Method for manufacturing a server power transformer

Abstract

The invention discloses a method for manufacturing a server power transformer, which relates to the technology in the field of transformers, and comprises the following steps: 1. Installing a copper sheet frame module: the copper sheet frame module comprises more than one copper sheet with tinned surface and a connection positioning sheet, and the copper sheet has a pre-positioning foot and an external pin; inserting the pre-positioning foot into the corresponding positioning welding hole and fixing it with soldering; 2. Installing a flat coil module: the flat coil module comprises more than two flat coils, firstly coating the coil body of each flat coil with glue and curing it, and then gathering the wire ends into corresponding common terminals; 3. Staggering the flat coil modules into the copper sheet frame module: inserting the flat coil into the gap between adjacent copper sheets; 4. Installing the magnetic core; 5. Installing the magnetic core; 6. Fixing it with dripping insulating glue. It has a simple structure, a simple manufacturing method, and is easy to control the assembly quality, and is suitable for manual assembly. For transformers for small batches, the manual assembly method saves costs and does not rely on automatic machines.

Description

Technical Field

[0001] The present invention relates to transformer technology, and in particular to a method for manufacturing a server power transformer. Background Art

[0002] At present, copper sheet transformers are increasingly used in server power supplies. Copper sheet transformers are small in size and can meet the application requirements of low voltage and high current.

[0003] For example, in CN 216980295 U, a transformer with multiple copper sheets grouped and wound and interconnected includes a magnetic core body and a guide pin assembly. The magnetic core body includes a magnetic core assembly, a primary winding group and multiple secondary winding assemblies. The guide pin assembly is arranged below the magnetic core body. The primary winding group and multiple secondary winding assemblies are arranged alternately and spaced apart. The secondary outlet pins of the secondary winding assembly are plugged into the guide pin assembly. Multiple secondary winding copper sheet assemblies are arranged in parallel to form the secondary winding assembly. By increasing or decreasing the number of secondary winding copper sheet assemblies, the requirements of different output currents can be met. When assembling, the primary winding group and multiple secondary winding assemblies need to be stacked and sleeved on the magnetic core. After the assembly is completed, the magnetic core body is installed on the guide pin assembly. Specifically, the guide pin assembly includes a U-shaped groove guide pin copper piece and a PCB bottom plate. The PCB bottom plate has a pin positioning hole. The secondary outlet pins of the assembled magnetic core body are inserted into the pin positioning hole.

[0004] This transformer structure and assembly method have some shortcomings. For example, when the primary winding group and multiple secondary winding components are stacked one by one and mounted on the magnetic core, it is difficult to accurately locate the circumferential position of the primary winding group and multiple secondary winding components. After multiple components are stacked up and down, the controllability of the extension position accuracy of the secondary output pin is not ideal. When the secondary output pin is subsequently inserted into the pin positioning hole, it is not easy to operate. Usually, the pin positioning hole needs to be opened wider to solve the problem of secondary output pin position accuracy deviation. Moreover, it is necessary to design a dedicated PCB base plate for different transformers. For the client (such as a server power supply manufacturer, a server manufacturer, etc.), installing and applying this transformer requires many processes. Even under the premise that the transformer manufacturer pre-installs the PCB base plate (the cost increases), space for placing the PCB base plate needs to be reserved in the server power supply, and it is necessary to design how to form a transition with the PCB base plate, resulting in more space being occupied inside the server power supply, which limits the internal space layout of the server power supply. In addition, the assembly of the magnetic core body depends on the automatic assembly of the machine. For small-batch special transformers, it costs a lot of money to modify the machine to adapt to the assembly process of small-batch special transformers. If it is done manually, the primary winding group and multiple secondary winding components are stacked one by one on the magnetic core, which is inefficient.

[0005] Therefore, it is necessary to study a new technical solution to solve the above problems. Summary of the invention

[0006] In view of this, the present invention aims to address the deficiencies in the prior art, and its main purpose is to provide a method for manufacturing a server power transformer, which has a simple structure, a simple manufacturing method, and is easy to control assembly quality. It is suitable for manual assembly, and for small batches of dedicated transformers, the manual assembly method saves costs and does not rely on automatic machines.

