Ina aiki akan ƙayyadaddun tubalan tashar da tallafi a J-GUAN, kuma ina ɓatar da lokaci mai yawa ina amsa tambayoyin tsarin PCB daga injiniyoyin ƙira waɗanda suka haɗa tubalin tashar sukurori 301-5.0 ɗinmu cikin allunan rarraba wutar lantarki. Tambayoyin da na bayar ba game da takamaiman tubalin tashar kansu ba ne - waɗannan suna kan takardar bayanai. Suna game da haɗin injina ne: yadda za a iya sanya tubalan da ke kusa da juna kusa, wane girman haƙa ramin da ke ba da mafi kyawun amincin haɗin haɗin solder, da kuma abin da ke faruwa da gidan PA66 lokacin da ya shiga cikin wanka mai zafin jiki na 260°C na daƙiƙa 8. Wannan labarin ya tattara amsoshin da na tattara daga rukuni 12 na gwajin cancantar abokin ciniki da muka gudanar tsakanin 2023 da 2025.

Girman Tafin PCB: Abin da Takardar Bayanai ta Nuna Idan Aka Yi Aiki a Samarwa

301-5.0 yana amfani da firam mai girman 5.0 mm, wanda yake daidaitacce ga wannan aji na toshewar tasha. Girman fil ɗin shine tagulla mai kusurwa 1.0 x 1.2 mm tare da rufin kwano. Girman ramin PCB da aka ba da shawarar shine diamita na 1.3-1.5 mm da aka gama - faɗin da ya isa ya ba da damar fil ɗin ya shiga tsakiya yayin haɗa raƙuman ruwa amma ya yi tsauri sosai don tabbatar da cewa aikin capillary yana jawo solder ta cikin ramin. A cikin gwajin amincin haɗin solder ɗinmu a cikin samfuran 500, ramuka a 1.4 mm sun samar da matsakaicin ƙarfin ja a 35 N tare da aƙalla N28. Ramuka a 1.6 mm sun rage matsakaicin ƙarfin ja zuwa N29 saboda gibin capillary ya yi faɗi sosai don cike solder mai daidaito.

Wani bayani da ba ya cikin takardar bayanai amma yana da mahimmanci a samarwa: sharewar fil-zuwa-rami yana canzawa tare da kauri PCB. A kan allon FR-4 na yau da kullun na 1.6 mm, ramin mm 1.4 tare da fil 1.2 mm yana ba da izinin sharewa na diamita 0.2 mm, wanda shine mafi kyau. A kan allon 2.4 mm don aikace-aikacen wutar lantarki mai yawa, sharewa iri ɗaya har yanzu yana aiki amma lokacin da solder ɗin raƙuman ruwa ya kasance dole ne ya ƙaru daga daƙiƙa 3 zuwa daƙiƙa 5 don tabbatar da cikewar rami. Muna da saitin sigogin solder ɗin raƙuman ruwa da aka ba da shawarar ta kauri allo wanda nake aikawa ga kowane abokin ciniki na farko.

Tsaftace Injin A kusa da Toshewar Tashar a kan PCB

Tsawon 301-5.0 ya kai mm 10.0 daga saman PCB zuwa saman gidan. Sukurin mannewa yana buƙatar samun damar sukudireba daga sama, kuma an saka ramin sukurori a cikin ramin 2.5 mm. Don wayoyi da hannu, wannan yana nufin mafi ƙarancin izinin 15 mm sama da PCB don ɗaukar mashin ɗin sukurori mai faɗi 3.0 mm a kusurwar sakawa ta digiri 15. Don tuƙin sukurori ta atomatik a lokacin samarwa, buƙatar sharewa ta ƙaru zuwa 20 mm don ɗaukar mariƙin bit na sukurori.

Tsakanin tubalan da ke kusa, ina ba da shawarar aƙalla izinin 2.0 mm daga gefen gidan zuwa sashi na gaba. Gidan yana da faɗi 8.5 mm a kowane matsayi na sanda, don haka tare da matakin 5.0 mm, rata tsakanin bangon gidaje da ke kusa shine 8.5 - 5.0 = 3.5 mm. Wannan rata 3.5 mm ya isa ga yawancin yanayin samarwa, amma idan allon ya wuce ta hanyar rufin tsari, bututun mai shafa shafi yawanci yana buƙatar izinin 5.0 mm. Mun sami abokin ciniki ɗaya wanda ya gano cewa robot ɗin su na shafa fenti yana buga bangon gidaje a tazara 3.5 mm - sun canza zuwa kowane sandar da ke cike don ƙirƙirar matakin 10 mm akan wurin rufewa sannan suka cika wuraren da aka tsallake da hannu.

