Every magnetic component follows a systematic, multi-step production workflow designed to preserve winding integrity, ensure high dielectric isolation, and guarantee long-term field reliability.
01. Winding
Precision copper wire winding with controlled tension to prevent enamel abrasion.
Step 01
02. Cutting
Accurate cutting of lead wires, sleeving, and insulating tapes according to engineering drawings.
Step 02
03. Core Insulation
High-grade dielectric film wrapping over magnetic cores to ensure safety isolation.
Step 03
04. Primary Winding
Evenly distributed primary coil winding for minimal leakage inductance and heat rise.
Step 04
05. Wiring Process
Lead soldering, secure crimping, and routing with reinforced insulating sleeves.
Step 05
06. In-Process Testing
Turns ratio, winding resistance, and polarity verification during intermediate assembly.
Step 06
07. Semi-Finished Test
Complete pre-varnishing and pre-potting electrical parameter compliance verification.
Step 07
08. Aging Test
Continuous full-load burn-in test to screen out infant component mortality.
Step 08
09. Unit Packing
Moisture-barrier sealing, labeling, and protective boxing for internal transport.
Step 09
10. Export Packing
Drop-tested export-grade cartons with corner protectors and pallet strapping.
Step 10Our Xi'an plant operates modern automated and semi-automated machinery ensuring tight winding tolerances, consistent core packaging, and scalable volume throughput.
CNC Winding Machine
High-precision programmable multi-axis winding for high frequency transformers and chokes.
Machinery
Circular Winding Machine
Dedicated toroidal gear winding units supporting compact inner core diameters.
Machinery
Industrial Winding Machine
Designed for heavy gauge magnet wires used in high-power industrial transformers.
Machinery
Wrapping Machine
Fast, uniform insulation tape wrapping ensuring consistent dielectric margins.
Machinery
Cutting Instrument
High-repeatability cutting of copper foils, insulation laminates, and silicone cables.
Tooling
Pipe Cutter
High-speed automated thermal sleeving and PVC tube segmenting unit.
Tooling
Crimping Machine
Controlled pressure wire crimping ensuring low contact resistance and pull-out safety.
Tooling
Production Fixtures
Custom-machined positioning jigs ensuring mechanical symmetry during assembly.
ToolingEvery production batch undergoes strict quality verification using calibrated precision instruments to comply with international safety standards including IEC 61558, IEC 62368-1, and CE.
Finished Inspection
100% comprehensive visual, dimensional, and final electrical parameter checkout.
Testing
Digital Power Meter
Measures power factor, active power, no-load current, and conversion efficiency.
Testing
AC Power Source
Simulates global grid voltages (85V–300V) and frequencies (47Hz–63Hz) for real-world load tests.
Testing
LCR Digital Bridge
High-frequency inductance, leakage inductance, capacitance, and Q-factor measurement.
Testing
DC Resistance Tester
Four-wire Kelvin method measurement for exact copper coil resistance balance.
Testing
Impulse Winding Tester
Verifies inter-turn dielectric strength via high-voltage surge waveform comparison.
Testing
Hi-Pot Tester
Primary-to-secondary and primary-to-ground dielectric withstand test up to 5kV AC.
TestingReady to Customize Your Power Solution?
Whether you require custom toroidal transformers, high frequency flyback inductors, or industrial power adapters, Shaanxi Zelqo Power Co., Ltd. provides prototype validation and scalable mass production.
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