Another three Main points of the manufacturing process of high-frequency transformers

The third key point of the manufacturing process of high frequency transformer casing

General casing location rules:
A External: The shorter the distance between the end of the casing and the PIN, the better, but remember to never wrap the casing around the PIN, as this will cause air welding.

B Interior: a without side wall, flat to BOBBIN length of about 1/2LB has a side wall to match, and the casing must be inside the retaining wall.
The width and material of the margin tape cannot be changed at will, because its width and material are related to safety regulations and require special attention when designing the transformer.

The width of the wall 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. However, if it is difficult to install the core, it will sometimes cover about 1/2-3/4. height, but the principle is that the winding wires do not overlap on the false wall.

Tips: Sometimes due to thick entrance and exit wires and casing, if it will affect its thickness, you can use the method of skipping the lead wire. At this time, special attention should be paid to the position of the casing, and there must be a sufficient safe distance (deep into the width of the false wall) .

This point must go deep into the false wall. Sometimes because the gap in the false wall is large or when the copper foil and M/F are wound side by side, it is not obvious whether it goes deep into the false wall or when the M/T is on the line, the same width as the M/T must be used. Safety stick, each piece is measured.

The fourth key point in the manufacturing process of high-frequency transformers
The principles of winding copper sheets generally include the following methods:
A. There are no leads connected to one circle. The head and tail cannot be short-circuited. 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 More than one circle of copper and two leadsD middle extension type copper sheet, three leads Five key points in the manufacturing process of high-frequency transformers.

Cable management
1) Upright cable management standard
A Thin wires and thick wires need to be arranged in more than one circle, and the wire management position is between 2/3 of the height of the base and the boss (if insufficient, increase the number of wires)The length of the B thread head cannot exceed half of the distance between two adjacent feet and the longest length cannot exceed 1mm.C. Multiple groups of wires are wound together. The thin wires are placed on the top layer and do not finish one strand before arranging another.D If there is a casing, the length of the casing shall not be shorter than the base E When the wires are arranged in the same slot but on different feet, they should be wound in the same direction.
2) Horizontal cable management standards A. The threads should be evenly distributed on the feet, and the thread ends should exceed at least half of the thread legs (if the number is insufficient, increase the number of threads to make up for it, but it should not exceed the length of the thread legs at most) B. The thread starts from the base of the foot and spirals upward and at least completes one circle.
C The length of the thread should not exceed half the distance between two adjacent feet and the longest length should not exceed 1mm.
D. Multiple groups of wires are wound together. The thin wires are placed on the top layer and do not finish one wire and then another.
E When managing cables on different pins in the same slot, it is okay to wind them in the same direction and the length of the sleeve should not be lower than the base and not close to the PIN.