Amincin Haɗin gwiwa na Solder: Sigogi na Solder na Wave da Bayanan Gwajin Ja

An ƙera gidan 301-5.0 daga PA66 tare da ƙimar UL94 V-0, kuma an ƙera shi don jure waƙar solder. Bayanin solder ɗin da muka amince da shi: kafin a kunna 100-120°C na daƙiƙa 60-90, zafin solder mafi girma 255-260°C, lokacin zama na daƙiƙa 3-5 don allon 1.6 mm da daƙiƙa 5-7 don allon 2.4 mm. Mun gwada samfura 500 ta wannan bayanin a cikin 2024 ba tare da lahani ga gidaje ba.

Gwajin jan haɗin solder shine hanyar QC da muke ba da shawara don tabbatar da layin samarwa. Muna amfani da ma'aunin ƙarfi tare da kayan haɗin ƙugiya wanda ke ja a tsaye akan jikin toshewar ƙarshe bayan an haɗa shi. Bayananmu daga samfuran 500: matsakaicin ƙarfin ja 35 N, mafi ƙarancin 28 N, karkacewar daidaito 3.2 N. Don samarwa, ina ba da shawarar maƙasudin Cpk na 1.33 tare da ƙarancin iyaka na 25 N - ma'ana kada haɗin solder ya wuce 1 a cikin 4,000 ya gaza ƙasa da ƙarfin ja 25 N. Babban abin da ke tura ƙarfin ja ƙasa da 25 N shine ƙarancin girman cika solder, wanda muka gano ga dalilai biyu na asali: diamita na ramin PCB ya wuce 1.55 mm, da ƙimar aikace-aikacen kwararar solder mai wave yana faɗuwa ƙasa da 0.3 mL a kowane allo saboda toshewar bututun feshi.

Gudanar da Zafi: Ƙarfin Yanzu a Yanayin Zafi Mai Girma

Wutar lantarki mai ƙimar 16A ta 301-5.0 tana a yanayin 25°C tare da dukkan sandunan da aka ɗora a lokaci guda. Rage wutar lantarki yana farawa a yanayin 40°C: mun auna raguwar ƙarfin wutar lantarki mai ci gaba da kashi 4% a kowace 10°C sama da 40°C ta hanyar gwaje-gwajen hoton zafi na cikin gida. A yanayin 70°C, ƙimar wutar lantarki mai ci gaba ta ragu zuwa 14.0A. Abin da ke iyakancewa ba shine fil ɗin tagulla ko maƙallin sukurori ba - zafi ne da aka samar a hanyar haɗin waya zuwa fil, wanda ke da juriyar hulɗa da aka auna na 2.0-3.5 mOhm a kowace sanda a gwajin samarwarmu. A 16A, kowane sanda yana wargaza kusan 0.45 W. A cikin toshe mai sanda 12 da aka ɗora cikakke a 16A a kowace sanda, jimlar wargazawar zafi shine 5.4 W da aka tara a yankin 60 x 10 mm akan PCB. Ba tare da isasshen nutsewar zafin jirgin sama na jan ƙarfe ba, zafin PCB a ƙarƙashin toshewar ƙarshe zai iya tashi 25-35°C sama da yanayi.

Mafita abu ne mai sauƙi: Haɗa faifan ramin zuwa aƙalla 50 mm² na yankin tagulla a kowace sandar PCB, ta amfani da jan ƙarfe mai nauyin 35 µm ko fiye. Toshe mai sanduna 12 tare da kowane sandar da aka haɗa da jan ƙarfe mai nauyin 50 mm² yana nuna ƙaruwar zafin PCB na 12°C kawai a ci gaba da ɗaukar kaya na 16A, idan aka kwatanta da 30°C ba tare da haɗin jirgin saman jan ƙarfe ba.

