Intertek Verified
Independent on-site factory qualification, verifying manufacturing premises and testing facilities.
100% In-Process QA
Systematic checkpoints from raw core insulation to semi-finished testing and hi-pot dielectric tests.
Custom OEM / ODM
Tailored turns, core geometry, thermal ratings, mounting configurations, and private label packaging.
Export Compliant
Built to meet global standards including IEC 61558, IEC 62368-1, CE, and RoHS requirements.
Verified Manufacturing & Testing Flow
At Shaanxi Zelqo Power Co., Ltd., our end-to-end manufacturing is structured with precision engineering, advanced automatic tooling, and exhaustive quality verification stations.
1. Standard Production Process
10 Workstations
High-precision tension-controlled winding ensuring uniform copper distribution and target turn ratios.
Accurate lead and insulation dimension sizing configured strictly to design schematics.
Multi-layer dielectric barrier tape application prevents magnetic core grounding and breakdown.
Even circular layering around toroidal cores minimizing leakage inductance and stray magnetic hum.
Sleeved terminal lead assembly, soldering, and mechanical lead anchorage for field durability.
In-process inspection checking winding continuity, polarity, and initial phase configuration.
Comprehensive electrical verification before final housing, encapsulation, or varnish impregnating.
Sustained full-load burn-in screening to eliminate infant mortality and confirm thermal stability.
Protective cushioning, labeling, barcoding, and moisture-barrier packaging tailored for overseas logistics.
Reinforced corrugated master cartons on drop-tested pallets ready for sea and air freight.
2. Specialized Production Machinery
8 Core Machines
High-precision structural clamping jigs ensuring mechanical tolerances across repetitive runs.
High-speed burr-free conductor cutting system guaranteeing clean stripped wire terminations.
Microprocessor-controlled winding heads for multi-secondary high-frequency coil bobbins.
Specialized shuttle ring machine built specifically for toroidal core winding programs.
Automatic tape tension and overlap control for primary-to-secondary dielectric barriers.
High-capacity coil winders for low-frequency laminated transformers and power chokes.
Calibrated feeding and cutting for heat-shrink, fiberglass, and Teflon insulation sleeving.
Heavy-duty crimper delivering gas-tight electrical joins on all terminal lugs and faston pins.
3. Precision Quality Control & Testing Lab
7 Quality Stations
Exhaustive testing against drawing specs before QA release stamp and shipping approval.
Accurate measurement of no-load losses, power factor, and operational energy efficiency.
Clean, variable-frequency 50Hz/60Hz/400Hz power simulation for international export markets.
Calibrated measurement of primary inductance, leakage inductance (Lk), and Q factor.
Four-terminal Kelvin sensing verifies winding DC resistance (DCR) and copper wire integrity.
High-voltage pulse waveform comparison to detect inter-turn micro-shorts and enamel insulation flaws.
Dielectric breakdown testing up to 4000VAC verifying primary-to-secondary galvanic isolation safety.