--- Material receipt
--- Engineering drawings and operating instructions to confirm
- Secondary side winding
--- Secondary side insulation
--- Soldering
- Processing of copper foil
--- Semi-finished product testing T1 --- Inductance testing
--- DC resistance test
--- Phase test
--- Turn ratio test
--- High voltage insulation test
--- Van Leeuwen treatment (vacuum impregnation)
--- Cloud drying
- --- Oven drying
--- Wrapped with peripheral tape
--- Foot finishing
--- Sewing and drying --- Appearance treatment
--- Finished product electrical test T --- Inductance value test
- -Phase test
- -Turn ratio test
- -High voltage insulation test
- -High voltage insulation test
- -High voltage insulation test
- -The test is performed on the product. --- High Voltage Insulation Test
--- QA to Final Inspection Area --- Dimensional Appearance Inspection
Electrical Test
Packing
--- Inventory
2. Flow chart of low frequency transformer production.
--- Material requisition
--- Drawing confirmation and work instruction
--- Primary side winding
--- Electrical test
Crating
--- Packing
--- Storage
2. -- Primary side winding
--- Primary side insulation
--- Secondary side winding
--- Tape assembly
--- Semi-finished product test T2 Voltage test
Current Test
High Voltage Insulation Test
--- Van Leeuwen Treatment (Vacuum Immersion)
--- Drying Process
--- Foot cutting
--- Hazardous labeling
--- Dangerous labeling
--- Appearance treatment
----- Finished product electrical test T3 Voltage test
Amperage test
High Voltage Insulation Test--- QA to Final Inspection Area --- Dimensional Appearance Inspection
Electrical Test
Packing
- -- Inventory
3. Flowchart of disk production.
--- Material requisition
--- Drawing confirmation and work instructions
--- Core processing
--- Electrical testing
--- Electrical testing
--- Packing
--- Storage
3.
--- Fixing the core
---- Winding the wire
--- Fixing the core
---- Winding the wire
--- Drying
---- Cutting the wire
-- --- Stripping
-- ---- Stripping the wire
--- Appearance
--- Labeling
--- Packaging
--- Storage
4.ADAPTOR production flow chart.
--- Receiving materials
--- Work instructions and work instructions confirmation
-. --- Insertion
--- Soldering
--- Pin cutting
--- Cleaning the PCB
--- Folding the PCB
. - Assemble CASE
--- Ultrasonic sealing
--- Finished product electrical test T3
--- Paste the nameplate
---- Dimension and appearance check
--- Packing
--- Packing the product - Packing
--- FQC inspection
--- Inventory
5. T CORE Coil Production flow chart.
--- Material requisitioning
--- Drawing confirmation and work instruction
--- Cutting
--- Cutting
--- Packing
--- FQC inspection
---- Stocking
5.
--- Cutting thread
--- Hooking thread
--- Putting on the base
--- Pressing foot. p>--- Presser foot.
--- Dip treatment
--- Shade drying
--- Bake treatment --- Appearance
--- Finished product test T2
--- Packaging
--- FQC Inspection
--- Inventory
6. Flowchart of R CORE coil production. --- Coil wire
--- Soldering
--- Coating the iron core (point A.
-- FQC inspection
-- Inventory
7. DR CORE coil production flow chart.
--- Material Receiving
--- Drawing Confirmation and Work Instruction
- --- Winding
- --- Packing
--- FQC Inspection
--- Inventory
7.
--- Wire winding
--- Wire presser
--- Soldering
. - Cut Foot--- Appearance
--- Test T1
. --- Packaging
--- FQC Inspection
--- Inventorying
--- Packaging - Inventory
V. Engineering drawings
Engineering drawings include: wiring diagrams, sectional drawings, the use of CORE, BOBBIN, winding instructions, electrical testing, appearance and other instructions
I. Wiring diagram:
1. Symbol description:
A. Indicates the winding point
B. Indicates that the wire leads to the terminal of the bobbin.
C. It means that the wire is not connected to the PIN. F1 is the beginning of the English word FLYING-LEAD, which means flying out of the wire, we can call it flying wire.
