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2020

Detailed explanation of the mistakes easy to make in the production of high frequency transformer

The quality problem in the production of high-frequency transformer is also a mistake easy to make in the production of high-frequency transformer. Transformer is a device to change the AC voltage, current and impedance. When there is AC current in the primary coil, the AC magnetic flux will be generated in the iron core (or core), making the voltage (or current) induced in the secondary coil. The production process of high frequency transformer is generally divided into several parts: winding, soldering, assembly, immersion and testing. Common mistakes are as follows.

What are the mistakes easy to make in the manufacturing process of high frequency transformer?

1. Assembly of magnetic core causes breakdown of winding to iron core and shield

To assemble a transformer is to install the required winding coil onto a magnetic core or iron core. It seems simple, but in fact, when the wire is full, the magnetic core is most likely to break the outer tape, leading to the bare enameled wire or touching the magnetic core. When the transformer is electrified and withstand voltage, it will cause the winding to break through the iron core and shield.

2. The unevenness of immersion affects the insulation strength and is fixed

Due to the lack of permeability, ordinary immersion will affect the insulation strength and fixation of high-frequency transformer. The transformer will have noise and loose magnetic core, which will seriously affect the quality of high-frequency transformer. Vacuum impregnation can effectively improve the permeability of insulating paint and increase the filling rate, thus improving the overall mechanical strength, insulation strength, moisture-proof and mildew proof properties of electrical coils.

3. The wrong wire leads to the increase of resistance and heating of transformer

The main wire of high-frequency transformer is polyester enameled wire and three-layer insulated wire. If the requirements are very high (such as power switch transformer), three-layer insulated wire is used. If the requirements are general, polyurethane products have no problem! Some specifications have the same wire diameter, flesh eye can not be identified, and calipers and other measuring instruments are required. In the process of issuing, it is easy to get the wrong wire diameter. If the wire diameter is thin, it will increase the resistance of the transformer and generate heat. If the wire diameter is thick, it will make the proportion of the winding too large, which will increase the overall size of the wire package. Because of the limited window of the magnetic core, it will be difficult to assemble the magnetic core.

4. Short circuit caused by too deep solder

If the temperature of the tin furnace is too low, the products are easy to be welded, and the pins are not bright. When the temperature is high, the soldering time shall be controlled well, and the phenomenon of too deep soldering tin is not allowed. Because of the high temperature, too deep soldering tin may melt the insulating tape, resulting in short circuit. If the flux is well prepared, the welding aid can achieve twice the result with half the effort.

5. The test conditions are wrong and the test results are invalid

Generally, the test items of high frequency transformer are turn ratio, inductance, withstand voltage, leakage inductance, etc. Testing is to actively deal with and prevent, so as to avoid the appearance of defective products when the finished products are sent to the client for testing. Testing is also the key to ensure the quality of high-frequency transformer, so the operators need to be careful and familiar with the debugging of testing instruments.