be sufficient. One end extends into the safety tape of the bobbin and the other end extends out of the BOBBIN, but not near the PIN.
5. The outermost tape is cut on the core combination face, and the cut must be covered by the core.
6. The edge of the tape is flush with the winding groove, the tape is not skewed, and it is not broken and not damaged.
7. Tape must be applied under the line to keep the crossing line insulated from the bottom coil. 
The main point of the manufacturing process of high frequency transformer
A vertical BOBBIN
Thick line: entangled line above 0.8φ
Thin line: 0.2-0.8φ entangled 1.5 laps
Very thin line: 2-3 turns of winding line below 0.2φ
The principle of vertical BOBBIN winding method: the winding line is pressed as far as possible to the principle of not exceeding the bump.
B Horizontal BOBBIN: about 2-3 turns, do not press the bottom to avoid scalding BOBBIN when soldering. If there is a width limit and the specifications are strict, use this method to compress the wire and then cut the PIN. To reduce the width of the entire transformer.
C Horizontal (horizontal, BOBBIN's winding method: about 2-3 turns around, do not press the bottom to avoid burning BOBBIN when soldering.
Note: If the product has a width limit and the specification must be short-cut when the wire is cut short, the winding wire must be pressed as far as possible. 
The main points of the manufacturing process of high frequency transformer
General rule of position of the casing:
A External: The shorter the distance between the end of the sleeve and the PIN, the better, but remember that it is absolutely impossible to wrap the sleeve around the PIN, which will cause an empty weld.
B Interior: a side wall fit, flat BOBBIN about 1/2L length
B has a side wall fit, and the casing must be inside the retaining wall.
The width and material of the margin tape cannot be changed arbitrarily, because the width and material of the transformer are specially designed to involve safety.
The width of the wall tape: generally needs to be equal to the height of the winding winding to prevent the copper wire from being stacked on the false wall when winding, but if it is difficult to install the core, it will sometimes be about 1/2-3/4. Height, but the principle of winding is not stacked on the false wall.
Tip: Sometimes it is possible to skip the lead wire if the thickness of the access line is thick and there is a casing. In this case, pay special attention to the position of the casing, and there must be a sufficient safety distance (depth into the width of the false wall). .
This point must be deep into the false wall. Sometimes, when the false wall gap is large or when the copper foil and the M/F are wound together, there is no obvious difference whether it is the same width as the M/T when it is deep into the false wall or the line M/T. Safety bars, each measuring. 
The fourth point of the manufacturing process of high frequency transformer
The principle of winding copper sheets generally has the following methods:
A does not connect the lead in one turn, the head and tail are not short-circuited, and there is insulation material between the head and the tail.
B One turn of the lead, the width of the tape must be greater than the width of the copper.
C one lead or more copper sheet two leads
D Middle extraction type copper piece, three lead wires 
Five points of the manufacturing process of high-frequency transformer
1) Upright cable management standard
A thin line, thick line should be more than one circle, the position of the line is between 2/3 of the base and the boss (the number of coils is increased)
The length of the B-line head shall not exceed half of the distance between the adjacent two legs and the longest shall not exceed 1 mm.
C sets more lines and lines around, the thin line is placed on the top layer and it is unreasonable to complete another one.
D If there is a casing, the length of the casing is not lower than the base
When E is different from the groove, it will go in the same direction.
2) Horizontal cable management standard
The A line is evenly distributed on the foot, and the line should be at least half of the line. (Insufficient increase the number of stitches, but not more than the length of the line)
The B line is spiraled up from the root of the foot and at least one circle is completed.
The length of the C-line head shall not exceed half of the distance between the adjacent two legs and the longest shall not exceed 1 mm.
D sets a number of lines and wraps around the line, the thin line is placed on the top layer and it is unreasonable to complete another one.
When the E is different from the groove in the same line, the same direction can be wound and the length of the sleeve is not lower than the base, not close to the PIN. 
The main points of the manufacturing process of high-frequency transformers
1) After soldering, the PIN foot is smooth and free from foreign matter.
2) The thread is not higher than the bump.
3) BOBBIN is complete after soldering, no damage and short legs.
4) Solder oil (flux) has little residue, no tin, no short circuit.
5) The tape is not damaged.
6) Solder soldering at least one turn.
7) There should be no transverse tin tips after soldering. 
Seven points of the manufacturing process of high-frequency transformers
1) The iron core combination surface is flat and has no skew.
2) BOBBIN, CORE, the wiring legs are kept clean and tidy, without impurities and glue.
3) Identify which direction the GAE CORE is placed in.
4) EE, EI, UU type CORE maximum skew can not be greater than 0.5mm or 1/10CORE width.