CN115792470A - High-frequency transformer testing method and system - Google Patents
High-frequency transformer testing method and system Download PDFInfo
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Abstract
The application relates to a high-frequency transformer testing method and a system, wherein the method comprises the following steps: carrying out semi-finished product test on the assembled semi-finished product of the high-frequency transformer, and carrying out plate arrangement, insulating paint coating, voltage withstanding test and finished product test on the semi-finished product of the high-frequency transformer passing the semi-finished product test, wherein the semi-finished product of the high-frequency transformer passing the finished product test is a finished product of the high-frequency transformer; and printing characters and arranging boards, carrying out interlayer test, carrying out lead wire voltage withstand test, and carrying out external inspection and pin combination on the high-frequency transformer finished product as required. The method and the device have the advantages that the high-frequency transformer is tested completely in quality and withstand voltage degree from a semi-finished product to a finished product, and the influence of the electromagnetic compatibility of the high-frequency transformer on the product quality is reduced.
Description
Technical Field
The application relates to the field of power transmission equipment, in particular to a high-frequency transformer testing method and system.
Background
With the development of the fast charging technology, the requirements on the power parameters of the switching power supply are higher and higher, so that the design structure of the transformer is more and more complex. Particularly, for a high-frequency transformer of a high-frequency power supply, the winding structure of the high-frequency transformer is complex, the number of machining procedures is large, and part of the procedures are finished manually. Factors such as flatness of an enameled wire in a high-frequency transformer winding, fullness of a wire slot, and deviation have a large influence on radiation interference (RE) characteristics in electromagnetic compatibility (EMC), and the factors are artificial and unavoidable, so that the product quality of the high-frequency transformer is influenced to a certain extent, and the quality of the high-frequency transformer needs to be tested in order to reduce the influence of the electromagnetic compatibility of the high-frequency transformer on the product quality of the transformer.
Disclosure of Invention
In order to test the quality of the transformer, the application provides a high-frequency transformer test method and a high-frequency transformer test system.
The high-frequency transformer testing method and system provided by the application adopt the following technical scheme:
a high-frequency transformer testing method comprises the following steps:
carrying out semi-finished product test on the assembled semi-finished product of the high-frequency transformer, and arranging plates on the semi-finished product of the high-frequency transformer passing the semi-finished product test, wherein both a winding and a magnetic core on the semi-finished product of the high-frequency transformer are loaded;
coating insulating paint on the high-frequency transformer semi-finished product finished by the plate arrangement;
after the insulating paint is coated, carrying out a voltage withstand test on the semi-finished product of the high-frequency transformer;
carrying out finished product test on the high-frequency transformer semi-finished product which passes the voltage withstanding test, wherein the high-frequency transformer semi-finished product which passes the finished product test is a high-frequency transformer finished product;
printing characters and arranging plates on the high-frequency transformer finished product passing the finished product test according to requirements;
carrying out interlayer testing on the finished high-frequency transformer product subjected to lettering and plate arrangement;
carrying out lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test;
and carrying out external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test.
By adopting the technical scheme, the quality of the high-frequency transformer can be detected after the main structure of the high-frequency transformer is assembled into a semi-finished product of the high-frequency transformer, the semi-finished product test is firstly carried out, whether the assembled semi-finished product is qualified or not is judged, the qualified semi-finished product is subjected to panel arrangement, then the high-frequency transformer semi-finished product is subjected to voltage withstanding test and finished product test after the insulating paint is coated, and the panel arrangement by printing, interlayer test, lead voltage withstanding test, external inspection, pin combination test and the like are sequentially carried out after the finished product passes through, so that the high-frequency transformer can be tested in multiple aspects after the high-frequency transformer is assembled into the semi-finished product, and the quality of the high-frequency transformer can be comprehensively tested.
Optionally, carry out semi-manufactured goods test and arrange the board to the high frequency transformer that passes semi-manufactured goods test to the high frequency transformer semi-manufactured goods that the assembly is accomplished, include:
setting test items and test parameters corresponding to the type of the high-frequency transformer semi-finished product in a semi-finished product test instrument according to requirements;
correcting the semi-finished product testing instrument through the correcting machine sample so that the corrected semi-finished product testing instrument performs semi-finished product testing on the high-frequency transformer semi-finished product;
and arranging the tested qualified products and carrying out classification identification placement on the tested defective products.
By adopting the technical scheme, the semi-finished product test can be carried out on the high-frequency transformer semi-finished product through the corresponding test items and test parameters.
Optionally, the step of coating insulating paint on the high-frequency transformer semi-finished product finished by the row plates comprises the following steps:
preparing insulating paint with preset concentration;
arranging PIN feet of the semi-finished product of the high-frequency transformer upwards on an impregnated iron disc in order;
placing the arranged impregnated iron disc in an impregnation furnace, covering the impregnation furnace, and adding blended insulating paint into the impregnation furnace, wherein the height of the oil surface of the insulating paint is not higher than the pins of the semi-finished product of the high-frequency transformer;
adjusting the air pressure in the impregnation furnace according to the requirement and vacuumizing until the impregnation of the semi-finished product of the high-frequency transformer is finished;
placing dripping paint on the impregnated high-frequency transformer semi-finished product in preset time;
and baking the high-frequency transformer semi-finished product after the paint dripping is finished until the high-frequency transformer semi-finished product is dried so as to fix the insulating paint on the high-frequency transformer semi-finished product.
By adopting the technical scheme, the high-frequency transformer semi-finished product passing the semi-finished product test can be coated with the insulating paint. The insulating paint further assembles and perfects the high-frequency transformer on one hand, and bonds the high-frequency transformer semi-finished product subjected to the semi-finished product test on the other hand, so that the structure of the high-frequency transformer semi-finished product is more stable.
