The following problems may be encountered during the production of high-frequency transformers, and solutions are provided:
1. Inter-turn capacitance: Add an insulating layer or use isolation materials to reduce the effect of inter-turn capacitance.
2. Linear expansion: Optimize the winding design, select appropriate materials and sizes, and ensure that linear expansion does not affect the tightness of the winding.
3. Iron loss: Use appropriate iron core material and structural design to reduce eddy current loss and Joule loss.
4. Electromagnetic interference: Reduce or eliminate electromagnetic radiation and conducted interference through reasonable shielding design and filters.
5. Insulation failure: Select high-quality insulation materials and conduct strict insulation testing and quality control.
6. Coupling between coils: Reduce mutual inductance coupling between coils through reasonable winding layout and isolation design.
7. Magnetic leakage loss: Consider the length, cross-sectional area and magnetic permeability of the magnetic leakage path in design to reduce magnetic leakage loss.
8. Vibration tolerance: Use reliable fixing solutions, such as mechanical clamping or adhesives, to ensure capacitor stability.
9. Poor welding: Strengthen welding process control and quality inspection to ensure the quality and reliability of welding points.
10. Uneven insulation coating: Use uniform spraying or coating technology to ensure the uniformity and quality of the insulation coating.
11. Short circuit between coils: Strengthen the testing and quality control of coil insulation to prevent short circuits caused by coil insulation breakdown.
12. Overheating problem: Optimize the heat dissipation design and add heat sinks or fans to reduce the operating temperature.
13. Frequency drift: Reasonably select components and perform precise frequency tuning and calibration.
14. Dimensional mismatch: Production is carried out in strict accordance with design requirements and standards to ensure dimensional accuracy and matching.
15. Poor magnetic coupling: Optimize the winding layout and insulation layer design to reduce the impact of magnetic coupling.
16. Excessive winding loss: Choose low-resistance materials, optimize the winding structure and size, and reduce the power consumption of the winding.
17. Bad contact: Strengthen the quality control of welding or crimping of connection points to ensure good electrical contact performance.
18. Short circuit problem: Strictly detect and control the insulation performance of the winding to avoid winding short circuit.
19. Noise problem: Reduce the noise generated during the operation of the transformer by adding noise reduction materials, optimizing the magnetic core structure and other measures.
20. Low overall efficiency: Optimize design, select efficient components, and rational winding layout to improve overall efficiency.