Gwajin Tukunya Mai Girma Bayan Haɗawa: Menene Ma'anar Matsayin AC 2000V a Samarwa

An ƙayyade 301-5.0 tare da ƙarfin lantarki mai jurewa na AC 2000V a minti ɗaya tsakanin sandunan da ke maƙwabtaka. Wannan yanayin gwaji ne na nau'in tubalin tashar kawai, ba akan PCB da aka haɗa ba. Da zarar an haɗa tubalin a kan allon, gwajin tukunya mai tsayi dole ne ya yi la'akari da kayan PCB (FR-4 yawanci yana ɗaukar 40 kV/mm, don haka 1.6 mm yana ba da ƙarfin dielectric 64 kV), bayanin haɗin gwiwar solder, da duk wani ragowar kwararar ruwa a saman allon. A cikin ƙwarewarmu, gazawar samarwa a gwajin tukunya mai tsayi a 1,500V AC kusan koyaushe yana faruwa ne ta hanyar haɗin ragowar kwararar ruwa tsakanin haɗin solder fil da ke kusa, ba ta hanyar toshewar tashar kanta ba. Muna ba da shawarar ƙayyade kwararar ruwa mara tsabta tare da juriyar rufin saman mafi ƙarancin 10¹¹¹ Ohm a 85°C da kuma 85% ɗanɗano na dangi ga IPC J-STD-001, kuma yana buƙatar duba saman fil kafin gwajin tukunya mai tsayi.

Don aikace-aikacen da ke buƙatar ƙarin rufin rufi - kamar su samar da wutar lantarki ta likitanci bisa ga IEC 60601 - ƙarar fil ɗin 5.0 mm yana ba da nisan 4.0 mm na rarrafe tsakanin sandunan da ke maƙwabtaka (gefen fil zuwa gefen fil a haɗin solder). Wannan ya isa ga ƙarfin lantarki na aiki na 250V tare da digiri na gurɓatawa 2 bisa ga IEC 60947-7-4. Ga ƙarfin lantarki na aiki na 300V, ƙarar da ake buƙata ita ce 5.0 mm, wanda ke nufin ya kamata a bar kowane fil ba tare da mutane ba don cimma ƙarar mm 10.0.

Binciken Samarwa da Gwaje-gwajen QC da Muke Yi a Kowanne Rukunin

Kowace rukunin samarwa na tubalan tashar 301-5.0 suna yin gwaje-gwajen QC guda huɗu na tilas a wurinmu kafin jigilar kaya. Na farko gwajin karfin juyi ne: muna amfani da 0.4 Nm a kan sukurin mannewa ta amfani da sukurin karfin juyi mai daidaitawa kuma muna duba cewa sukurin yana juyawa cikin 'yanci ta hanyar digiri 360 ba tare da ɗaurewa ba. Na biyu kuma gwajin jan waya ne: muna manne waya mai lamba 14 AWG a 0.4 Nm kuma muna ja a 50 N na tsawon daƙiƙa 10 - wayar ba za ta motsa ba. Na uku kuma gwajin hazo mai gishiri ne akan samfura 5 a cikin guda 10,000 - awanni 48 a cikin 5% NaCl a 35°C bisa ga IEC 60068-2-11, ba tare da tsatsa da ake gani a kan fil ɗin tagulla ko sukurin da aka yi da tin ba. Na huɗu shine duba girma bisa ga IEC 60947-7-4 don tazara tsakanin fil, faɗin gida, da tsayi ta amfani da tsarin auna gani tare da daidaiton ±0.01 mm.

A shekarar 2024, mun gwada rukunin samarwa guda 47 ta hanyar wannan yarjejeniya kuma mun ƙi rukuni 3: ɗaya don karatun ƙarfin juyi wanda ba za a iya maimaitawa ba akan tashar haɗuwa ta atomatik guda ɗaya, ɗaya don rukunin ƙwayoyin PA66 waɗanda ke nuna hazo wanda ke nuna shaƙar danshi yayin ajiya, da kuma ɗaya don karkacewar girma a tsayin fil wanda ya faru sakamakon lalacewar mannewar tambari. An gyara dukkan matsaloli uku kafin rukunin samarwa na gaba.

