English
Reliable Nanocrystalline Magnetic Core - full chain quality inspection system in Shanxi Leimai
Created on 06.18
Preface
Nanocrystalline cores are indispensable electromagnetic components widely used in inverters, EV charging piles, precision current transformers, and communication power supplies. Tiny fluctuations in magnetic permeability, Al inductance value, dimensional accuracy, high-frequency loss, and packaging structure will result in inaccurate measurement, severe equipment overheating, EMC failure, and large-scale batch rework for end devices.
Shanxi Leimai has built a full-process closed-loop quality inspection system covering incoming material inspection, online production patrol, semi-finished product lab testing, finished product final inspection and pre-shipment recheck. For customized products including fixed Al inductance parameters, high-precision engineering drawings, plastic housings with protrusion buckles and matched removable partition pieces, we realize full quality traceability, guaranteed performance indicators and complete official technical document delivery.
1. Incoming Material Inspection
100% batch sampling inspection is implemented for all raw materials, including nanocrystalline ribbons, insulating films, plastic raw materials and matching accessories. Unqualified materials will be rejected directly to eliminate hidden quality risks from the source. We maintain the average grain size of nanocrystalline ribbons at 10nm steadily, and control ribbon thickness tolerance within ±1μm. All plastic parts and insulating films pass strict high and low temperature aging and voltage resistance tests to adapt to harsh operating environments. Meanwhile, dimension and hardness tests for partition pieces ensure seamless assembly with plastic buckles. Each batch is marked with an exclusive quality inspection code for full reverse traceability.
2. In-process Patrol Inspection
Full-time quality inspectors conduct regular sampling during five core production processes, namely winding, magnetic field annealing, insulation coating, plastic injection and accessory assembly, with full inspection implemented on key working stations. Magnetic field annealing, the core process determining final magnetic performance, adopts closed-loop temperature and magnetic field control. We adjust annealing curves dynamically to keep Al parameter deviation within ±3%, complying with customers’ requirement for fixed single inductance value instead of vague parameter ranges. For custom plastic-coated cores, we conduct targeted tests on buckle dimension and assembly performance to avoid structural defects and assembly failures.
3. Semi-finished Product Laboratory Testing
All semi-finished cores are delivered to professional electromagnetic laboratories for comprehensive performance and dimensional tests. All measured data serve as the authentic basis for official datasheets and engineering drawings. We provide accurate fixed Al inductance calibration, wide-band high-frequency loss test and DC bias performance test. Every product undergoes 48-hour thermal cycling test ranging from -50℃ to 180℃, with qualified products requiring less than 3% performance attenuation after aging. High-precision measuring equipment is adopted to complete dimensional mapping, supplying qualified drawings for customers’ project certification and approval.
4. Finished Product Final Inspection
Before packaging and delivery, we adopt dual inspection standards including full appearance inspection and random performance recheck. Differentiated inspection criteria are set for bare cores, insulated cores and complete plastic-coated assemblies with partition pieces. We check core appearance, intact buckles and complete supporting accessories one by one. Simulated transportation drop tests are carried out to optimize shockproof and moisture-proof packaging, ensuring consistent quality between bulk products and samples.
5. Pre-delivery Recheck & Technical Document Delivery
Prior to shipment, our quality team rechecks product model, inductance parameter, structural specification and matching accessories to ensure full compliance with customer orders. We provide complete supporting documents including tolerance-marked engineering drawings, official datasheets with fixed Al values, batch test reports, as well as ISO9001 and IATF16949 quality certificates, supporting overseas factory audits and product certification. All quality inspection records are permanently filed for lifelong traceability and reliable after-sales quality support.
6. Special Quality Inspection for Customized Products
An independent inspection station is arranged for customized plastic-coated cores equipped with protrusion buckles and removable partition pieces. Tens of thousands of assembly and disassembly simulation tests are conducted to verify long-term buckle stability. We unify assembly gap standards and update complete assembly drawings accordingly. Each bulk order is delivered with structural test reports and physical samples to accelerate customers’ product assembly and project development.
Conclusion
Against increasingly strict quality requirements for magnetic components in power electronics industry, we abandon simple final sampling inspection and implement refined full-process quality control. With reliable electromagnetic performance, precise dimension control and stable packaging structure, our nanocrystalline cores serve global customers in new energy vehicles, energy storage, smart grid and industrial power supply industries with consistent and guaranteed quality.
Contact
Leave your information and we will contact you.
电话