Optionally, after the insulating varnish is coated, a voltage withstanding test is performed on the high-frequency transformer semi-finished product, including:
presetting test parameters of a withstand voltage tester according to requirements;
correcting the withstand voltage tester by adopting a corresponding corrector sample;
placing the magnetic core insulated wire of the high-frequency transformer semi-finished product coated with the insulating paint on a conveying belt towards the front side;
the high-frequency transformer semi-finished products conveyed on the conveying belt are subjected to voltage withstanding test through a voltage withstanding tester, and good products passing the test and defective products failing the test are distinguished and circulated.
By adopting the technical scheme, the corresponding test parameters are set on the withstand voltage tester, and the high-frequency transformer semi-finished product is subjected to withstand voltage test through the corrected withstand voltage tester.
Optionally, the performing a finished product test on the high-frequency transformer semi-finished product passing the voltage withstanding test includes:
setting test items and test parameters of a finished product test in a finished product test instrument according to requirements;
correcting the finished product testing instrument through the corresponding correcting machine sample;
and automatically testing the high-frequency transformer semi-finished product subjected to the voltage withstanding test on a finished product tester, distinguishing and circulating the good product passing the test and the defective product failing the test, and obtaining the good product passing the test as the high-frequency transformer finished product.
By adopting the technical scheme, the finished product testing instrument can be corrected, and the high-frequency transformer semi-finished product subjected to voltage withstanding testing is subjected to voltage withstanding testing after correction.
Optionally, printing and arranging the high-frequency transformer finished product passing the finished product test according to the requirement includes:
printing characters on one side of the finished high-frequency transformer product close to the positions of the PINs PIN1-5 as required;
inserting the high-frequency transformer finished product subjected to printing into the pearl wool according to the array of the row plates.
By adopting the technical scheme, the finished product of the high-frequency transformer passing the finished product test can be printed according to the requirement, and the product type of the high-frequency transformer can be known through the printing.
Optionally, the performing interlayer testing on the high-frequency transformer finished product subjected to printing and plate arrangement comprises:
setting test items and test parameters of interlayer testing in the interlayer tester according to requirements;
correcting the interlayer tester through the corresponding calibrator sample;
carrying out interlayer testing on the high-frequency transformer finished product on an interlayer tester;
inserting the good products passing the test on the pearl cotton according to the array of the arranging plates for circulation, and placing the defective products not passing the test in a defective product box.
By adopting the technical scheme, the interlayer tester can be corrected, and the corrected interlayer tester is adopted to carry out interlayer test on the high-frequency transformer finished product.
Optionally, the step of performing a lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test includes:
setting test parameters of a withstand voltage tester according to the type of the high-frequency transformer;
correcting the interlayer testing instrument through the corresponding correcting machine sample;
placing the finished high-frequency transformer on a terminal board in the same direction;
starting a handle power supply of the voltage-withstanding tester at the contact position of the appointed probe to carry out lead voltage-withstanding test;
and (4) flowing the high-frequency transformer finished product passing the test into the next process, and placing the defective product not passing the test in a defective product box.
By adopting the technical scheme, the voltage-resistant tester can be corrected and the corrected voltage-resistant tester is adopted to carry out voltage-resistant test on the finished high-frequency transformer.
Optionally, the external inspection and pin combination of the finished high-frequency transformer product passing through the lead voltage withstand test includes:
carrying out external inspection on the high-frequency transformer finished product passing the interlayer test, wherein the range of the external inspection comprises the states of a skeleton, a magnetic core, adhesive paper and soldering tin of the high-frequency transformer finished product and the integral cleaning degree of the high-frequency transformer finished product;
inserting the pins of the finished high-frequency transformer products which pass the external inspection into the pin combining plate to judge whether the pins are smoothly inserted;
if the judgment result is yes, the pin fitting inspection is passed, and the high-frequency transformer finished products passing the inspection are boxed;
and if the judgment result is no, the pin fitting inspection is failed, straightening the high-frequency transformer finished product which is not checked, and then testing again, and if the high-frequency transformer finished product which is not checked passes the re-testing, repairing.
By adopting the technical scheme, the high-frequency transformer can be subjected to external inspection and pin combination inspection, and the influence of appearance factors and pin faults on the high-frequency transformer is reduced as much as possible.
A high frequency transformer test system comprising:
the semi-finished product testing module is used for carrying out semi-finished product testing on the assembled semi-finished product of the high-frequency transformer and arranging the plates of the semi-finished product of the high-frequency transformer passing the semi-finished product testing, and the winding and the magnetic core on the semi-finished product of the high-frequency transformer are loaded;
the insulating module is used for coating insulating paint on the high-frequency transformer semi-finished product finished by the plate arrangement;
the voltage withstand test module is used for carrying out voltage withstand test on the semi-finished product of the high-frequency transformer after the insulating paint is coated;
the finished product testing module is used for carrying out finished product testing on the high-frequency transformer semi-finished product which passes the voltage withstanding test, and the high-frequency transformer finished product which passes the finished product testing is the high-frequency transformer finished product;
the printing and plate arranging module is used for printing and arranging the high-frequency transformer finished product passing the finished product test according to the requirement;
the interlayer testing module is used for performing interlayer testing on the high-frequency transformer finished product which is printed and subjected to plate arrangement;
the lead testing module is used for carrying out lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test;
and the external inspection pin combination module is used for performing external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test.
By adopting the technical scheme, the semi-finished product testing module performs semi-finished product testing on the high-frequency transformer semi-finished product; coating insulating paint on the high-frequency transformer semi-finished product which is tested by the insulating module; the voltage-withstanding test module is used for carrying out voltage-withstanding test on the high-frequency transformer semi-finished product coated with the insulating paint; the finished product testing module is used for carrying out finished product testing on the high-frequency transformer semi-finished product which passes the voltage-withstanding test, and the passed high-frequency transformer semi-finished product can be regarded as a high-frequency transformer finished product; the printing plate arranging module is used for printing and arranging the characters on the high-frequency transformer; the interlayer testing module carries out interlayer testing on the high-frequency transformer finished product which is printed and arranged on the board; the lead testing module is used for carrying out lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test; and the external inspection pin combination module is used for carrying out external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test. The high-frequency transformer can be tested in multiple aspects after being assembled into a semi-finished product, so that the quality of the high-frequency transformer can be comprehensively tested.
