1. Material confirmation
Confirm the specification of 1. 1 spool.
1.2 When unused pins need to be cut, they should be cut before winding, so as to avoid scratching the wires or cutting the wrong feet when cutting after winding, and avoid winding the wrong feet.
1.3 Confirm that the spool is complete: there should be no damage and cracks.
1.4 Insert the bobbin into the fixture correctly. General special mark is 1 pin (oblique angle is 1). If not indicated in the figure, the 1 pin faces the machine.
1.5 If you need to wrap acetate fiber cloth, you should wrap it according to the requirements of the engineering drawing, and both sides of the bobbin are important. Then, before winding, the wire should be wound (or hooked) on the designated pin. In principle, the winding should be within the specified range.
2. Winding mode
According to the different requirements for transformers, winding modes can be roughly divided into the following categories.
2. 1 one-layer dense winding: wiring only occupies one layer, and there is no gap between tight wires. Neat winding.
2.2 Equal winding: winding at equal intervals within the winding range; The interval error is allowed within 20%
Collection.
2.3 Multi-layer dense winding: one layer of a winding cannot be completely wound, and it must be wound to the second or more layers. This winding method can be divided into three situations:
A. arbitrary winding: to a certain extent, it is neatly arranged. At the top floor, the wiring is messy and uneven, which is the roughest winding method.
B. Full-column dense winding: almost all wires are arranged neatly, but some wires are messy (about 30% of the total, and about 5% have fewer turns).
C. complete winding: winding to the top floor is not messy, and the winding is arranged neatly, which is the most difficult winding method.
2.4 Positioning winding: wiring is specified at a fixed position, which is generally divided into five situations.
2.5 Parallel winding: Two or more wires are wound in parallel on the same group of wires at the same time, and each wire is wound in parallel and cannot cross *. This winding method can be roughly divided into four situations.
3. Precautions:
3. 1 When the starting and ending access lines are located on the same side of the spool, cross tape shall be attached for isolation before ending the loop.
3.2 In principle, when the spool slot is used for incoming and outgoing lines, one line is outgoing from one slot. If there are multiple groups of the same pin, the same slot or adjacent slots can be used to lead out the wires, but attention should be paid to avoid short circuit during welding and sleeve installation.
3.3 The winding principle should be that the winding area of the bobbin is even and orderly, unless there are special provisions on the winding method on the engineering drawing, the drawing shall prevail.
3.4 If there are PTFE bushings and return lines in the transformer, the PTFE bushings added to the incoming and outgoing lines must be flush with the spool slot (or at least 2/3 high) and lead out from the spool slot to prevent the line from breaking due to the tensile force generated by the long bushing. However, in the case of winding the L pin horizontally, the sleeve should be flush with the spool side (or at least 2/3 long).
3.5 When acetate fiber cloth is required to be used as isolation belt in the transformer, the isolation belt must be tightened on both sides of the model. In order to avoid over-wrapping and high leakage of wires, it is required that the lap of acetate cloth over 2TS should not exceed 5mm, and a circle of wrapped acetate cloth only needs 0.9T, leaving a gap, which is convenient for vertical water to penetrate into the bottom layer well. The choice of width of acetate cloth is related to the requirements of transformer safety regulations. The VED winding method with ACT width of 3.2mm should be double-sided winding and tube winding. When the tip is 3mm/2.4mm/2.2mm/2mm, no tube is needed. When winding, the copper wire should not go up to the protective wall. If there is a sleeve, the sleeve must extend more than 3 mm into the retaining wall. .
4. Lead points:
4. 1 flying line
4. 1. 1 lead, the length and length shall be controlled according to the requirements of engineering drawings. If stranded wires are needed, the length should be reserved 10%.
4. 1.2 The casing shall be more than 3mm deep into the retaining wall.
2. Copper clad
1. copper foil winding method
1. 1 Types of copper foils and their functions in transformers;
According to the shape of copper foil, we can divide it into two types: the one with a layer of adhesive tape on the surface of copper foil is adhesive, and the other is bare copper; According to the position in the transformer, it can be divided into inner copper and outer copper. Bare copper is generally used as the outer copper of transformer. Copper foil generally plays a shielding role in transformers, mainly to reduce leakage inductance and excitation current, and acts as a conductor instead of copper wire when the current flowing through windings is too large.
Processing of 1.2 copper foil.
A. General processing method of inner copper foil: two ends of lead-welded copper foil are stuck in the center of acetate cloth, and the vinegar is turned back.
Cut off the acid cloth (the acid cloth must completely cover the solder joint) (there should be more than 1mm on both sides of the copper foil).
B. Processing method of inner copper Hong Fei:
C. external copper processing method:
2. Technical requirements for using copper foil in transformer:
A. The winding method of copper foil must flatten the winding edge of the outer copper foil except the solder joint. The winding edge should not be pressed on the corner of the bobbin, but should be wound from the center of the bobbin to prevent the second layer of copper foil and the first layer from forming a short circuit due to squeezing and puncturing the adhesive tape.
B. When shielding winding is arranged between layers, the width of inner copper sheet should cover the winding area of this layer as much as possible, and both ends can be rounded when the thickness is below 0.025mm( 1mil), but both ends of copper sheet with the thickness above 0.05mm(2mils) should be rounded.