D. represents the transformer core, the left side of the primary, the right side of the secondary,
E. represents the copper foil.
F. denotes outer copper foil
G. denotes bushing
VI. Transformer Production Methods (A: High Frequency)
I. Winding
1. Material Confirmation
1.1 BOBBIN specification confirmation.
1.2 If you don't need to cut the PIN, you should cut it off before winding to prevent scratching the WIRE or cutting the wrong foot after winding, and to avoid wrapping the wrong foot when winding.
1.3 Make sure your BOBBIN is intact: no tears or cracks.
1.4 Insert the BOBBIN into the fixture correctly, usually marked with a special pin 1 (PIN 1 at an oblique angle), or pin 1 towards the machine if it is not indicated on the drawing.
1.5 must be wrapped in acetate first according to the requirements of the project drawings wrapped, close to the sides of the BOBBIN, and then wrapped in the designated PIN first (or first hook line) after the start of winding, in principle, the winding should be in the specified range of the winding
2. Winding
According to the requirements of the transformer can be divided into the following ways of winding
2.1 A layer of dense winding: the wiring accounts for only one layer, tight line and no gap between the lines. Neat winding. (As shown in Figure 6.1)
2.2 equalization of winding: in the winding range at equal intervals for winding; interval error within 20% can be allowed
received. (Figure 6.2)
2.3 Multi-layer dense winding: in a winding of a layer can not be wound, must be wound to the second layer or more than two layers, this winding method is divided into three cases:
a. Arbitrary Winding: to a certain extent, neatly arranged, up to the top layer, the wiring has been chaotic, uneven conditions, this is the most cursory winding in the winding of the winding method .
b. Whole dense winding: almost all the wires are neatly arranged, but there are some dry wiring disorder (about 30% of the whole, the number of turns accounted for about 5% REF).
c. Completely dense winding: winding to the top layer is not messy, the wires are very neatly arranged, which is the most difficult winding method in the winding.
2.4 Positional Winding: The wires are designated in a fixed position, generally divided into five cases (as shown in Figure 6.3)
2.5 Parallel Winding: Two or more wires are wound parallel to the same group of wires at the same time, and they are wound parallel to each other and cannot be crossed. This winding method can be roughly divided into four cases: (Figure 6.4)
3. Note:
3.1 When the start winding (START) and the end (FINISH) in and out of the line on the same side of the BOBBIN, the end of the end of the line back to the end of the line before a piece of CROSSOVER TAPE (CROSSOVER TAPE) must be attached to the isolation.
3.2 When using the BOBBIN's notch out of the line, in principle, a line a notch way out of the line, if the same PIN has more than one group can be used in the same notch or adjacent to the notch out of the line, but in the soldering and installation of casing should be careful to avoid a short-circuit.
3.3 The principle of even and neat winding of the wire around the BOBBIN winding area, except for the engineering drawings have special provisions for the winding method, then the drawings shall prevail.
3.4 Transformer with Teflon sets and folded back to the line, its access to the line added to the Teflon casing and BOBBIN groove flush (or at least up to 2/3 high), and from the BOBBIN groove out of the line in order to prevent excessive length of the casing caused by the tensile force of the line will be ripped off. However, for L PIN horizontal winding, the sleeve should be flush with the BOBBIN side (or at least 2/3 of the length). (Fig. 3)
3.5 When the transformer has to be taped with acetate tape, the tape must be close to both sides of the model. In order to avoid the line package is too fat and the impact of leakage inductance is too high, it is required more than 2TS of the acetate overlap not more than 5mm, pack a circle of acetate only 0.9T, leaving a gap in order to facilitate the good penetration of Van Lee's water into the bottom layer. Acetate cloth width selection and transformer safety requirements, VED winding method ACT width 3.2mm package on both sides and must be added TUBE. winding method: PIN end 6mm/4.8mm/4.4mm/4mm; TOP end 3mm/2.4mm/2.2mm/2mm do not have to TUBE. winding of copper wires can not be on the wall of the stall, if there is a casing, the casing must be inserted into the wall of the stall 3mm. If there is a sleeve, the sleeve must extend into the wall 3mm or more.