In summary, the present application includes at least one of the following beneficial technical effects:
the method comprises the steps of assembling a main structure of the high-frequency transformer into a semi-finished product of the high-frequency transformer, detecting the quality of the high-frequency transformer, testing the semi-finished product, judging whether the assembled semi-finished product is qualified or not, arranging the semi-finished product which is qualified, then performing voltage-withstanding test and finished product test on the semi-finished product of the high-frequency transformer after insulating paint is coated, sequentially performing printing, arranging the plates, performing interlayer test, leading wire voltage-withstanding test, external inspection, pin combination test and the like after the semi-finished product passes through the semi-finished product, performing multi-aspect test on the high-frequency transformer after the high-frequency transformer is assembled into the semi-finished product, comprehensively testing the quality of the high-frequency transformer, and reducing the influence of electromagnetic compatibility of the high-frequency transformer on the product quality.
Drawings
Fig. 1 is a block flow diagram of one embodiment of a high-frequency transformer testing method according to an embodiment of the present disclosure;
FIG. 2 is a block flow diagram of one embodiment of a high-frequency transformer testing method according to an embodiment of the present disclosure;
FIG. 3 is a block flow diagram of one embodiment of a high-frequency transformer testing method according to an embodiment of the present disclosure;
FIG. 4 is a block flow diagram of one embodiment of a high-frequency transformer testing method according to an embodiment of the present disclosure;
FIG. 5 is a block flow diagram of one embodiment of a method for testing a high-frequency transformer according to an embodiment of the present disclosure;
FIG. 5-1 is a schematic diagram of a high frequency transformer loop and pins in the corresponding embodiment of FIG. 5;
FIG. 6 is a block flow diagram of one embodiment of a high-frequency transformer testing method according to an embodiment of the present disclosure;
FIG. 6-1 is a schematic diagram of a printing position of a finished high-frequency transformer in the embodiment corresponding to FIG. 6;
FIG. 7 is a block flow diagram of one embodiment of a high-frequency transformer testing method according to an embodiment of the present application;
FIG. 8 is a block flow diagram of one embodiment of a method for testing a high-frequency transformer according to an embodiment of the present disclosure;
FIG. 9 is a block flow diagram of one embodiment of a method for testing a high-frequency transformer according to an embodiment of the present disclosure;
fig. 9-1 and 9-2 are schematic diagrams illustrating a normal state of the pin in the embodiment corresponding to fig. 9, and fig. 9-3 is a schematic diagram illustrating an abnormal state of the pin in the embodiment corresponding to fig. 9;
fig. 10 is a block diagram of a high-frequency transformer testing system according to an embodiment of the present application.
Reference numerals: 1. a semi-finished product testing module; 2. an insulating module; 3. a voltage withstanding test module; 4. a finished product testing module; 5. a lettering plate arrangement module; 6. an interlayer test module; 7. a lead test module; 8. an external inspection foot module.
Detailed Description
The present application is described in further detail below with reference to the accompanying drawings.
In order to test the quality of the transformer, the application provides a high-frequency transformer test method and a high-frequency transformer test system.
Referring to fig. 1, a high frequency transformer testing method includes:
and S110, carrying out semi-finished product test on the assembled high-frequency transformer semi-finished product, and arranging the high-frequency transformer semi-finished product passing the semi-finished product test, wherein the winding and the magnetic core on the high-frequency transformer semi-finished product are loaded.
A high frequency transformer refers to a switching power transformer having an operating frequency exceeding a medium frequency (10 KHz). The high-frequency transformer is preliminarily assembled before semi-finished product testing, and comprises the steps of loading winding of each winding and winding of a corresponding coil adhesive tape, peeling insulating wires on end PINs by laser, conveniently accessing a magnetic core to a lead on a PIN4 PIN in a follow-up manner by tin dipping, pressing a coil, loading the magnetic core, winding magnetic core adhesive paper and tin dipping of all PINs. And testing the semi-finished product of the high-frequency transformer formed after the steps. And (4) carrying out semi-finished product test on the high-frequency transformer, namely testing whether the performance of the high-frequency transformer produced in the previous step meets the standard. And automatically arranging the high-frequency transformers passing the test, so that the high-frequency transformer semi-finished products passing the semi-finished product test are convenient for the next action, and automatically separating and recycling the high-frequency transformer semi-finished products failing the semiconductor test.
And S120, coating insulating paint on the high-frequency transformer semi-finished product finished by the plate arrangement.
The insulating paint is coated on the semi-finished product of the high-frequency transformer, so that the insulating property between the high-frequency transformer and the external environment is improved, and the high-frequency transformer is isolated from the external environment.
And S130, carrying out voltage withstanding test on the semi-finished product of the high-frequency transformer after the insulating paint is coated.
The voltage withstand test is a test on the insulativity of a semi-finished product of the high-frequency transformer, and after the insulating paint is coated in the previous step, the insulating property of the insulating paint needs to be tested, so that the insulation damage of the high-frequency transformer is reduced.
And S140, carrying out finished product test on the high-frequency transformer semi-finished product which passes the voltage withstanding test, and obtaining the high-frequency transformer finished product which passes the finished product test.
In this embodiment, the semi-finished product that passes the withstand voltage test needs to be subjected to the finished product test, and when the performance of each aspect of the test meets the requirements, the high-frequency transformer can be indicated to pass the finished product test, and the high-frequency transformer at this time is the finished high-frequency transformer.
And S150, printing characters and arranging plates on the high-frequency transformer finished product passing the finished product test according to the requirement.