C the copper foil must be wrapped straight and flat, not to one side or to the retaining wall.
D. welding external copper (e.g.
Note: 1. Solder joint of copper foil According to the engineering drawing, the copper foil must be tightly wrapped and not biased to one side.
2. The correct point of tin, solder joints must be smooth and without thorns. It takes too long to spot tin, so as not to burn the adhesive tape.
3. In practice, the thickness of short-circuit copper foil is 0.64mm, and the width of copper foil is only half of the width of copper window winding.
Step 3: Tape wrapping
1. Generally speaking, there are the following ways to wrap tape.
Note: the tape should be tightly wrapped, and it should not be turned up and punctured, and the copper wire should not be exposed. Don't wrap the outermost tape too tightly, so as not to affect the appearance of the product.
Step 4: Press your feet.
1. Foot pressing operation
1. 1 Straighten the copper wire and wind it around the corresponding feet.
1.2 presser foot: wrap the copper wire tightly with diagonal pliers and press it until the sole of the foot is close to the retaining wall.
1.3 Cut off redundant threads.
The number of turns of 1.4 depends on the number of wire diameters.
Note: the copper wire must be close to the foot, and the estimated height after welding should not exceed the pier point; Do not leave thread ends, presser feet, broken copper wires or damage the model.
1.5 twisted wire, too much copper wire.
1.60.8t winding standard.
Verb (abbreviation for verb) solder
1. Welding operation steps:
1. 1 Put the products in order.
1.2 clip a row of products.
1.3 ft belt flux;
1.4 Scrape the tin surface by hand.
1.5 Soldering: When the vertical die is used for tin plating, the feet are vertically inserted into the tin bath (when the horizontal die is inclined, the feet are inserted into the tin bath), and the tin plating depth is that the tin surface is flush with the bottom of the copper needle.
2. Complete confirmation.
2. 1 Tin plating shall be even and smooth, and there shall be no cold welding, package welding, missing welding, continuous welding, oxygen welding or tin block.
A. When the pin is an I-pin (vertical pin), the tin tip can be left, but the length of the tin tip is not more than1.5 mm..
B when the PIN is L-PIN (L-PIN) and the wire is wound in the horizontal direction, no tin tip can be left on the pin in the horizontal direction, but on the pin in the vertical direction, and the length of the tin tip shall not exceed1.5 mm. ..
C. The exposed part of C.PVC wire (multi-stranded wire) should be free of nicks and broken strands, and there should be no exposed copper, glue or other impurities (such as styrofoam) after welding.
D. neutral solvent is applied to flux.
E. The temperature of the tin furnace must be kept between 450℃ and 500℃, and the welding time varies with the wire diameter, as follows:
Above AWG#30 line (AWG#30, AWG # 3. ) 1 ~ 2 seconds.
American Wire Gauge # 2 1 ~ American Wire Gauge # 29 .............) 2 ~ 3 seconds.
C is lower than AWG # 20 line (such as AWG20, AWG19) for 3 ~ 5 seconds.
F for tin bars used in tin furnaces, the standard of tin-lead ratio is 60/40. New tin must be added once a month, which is about 1/3 tin furnace capacity.
G after each welding, the tin surface shall be scraped clean for the second time.
H. Clean the tin furnace once a week and add new tin until the tin furnace is full.
Note: 1. The white coating model contains a lot of tin oil, so the welding time should not be too long.
2. The plastic model is not resistant to high temperature, and it is easy to produce package welding or pin displacement.
3. Don't burn the tape.
4. The three-layer insulated wire must be peeled first and then tinned.
5. The minimum gap between solder joints must be greater than 0.5 mm.. (Figure 6. 19)
The assembly core of intransitive verbs
1. Iron core assembly work
1. 1 Core confirmation: deformation cannot be damaged.
1.2 The engineering drawing stipulates that there must be clearance grinding and core processing.
1.3 assembly: unless otherwise specified, the horizontal grounding core shall be installed at the primary end and the grounding pin end of the vertical type.
1.4 iron core can be fixed by iron clip or three-layer adhesive tape, and the joint of iron core can be fixed by epoxy adhesive. After coating, it must be dried in the shade for half an hour, and then baked in an oven at 120℃ for one hour. The iron core fixing belt shall be the same color as the wire package (unless there are special requirements in the drawing), and the manufacturer shall comply with UL specifications.
Note: winding and ending of core tape; Vertical winding starts from the center of the pin end and ends at the center; Horizontal winding starts at pin 1 and ends at pin 1. If copper is added, it starts from the welding point and ends at the welding point.
2. Matters needing attention in assembling iron core.
2. 1 When assembling cores, cores made of different materials cannot be assembled on the same product.
2.2 For transformers and inductors with air gaps, the air gaps must conform to the air gaps specified in the drawings, and the materials placed in the air gaps must be able to withstand the temperature above 130℃, and the materials are certified or the iron cores are processed and grounded.
2.3 No matter whether there is any gap in the iron core combination, the contact surface between the iron cores should be kept clean, otherwise the L value will be reduced after impregnation.
2.4 The width of the core tape should be specified, with physical appearance as the main factor, followed by the core width minus the bandwidth gap of about 0.3mm~0.7mm as the best.
This is the manufacturing process of high frequency electronic transformer. I don't know if you want high frequency. You can come to me if you need anything else.