The manufacturing process of filter coil is a delicate and multi-step process, which ensures that the performance and quality of the coil can meet the design requirements. The following are the main steps of the process, and each step is described in detail:
1. Pre-production preparation and inspection
Before the start of production, a series of preparation and inspection work is required. This includes confirming the correctness of the production specification and ensuring that the size, specifications and performance of raw materials such as the core, skeleton, copper wire, etc. meet the production requirements. In addition, it is necessary to check whether the machinery and equipment such as the winding machine are adjusted correctly, and confirm whether the packaging materials and packaging sequence meet the customer standards. These preparations are the basis for ensuring the smooth progress of subsequent production.
2. Copper wire winding
Copper wire winding is the core step of filter coil manufacturing. At this stage, the copper wire needs to be tightly and evenly wound on the skeleton according to the prescribed winding method and parameters. During the winding process, it is necessary to pay attention to maintaining the insulation of the copper wire to avoid damage or contamination. At the same time, it is also necessary to control the number of turns and other parameters of the winding to ensure that the inductance value and performance of the coil meet the design requirements.
3. Welding and Assembly
After winding, welding and assembly are required. This includes welding the pins of the coil to the circuit board or other components, and assembling the coil with the core, skeleton and other components. During the welding process, it is necessary to control the welding temperature and time to avoid overheating or overcooling resulting in poor welding quality. During assembly, it is necessary to ensure that the connection between the various components is tight and firm.
4. Impregnation and Baking
In order to improve the insulation performance and stability of the coil, impregnation and baking are usually required. During the impregnation process, the coil is immersed in a liquid containing insulating material so that the insulating material penetrates into the inside and surface of the coil. Baking is to solidify the insulating material by heating to form a hard insulating layer. This step is crucial to improving the electrical performance and durability of the coil.
5. Testing and Inspection
Strict testing and inspection are required during and after the production process. This includes testing whether the parameters such as the inductance value, resistance value, and withstand voltage performance of the coil meet the design requirements. At the same time, it is also necessary to check whether the appearance of the coil is intact, without damage or pollution. Testing and inspection can timely discover and correct problems in the production process to ensure that product quality meets standards.
6. Packaging and warehousing
The last step is to package and store qualified filter coils. During the packaging process, it is necessary to pay attention to the selection of appropriate packaging materials and methods to protect the coils from damage during transportation and storage. At the same time, it is also necessary to mark the product model, specifications, production date and other information on the packaging for easy traceability and management. After packaging is completed, the product is sent to the warehouse for storage or shipment.
