The production process of one-piece inductors involves several key links, each of which plays a vital role in the performance and quality of the final product. The following are these key links and their detailed explanations:
1. Winding
Winding is the first step in the production of one-piece inductors, and it is also one of the most basic and critical links. In this step, the copper wire needs to be accurately wound into a specific shape and size according to the specified number of turns and spacing to form the core part of the inductor - the coil. The accuracy and consistency of the winding directly affect the key parameters of the inductor, such as the inductance and quality factor. Therefore, a high-precision automatic winding machine is required during the winding process, and the speed, tension and direction of the winding are strictly controlled to ensure the accuracy and stability of the coil.
2. Spot welding
Spot welding is an important step to fix the wound coil to the inductor frame or sheet foot. Through the action of current, the end of the coil is welded to the frame or sheet foot to form a firm connection. The quality of spot welding directly affects the mechanical strength and electrical performance of the inductor. If the spot welding is not firm, the inductor may become loose or fall off during use; if there is a cold weld or short circuit during the spot welding process, it will affect the electrical performance of the inductor. Therefore, the current, time, pressure and other parameters need to be strictly controlled during the spot welding process to ensure the welding quality.
3. Molding
Molding is the step of placing the spot-welded inductor into a mold, wrapping and stamping the iron powder or other powder materials with a hydraulic press. During the molding process, the mold temperature, pressure and time and other parameters need to be strictly controlled to ensure that the powder material can fully fill the mold and form a dense structure. At the same time, attention should also be paid to the design and manufacturing accuracy of the mold to ensure that the size and shape of the molded inductor meet the design requirements. The molded inductor has higher mechanical strength and better electrical performance.
4. Sandblasting and gluing
Sandblasting is to use a sandblasting machine to polish the surface of the molded inductor to remove burrs and impurities on the surface and improve the smoothness and flatness of the inductor surface. Gluing is to spray the corresponding paint or glue on the surface of the molded product to play a protective and decorative role. During the sandblasting and gluing process, the pressure and angle of the sandblasting, as well as the type and thickness of the paint or glue, need to be controlled to ensure that the quality and appearance of the inductor surface meet the design requirements.
5. Bending feet and braiding
Bending feet is the step of cutting off the excess sheet of the molded product and bending the end feet flat against the surface of the product. This step helps to reduce the volume and weight of the inductor and improve its installation convenience. Braiding is to put the qualified inductors into the braided carrier in a certain number and order for subsequent packaging and transportation. During the bending feet and braiding process, the bending angle and strength, as well as the tightness and direction of the braiding, need to be strictly controlled to ensure the neatness and stability of the inductor.
6. Testing and screening
Testing is the process of using professional testing equipment to test the electrical performance of the inductor. Through testing, we can understand whether the key parameters of the inductor, such as inductance, quality factor, DC resistance, etc., meet the design requirements. Screening is the process of removing and reworking unqualified inductors based on testing. Testing and screening are one of the important links to ensure the quality of inductors. High-precision testing equipment and strict screening standards are required to ensure the qualified rate and reliability of products.
7. Packaging and packaging
Packaging is the step of packaging qualified inductors according to customer requirements. There are many packaging methods, such as SMD packaging, plug-in packaging, etc. During the packaging process, it is necessary to control the type and thickness of the packaging material and the temperature and time of the packaging process to ensure the packaging quality and reliability of the inductor. Packaging is to put the packaged inductor into the packaging box and add necessary shockproof and moisture-proof measures to ensure that the product is not damaged during transportation and storage.
8. Quality control and traceability
In the entire production process, quality control and traceability are one of the important links to ensure the quality of inductors. By establishing a complete quality control system and traceability mechanism, each link in the production process can be monitored and recorded in real time to detect and correct problems in a timely manner. At the same time, the production batch, production date, production personnel and other information of the product can also be traced and managed to facilitate subsequent quality traceability and problem troubleshooting.
9. Environmental protection and sustainable development
With the continuous improvement of environmental awareness and the popularization of the concept of sustainable development, the production of one-piece inductors also needs to focus on environmental protection and sustainable development. Environmentally friendly materials and processes need to be used in the production process to reduce the impact on the environment; at the same time, it is necessary to strengthen the treatment and recycling of waste to achieve resource recycling and sustainable development.
10. Technological innovation and upgrading
The production process and technology of one-piece inductors are constantly developing and innovating. With the continuous advancement of science and technology and changes in market demand, it is necessary to continuously introduce new technologies, new processes and new equipment to improve production efficiency and product quality; at the same time, it is necessary to strengthen the cultivation of technical research and development and innovation capabilities to promote the continuous progress and development of the industry. For example, the introduction of automated production lines and intelligent control systems can greatly improve production efficiency and product consistency; the use of new materials and processes can further improve the performance and reliability of inductors.