[0007] To achieve the above purpose, the present invention adopts the following technical solutions:

[0008] A method for manufacturing a server power transformer comprises the following steps

[0009] Step 1, installing the copper sheet frame module: the copper sheet frame module includes more than three tinned copper sheets and a connection positioning sheet, the copper sheet has a first through hole that runs vertically, and the copper sheet has a pre-positioning foot and an external pin; the connection positioning sheet is provided with more than three positioning welding holes arranged vertically and oppositely at intervals; the pre-positioning feet of the copper sheet are inserted into the corresponding positioning welding holes, and soldering is performed on the front side of the connection positioning sheet to weld and fix all the pre-positioning feet on the connection positioning sheet;

[0010] Step 2, assembling a flat coil module: the flat coil module includes more than two flat coils, the flat coils have a second through hole extending vertically, firstly coating the coil bodies of the flat coils with glue and curing them, then assembling the ends of the first wire ends of all the flat coils into a first common terminal, and assembling the ends of the second wire ends of all the flat coils into a second common terminal;

[0011] Step 3, stagger the flat coil modules into the copper sheet frame module: insert the flat coils of the flat coil module into the gaps between adjacent copper sheets, with the second through holes facing and penetrating the first through holes;

[0012] Step 4, install the magnetic core: the upper magnetic core includes a top plate, an upper middle column and an upper side plate, the upper middle column is integrally extended downward from the center of the bottom of the top plate, and the upper side plates are integrally extended downward from the left and right sides of the top plate respectively; the upper middle column of the upper magnetic core extends downward into the first through hole of the top copper sheet and continues to extend downward, but does not reach the first through hole of the bottom copper sheet;

[0013] Step 5, install the lower magnetic core: the lower magnetic core includes a bottom plate, a lower middle column and a lower side plate, the lower middle column is integrally extended upward from the center of the top of the bottom plate, and the lower side plates are integrally extended upward from the left and right sides of the bottom plate respectively; first, turn the semi-finished product installed in step 4 upside down so that the top of the upper magnetic core is placed downward, and then extend the lower middle column of the lower magnetic core downward into the first through hole of the copper sheet and continue to extend downward until the lower middle column and the upper middle column are bonded and spliced ​​into the middle column, and the lower side plate of the lower magnetic core and the upper side plate of the upper magnetic core are bonded and spliced ​​into the side plate;

[0014] Step 6: drip insulating glue on the front and rear ends of the side panels respectively, and glue the insulating glue to fix the upper side panel and the lower side panel. At the same time, glue the copper sheet to the side panel.

[0015] As a preferred embodiment, the copper sheet includes an annular body extending around the first through hole, the front end of the annular body is broken into a broken groove away from the center to connect the first through hole and the outer ring side of the annular body, the predetermined positioning pin extends forward from the center of the front end of the annular body, and the external pin is integrally extended forward at the front end of the annular body corresponding to the left or right side of the broken groove, and the predetermined positioning pin and the external pin are respectively located on both sides of the broken groove.

[0016] As a preferred solution, in step 1, during assembly, first insert the lower end of the connecting positioning plate into the positioning hole of the jig so that the connecting positioning plate is vertically positioned, and then insert the pre-positioning pins of the copper plate into the corresponding positioning welding holes. All copper plates are located on the rear side of the connecting positioning plate, and the external pins of the two adjacent copper plates above and below extend forward on the left and right sides of the connecting positioning plate respectively.

[0017] As a preferred solution, in step 1, solder is applied to the front side of the connection positioning piece to form a single piece.

[0018] As a preferred solution, an arm that can be bent by external force is connected between the pre-positioning foot and the front center part of the annular body, so that in step 2, when the flat coil module is subsequently installed, the copper sheet can swing up and down within a certain angle range around the arm that can be bent by external force.

[0019] As a preferred solution, the first wire end and the second wire end of the flat coil are reserved with extended sections for sleeve-mounting the identification protection tube, and the first wire end and the second wire end both extend from the left and right spacings on the rear side of the flat coil; after winding is completed, glue is applied to the upper and / or lower sides of the coil body to fix the size of the coil body, and then the ends of the first wire end of all the flat coils are peeled and the cores are exposed to be gathered into a first common terminal, and the ends of the second wire end of all the flat coils are peeled and the cores are exposed to be gathered into a second common terminal, and the first common terminal and the second common terminal are formed by winding the core wires into bundles and then covering them with solder.

[0020] As a preferred solution, in step 3, the flat coil is pushed forward to the bottom, and the front end of the flat coil abuts against the rear side of the connecting positioning piece, indicating that it is installed in place.