4. Leads essentials:
4.1 Flying leads
4.1.1 Leads, length length control according to the requirements of the project program map, such as stranded, the length of the length must be more than 10% reserved.
4.1.2 Casing shall be deeper than 3mm into the retaining wall. (Figure 6.5)
II. Package copper foil
1. copper foil winding method
1.1 Types of copper foil and its role in the transformer;
We use the shape of the copper foil is divided into a bare copper backing two kinds of: the surface of the copper foil is covered with a layer of TAPE for the backing, and vice versa, for the bare copper; in the transformer is divided into different positions in the inner copper and outer copper. Bare copper is generally used in the transformer's outer copper. Copper foil in the transformer generally play a shielding role, mainly to reduce the leakage inductance, excitation current, in the winding through the current is too high, instead of copper wire, play the role of conductor.
1.2 Processing of copper foil.
A. Inside the copper foil general processing methods: welding lead copper foil ends flat on the center of the acetate cloth folded back to the acetate
Acid cloth (sound acid cloth must be completely covered with soldering points) cut sound acid cloth (copper foil must be left on both sides of the more than 1mm).
(As shown in Figure 6.6)
B. Inside the copper Faihong processing method: (As shown in Figure 6.7)
C. Outside the copper processing method: (As shown in Figure 6.8)
2. Transformer using copper foil in the process requirements:
a. Copper foil winding in addition to the soldering joints must be flattened outside of the copper foil winding edge should be avoided to avoid the pressure on the corner of the BOBBIN, must be from the center of the BOBBIN. BOBBIN the center of the winding to prevent the second layer of copper foil and the first layer of the first layer of the extrusion of the tape and the formation of a short circuit. (Figure 6.9)
b. Inside the copper foil in the layer for SHIELDING winding, its width should cover the winding area of the layer as much as possible, and the thickness of 0.025mm (1mil) can be exempted from chamfering the ends, but the thickness of the copper foil in 0.05mm (2mils) (including) the ends of the copper foil need to be chamfered way to deal with.
c. Copper foil must be wrapped properly and flat, not to the side, not on the wall. (As shown in Figure 6.10)
d. Weld the outer copper (as shown in Figure 6.11)
NOTE: 1. Copper foil welding point according to the engineering drawings, the copper foil should be tightened and wrapped flat, not to one side.
2. The right amount of tin, the solder joints must be smooth, not spiked. The soldering time should not be too long, so as not to burn the tape.
3. In practice, the thickness of the short-circuit copper foil can be 0.64mm, and the width of the copper foil only half of the width of the copper window winding
Three. Packing tape
1. Packing tape is generally available in the following ways. (Figure 6.12)
NOTE: The tape should be tightly wrapped flat, not turned up punctured, not exposed copper wire. The outermost tape should not be wrapped too tightly, so as not to affect the product aesthetic.
Four. Pressure foot
1. Pressure foot operation
1.1 Straighten and straighten the copper wire and wrap it around the corresponding foot.
1.2Pressing the foot: use diagonal pliers to tighten the copper wire and press it until the bottom of the foot is close to the wall.
1.3 Cut off the excess wire.
1.4 The number of coils depends on the number of wires. (Figure 6.14)
NOTE: The copper wire should be close to the root of the foot, and the height of the wire is not expected to exceed the pier point after soldering; do not leave any wire ends, do not hurt the foot, do not break the copper wire, and do not damage the model.
1.5 Too much copper wire can be twisted. (As shown in Figure 6.15)
1.6 0.8T wire wrapping standards as shown in Figure 6.16
V. Soldering
1. Soldering operation steps:
1.1 Place the products neatly.
1.2 Pick up a row of products with a clamp.
1.3 Dip your feet in the flux;
1.4 Scrape the surface of the tin with a white hand cupped.
1.5 soldering: vertical model tinned feet into the tin slot vertically (horizontal model will be tilted feet into the soldering slot), the depth of tin plating to the tin surface flush copper PIN bottom until. (As shown in Figure 6.17)
2.
