Case Overview
We recently delivered a targeted quality optimization solution for an inverter welding machine manufacturer, resolving recurring hipot test failure issues on EE70 transformers supplied by their former vendor.
Product Specifications
Model: EE70
Turns Ratio: 2:7:11:2
Inductance: 1.24 mH
Withstand Voltage Standard: 4500V/AC, 0.8mA, 1s
Customer's Core Challenges
Transformer batches from the previous supplier repeatedly failed high voltage withstand inspection during production:
Unrestrained copper strips shifted randomly during taping, creating uneven thin insulation and inadequate creepage distance, which produced burnt breakdown spots under high voltage.
Contamination on copper foil surfaces further degraded insulation performance, posing notable safety hazards to complete welding inverter equipment.
Customized Optimization Solutions
Our technical team rolled out three core upgrades to address the root cause of copper strip offset:
Mount centering limit wheels at the taping station to lock copper strips in a centered position and prevent lateral shifting.
Recalibrate unwinding tension to maintain stable tension output throughout the taping process.
Upgrade workshop environmental dust control to reduce surface contaminants on copper foil, ensuring uniform insulation thickness on both sides of all strips.
Project Outcomes
All finished products pass hipot testing consistently, with no breakdown scrapped parts during mass production
This centering control procedure has been standardized and applied to all copper foil transformer production lines
The customer acknowledged our professional process improvement capabilities and placed extra follow-up orders
Conclusion & Our Professional Strength
Copper strip offset during taping is the fundamental trigger for hipot failure. Custom centering limit wheels resolve insufficient insulation creepage distance at the source.
As a professional transformer manufacturer, we hold mature process optimization capabilities. We can quickly identify core quality defects of transformers and inductors, then design customized fixtures and standardized improvement workflows. We deliver stable, fully compliant magnetic components and reliable technical support to all industrial partners.
For any inquiries about transformer process optimization and custom development, please contact me.
Yvette
+86-153-3836-7956 (wechat, whatsapp)
Mail: yvette@dghensiron.com
Add: Building 4, Xinxing Industrial Zone, Wangao Road, Wanjiang Street, Dongguan City, 523000, China
Website: www.dghensiron.com