[0021] As a preferred solution, the rear end of the annular body of the copper sheet is integrally extended backward with a widened portion, and the widened portion protrudes beyond the rear end of the upper magnetic core, and is positioned with the left and right sides of the widened portion or positioned by adhesive connection with the inner wall surface of the upper side plate of the upper magnetic core, and a gap is formed between the two adjacent widened portions above and below for the extended extension section to extend and position, and the extended extension section extends out from the gap, and when the subsequent extended extension section is bent, it is limited by the limiting effect of the widened portion to prevent the connection between the extended extension section and the ring body from being pulled loose due to force.

[0022] As a preferred solution, the insulating adhesive bonds and fixes the widened portion to the side plate.

[0023] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, it can be seen from the above technical scheme that it mainly forms two windings by setting up a copper sheet frame module and a flat coil module, and cleverly uses the copper sheet winding as a frame. The copper sheet frame module is first installed, and then the flat coil module is inserted into the frame, and then the magnetic core and the lower magnetic core are installed. It has a simple structure, a simple manufacturing method, and easy control of assembly quality. It is suitable for manual assembly. For small batches of special transformers, the manual assembly method saves costs and does not rely on automatic machines. Moreover, the assembled transformer is easy to wire when used on a PCB board. When used on a server power supply, it is very convenient to install and apply on the client, simplifying the client assembly process.

[0024] In order to more clearly illustrate the structural features and effects of the present invention, the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is a top view of a server power transformer according to an embodiment of the present invention;

[0026] Figure 2is a partial top view of the server power transformer according to an embodiment of the present invention after hiding the upper magnetic core and the wire end of the flat coil;

[0027] Figure 3 is a top view of an upper magnetic core and a lower magnetic core of a server power transformer according to an embodiment of the present invention;

[0028] Figure 4 is a top view of a copper sheet frame module of a server power transformer according to an embodiment of the present invention;

[0029] Figure 5 is an exploded view of a copper sheet frame module of a server power transformer according to an embodiment of the present invention;

[0030] Figure 6 1 is a front view (i.e., a front view) of a server power transformer according to an embodiment of the present invention;

[0031] Figure 7 is an exploded view of a flat coil module according to an embodiment of the present invention;

[0032] Figure 8 is a three-dimensional diagram of a flat coil module according to an embodiment of the present invention (roughly illustrating that the wire ends thereof are gathered into corresponding common terminals);

[0033] Fig. 9 It is a physical diagram of a flat coil module according to an embodiment of the present invention.

[0034] Description of the accompanying drawings: copper sheet frame module 10, copper sheet 11, connecting positioning sheet 12, first through hole 111, annular body 112, broken slot 113, pre-positioning foot 114, external pin 115, widened portion 116, positioning welding hole 121, arm 117 that can be bent by external force, flat coil 21, second through hole 211, coil body 212, wire end 213, identification protection tube 214, first common terminal 215, second common terminal 216, upper magnetic core 30, upper middle column 31, lower magnetic core 40, lower middle column 41, insulating glue 50. DETAILED DESCRIPTION

[0035] Please refer to Figures 1 to 9 As shown, it shows the specific structure of an embodiment of the present invention.

[0036] In the description of the present invention, it should be noted that the directions or positional relationships indicated by the terms "up", "down", "left", "right", etc. are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation on the present invention.

[0037] A method for manufacturing a server power transformer comprises the following steps