Bayanan Gwajin Juyin Juya Hali da Ingancin Haɗin

Sukurin mannewa da ke kan 301-5.0 ƙarfe ne na M2.6 wanda aka yi masa fenti da zinc. A cikin gwajin karfin juyi na samarwa, muna amfani da 0.4 Nm kuma muna duba yanayi uku: sukurin yana juyawa cikin 'yanci ta hanyar digiri 360 ba tare da ɗaurewa ba, matsin lamba yana kaiwa aƙalla N20 akan waya, kuma kan sukurin bai tsinke ba. Bayananmu na 2024 daga rukuni 47 sun nuna matsakaicin karfin juyi na aiki na 0.38 Nm tare da karkacewar 0.03 Nm. Babu samfuran da suka gaza a iyakar 0.4 Nm.

Ga odar da ake maimaitawa wadda ta wuce guda 5,000 a kowane wata, muna yin zagayen zafi a kan samfura 10 a kowane wata: zagaye 500 daga -40°C zuwa +110°C. Gidan PA66 yana da CTE na 80 x 10⁻⁶ /°C idan aka kwatanta da 17 x 10⁻⁶ /°C don fil ɗin tagulla. Faɗaɗar bambancin da ke -40°C yana haifar da gibin 0.02 mm a cikin jurewar ƙira na 0.05 mm. Ana kiyaye ƙa'idodin aminci na lantarki na duniya ta hanyar Hukumar IECMatsakaicin canjin ƙarfin matsewa bayan zagayowar 500 ya kasance kashi 6.2% a cikin bayananmu na 2024.

Duba namu cikakken kewayon toshewar tashoshi kuma bayanin martaba na kamfaniKa'idojin tsaro da ake kiyayewa ta hanyar Hukumar Kula da Makamashi ta Duniya (IEC).

Bayanan Gwajin Juriya da Juriyar Rufi

An gwada juriyar rufin toshewar 301-5.0 tsakanin sandunan da ke maƙwabtaka a DC 500V ga kowace IEC 60512-3-1. A cikin gwajin samarwarmu ta 2024 na samfuran 1,200 a cikin rukuni 12, mafi ƙarancin juriyar rufin da aka rubuta shine 5,200 MOhm, tare da matsakaicin rukuni na 8,700 MOhm. Bayanan kayan PA66 sun nuna juriyar girma na 10¹⁵ Ohm·cm a 23°C da 50% RH, amma ainihin juriyar rufin a cikin toshewar ƙarshe da aka haɗa ya ragu ta hanyar gurɓatar saman daga tsarin ƙera. Mun gano cewa walƙiyar ƙirar allura - ƙananan fitowar kayan PA66 a layin rabuwa na mold - na iya rage nisan rarrafe tsakanin sandunan da ke maƙwabtaka daga ƙimar ƙira na 4.0 mm zuwa 3.2 mm a cikin mafi munin yanayi. Mun aiwatar da tsarin kula da mold wanda ke goge layin rabuwa a kowane zagaye 50,000, wanda ya rage tsayin walƙiya daga 0.08 mm zuwa ƙasa da 0.02 mm.

Gwajin ƙarfin lantarki mai jure wa dielectric a AC 2000V a minti ɗaya ga kowace IEC 60947-7-4 ba ya buƙatar rushewa ko walƙiya. A cikin gwajinmu, ƙarfin lantarki mai lalacewa tsakanin sandunan da ke maƙwabtaka a cikin tsarin 301-5.0 yawanci AC 3,800-4,200V ne, yana ba da iyakar aminci na kusan sau 2 akan ƙarfin lantarki mai jure wa da aka ƙididdige. Abin da ke iyakance ba shine wurin PA66 ba - wanda ke da ƙarfin dielectric na 25 kV/mm - amma hanyar rarrafe tsakanin fil biyu na tagulla a matakin saman PCB, inda fillet ɗin solder ke rage tazara mai tasiri.

Duba cikakken kewayon toshewar tashoshi kuma takaddun shaidaMa'auni Hukumar Kula da Makamashi ta Duniya (IEC).