Because in the production process, the winding of the high-frequency transformer is wound with the coil adhesive tape, the type of the high-frequency transformer is inconvenient to identify through observation, the type or the type of the finished high-frequency transformer product is convenient to identify, printing and arranging plates are required to be carried out on the finished high-frequency transformer product which passes through the finished product test according to requirements, the printing is to print an identifier for identifying the type of the transformer on the surface of the finished high-frequency transformer product, and the arranging plates are orderly arranged for the finished printed high-frequency transformer product, so that the identification and the transportation are convenient.
And S160, carrying out interlayer test on the finished high-frequency transformer product subjected to printing and plate arrangement.
The interlayer test is carried out for further detecting the insulation performance of the high-frequency transformer and further reducing the leakage risk of the finished high-frequency transformer.
And S170, conducting lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test.
The purpose of the lead wire voltage-withstanding test is to test the insulation performance between turns and between layers of the winding.
And S180, carrying out external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test.
After the voltage withstanding test is carried out, the external inspection of the finished high-frequency transformer product refers to the inspection of the outer surface state, the pin combination of the finished high-frequency transformer product refers to the inspection of the pin shape of the high-frequency transformer, and the high-frequency transformer passing the external inspection and the pin combination indicates that the high-frequency transformer passes the last test and can be put into use.
The implementation principle of the high-frequency transformer testing method and system in the embodiment of the application is as follows: the quality of the high-frequency transformer can be detected after the main structure of the high-frequency transformer is assembled into a semi-finished product of the high-frequency transformer, the semi-finished product is tested firstly, whether the assembled semi-finished product is qualified or not is judged, the qualified semi-finished product is subjected to panel arrangement, then the semi-finished product of the high-frequency transformer is subjected to voltage withstanding test and finished product test after insulating paint is coated, and printing panel arrangement, interlayer test, lead wire voltage withstanding test, external inspection, pin combination test and the like are sequentially performed after the semi-finished product passes through the semi-finished product, so that the high-frequency transformer can be tested in multiple aspects after the high-frequency transformer is assembled into the semi-finished product, and the quality of the high-frequency transformer can be comprehensively tested.
Referring to fig. 2, the semi-finished product test is performed on the assembled high frequency transformer semi-finished product and the high frequency transformer passing the semi-finished product test is arranged, including:
s210, setting test items and test parameters corresponding to the type of the high-frequency transformer semi-finished product in a semi-finished product test instrument according to requirements.
The semi-finished product tester selects a corresponding instrument according to actual requirements, in this embodiment, a ZX2798 comprehensive tester or a tester with the same function may be selected, and a test item and a test parameter corresponding to the type of the semi-finished product of the high-frequency transformer are set in the semi-finished product tester. In the present embodiment, the set test items include a test for the number of turns, a test for the inductance, a test for the leakage inductance, and a test for the direct current resistance. In the testing of the number of turns, the testing condition is 20KHz/1V, the specification requirement of the testing can be N1 (2-1) 130Ts, N2 (8-7) 13Ts, N3 (9-8) 7Ts and N4 (5-4) 17Ts, and in other possible embodiments, the corresponding testing condition is set according to the number of turns of different coils, namely the number of turns. In the test of the inductance, the test condition is 10KHz/1V, and the test specification requirement is L (2-1): 2.07-2.33mH. In the test of the leakage inductance, the test condition is 10KHz/1V, and the test specification is Lk (2-1): 100uHMax (short circuit other pins). In testing the direct current resistance, the test conditions may be 20 ℃ and the test specification requirements are DCR (2-1): 3.45 Ω Max.
And S220, correcting the semi-finished product testing instrument through the correcting sample so that the corrected semi-finished product testing instrument performs semi-finished product testing on the high-frequency transformer semi-finished product.
The checking machine sample is a high-frequency transformer semi-finished product sample with the number of turns, inductance, leakage inductance and direct-current resistance meeting requirements, and is used for correcting the semi-finished product testing instrument so as to prevent related testing items and testing parameters from changing when the semi-finished product testing instrument is used after other machines are measured.
And S230, arranging the tested qualified products and carrying out classification, identification and placement on the tested defective products.
When the tested semi-finished product of the high-frequency transformer meets the requirement of the test specification in the test process, namely the used semi-finished product tester is a ZX2798 comprehensive tester, when PASS green lamps appear in the test process, the tested product is a qualified product, the tested qualified product is arranged on a transmission plate, and the tested qualified product is placed on the transmission plate in order and is transferred to the next process. And when the tested semi-finished product of the high-frequency transformer does not meet the requirement of the test specification in the test process, automatically flowing the defective product to the longitudinal direction for drawing and recycling.
Referring to fig. 3, the insulating varnish is applied to the high-frequency transformer semi-finished product completed by the panel arrangement, and comprises:
s310, preparing insulating paint with preset concentration.
The type of the prepared insulating paint is set according to the type of the high-frequency transformer, JX1150Y1 drying insulating paint can be set in the embodiment, JX1150B5-X diluent is used for diluting, and insulating paint with the concentration of 13-16 seconds measured by a Tu 4# measuring cup meets the insulating requirement of the embodiment of the application.
And S320, arranging the PIN of the semi-finished product of the high-frequency transformer on an impregnated iron disc in an upward and regular manner.
The PIN is upward and the insulating paint is prevented from covering the PIN, so that the insulating paint on the impregnated iron disc has certain requirements on the depth.
S330, placing the arranged impregnated iron disc in an impregnation furnace, covering the impregnation furnace, and adding blended insulating paint into the impregnation furnace, wherein the height of the oil surface of the insulating paint is not higher than the pins of the semi-finished product of the high-frequency transformer.
The depth of the insulating paint of different high-frequency transformer semi-finished products has different requirements, but the largest requirement is that the oil level height of the insulating paint is not higher than the pins of the high-frequency transformer semi-finished products.
