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Plastic transformer skeleton product design and mold design and manufacture;
In this process, the detailed structure of the skeleton is generally designed according to the requirements of the customer (transformer manufacturer). At present, the skeleton is mostly designed for the customer, and the skeleton manufacturer directly opens the mold according to the designed skeleton. However, there are a few cases where customers provide samples or simple design drawings, and skeleton manufacturers cooperate to complete the preliminary design work. When designing the skeleton, the following details should be paid attention to in order to reduce some defects that often occur in production.
(1) in the early stage of skeleton design, designers need to know clearly the usage of skeleton in customers. Including the customer's transformer finished product requirements, such as overall dimensions; Transformer production process and production conditions of each process, such as soldering temperature, soldering time, baking temperature, winding mode, etc.; Model and size of magnetic core matched with the skeleton. In a word, it is necessary to know clearly the matters needing attention when using the skeleton in the client, so as to better carry out the next design work.
② When designing the skeleton structure, the model should be designed in 3D as far as possible according to the drawings or samples provided by customers and their own design experience, so as to avoid the defects of 2D drawing and modification, and then be modified step by step, and finally finalized. If the customer's design is unreasonable, he should take the initiative to reconfirm the skeleton structure with the customer's technical personnel. When designing the skeleton, attention should be paid to the following aspects:
A raw materials must conform to the customer's process and requirements, and skeleton design must be carried out according to the characteristics of materials. Generally refer to Huang Ka for confirmation of skeleton wall thickness; At the same time, refer to the temperature shown in Huang Ka and compare it with the baking and soldering temperature of the customer's process to see if it meets the customer's process conditions. For example, the RTIElec temperature of GE's N300X raw material is 105℃, and the baking temperature of customers is 130℃. Obviously, this raw material does not meet the technological conditions of customers.
B metal pins, which can pass through the PCB board of the client smoothly or horizontally, generally use more iron (steel) pins. When customers have special requirements for better conductivity of pins, copper and other materials with better conductivity should be considered.
C at present, RoHS, halogen-free, SVHC and other environmental protection requirements are becoming more and more urgent, and these requirements should be met while selecting materials.
D The model requirements of transformer should be met, and the overall dimensions should be smaller than the finished transformer dimensions.
E core hole needs to match the size of the core column, which is generally larger than the upper limit tolerance of the core; The blade of fixed magnetic core is generally smaller than the lower tolerance of inner diameter of magnetic core. The purpose of this design is to facilitate the subsequent wear and repair. In order to meet the customer's proper tightness requirements in the automatic winding operation (loose matching will cause the skeleton to fall off in the winding process, while tight matching will make it difficult for the operator to insert or pull out), the matching tolerance between the core hole and the winding jig should be controlled at about 0.05.
F The trough is the turning path of copper wire. Meanwhile, in order to avoid abnormal situations such as breakage, pin crack and sand inclusion in production, the width of the trough should be considered finally: the diameter of copper wire, the wall thickness of pinhole edge and the size of rough edge sand. Under normal circumstances, the wire slot is suitable to be enlarged, which can avoid sand inclusion and facilitate customers to pass through copper wires. However, after the wire slot is enlarged, the wall thickness of the remaining pinhole edge will be smaller, and the pin is prone to crack during pin production.
G the pinhole should not be too deep, and the wall thickness at the bottom of the pinhole should be more than 0.5mm, so as to avoid the defect of inserting cracks or holes when inserting pins.
The transition of R angle is needed for H, which can not only increase the strength to prevent damage, but also improve some problems in production. Especially the edge of the wire slot, can prevent the insulating paint coating on the outer layer of copper wire from being scratched; The edge of the core hole can facilitate the insertion of the magnetic core; The strength of blades can be increased around the bobbin.
I need to design the anti-reverse structure of the pin, and the bump effect is the best, so that the groove can be added in the direction corresponding to the runway to correspond to the bump, thus avoiding the wrong foot position caused by the product placement.