Yarjejeniyar Soldering tare da Taro na PCB Mai Sarrafawa

An tsara tubalin tashar 301-5.0 don haɗa raƙuman ruwa amma kuma ya dace da haɗa raƙuman ruwa da kuma haɗa su da hannu. Don haɗa raƙuman ruwa a kan allunan FR-4 na 1.6 mm, ma'aunin da muka ba da shawarar su ne: a kunna 100-120°C na daƙiƙa 60-90, zafin mai haɗawa 255-260°C, lokacin zama na daƙiƙa 3-5. Don haɗa sandunan da aka zaɓa tare da bututun ƙarfe guda ɗaya, lokacin zama da aka ba da shawarar yana ƙaruwa zuwa daƙiƙa 6-8 a kowace fil don tabbatar da isasshen cikawar mai haɗawa. Gidan PA66 zai iya jure wa 260°C na daƙiƙa 10 jimillar lokacin fallasa a kowace fil, wanda ya isa ga duk hanyoyin haɗa sandunan da aka saba. Don haɗa sandunan da hannu, yi amfani da ƙarfe 350-380°C tare da tip na 2.0 mm, iyakance lokacin hulɗa zuwa daƙiƙa 3 a kowace fil, kuma a ba da damar sanyaya daƙiƙa 10 tsakanin fil don hana taruwar zafi a cikin gidan. Ga aikace-aikacen da suka wuce raka'a 10,000 a kowace shekara, muna ba da shawarar marufi na tef-da-reel don toshewar tashar 301-5.0, wanda ke ba da damar sanyawa ta atomatik akan PCB kafin a haɗa raƙuman ruwa. Tsarin tef-da-reel ɗinmu yana ɗaukar guda 500 a kowace reel tare da madaidaicin mm 12.7 tsakanin tubalan. Injin sanyawa yana ɗaukar kowane toshe ta jikin ginin ta amfani da bututun tsotsa, yana sanya shi a kan PCB, kuma ƙarfin riƙe fil ɗin a cikin manne mai solder yana riƙe toshe a wurin yayin jigilar zuwa tashar solder mai rarrafe. Ƙarfin da aka ba da shawarar shine 5-8 N, wanda ya isa ya tura fil ɗin ta cikin manne ba tare da lanƙwasa su ba.

Zaɓin Kayan Aiki da Bin Ka'idojin Ƙimar Ƙonewa

An ƙera wurin da aka yi amfani da allurar 301-5.0 daga PA66 (nailan 66) tare da ƙimar ƙonewa ta UL94 V-0 a kauri 0.8 mm. Matsayin V-0 yana buƙatar kowane samfurin ya mutu cikin daƙiƙa 10 bayan an cire mai ƙonawa, ba tare da an yarda da digo mai ƙonewa ba. A cikin gwajinmu na ciki na samfuran 100 daga wuraren samarwa 10, matsakaicin lokacin kashewa shine daƙiƙa 3.2 tare da matsakaicin daƙiƙa 7. Kayan PA66 kuma yana ba da ma'aunin bin diddigi na kwatancen (CTI) na 600V ga kowane IEC 60112, wanda ke nufin saman gidan zai iya jure ƙarfin bin diddigin 600V ba tare da samar da hanyar carbon mai sarrafawa ba. Matsayin CTI yana da mahimmanci ga aikace-aikacen allon rarraba wutar lantarki a cikin yanayin zafi mai yawa inda danshi na saman zai iya ƙirƙirar hanyar zubewa tsakanin sandunan ƙarshe da ke kusa. Cancantar kayan PA66 ɗinmu mai shigowa ta haɗa da gwajin CTI akan samfura uku a kowane rukuni, tare da iyakancewar ƙayyadaddun lokaci na 575V. A shekarar 2024, wani rukuni ya gaza a ƙarfin wutar lantarki na 560V kuma aka mayar da shi ga mai samar da wutar lantarki.

Toshewar tashar 301-5.0 tana samuwa a cikin tsarin sanduna 2 zuwa 12 a kowane tubali. Kowane sanda yana riƙe da ƙimar wutar lantarki ta 16A 300V iri ɗaya ba tare da la'akari da jimlar adadin sandunan ba. Ana iya ɗora tubalan sandunan da yawa gefe da gefe akan PCB don ƙirƙirar manyan haɗin lambobi, kuma matakin 5.0 mm yana tabbatar da dacewa da grid ɗin tsarin PCB na yau da kullun. Don allunan rarraba wutar lantarki waɗanda ke buƙatar sanduna sama da 12, muna ba da shawarar amfani da tubalan da yawa tare da mafi ƙarancin izinin 2.0 mm tsakanin gidajen tubalan da ke kusa.

Tambayoyin da Ake Yawan Yi