And S340, adjusting the air pressure in the impregnation furnace according to the requirement, and vacuumizing until the impregnation of the semi-finished product of the high-frequency transformer is finished.
In the embodiment, the air pressure is adjusted to be 0.08-0.1Mpa, the first vacuumizing is performed for 3-5min, so that air bubbles between the insulating paint and the high-frequency transformer semi-finished product in the impregnation process are discharged, then the insulating paint is discharged, the vacuumizing is performed again for 3-5min, and the air bubbles between the insulating paint and the high-frequency transformer semi-finished product in the impregnation process are further discharged, so that the contact effect between the insulating paint and the high-frequency transformer is better.
And S350, placing dripping paint on the impregnated high-frequency transformer semi-finished product in preset time.
And after impregnation is finished, taking out the impregnated high-frequency transformer semi-finished product, wherein the paint dripping is used for dripping excessive insulating paint on the high-frequency transformer semi-finished product, and the time for placing the paint dripping is 4-5min, so that excessive adhesion of the insulating paint is reduced.
And S360, baking the high-frequency transformer semi-finished product after the paint dripping is finished until the high-frequency transformer semi-finished product is dried, so that the insulating paint is fixed on the high-frequency transformer semi-finished product.
In this embodiment, the high-frequency transformer semi-finished product after the paint dripping is pushed into an oven to be baked, the baking temperature is set to be 110 ± 10 ℃, and the baking time is 90min, so that the insulating paint on the high-frequency transformer semi-finished product has a better adhesion effect. After the insulating paint is dried, the insulating paint seals the semi-finished product of the high-frequency transformer to increase the resistance with the surrounding environment, and simultaneously bonds the semi-finished product of the high-frequency transformer to increase the stability of the structure of the semi-finished product of the high-frequency transformer.
Referring to fig. 4, after the insulating varnish is coated, a high-frequency transformer semi-finished product is subjected to a voltage withstanding test, which includes:
and S410, presetting test parameters of the withstand voltage tester according to requirements.
The voltage-withstanding tester can be set to be YD2672A voltage-withstanding tester or equivalent in the embodiment according to corresponding testing parameters of different types of semi-finished high-frequency transformers, the testing parameters comprise testing conditions, primary to secondary voltage-withstanding testing parameters and winding to magnetic core voltage-withstanding testing parameters, wherein the testing conditions can be AC50Hz/60Hz, the primary to secondary voltage-withstanding testing parameters are 3000VAC/5mA/3S, and the winding to magnetic core voltage-withstanding testing parameters are 3000VAC/5mA/3S.
And S420, correcting the withstand voltage tester by adopting a corresponding corrector sample.
The proof test sample provided in this embodiment corresponds to a proof test sample of a pressure tester. And the calibration samples of the corresponding instruments are correspondingly set in different embodiments.
And S430, placing the magnetic core insulated wire of the high-frequency transformer semi-finished product coated with the insulating paint on a conveying belt towards the front side.
When the magnetic core insulating wire nest of the high-frequency transformer semi-finished product is placed on the belt at the front side, the high-frequency transformer semi-finished product is conveniently transmitted through the conveying belt, and meanwhile, the magnetic core insulating wire nest is placed in the direction so that the high-frequency transformer semi-finished product can be conveniently detected by the withstand voltage tester.
S440, carrying out voltage withstanding test on the high-frequency transformer semi-finished products conveyed on the conveying belt through a voltage withstanding tester, and distinguishing and circulating good products passing the test and defective products failing the test.
Wherein, the withstand voltage tester needs to carry out the school machine again every two hours of detection to can use in school machine rear. The good products that will pass through when the test passes through flow to next process, and different good products are according to the categorised sign of trouble type and are put to the improvement to the process is carried out to the fault distribution of defective products in order to, for example, to the fault rate and the fault position of the defective products of a period of time establish the bar graph, judge the location to the position that the trouble height was sent out, so that pertinence improves this process.
After the above steps are completed, the obtained high-frequency transformer semi-finished product, or a part of the high-frequency transformer semi-finished product is automatically tested, so that, referring to fig. 5 and 5-1, the high-frequency transformer semi-finished product passing the voltage withstanding test is subjected to a finished product test, which includes:
and S510, setting test items and test parameters of the finished product test in the finished product test instrument according to requirements.
And S520, correcting the finished product testing instrument through the corresponding correcting machine sample.
And S530, automatically testing the high-frequency transformer semi-finished product subjected to the voltage withstanding test on a finished product tester, and distinguishing and circulating good products passing the test and defective products failing the test, wherein the good products passing the test are the high-frequency transformer finished product.
The finished product testing instrument provided in this embodiment is a ZX2789 comprehensive testing instrument or other instruments with equivalent functions, and a corresponding testing rack. The test parameters mainly include test conditions of test items and corresponding test specifications. Meanwhile, referring to the high-frequency transformer loop schematic and the pin distribution of fig. 5-1, wherein the test items comprise parameters such as turn number, inductance, leakage inductance and direct current resistance, so that the turn number, the inductance, the leakage inductance and the direct current resistance are tested for the last time after the semi-finished product test, the arranging, the impregnation, the baking and the voltage withstanding test are carried out, the performance of the high-frequency transformer can be considered to be better after the test steps are carried out, the requirement of a finished product is met, and the high-frequency transformer can be represented as a finished product of the high-frequency transformer. In the test of the number of turns, the test condition is 20KHz/1V, and the specification requirements of the test can be N1 (2-1) 130Ts, N2 (8-7) 13Ts, N3 (9-8) 7Ts and N4 (5-4) 17Ts. In the test of the inductance, the test condition is 10KHz/1V, and the test specification requirement is L (2-1): 2.05-2.35mH. In the test of the leakage inductance, the test condition is 10KHz/1V, and the test specification is Lk (2-1): 105uHMax (short circuit other pins). In testing the direct current resistance, the test conditions may be 20 ℃ and the test specification requirements are DCR (2-1): 3.48 Ω Ma. Different from the semi-finished product test, the inductance test range and the test maximum value of the direct current resistance are increased properly to adapt to the steps of impregnating insulating paint and the like. In other possible embodiments, the corresponding test conditions are set according to the number of turns, i.e. turns, of the different coils.
