01
Winding
Precision multi-spindle and toroidal winding to exact turn counts, tension profiles, and uniform wire distribution.
High Precision Standardized Workflows
End-to-End Production Process
From magnetic core prep and precision winding to vacuum aging and export packing, each operational stage is executed to strict electrical standards.
02
Cutting
Calibrated shearing and trimming of insulating films, silicon steel strips, and lead sleeves to millimeter accuracy.
Dimensional Accuracy
03
Core Insulation
Multi-layer dielectric tape wrapping and barrier coating to isolate magnetic cores from direct copper wire contact.
Dielectric Reliability
04
Primary Winding
Controlled layer-by-layer primary coil winding with precise interleaving to minimize leakage inductance and proximity losses.
Optimized Coupling
05
Wiring Process
Lead termination, tin-bath soldering, and sleeving compliant with thermal resistance and strain-relief engineering standards.
IPC Standards
06
Testing
Intermediate checkpoint verifying turn ratio, open-circuit voltage, polarity, and pin configuration consistency.
100% Checkpoint
07
Semi-finished Products Test
Comprehensive parameter assessment before encapsulation, varnish dip, or final casing assembly.
Early Defect Screen
08
Aging Test
Elevated thermal and electrical stress testing under full-load conditions to screen out early-life component failures.
Thermal Stability
09
Packing
Anti-static protective packaging, custom compartment trays, and shock-resistant cushioning tailored for transit.
Transit Protected
10
Export Packing
Reinforced multi-wall corrugated cartons and palletized strapping meeting ocean and air export regulations.
Global Shipping Ready Advanced Manufacturing Machinery
Specialized Production Equipment
State-of-the-art winding systems, automated wire processors, and precision crimping machines driving consistent OEM/ODM batch manufacturing.
CNC Winding Machine
Programmable multi-axis winding systems with automated traversing, programmable turns, and precision tension control.
High-Density Coils
Circular Winding Machine
Dedicated shuttle heads tailored for toroidal cores, producing clean, tightly wound annular magnetic components.
Toroidal Specialist
Winding Machine
Heavy-duty, versatile coil winding station engineered for low-frequency power transformers and multi-tap secondary layers.
High Torque
Wrapping Machine
Automated taping platform applying uniform tension to ensure consistent dielectric overlap and insulation thickness.
Uniform Barrier
Cutting Instrument
Calibrated rotary and linear cutting instruments that guarantee clean, burr-free edges on conductive and insulating raw materials.
Burr-Free Shearing
Pipe Cutter
Automated cutting system for insulation tubes, heat-shrink sleeves, and silicone sleeving according to specified drawing lengths.
Accurate Sleeving
Crimping Machine
Pneumatic and motorized terminal crimpers delivering gas-tight wire-to-terminal bonds with optimal tensile pull strength.
Gas-Tight Crimp
Fixture
Custom-engineered tooling jigs designed to lock bobbin, core, and terminal orientations for high geometric consistency.
Modular Tooling Quality Assurance & Verification
Testing & Inspection Equipment
Every production lot undergoes rigorous electrical, dielectric, and magnetic testing. We leave zero room for field failures.
Finished Goods Inspection
Comprehensive 100% final testing confirming complete parameter compliance, appearance, terminal integrity, and labeling accuracy.
Final Quality Gate
Digital Power Meter
High-precision power analysis quantifying input power, efficiency, power factor, and idle iron core losses.
No-Load Loss Check
AC Power Source
Stable, distortion-free programmable AC supply simulating diverse global grid voltages (100V–240V, 50Hz/60Hz/400Hz).
Global Grid Simulation
LCR Digital Bridge Tester
Measures primary/secondary inductance (L), leakage inductance (Lk), quality factor (Q), and winding capacitance across frequencies.
Impedance Analysis
DC Low Resistance Tester
Four-wire Kelvin testing verifying copper winding resistance (DCR), identifying subtle solder joints or wire diameter variances.
mΩ Precision DCR
Impulse Winding Tester
Applies high-voltage impulse waveforms to detect microscopic turn-to-turn insulation breakdown and layer shorts instantly.
Interturn Spark Screen
Hi-pot Tester
High-voltage dielectric withstand test verifying primary-to-secondary and primary-to-core isolation safety under IEC/UL criteria.
Safety Insulation GateComplete Batch Traceability & Calibration Standards
At Shaanxi Zelqo Power Co., Ltd., all testing equipment undergoes routine third-party calibration against traceable metrology benchmarks. Every production batch of toroidal, low frequency, and high frequency transformers is documented with individual test records, ensuring full accountability for industrial and medical applications.
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