[0038] Step 1, install the copper sheet frame module 10: the copper sheet frame module includes more than three copper sheets 11 with tinned surfaces and a connection positioning sheet 12, and the connection positioning sheet 12 is also tinned on the surface of the copper substrate; the surface tinned copper sheet, that is, a layer of bright metal tin is deposited on the surface of the copper, which can increase the weldability and decorativeness of the copper without affecting the conductivity. At the same time, it can prevent oxidation and discoloration, extend the anti-rust period, and increase the beauty of the copper workpiece. During production, the bare copper sheet is first punched out, and then the bare copper sheet is degreased, polished, washed, chemically tinned (referring to putting the copper sheet into the chemical tinning solution, and the tinning time is about 6 minutes), washed, and dried with cold air to obtain the surface tinned copper sheet. Considering the thickness requirements of the tin, the tinning time can be adjusted and / or the tinning operation can be repeated more than twice. The copper sheet 11 has a first through hole 111 extending from top to bottom, and the copper sheet 11 includes an annular body 112 extending around the first through hole 111. The front end of the annular body 112 is deviated from the center and is broken with a broken groove 113 to connect the first through hole 111 and the outer ring side of the annular body 112 by using the broken groove 113. The front end of the annular body 112 is centered and extends forward with a predetermined positioning foot 114. The front end of the annular body 112 is integrally extended forward with an external pin 115 corresponding to the left or right side of the broken groove 113. The predetermined positioning foot 114 and the The external pins 115 are two pins of the copper sheet, and the pre-positioning pins 114 and the external pins 115 are respectively located on both sides of the broken slot 113 in the left and right directions; the connecting positioning piece 12 is in the shape of a vertically extending sheet, and is provided with more than three positioning welding holes 121 arranged at intervals in the upper and lower directions. A PCB board connecting pin extends from the lower end of the connecting positioning piece 12, and the left and right widths of the PCB board connecting pins are slightly smaller than the main body of the connecting positioning piece 12, and the structure is T-shaped, so that when the subsequent transformer is inserted downward into the first connecting hole on the PCB board, it is easy to position. During assembly, first insert the lower end of the connection positioning sheet 12 into the positioning hole of the jig so that the connection positioning sheet 12 is vertically positioned, and then insert the pre-positioning pin 114 of the copper sheet into the corresponding positioning welding hole 121 (before assembly, the surface of the copper sheet is covered with an insulating film, and only the pre-positioning pin 114 and the external pin 115 are exposed. Usually, the copper sheet is automatically stamped out and the insulating film is automatically attached). All copper sheets are located at the rear side of the connection positioning sheet 12, and the external pins 115 of the two adjacent copper sheets above and below are They extend forward on the left and right sides of the connecting positioning piece 12 respectively, and the external pins 115 maintain a distance from the connecting positioning piece 12 to avoid short circuit; finally, soldering is performed on the front side of the connecting positioning piece 12 to weld and fix all the pre-positioning pins 114 on the connecting positioning piece 12, so as to form a copper sheet frame module 10; solder can be applied to the front side of the connecting positioning piece 12 to connect them into one piece, which increases the front and rear thickness of the connecting positioning piece 12 and strengthens the structural strength of the connecting positioning piece 12.An arm that can be bent by external force is connected between the pre-positioning foot 114 and the front center part of the annular body 112. The left and right widths of the arm that can be bent by external force are smaller than the left and right widths of the pre-positioning foot 114. Usually, two arms 117 that can be bent by external force are formed with a left and right spacing by openings, which are easy to process and ensure that the copper sheet can swing up and down within a certain angle range around the arm 117 when the flat coil module is subsequently installed, so as to ensure that the flat coil module can be installed smoothly and quickly. Since the arm 117 that can be bent by external force will generally only swing within a small angle range (for example, 5 to 15 degrees up and down) that may be required for installing the flat coil module, the arm 117 that can be bent by external force will not be damaged.

[0039] Step 2, assembling the flat coil module 20: The flat coil module 20 includes more than two flat coils 21, and the flat coil 21 has a second through hole that runs vertically through. The flat coil 21 is formed by winding a thin wire with an outer surface insulation around the second through hole 211, and the winding coil body 212 can be wound in one layer or two layers stacked up and down. The two wire ends 213 (i.e., the first wire end end and the second wire end end) of the flat coil 21 are reserved with an extended extension section for sleeve identification protection tube 214. The first wire end end is provided with a plurality of wire ends 213, and the second wire end end is provided with a plurality of wire ends 214. The head end and the second wire head end both extend from the left and right spacing on the rear side of the flat coil 21. The coil body 212 of the flat coil 21 is dipped in glue and solidified (that is, the wound coil body 212 is placed in liquid glue and taken out to dry or bake or air-dry to solidify). Glue coating, glue printing and the like can also be used. For example, when the coil body 212 is wound, the position of the second through hole 211 is passed through by a jig boss to facilitate control of the winding shape and size. After winding is completed, glue is applied to the upper and / or lower sides of the coil body 212 to fix the size of the coil body 212 and provide good consistency. Then, the ends of the first wire ends of all the flat coils 21 are peeled and the cores are exposed to form a first common terminal 215, and the ends of the second wire ends of all the flat coils 21 are peeled and the cores are exposed to form a second common terminal 216. The first common terminal 215 and the second common terminal 216 are made by winding the core wires into bundles and then covering them with solder. They are cylindrical or roughly cylindrical, which is convenient for subsequent direct insertion into the corresponding second connecting holes and third connecting holes of the PCB board and then welding and fixing them.