Referring to fig. 6, the printing and the plate arrangement are performed on the high-frequency transformer finished product passing the finished product test according to the requirement, and the method comprises the following steps:
and S610, printing on the position, close to the PIN1-5, of one side of the finished high-frequency transformer according to the requirement.
Referring to fig. 6-1, the position of the printing is at the position where the core adhesive paper is close to PINs PIN1-5, and PINs PIN1-5 are all on the same side, so that position identification is facilitated, for example, in the present embodiment, the content of the printing on the core adhesive paper is set according to the requirement, and batch, model, production date and the like can be printed, for example, XXX-XY123 in the figure can be set, and according to the reading sequence of the printing, the leftmost PIN1 PIN and the rightmost PIN5 PIN are provided.
And S620, inserting the finished high-frequency transformer product after printing into the pearl wool according to the row plate array.
Wherein, in order to place and reduce the influence to high frequency transformer in order to facilitate the high frequency transformer finished product that the printing was accomplished, insert the finished pin of high frequency transformer and establish on pearl cotton, and insert according to the array and establish, the finished direction of every high frequency transformer is all unanimous, makes the finished product of high frequency transformer be convenient for take in follow-up test.
Referring to fig. 7, the interlayer testing of the finished high-frequency transformer product finished by printing and plate arrangement comprises the following steps:
s710, setting test items and test parameters of interlayer testing in an interlayer tester according to requirements;
s720, correcting the interlayer tester through the corresponding correcting sample;
s730, carrying out interlayer testing on the high-frequency transformer finished product on an interlayer tester;
and S740, inserting the good products passing the test into the pearl cotton according to the array of the arranging plates for circulation, and placing the defective products not passing the test into a defective product box.
The interlayer tester used in the embodiment is a TH2882A-3 pulse tester and a corresponding test frame, the test parameters and test items are to test whether a loop is normal when the pulse frequency of a corresponding PIN is once under 500V pulse voltage, the purpose of performing interlayer test is to judge whether the loop of the PIN7-9 PIN meets the requirement under the corresponding pulse voltage, the interlayer tester also comprises a terminal board, a hole position connected with the TH2882A-3 pulse tester is arranged on the terminal board, and when the PIN7-9 PIN is inserted into the corresponding hole position, the test circuit is connected to the TH2882A-3 pulse tester, so that pulse test can be performed on the PIN7-9 PIN, and the convenience of the PIN7-9 PIN is improved.
Referring to fig. 8, after the interlayer test, the test with the corresponding lead is also performed, and therefore, performing the lead withstand voltage test on the finished high-frequency transformer product passing the interlayer test includes:
and S810, setting test parameters of the voltage resistance tester according to the type of the high-frequency transformer.
Wherein, the test parameter is PIN4 lead wire to the magnetic core: 300VAC/5Ma/1S, and corresponding test parameters are set according to requirements when the lead test is carried out in other embodiments. In the embodiment, the withstand voltage tester can be set as a CS2672C withstand voltage tester or the like, and a corresponding withstand voltage test terminal board, the terminal board is a strip shape adapted to the model of the high-frequency transformer, and the finished high-frequency transformer can be placed on the terminal board at one time to limit the position of the finished high-frequency transformer, so as to prevent abnormal motion in the test process as much as possible, and facilitate the lead withstand voltage test.
And S820, correcting the interlayer testing instrument through the corresponding correcting sample.
And S830, placing the finished high-frequency transformer on a terminal board in the same direction.
In order to facilitate the lead testing, the finished high-frequency transformer is placed on the terminal board in the same direction, and the placing angle is such that the printed side is far away from the tester, so that the placing angle of the finished high-frequency transformer is unified.
S840, starting a handle power supply of the voltage-withstanding tester at the contact position of the appointed probe to carry out lead voltage-withstanding test;
and S850, flowing the high-frequency transformer finished product passing the test into the next process, and placing the defective product not passing the test in a defective product box.
The defective product box is internally provided with a plurality of areas, the areas are mutually separated, when the test is failed, the defective products are placed at corresponding positions, the defective products in the defective product box are counted and processed in time after the test is finished, and if the number of the defective products in a unified batch is too large, the test is stopped and reported so as to stop the production of the corresponding process and overhaul.
Referring to fig. 9, the external inspection and pin fitting of the finished high-frequency transformer passing the lead withstand voltage test includes:
s910, carrying out external inspection on the high-frequency transformer finished product passing the interlayer test, wherein the external inspection range comprises the states of a skeleton, a magnetic core, adhesive paper and soldering tin of the high-frequency transformer finished product and the integral cleaning degree of the high-frequency transformer finished product.
The external inspection is the appearance inspection of the finished high-frequency transformer, and the phenomena of printing double images, printing blurring, exposed wire rods, broken wires attached to wire tails, wiring higher than a framework boss, scalding of gummed paper, adhesion of glue on the gummed paper, framework collapse, incomplete soldering, adhesion of the gummed paper on a magnetic core, dislocation of the gummed paper, damage of the gummed paper and the like are easy to occur during production and inspection in the previous steps. The range of the external inspection includes, but is not limited to, inspection of the state of the bobbin, the core, the adhesive tape, and the solder, and the cleanliness of the entire high-frequency transformer product. The inspection standard of the framework is that the framework cannot be damaged or scored, and the stitch needs to be vertical and smooth and cannot be loosened or broken; the inspection standards of the magnetic core include that the magnetic core cannot be damaged or misplaced and cannot be loosened; the inspection standard of the adhesive paper is that the adhesive paper can not have the bad phenomena of puncture, upwarp, reverse folding, copper wire exposure, magnetic core exposure and the like; the inspection standard of the soldering tin is that the soldering tin needs to be complete and bright, no missing soldering, insufficient soldering, tip pulling and high soldering point exist, foreign matters such as tin slag, glue blocks and the like cannot exist, the inspection standard of the cleanness degree is that the whole body has no phenomena such as tin slag, dirt and the like, and printed characters are clear and have no phenomena such as dislocation.
