High Frequency Isolation Transformers are an important part of electronic equipment and are widely used in a variety of applications, including communications, industrial, and medical. However, due to the high power losses incurred in high-frequency applications, high-frequency transformers generate heat during operation, so heat dissipation and temperature management are critical to ensure the reliability and performance of the equipment.
The manufacturing process of high-frequency transformer
One of the key points of the manufacturing process of high-frequency transformers
Winding
A. DETERMINE THE PARAMETERS OF BOBBIN
B. All winding requirements are flat and do not overlap, as the principle
C. Single-group winding can be single-colour wire; double-group winding must be double-colour wire or open-wire immersion tin to divide the pins to avoid wrong winding
D. The cross-line must be isolated with tape
1. Wrap completely and evenly, unwinding
2. The tightly wound cable is even and tight
3. Keep a sufficient safety distance between both sides of the coil and the edge of the winding grooves A and B.
4. THE LENGTH OF THE SLEEVE MUST BE SUFFICIENT; ONE END EXTENDS INTO THE SAFETY TAPE OF THE WINDING PIPE, AND THE OTHER END EXTENDS OUT OF THE UPPER EDGE OF THE BOBBIN, BUT NOT CLOSE TO THE PIN
5. The outermost layer of tape is cut on the core assembly surface, and the cutting area must be covered by the core.
6. The edge of the tape is flush with the winding groove, and the tape is not skewed, folded, or damaged.
7. Tape should be attached under the crossing wire to keep the crossing wire insulated from the coil underneath.
The second key point of the manufacturing process of high-frequency transformer
Wrap the thread
A. VERTICAL BOBBIN
Thick wire: 1 coil of wire above 0.8φ
Fine wire: 0.2-0.8φ winding wire, 1.5 turns
Very fine wire: 2–3 coils of wire below 0.2φ
THE PRINCIPLE OF VERTICAL BOBBIN WINDING: THE WINDING WIRE SHOULD BE PRESSED TO THE END AS MUCH AS POSSIBLE TO NOT EXCEED THE CONVEX POINT.
B. horizontal BOBBIN: about 2–3 turns; do not press to the end of the winding, so as not to burn the BOBBIN when soldering. If there is a width limit and strict specifications are used in this way, the winding wire is pressed to the bottom after soldering, and then the PIN is trimmed in order to reduce the width of the entire transformer.
C. Horizontal (BOBBIN) winding method: about 2–3 times of thinning; do not press to the bottom to avoid burning BOBBIN during soldering.
Note: If the product has a width limit and the specifications are tight, the winding part must be cut short as a special case. At this time, the winding wire must be pressed to the bottom as much as possible.
The third key point of the manufacturing process of High frequency isolation transformers
casing
General casing position rules:
A. External: The shorter the distance between the end of the casing and the PIN, the better, but remember that the casing should never be wrapped around the PIN to cause air welding.
B. Interior: a Boundless wall fit, flat BOBBIN about 1/2L length
B has a side wall fit, and the casing must be on the file wall.
The width and material of the margin tape cannot be replaced arbitrarily because the width and material of the margin tape are related to safety regulations when designing the transformer, and special attention needs to be paid.
The width of the baffle tape: Generally, it needs to be the same height as the height of the winding to prevent the copper wire from stacking on the false wall during winding, but if it is difficult to install the core, it will sometimes wrap about 1/2–3/4 of the height, but the principle is that the winding is not stacked on the false wall.
Tips: Sometimes, due to the thickness of the inlet and outlet lines and the casing, if it will affect its thickness, you can use the practice of skipping the lead wire. At this time, pay special attention to the position of the casing, and there must be a sufficient safety distance (the width of the false wall).
This point must be deep into the false wall; sometimes, due to the large gap in the false wall or when the copper foil and M/F are wound together, there is no obvious judgment whether to penetrate into the false wall or M/T on the line, and the safety rod of the same width as M/T must be selected, and each one is measured.
The fourth key point of the manufacturing process of high-frequency transformer
The winding principle of copper sheet generally has the following methods:
A. A circle is not connected to the lead, the head and tail can not be short-circuited, and there is an insulating material between the head and tail
B. For a circle of leads, the width of the tape must be greater than the width of the copper sheet.
C. Two leads of copper sheets with more than one circle
D. Intermediate-drawn copper sheet, three leads
The fifth key point of the manufacturing process of high-frequency transformer
Cable management
1) Vertical cable management standard
A. thin line, thick wire need to be sorted more than one circle; the position of the line management is between the base and the boss, 2/3 of the height (insufficient to increase the number of coils)
The length of the B-wire head should not exceed half of the distance between the two adjacent feet, and the longest length should not exceed 1 mm.
