-Acquisition
—— Confirmation of engineering drawings and work instructions
—— Primary side winding
-Primary side insulation
-secondary side winding
-Secondary side insulation
-Solder
-Grinding iron powder core
-Iron core assembly
-Processing copper foil
-semi-finished product test t 1- inductance value test
-Leakage inductance test
-DC resistance test
-Phase test
-Lap rate test
-High voltage insulation test
-Full vertical water treatment (vacuum impregnation)
-Dry in the shade
-Drying treatment
-Wrap the peripheral tape
-Foot care
-Foot cutting therapy
-Attach hazard labels and material number labels.
-Appearance treatment
-Electrical test of finished product T-Inductance value test
-Leakage inductance test
-Phase test
-Lap rate test
-High voltage insulation measurement
-Quality Assurance of Final Inspection Area-Dimensional Appearance Inspection
Electrical test
carve
-warehousing
2. Flow chart of low-frequency transformer production.
-Acquisition
—— Confirmation of engineering drawings and work instructions
—— Primary side winding
-Primary side insulation
-secondary side winding
-Secondary side insulation
-Lead assembly and welding
—— Fracture test of semi-finished products T 1
-Wireframe assembly and silicon steel sheet assembly
-silicon steel sheet was knocked flat.
-Assemble the iron belt
-T2 voltage test for semi-finished product test
Current test
High voltage insulation test
-Full vertical water treatment (vacuum impregnation)
-Dry in the shade
-Drying treatment
-Wrap the peripheral tape
-Foot care
-Foot cutting therapy
-Attach hazard labels and material number labels.
-Appearance treatment
-Electrical test of finished products T3 voltage test
Current test
High voltage insulation test
-Quality Assurance of Final Inspection Area-Dimensional Appearance Inspection
Electrical test
carve
-warehousing
3. Flow chart of CD production.
-Acquisition
—— Confirmation of engineering drawings and work instructions
-iron core processing
-Fixed iron core
-Winding
-Fixed
-On-line coil
-Brush every vertical water.
-Dry in the shade
-Cut the wire
-Stripping paint
-Upper shell and terminal
-Solder
-Appearance
-Label
-Packaging
-warehousing
4. Flow chart of adapter production.
-Acquisition
-Work instruction and confirmation of work instruction
-Plug-in
-Solder
-Cut your feet
-Repair welding
-welding DC wire
-cut the DC line.
-clean PCB board
-folding PCB board
-PCB board test T 1
Secondary welding of PCB
-Solder the primary to the AC pin.
-T2 electrical test of semi-finished products
-Assemble boxes
-Ultrasonic sealing
—— Electrical test of finished T3.
-paste the nameplate
-dimensional appearance inspection
-Packaging
-fqc test
-warehousing
5.t-core coil manufacturing flow chart.
-Acquisition
—— Confirmation of engineering drawings and work instructions
-Cut the line
-Hook the rope
-Upper base
-Foot press. Whole foot
-Solder
-semi-finished product test T 1
-Soaking treatment
-Dry in the shade
Baking treatment
-Cooling treatment
-Cut off your foot
-Appearance
-Finished product test T2
-Packaging
-fqc test
-warehousing
6.r core coil manufacturing flow chart.
-Acquisition
—— Confirmation of engineering drawings and work instructions
-Winding
-Solder
—— Upper iron core (point A.B glue)
-Baking glue
—— Casing (or soaking treatment)
-baking casing (or drying valium)
-Cut your feet
-Appearance
-test T 1
-Packaging
-fqc test
-warehousing
7. Manufacturing flow chart of magnetic core coil.
-Acquisition
—— Confirmation of engineering drawings and work instructions
-Winding
-Thread cutting and presser foot
-Solder
-Shell casings.
-Bake casing.
-Cut your feet
-Appearance
-test T 1
-Packaging
-fqc test
-warehousing
Verb (abbreviation of verb) engineering drawing
The contents of the engineering drawing include: circuit diagram, sectional view, iron core, bobbin, winding description, electrical test, appearance drawing and other descriptions.
I. Circuit diagram:
1. Symbol Description:
A. indicate the winding point
B indicates that the lead wire leads to the terminal of the spool.
C stands for leadless lead. F 1 is the prefix of English FLYING-LEAD, which means flying lead. We can call it a flying line.
D stands for iron core of transformer, with primary on the left and secondary on the right.
E. stands for copper foil
F. indicates the outer copper foil.
G. stands for shell
ⅵ. Construction method of transformer (A: high frequency)
I. Winding
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 it is necessary to wrap acetate fiber cloth, it should be wrapped according to the requirements of the engineering drawing, tightly attached to both sides of the spool, and then wound (or hooked) on the specified stitches before winding. 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. Wires are wound neatly (as shown in Figure 6. 1).
2.2 Equal winding: winding at equal intervals within the winding range; The interval error is allowed within 20%
Close. (Figure 6.2)
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 all wires, and about 5% of them 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: The wiring is designated at a fixed position, which is generally divided into five situations (as shown in Figure 6.3).
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 (as shown in Figure 6.4).
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). (as shown in figure 3)
3.5 When acetate cloth is required to be used as isolation belt in the transformer, the isolation belt must be close to both sides of the model. In order to avoid over-wrapping and high leakage, it is required that the overlap of acetate cloth over 2TS should not exceed 5mm, and a circle of wrapped acetate cloth only needs 0.9T, leaving a gap, so that the accumulated water can penetrate into the bottom layer well. The choice of acetate cloth width is related to the requirements of transformer safety regulations. VED winding method with effective width of 3.2 mm covers both sides, and conduits should be added. Winding mode: When the top end is 3mm/2.4mm/2.2mm/2mm, no tube is needed. When winding, the copper wire can't get on the retaining 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 penetrate into the retaining wall for more than 3mm (as shown in Figure 6.5).