[0040] Step 3, stagger the flat coil 21 and the flat coil 21 module 20 into the copper sheet frame module 10: insert the flat coil 21 of the flat coil 21 module 20 into the gap between adjacent copper sheets, push the flat coil 21 to the bottom, that is, the front end of the flat coil 21 is against the rear side of the connecting positioning sheet 12, indicating that it is installed in place, at this time, the second through hole 211 is directly connected with the first through hole 111;

[0041] Step 4, install the magnetic core 30: the upper magnetic core 30 includes a top plate, an upper middle column 31 and an upper side plate, the upper middle column 31 is integrally extended downward from the center of the bottom of the top plate, and the upper side plates are integrally extended downward from the left and right sides of the top plate respectively; the upper middle column 31 of the upper magnetic core 30 extends downward into the first through hole 111 of the top copper sheet and continues to extend downward, but does not reach the first through hole 111 of the bottom copper sheet; since the rear end of the annular body 112 of the copper sheet is integrally extended backward with a widened portion 116, the widened portion 116 protrudes Extending beyond the rear end of the upper magnetic core 30, the left and right sides of the widened portion can be positioned with the inner wall surface of the upper side plate of the upper magnetic core 30 or glued and connected for positioning. At the same time, the rear end of the widened portion protects the upper magnetic core 30. For the entire transformer, the rear end limit size is limited to the rear end of the widened portion 116, and a gap can be formed between the two adjacent widened portions 116 above and below for the extended extension section to extend for positioning. When the subsequent extended extension section is bent, it is limited by the limiting effect of the widened portion to prevent the connection between the extended extension section and the ring body 212 from being pulled loose by force.

[0042] Step 5, install the lower magnetic core 40: the lower magnetic core 40 includes a bottom plate, a lower middle column 41 and a lower side plate, the lower middle column 41 is integrally extended upward from the center of the top of the bottom plate, and the lower side plates are integrally extended upward from the left and right sides of the bottom plate respectively; first, lift the semi-finished product installed in step 4 from the jig, and turn it upside down so that the top of the upper magnetic core 30 is placed downward, and then the lower middle column 41 of the lower magnetic core 40 extends downward into the first through hole 111 of the copper sheet and continues to extend downward until the lower middle column 41 and the upper middle column 31 are bonded and spliced ​​into a middle column, and the lower side plate of the lower magnetic core 40 and the upper side plate of the upper magnetic core 30 are bonded and spliced ​​into side plates (i.e., left plate and right plate).

[0043] Step 6: drip insulating glue 50 on the front and rear ends of the side panels respectively, the insulating glue 50 is bonded and fixed to the upper side panel and the lower side panel, and the insulating glue 50 also bonds and fixes the widened portion 116 to the side panels; at this point, the transformer quality assembly is completed.

[0044] It should be noted that in this embodiment, the stamping and insulating film coating of the copper sheet are performed on an automatic machine, and the connection positioning sheet 12 is also punched by an automatic machine. The copper sheet can be manually inserted into the connection positioning sheet 12, and welding can be done manually or by a welding machine. The flat coil 21 of the flat coil 21 module 20 is wound by an automatic machine, coated with glue and cured, and the identification protection tube can be put into the label protection tube manually or automatically. The end of the flat coil 21 is peeled and the core is exposed to be gathered into a common terminal, preferably manually, or manually combined with a semi-automatic machine to complete the peeling, the core wire is wound into a bundle and then coated with solder manually, steps 3, 4, and 5 are completed manually, and step 6 can be dripped with insulating glue manually or automatically on an automatic machine. In short, the entire process does not rely on an automatic machine, and the process that can be automatically completed by an automatic machine can be selected. All of them can be performed by a general machine without the need to modify the machine. The first step is to wind the copper sheets into a frame, ensuring the precise control of the position of the pre-positioning pin 114 (also referring to one of the pins of the copper sheet), and the precise control of the gap between adjacent copper sheets. For the copper sheet, stamping metal parts can easily control the relative position of the pre-positioning pin 114 and the external pin 115. During assembly, the position of the pre-positioning pin 114 is determined, which ensures the position accuracy of the external pin 115. Therefore, for several copper sheets, the position accuracy of the pre-positioning pin 114 and the external pin 115 are reliably guaranteed; on the basis of forming the frame, the flat coil 21 flat coil 21 module 20 can be simply and quickly inserted into place, and the size consistency of the flat coil 21 is well controllable, and it is easy to ensure that the first through hole 111 and the second through hole 211 are completely opposite to each other, so that it is very smooth when the magnetic core 30 and the lower magnetic core 40 are installed later. During the entire assembly process, in step 1, the PCB board connection pin at the lower end of the connection positioning piece 12 is simply used temporarily as a process positioning, so that no additional positioning tool is required in the frame assembly process of step 1. After obtaining the frame, the step of inserting the flat coil 21 and the flat coil 21 module 20 into the frame in step 3, and the step of installing the magnetic core 30 in step 4, all do not require additional positioning tools. After installing the upper magnetic core 30, the semi-finished product is turned upside down so that the top of the upper magnetic core 30 is placed downward, so that the bottom reference positioning can be achieved. The subsequent step 5 is installed. The lower magnetic core 40 also does not require additional positioning tools. Similarly, after the lower magnetic core 40 is assembled, the insulating glue application step in step 6 does not require additional positioning tools. Therefore, the entire assembly process is very simple, feasible and easy to control, suitable for manual operation, and has no requirements for personnel operating skills. There are almost no requirements for the configuration of the operator's workstation. It only needs to have a hole position on the workstation (referring to the aforementioned fixture positioning hole) for the PCB board connection pin to temporarily insert for positioning. After completing steps 1-5, the operator can hold the glue pen / glue gun to apply glue to complete step 6.