In multiple sets of lines and winding the line, the thin wire is placed on the top layer and cannot be sorted out one strand after the other.
D. When there is a casing, the length of the casing is not less than the base
When the same groove is a different foot management line, the same direction and winding.
2) Horizontal cable management standard
A. The cable management is evenly distributed on the feet, and the end of the wire should be at least more than half of the wire feet (if it is insufficient, increase the number of coils to make up, but not more than the length of the wire legs)
B. The line is straightened from the root of the foot, spirals upwards, and is at least full of more than one circle.
The length of the C-wire head should not exceed half of the distance between the two adjacent feet, and the longest length should not exceed 1 mm.
D. multiple sets of lines and winding the line; the thin line is placed on the top layer and cannot be sorted out one strand after the other.
When the same groove is not the same foot and the foot is managed, the length of the sleeve is not lower than the base, not close to the PIN.
The sixth key point of the manufacturing process of high-frequency transformer
Solder
1) After soldering, the PIN foot is flat and smooth and does not stick to foreign matter.
2) The end of the thread is not higher than the bump.
3) AFTER SOLDERING, THE BOBBIN IS COMPLETE, AND THERE IS NO TOLERANCE AND A SHORT FEET.
4) Less residue of solder oil (flux), no tin, no short circuit.
5) The tape has no tolerance.
6) Solder at least one full turn.
7) There can be no transverse tin tip after soldering.
The seventh key point of the manufacturing process of high-frequency transformer
combination
1) The combined surface of the iron core is flat and has no skew.
2) BOBBIN, CORE, and the wiring pins should be kept clean and tidy, free of impurities and glue.
3) RECOGNIZE WHICH DIRECTION TO PLACE THE CORE WITH GAP.
4) The maximum skew of EE, EI, and UU cores should not be greater than 0.5 mm, or 1/10 of the width of the core.
Group Profile
Zhuhe Group is a comprehensive service provider of electronic technology and electronic products, providing customers with professional OEM/ODM services. The group's products and technologies are diversified, including semiconductor devices, pulse motors, high-frequency transformers, inductors, PCBA (printed circuit board assembly) & FPCA (flexible printed circuit assembly), and other products, which are the core components of various electronic products.
In recent years, through the integration and layout of the industrial chain, its products and technologies have been diversified, including semiconductor devices, pulse motors, high-frequency transformers Inductors, etc., mainly focusing on high-speed data transmission and communication, automotive electronics, medical electronics, industrial control products, energy-efficient power supply technology, and other fields.
Under the guidance of "taking scientific and technological innovation as the purpose and creating a safe, efficient, and portable backup power supply as the mission", the Group continues to improve its own strength and level while providing customers with advanced technology and products. The group attaches great importance to the construction and management of corporate culture, continuously promotes the learning and development of employees, improves the professional level and innovation ability of employees, and lays a solid foundation for the future development of the company.
Q: What are the application fields of high-frequency transformers?
A: High-frequency transformers are widely used in many fields, including radio communications, electronics, power converters, power control, computer monitors, medical equipment, sound and lighting systems, automotive equipment, aerospace technology, military applications, etc. They can effectively transfer power, reduce energy loss in circuits, and improve work efficiency.
Q: What is the working principle of a high-frequency transformer?
A: In a high-frequency transformer, when the AC power is input into the main winding of the transformer, a magnetic field will be formed in the winding, and then the power will be transmitted through the corresponding induction of the secondary winding of the transformer. Because the magnetic field is perpendicular to the secondary and primary side windings, the two windings are placed tightly together. This physical structure makes high-frequency transformers very efficient when it comes to energy transfer.
Q: What are the characteristics of high frequency isolation transformers?
A: High-frequency transformers perform better than traditional transformers in many aspects. They excel in terms of efficiency, voltage drop, output power, noise, and heat dispersion. High-frequency transformers can help optimize circuit parameters to operate more efficiently, which is valuable in industrial and commercial applications.
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