S920, inserting the pins of the finished high-frequency transformer which passes the external inspection into the pin combining plate to judge whether the pins are smoothly inserted.
Referring to fig. 9-1, 9-2 and 9-3, fig. 9-1 and 9-2 show a pin of a finished high-frequency transformer in a normal state, fig. 9-3 show a pin of a finished high-frequency transformer in a distorted state, before the finished high-frequency transformer is inserted into a pin combining plate, a pin combining plate adapted to the high-frequency transformer needs to be arranged and manufactured for the pin of the high-frequency transformer, a plurality of pin holes are formed in the pin combining plate, the distribution positions of the pin holes are consistent with the distribution positions of the pins of the high-frequency transformer, and the inner diameters of the pin holes are consistent with the diameters of the pins. When the pin is closed, the pin of the finished high-frequency transformer product which is inspected externally is inserted into the pin closing plate to judge whether the pin is inserted smoothly.
And S930, if the judgment result is yes, the pin fitting inspection is passed, and the high-frequency transformer finished products passing the inspection are packed into a box.
And if so, indicating that the diameters of the pins and the positions of the pins are qualified, and attaching no foreign matters such as soldering tin and the like which influence the diameters of the pins on the pins, and boxing the high-frequency transformer finished products which pass the inspection. The number of the finished high-frequency transformer products in each box is consistent, and the pearl cotton is padded in the box to play a role in shock resistance and fix the position of the finished high-frequency transformer products in the box.
And S940, if the judgment result is negative, the pin fitting inspection is not passed, straightening the high-frequency transformer finished product which is not passed through the inspection, testing again, and if the high-frequency transformer finished product which is not passed through the inspection passes again, repairing.
And when the judgment result is negative, straightening the pins of the finished high-frequency transformer through the flat tongs, and covering the flat tongs with a buffer adhesive tape to avoid the direct contact between the metal surface on the flat tongs and the pins as much as possible, so that the influence on the conductivity and the integrity of the pins is reduced.
Another embodiment of the present application further discloses a high-frequency transformer testing system, referring to fig. 10, including:
the finished product testing module 4 is a semi-finished product testing module 41 and is used for carrying out semi-finished product testing on the assembled high-frequency transformer semi-finished product and arranging plates on the high-frequency transformer semi-finished product which passes the semi-finished product testing, wherein both the upper winding and the magnetic core of the high-frequency transformer semi-finished product are completely loaded; the insulation module 2 is used for coating insulating paint on the high-frequency transformer semi-finished product finished by the plate arrangement; the voltage withstand test module 3 is used for carrying out voltage withstand test on the semi-finished product of the high-frequency transformer after the insulating paint is coated; the finished product testing module 4 is used for carrying out finished product testing on the high-frequency transformer semi-finished product which passes the voltage withstanding test, and the high-frequency transformer finished product which passes the finished product testing is the high-frequency transformer finished product; the printing and plate arranging module 5 is used for printing and arranging the high-frequency transformer finished product passing the finished product test according to the requirement; the interlayer testing module 6 is used for performing interlayer testing on the high-frequency transformer finished product which is printed and subjected to plate arrangement; the lead testing module 7 is used for carrying out lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test; and the external inspection pin combination module 8 is used for performing external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test.
The above embodiments are preferred embodiments of the present application, and the protection scope of the present application is not limited by the above embodiments, so: all equivalent changes made according to the structure, shape and principle of the present application shall be covered by the protection scope of the present application.
Claims (10)
1. A high-frequency transformer test method is characterized by comprising the following steps:
carrying out semi-finished product test on the assembled semi-finished product of the high-frequency transformer, and arranging plates on the semi-finished product of the high-frequency transformer passing the semi-finished product test, wherein both a winding and a magnetic core on the semi-finished product of the high-frequency transformer are loaded;
coating insulating paint on the high-frequency transformer semi-finished product finished by the plate arrangement;
after the insulating paint is coated, carrying out a voltage withstand test on the semi-finished product of the high-frequency transformer;
carrying out finished product test on the high-frequency transformer semi-finished product which passes the voltage withstanding test, wherein the high-frequency transformer semi-finished product which passes the finished product test is a high-frequency transformer finished product;
printing characters and arranging plates on the high-frequency transformer finished product passing the finished product test according to requirements;
carrying out interlayer test on the finished high-frequency transformer product finished by printing and plate arrangement;
carrying out lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test;
and carrying out external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test.
2. The method for testing a high frequency transformer according to claim 1, wherein the step of performing a semi-finished product test on the assembled semi-finished product of the high frequency transformer and the step of arranging the high frequency transformer passing the semi-finished product test comprises:
setting test items and test parameters corresponding to the type of the high-frequency transformer semi-finished product in a semi-finished product test instrument according to requirements;
correcting the semi-finished product testing instrument through the correcting machine sample so that the corrected semi-finished product testing instrument performs semi-finished product testing on the high-frequency transformer semi-finished product;
and arranging the tested qualified products and carrying out classification identification and placement on the tested defective products.
