China customized high frequency transformer factory

FKS CoilS specializes in the production of high frequency transformers, medium-frequency transformers, pulse transformers and other high-quality products. For high-frequency transformers, you can find FKS CoilS, an old brand, professional and trustworthy.

So what are the main process points for manufacturing high-frequency transformers?

Winding

A Determine the parameters of BOBBIN

B All windings are required to be flat and non-overlapping.

C A single set of winding wires can be single-color wires, and double-set winding wires must be divided into two-color wires or open wires soaked in tin to avoid wrong winding

D The crossing line must be isolated with tape

1. The winding is completely and evenly loosened

2. Dense winding and even tight wiring

3. Keep a sufficient safety distance A, B between both sides of the coil and the edge of the winding slot

4. The length of the casing must be sufficient, one end extends into the safety tape of the bobbin, 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 surface of the iron core assembly, and the cut must be covered by the iron core.

6. The edge of the tape is flush with the winding groove, and the tape is not skewed, folded back or damaged.

7. Adhesive tape should be pasted under the jumper wire to keep the jumper wire insulated from the bottom coil.

The second key point of manufacturing process of high frequency transformer

Tangled

A Vertical BOBBIN

Thick thread: above 0.8φ, wound 1 turn

Thin wire: 0.2-0.8φ winding 1.5 turns

Ultra-fine wire: 2-3 turns of winding wire below 0.2φ

The principle of vertical BOBBIN winding method: the principle is to press the winding wire to the bottom as much as possible so as not to exceed the convex point.

B Horizontal BOBBIN: about 2-3 turns, do not press the winding to the bottom, so as not to burn the BOBBIN when soldering, if there is a width limit and strict specifications, use this method, press the winding to the bottom and then solder, then trim the edge PIN, to reduce the width of the entire transformer.

C Horizontal type (horizontal type, BOBBIN's winding method: about 2-3 turns, loose winding, do not press to the bottom to avoid scalding BOBBIN during soldering.

Note: If the product has a width limit and the specifications are tight, it is a special case that the winding part must be cut short. At this time, the winding must be pressed to the bottom as much as possible.

The third key point of manufacturing process of high frequency transformer

Casing

General casing position rules:

A External: The shorter the distance between the end of the sleeve and the PIN, the better, but remember that the sleeve must not be wrapped around the PIN to cause empty welding.

B interior: fit with a borderless wall, flatten the length of BOBBIN about 1/2L

B is matched with the side wall, and the casing must be inside the retaining wall.

The width and material of the margin tape cannot be changed arbitrarily, because the width and material of the transformer are related to safety regulations and require special attention.

Width of retaining wall tape: Generally, it needs to be equal to the height of the winding winding to prevent the copper wire from stacking on the false wall during winding, but if it is difficult to install the core, sometimes it will wrap about 1/2-3/4 Height, but the principle is that the winding wires are not stacked on the false wall.

Tips: Sometimes due to the thickness of the incoming and outgoing lines and the bushing, if it will affect its thickness, the method of skipping the lead-out line can be used. At this time, special attention should be paid to the position of the bushing, and there must be a sufficient safety distance (depth into the width of the false wall) .

This point must go deep into the false wall. Sometimes because the gap of the false wall is large or when the copper foil and M/F are wound together, it is not obvious whether it is deep into the false wall or the M/T on the line must be selected with the same width as the M/T. Safety sticks, measure each.

The fourth key point of manufacturing process of high frequency transformer

Copper sheet winding principles generally have the following methods:

A circle is not connected to the lead wire, the head and the tail cannot be short-circuited, and there is insulating material between the head and the tail

B Connect the lead wire in one circle, the width of the tape must be greater than the width of the copper sheet,

C Two lead wires of copper sheet with more than one circle

D Copper sheet with extension type in the middle, three lead wires

The fifth key point of manufacturing process of high frequency transformer

Cable Management

1) Vertical cable management standard

A Thin wire and thick wire need to be arranged more than one circle, and the wire management position is between the base and the 2/3 height of the boss (if it is insufficient, increase the number of coils)

The length of the B thread end shall not exceed half of the distance between two adjacent feet and the longest shall not exceed 1mm.

C Multiple groups of wires are wound and arranged, and the thin wires are placed on the top layer, and it is not possible to arrange another strand after finishing one strand.

D If there is a casing, the length of the casing should not be lower than the base

E When the wires are arranged on different feet in the same groove, they should be wound in the same direction.

2) Horizontal cable management standard

A. The wires are evenly distributed on the feet, and the thread ends must exceed half of the wires at least (if it is insufficient, increase the number of wires to make up for it, but it should not exceed the length of the wires at most)

The B line starts from the heel and spirals upwards and at least completes a circle.

The length of the C thread should not exceed half of the distance between two adjacent feet and the longest should not exceed 1mm.

D Multiple groups of wires are wound and arranged, and the thin wires are placed on the top layer, and it is not possible to arrange another strand after finishing one strand.

E When the wires are arranged in the same groove and different pins, they can be wound in the same direction, and the length of the sleeve should not be lower than the base, and should not be close to the PIN. [2] 

The sixth key point of manufacturing process of high frequency transformer

Solder

1) After soldering, the PIN feet are smooth and free from foreign matter.

2) The thread head is not higher than the bump.

3) After soldering, the BOBBIN is complete, without damage and short legs.

4) Less solder oil (flux) residue, no tin staining, no short circuit.

5) The tape has no damage tolerance.

6) Solder at least one full circle.

7) There should be no horizontal tin tip after soldering.

The seventh key points of the manufacturing process of high-frequency transformers

combination

1) The combined surface of the iron core is flat and free of skew.

2) BOBBIN, CORE, and wiring pins should be kept clean and free from impurities and glue.

3) Recognize which direction the CORE with GAP is placed.

4) The maximum skew of EE, EI, UU type CORE should not be greater than 0.5mm or 1/10CORE width

Technical Parameters

Rated power: 1000/10000(KVA)

Efficiency (η): 97%

Voltage ratio: 400/220(V)

Appearance structure: vertical

Cooling method: natural cooling

Moisture-proof method: open

Number of windings: double winding

Core structure: heart type

Cooling form: dry

Core shape: R type

Number of power phases: single phase

Frequency characteristics: high frequency

Application range: special

Protective device

The high-frequency transformer microcomputer protection device is a high-tech power automation product that integrates protection, monitoring, control, communication and other functions. It is an ideal electrical unit that constitutes an intelligent high-frequency transformer.

Protector properties

Scope of application: mainly applicable to user projects such as 10KV;

Protection function: It integrates more than 20 kinds of protection functions, and is a general-purpose protection device with 0.5-level measurement accuracy;

Protection unit: line, main transformer backup, motor, capacitor, reactor, backup self-injection, PT, non-electricity;

Product appearance: 100mm ultra-thin body is especially suitable for cabinets such as ring network cabinets, and also suitable for central cabinets such as KYN28;

Product material: alloy shell, anti-electromagnetic interference test conforms to national standards;

Operation circuit: without anti-jump, can be used with various switches with anti-jump;

Communication: optional with or without RS485 communication interface