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).
(as shown in figure 6.6)
B. Processing method of inner copper Hong Fei: (as shown in Figure 6.7)
C. External copper processing method: (as shown in Figure 6.8)
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. (as shown in figure 6.9)
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 (as shown in fig. 6. 10).
D. Welding external copper (as shown in Figure 6. 1 1).
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 packaging
1. Generally, there are the following ways to wrap adhesive tape (as shown in Figure 6. 12).
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 abuts against the retaining wall.
1.3 Cut off redundant threads.
1.4 The number of windings depends on the number of wire diameters (as shown in Figure 6. 14).
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 excessive copper stranded wire (as shown in figure 6. 15)
The winding standard of 1.6 0.8T is shown in Figure 6. 16.
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 model is tinned, the feet are vertically inserted into the tin bath (when the horizontal model is used, the feet are obliquely inserted into the tin bath), and the tin plating depth is that the tin surface is flush with the bottom of the copper feet (as shown in Figure 6. 17).
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 (as shown in Figure 6. 18).
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 bandwidth of iron-clad core shall be determined according to the physical appearance, followed by the iron core width minus the bandwidth gap of about 0.3 mm ~ 0.7 mm.
Seven. be immersed in sth
1. Operating steps: (as shown in Figure 6.2 1)
1. 1 Put the products neatly in the iron plate.
1.2 Adjust the still water concentration: 0.9 15 0.04.
1.3 put the iron plate with the product in the soaking tank.
Start the vacuum impregnator at 1.4, pump air to 40-50 cm/kg, put it into still water, and pump air to 65-75 cm/kg. Vacuum must be continuously pumped, vacuum must be broken for 3-5 times, and impregnation 10-
15 minutes, depending on whether the product has no bubble overflow.
1.5 deflate, put down the standing water, pump back 65-75Cm/Kg again, deflate, take out the product after a little drying, and put it on the filter screen to dry in the shade.
Drainage 1.6 exceeds 10 minute, depending on whether there is water dripping on the product.
1.7 drying: firstly, adjust the oven temperature to 80℃, preheat 1 hour, then adjust the temperature to 100℃ and bake for 2 hours.
Finally, adjust the temperature to 1 10℃ and bake for 4 hours.
Open the sample for confirmation.
1.8 Take the product out of the oven.
1.9 heat dissipation: use fan to supply air to accelerate heat dissipation.
1. 10 is delivered to the production line.
2. Precautions:
2. 1 The mixing ratio of still water and diluent is 2: 1.
2.2 When placing any accumulated water, the height of accumulated water shall be subject to completely submerging the product, but copper feet shall not be placed on the accumulated water (except special models).
8. Labeling (or printing)
1. Label confirmation: check whether the contents of the label are correct, whether there are any missing words or typos, and whether the handwriting is clear. Check whether the label
It's expired. When spraying words, it must be confirmed that the set label is completely correct (as shown in Figure 6.22).
2. When labeling, put the products neatly in the same direction. When painting, the products should be placed on the conveyor belt, and the painting should face the nozzle, and the products must be placed neatly.
3. Labels: Material labels and hazard labels shall be stamped or pasted in the direction specified in the drawings. Labels marked with "Danger", "High Voltage" and lightning symbols shall be attached to the center above the transformer. The pasting direction is the arrow direction towards the primary winding of the transformer. (as shown in figure 6.23)
4. Note: 1. The label must be pasted flat, and it must be pressed by hand after pasting to make it completely contact with the product.
2. Labels shall not be mislabeled, reversed, skewed or omitted.
Nine. appear
1. Operation steps
1. 1 Confirm whether the product is complete.
1. 1. 1 Whether the model is cracked or broken.
1. 1.2 Whether the iron core is damaged.
1. 1.3 Whether the adhesive tape is punctured.
1. 1.4 Whether the shell is damaged or too short.
1. 1.5 Did you cut the wrong foot position?
1.2 decontamination: strictly keep the transformer body clean, and improve the sense of product value.
1.2. 1 After soaking, there should be no residual glue around the transformer core (any standing solid), so as not to make the transformer unable to stick the PCB or label flat.
1.2.2 Remove copper slag and tin slag.
1.3 The horizontal iron core shall not be tilted after being immersed in still water (the coil shall not exceed the spool).
1.4 PCB board: transformer with bracket. When inserting the PCB, it is allowed to stick the PCB (bracket) at three points.
1.5 The iron core shall not be loose.
1.6 feet should be vertical and smooth, without looseness, fracture and nicks.
The pin of 1.7 should be adjusted, and there should be no bending deformation or exposed copper oxidation. The spacing shall be as specified in the drawing or the actual PC board, and the pin length of the spool shall be as specified in the drawing.
1.8 Check whether the solder is complete.
1.9 Check whether the label is correct, and whether there is any mislabeling, reverse labeling or missing labeling.
1. 10 Check whether the dot is clear, whether the position is correct, and whether there is any mistake, reversal or omission.
2. Preventive measures
2. 1 Defective products must be repaired, and they can only be scrapped if they cannot be repaired.
2.2 tape repair: if the coil is exposed due to the damage of the outermost tape, the damaged part must be completely covered with tape, and the number of tape layers must be the same as that of the original outermost tape, and it can only be dried after being coated with water. The first and second ends of the adhesive tape must extend into both sides of the core, and the length of the adhesive tape extending into both sides of the core shall not exceed the thickness of the core (the adhesive tape extends at least 2/3 of the thickness of the core).
X. electrical testing
1. Inductance test: Test the inductance of the main coil. When testing semi-finished products, the range of inductance value should be appropriately reduced.
2. Turn number test: Test the turn number, phase and inductance of the product.
3. high voltage test time