3. The method for testing a high-frequency transformer according to claim 1, wherein the step of coating insulating paint on the semifinished high-frequency transformer finished in the row plate comprises the following steps:
preparing insulating paint with preset concentration;
arranging PIN feet of the semi-finished product of the high-frequency transformer upwards on an impregnated iron disc in order;
placing the arranged impregnated iron disc in an impregnation furnace, covering the impregnation furnace, and adding blended insulating paint into the impregnation furnace, wherein the height of the oil surface of the insulating paint is not higher than the pins of the semi-finished product of the high-frequency transformer;
adjusting the air pressure in the impregnation furnace according to the requirement and vacuumizing until the impregnation of the semi-finished product of the high-frequency transformer is finished;
placing dripping paint on the impregnated high-frequency transformer semi-finished product in preset time;
and baking the high-frequency transformer semi-finished product after the paint dripping is finished until the high-frequency transformer semi-finished product is dried so as to fix the insulating paint on the high-frequency transformer semi-finished product.
4. The method for testing a high-frequency transformer according to claim 1, wherein the step of performing a withstand voltage test on the semi-finished product of the high-frequency transformer after the insulating varnish is coated comprises the following steps:
presetting test parameters of a withstand voltage tester according to requirements;
correcting the withstand voltage tester by adopting a corresponding corrector sample;
placing the magnetic core insulated wire of the high-frequency transformer semi-finished product coated with the insulating paint on a conveying belt towards the front side;
the high-frequency transformer semi-finished products conveyed on the conveying belt are subjected to voltage withstanding test through a voltage withstanding tester, and good products passing the test and defective products failing the test are distinguished and circulated.
5. The method for testing a high-frequency transformer according to claim 1, wherein the step of performing a finished product test on the high-frequency transformer semi-finished product which passes the withstand voltage test comprises the steps of:
setting test items and test parameters of a finished product test in a finished product test instrument according to requirements;
correcting the finished product testing instrument through the corresponding correcting machine sample;
and automatically testing the high-frequency transformer semi-finished product subjected to the voltage withstanding test on a finished product tester, distinguishing and circulating the good product passing the test and the defective product failing the test, and obtaining the good product passing the test as the high-frequency transformer finished product.
6. The method for testing the high-frequency transformer as claimed in claim 1, wherein the printing and the board arrangement are performed on the high-frequency transformer finished product passing the finished product test according to the requirement, and the method comprises the following steps:
printing characters on one side of the finished high-frequency transformer product close to the positions of the PINs PIN1-5 as required;
inserting the high-frequency transformer finished product subjected to printing into the pearl wool according to the array of the row plates.
7. The method for testing the high-frequency transformer according to claim 1, wherein the step of performing interlayer testing on the finished high-frequency transformer product which is printed and arranged on a plate comprises the following steps:
setting test items and test parameters of interlayer testing in the interlayer tester according to requirements;
correcting the interlayer tester through the corresponding calibrator sample;
carrying out interlayer testing on the high-frequency transformer finished product on an interlayer tester;
inserting the good products passing the test on the pearl cotton according to the array of the arranging plates for circulation, and placing the defective products not passing the test in a defective product box.
8. The method for testing the high-frequency transformer according to claim 1, wherein the step of conducting a lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test comprises the steps of:
setting test parameters of a withstand voltage tester according to the type of the high-frequency transformer;
correcting the interlayer testing instrument through the corresponding correcting sample;
placing the finished high-frequency transformer on a terminal board in the same direction;
starting a handle power supply of the voltage-withstanding tester at the contact position of the appointed probe to carry out lead voltage-withstanding test;
and (4) flowing the high-frequency transformer finished product passing the test into the next process, and placing the defective product not passing the test in a defective product box.
9. The method for testing the high-frequency transformer according to claim 1, wherein the step of performing external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test comprises the following steps:
carrying out external inspection on the high-frequency transformer finished product passing the interlayer test, wherein the range of the external inspection comprises the states of a skeleton, a magnetic core, adhesive paper and soldering tin of the high-frequency transformer finished product and the integral cleaning degree of the high-frequency transformer finished product;
inserting the pins of the finished high-frequency transformer products which pass the external inspection into the pin combining plate to judge whether the pins are smoothly inserted;
if the judgment result is yes, the pin fitting inspection is passed, and the high-frequency transformer finished products passing the inspection are packaged into boxes;
and if the judgment result is no, the pin fitting inspection is failed, straightening the high-frequency transformer finished product which is not checked, and then testing again, and if the high-frequency transformer finished product which is not checked passes the re-testing, repairing.
10. A high frequency transformer test system, using the method of any one of claims 1-9, comprising:
the finished product testing module (4) and the semi-finished product testing modules (4) and (1) are used for carrying out semi-finished product testing on the assembled high-frequency transformer semi-finished product and arranging plates on the high-frequency transformer semi-finished product which passes the semi-finished product testing, and the upper winding and the magnetic core of the high-frequency transformer semi-finished product are loaded;
the insulating module (2) is used for coating insulating paint on the high-frequency transformer semi-finished product finished by the plate arrangement;
the voltage withstand test module (3) is used for carrying out voltage withstand test on the semi-finished product of the high-frequency transformer after insulating paint is coated;
the finished product testing module (4) is used for carrying out finished product testing on the high-frequency transformer semi-finished product which passes the voltage withstanding test, and the high-frequency transformer finished product which passes the finished product testing is the high-frequency transformer finished product;
the printing and plate arranging module (5) is used for printing and arranging the high-frequency transformer finished product passing the finished product test according to the requirement;
the interlayer testing module (6) is used for performing interlayer testing on the high-frequency transformer finished product which is printed and arranged;
the lead testing module (7) is used for carrying out lead voltage withstand test on the high-frequency transformer finished product passing the interlayer test;
and the external inspection pin combination module (8) is used for carrying out external inspection and pin combination on the high-frequency transformer finished product passing the lead voltage withstand test.
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| CN202211676291.7A CN115792470A (en) | 2022-12-26 | 2022-12-26 | High-frequency transformer testing method and system |
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| CN202211676291.7A CN115792470A (en) | 2022-12-26 | 2022-12-26 | High-frequency transformer testing method and system |
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Application publication date: 20230314 |