Process 01
Winding
High-accuracy layer and continuous winding with controlled wire tension.
Standardized SOP Workflow
Precision Transformer Assembly Process
Every toroidal core, low frequency transformer, and high frequency ferrite assembly follows a calibrated 10-step sequence with strict in-process tolerance controls.
Process 02
Cutting
Precision lead trimming and mechanical silicon sheet sizing.
Process 03
Core Insulation
High-dielectric barrier film wrapping on core edges to prevent flashover.
Process 04
Primary Winding
Primary copper turn counting with automated micro-gap control.
Process 05
Wiring Process
Lead attachment, sleeving insulation, and solid solder terminal connections.
Process 06
Testing
In-line phase, polarity, and electrical continuity screening.
Process 07
Semi-finished Products Test
Open-circuit voltage, turn ratio verification, and inductance evaluation.
Process 08
Aging Test
Continuous elevated-temperature burn-in to weed out early infant mortality.
Process 09
Packing
Moisture-proof polybagging, buffer protection, and clear barcode labeling.
Process 10
Export Packing
Heavy-duty corrugated master cartons strapped on fumigated sea pallets.
Modern Machinery
Automated Production Equipment
High-precision computerized winders, automatic tape wrapping units, and calibration tooling guarantee batch consistency and rapid production scaling.
CNC Winding Machine
Programmable axis drive for precise turn distribution and pitch accuracy.
Circular Winding Machine
Specialized toroidal shuttle heads accommodating heavy-gauge magnet wire.
Winding Machine
High-speed bobbin spindle winder for switch-mode and flyback transformers.
Wrapping Machine
Uniform insulation film taping preventing pinholes and creepage failure.
Fixture
Model-dedicated positioning jigs ensuring accurate physical tolerances.
Cutting Instrument
Burr-free copper and silicon steel sheeting cutter.
Pipe Cutter
Clean sizing of fiberglass insulating sleeves and conduit tubing.
Crimping Machine
Gas-tight cold press connection for low-contact-resistance joints.
Zero Defect Commitment
Inspection & Laboratory Test Equipment
Calibrated digital bridge testers, impulse winding surge testers, and dielectric hi-pot benches verify compliance with IEC 61558 and international safety mandates.
Finished Goods Inspection
AQL 0.4 strict visual and dimensional outgoing inspection station.
Digital Power Meter
Precision measurement of no-load current, power factor, and watt loss.
AC Power Source
Pure sinusoidal reference supply from 45 Hz to 400 Hz for international grids.
LCR Digital Bridge Tester
Accurate reading of inductance (L), capacitance (C), and leakage flux.
DC Low Resistance Tester
Four-terminal Kelvin sensing down to micro-ohms to confirm copper gauge.
Impulse Winding Tester
High-voltage surge waveform comparison detecting microscopic turn-to-turn shorts.
Hi-pot Tester
Dielectric withstand up to 5 kVAC between windings and safety earth.