2.1 Tin plating must be uniform and smooth, there can be no cold welding, soldering, leakage, continuous welding, oxygen welding or tin mass (Figure 6.18).
A. When the PIN pin is I PIN (Vertical PIN), the tip of the tin can be left, but the length of the tip should not exceed 1.5mm.
B. When the PIN pin is L PIN (L-type PIN) and the wire is wrapped in the horizontal direction, the pin in the horizontal direction should not be left with the tip of the tin, but the pin in the vertical direction should be left with the tip of the tin, and the length of the tip should not exceed 1.5mm.
C . The bare wire portion of PVC wire (multi-stranded wire) should not be scored or broken, and there should be no exposed copper or glue after soldering, or other impurities (such as Styrofoam). . ...)
D. Flux must be a neutral solvent.
E. The temperature of the soldering furnace must be maintained at 450℃～500℃, and the soldering time varies depending on the wire diameter, as follows:
a. AWG#30 above the wire (AWG#30, AWG#3.) 1～2 seconds.
b. AWG#21 to AWG#29 wire ......... .) 2 to 3 seconds.
c. AWG#20 wire or less (e.g. AWG20, AWG19) 3 to 5 seconds.
F. The standard tin/lead ratio for soldering furnace is 60/40. 1/3 of the volume of the furnace should be refilled with new tin once a month.
G. Every time you solder, the surface of the tin must be scraped clean before the second time.
H. Clean the furnace once a week and add new tin until the furnace is full.
NOTE: 1. The white package model contains a lot of tin oil, the soldering time should not be too long.
2. Plastic models are not resistant to high temperatures and are prone to cladding or PIN shifting.
3. Don't burn the tape.
4. Triple insulated wires must be stripped and then tinned.
5. The minimum gap between solder joints must be 0.5mm or more. (Figure 6.19)
VI. CORE ASSEMBLY
1. Core assembly
1.1 CORE confirmation: no breakage or deformation.
1.2 The engineering drawings stipulate that there must be a GAP of CORE grinding, CORE processing must be processed.
1.3 Assembly: If there is no special regulation, the horizontal model has been grounded core installed primary end, vertical model has been ground PIN end.
1.4 Iron core can be fixed iron clips (CLIP) or three layers of tape (TAPE)) way of fixing, and can be fixed in the core joints point EPOXY adhesive fixed, pointing adhesive after half an hour of drying and then placed in the 120 ℃ oven in the baking for one hour. The fixing tape of the iron core shall use the same color of the tape with the wire package (except for the special requirements of the drawing), and the manufacturer shall comply with the UL specifications.
NOTE: The core tape starts and ends at the center of the PIN end of the vertical winding and ends at the center; the horizontal winding starts at PIN 1 and ends at PIN 1. If there is a COPPER, it starts at the welding point and ends at the welding point.
2. Precautions for assembling CORE.
2.1 When assembling CORE, CORE made of different materials should not be assembled on the same product.
2.2 GAP transformers and inductors, the GAP method must be in accordance with the specified GAP, and the material in the GAP must be able to withstand temperatures of 130°C or higher, and there is a material proof or the core has been processed and ground.
2.3 Whether the core combination with GAP or without GAP, the contact surface between the core and the core must be kept clean, otherwise the L value will be decreased after immersion operation.
2.4 Iron core of the tape width regulations, to the physical appearance of the priority of the eye, followed by the core width minus the tape width gap of about 0.3mm ~ 0.7mm for the best.
VII. Containing immersion
1. Operation steps: (Figure 6.21)
1.1 will be neatly placed in the iron disk.
1.2 Adjust the concentration of Van Leeuwen: 0.915±0.04.
1.3 Put the iron plate with the products in the dip tank.
1.4Start the vacuum immersion machine, pumping to 40-50Cm/Kg, put into the Van Leeuwen, and then pumping to 65-75Cm/Kg, must be continuously pumping the vacuum, break the vacuum for 3-5 times, immersed in 10-
15 minutes, depending on the product without bubbles overflow.
1.5 Degassing, put down the Van Leeuwen, and then pumped to 65-75Cm/Kg once, degassing, to be slightly dry after the product is taken out and placed on the filter dry car dry.
1.6 Filter dry for more than 10 minutes, depending on the product without Van Leeuwen dripping.
1.7 Drying: First set the oven temperature to 80 ℃, preheat for 1 hour and then set the temperature to 100 ℃, bake for 2 hours
Finally set the temperature to 110 ℃, bake for 4 hours
Demolition of samples to confirm.
1.8 Remove the product from the oven.
1.9Cooling: accelerate the cooling by fan
1.10Plate the products and send them to the production line.
2. Note:
2.1 The ratio of Van Leeuwen and thinner is 2:1
2.2 When putting Van Leeuwen into the oven, the height of Van Leeuwen is subject to the product being completely submerged, but Van Leeuwen can't be put on the copper feet. (Except for special machines)
VIII. Labeling (or spray lettering)
1. Labeling confirmation: check whether the label content is correct, there is no omission of the wrong word, whether the handwriting is clear. Check whether the label is
expired. When spraying words, you must make sure that the set label is completely correct. (As shown in Figure 6.22)
2. When labeling, place the products neatly in the same direction. Inkjet should be placed on the conveyor belt with the print side of the product facing the nozzle, and the product must be placed correctly.
3. Labeling: Material number labels and hazardous labels should be stamped or glued according to the placement and direction specified in the drawing. Labeled "DANGER" "HIGH VOLTAGE" and lightning symbol label should be affixed to the transformer in the upper center position. The direction of the label should be in the direction of the arrow towards the primary winding of the transformer. (Figure 6.23)
4. Note: 1. The label must be affixed correctly and flatly, and after affixing it, it must be pressed by hand to make it contact with the product completely.
2. Labeling can not be wrong, paste the reverse, paste crooked or missed.
9. Appearance
1. Steps
1. 1 Make sure the product is complete.
1.1.1 The model is not cracked or disconnected.
1.1.2 Whether the iron core is broken.
1.1.3 Whether the tape is punctured.
1.1.4 If the sleeve is broken or too short.
1.1.5 Whether to cut the wrong foot
1. 2 Remove dirt: the transformer body is strictly kept clean to improve the sense of value of the product.
1.2.1 After immersion transformer core shall not be left around the residual glue (Van Leeuwen solid) so that the transformer can not be flat paste PCB, or stick labels can not be flat.
1.2.2 Remove copper slag tin slag.
1.3 Horizontal iron core can not have tilting phenomenon (wire package can not exceed the BOBBIN).
1.4 Combined PCB board: STAND-OFF transformer, inserted into the PCB allows three points (STAND-OFF) flat against the PCB can be.
1.5 Iron core must not be loose.
1.6 The foot must be vertical and smooth, not loose and broken phenomenon, and there can not be engraved marks.
1.7 PIN must be whole foot, no bending and deformation or oxidized copper exposure, PITCH is based on the drawing or the actual set of PC boards, the length of the PIN of the BOBBIN is based on the drawing.
1.8 Check whether the soldering is complete.
1.9 Check for proper labeling, mislabeling, backsplitting, or missing labels.
1.10 Check whether the dot is clear, the position is correct, there is no wrong hit, hit the reverse or omitted to hit.
2. Attention
2.1 Defective products must be repaired and can not be repaired before scrapping.
2.2 Tape Repair: If the outermost layer of tape is damaged and the coil is exposed, tape must be added to completely cover the damaged area, and the number of layers of tape must be the same as the number of layers of the original outermost layer of tape, and the tape must be coated with Vanillin and baked dry before use. The head and tail end of the additional tape must be extended into both sides of the core, and the length of the tape extended into both sides of the core is limited to not exceeding the thickness of the core. (Tape into at least 2/3 of the core thickness).
Ten. Electrical Test
1. Inductance Test: Test the inductance of the main coil. When testing semi-finished products, the inductance value range must be appropriately narrowed.
2. Turn Test: Test the number of turns, phase and inductance of the product.
3. High-voltage test