[0045] The design focus of the present invention is that it mainly forms two windings through the arrangement of the copper sheet frame module 10 and the flat coil 21 flat coil 21 module 20, and cleverly uses the copper sheet winding as a frame. The copper sheet frame module 10 is first installed, and then the flat coil 21 flat coil 21 module 20 is inserted into the frame, and then the magnetic core 30 and the lower magnetic core 40 are installed. It has a simple structure, a simple manufacturing method, and easy control of assembly quality. It is suitable for manual assembly. For small batches of special transformers, the manual assembly method saves costs and does not rely on automatic machines. Moreover, the assembled transformer is easy to wire when used on the PCB board. When used on the server power supply, the client installation and application is very convenient, which simplifies the client assembly process.

[0046] The above description is only a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any slight modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A method for manufacturing a server power transformer, characterized in that: The following steps are included in order Step 1, install the copper sheet frame module: the copper sheet frame module includes more than three copper sheets with tinned surfaces and a connecting positioning sheet, the copper sheet has a first through hole that runs through from top to bottom, the copper sheet has a predetermined positioning foot and an external pin, the copper sheet includes an annular body extending around the first through hole, the front end of the annular body is deviated from the center and is broken with a broken groove to connect the first through hole and the outer ring side of the annular body, the predetermined positioning foot extends forward from the center of the front end of the annular body, the external pin is integrally extended forward at the front end of the annular body corresponding to the left or right side of the broken groove, and the predetermined positioning foot and the external pin are respectively located on both sides of the broken groove ; The connection positioning sheet is provided with more than three positioning welding holes arranged at intervals in a vertical direction; the pre-positioning pins of the copper sheet are inserted into the corresponding positioning welding holes, and soldering is performed on the front side of the connection positioning sheet, and the solder is covered on the front side of the connection positioning sheet to form a piece, so that all the pre-positioning pins are welded and fixed on the connection positioning sheet; during assembly, the lower end of the connection positioning sheet is first inserted into the positioning hole of the jig so that the connection positioning sheet is vertically positioned, and then the pre-positioning pins of the copper sheet are inserted into the corresponding positioning welding holes, all the copper sheets are located on the rear side of the connection positioning sheet, and the external pins of the two adjacent copper sheets extend forward on the left and right sides of the connection positioning sheet respectively; Step 2, installing a flat coil module: the flat coil module includes more than two flat coils, the flat coils have a second through hole that runs vertically, the coil bodies of each flat coil are first coated with glue and solidified, and then the ends of the first wire ends of all the flat coils are gathered into a first common terminal, and the ends of the second wire ends of all the flat coils are gathered into a second common terminal; and an arm that can be bent by external force is connected between the pre-positioning foot and the front center of the annular body, so that in step 2, when the flat coil module is subsequently installed, the copper sheet can swing up and down within a certain angle range around the arm that can be bent by external force; Step 3, stagger the flat coil modules into the copper sheet frame module: insert the flat coils of the flat coil module into the gaps between adjacent copper sheets, with the second through hole and the first through hole facing each other; push the flat coil forward to the bottom, and the front end of the flat coil abuts against the rear side of the connection positioning sheet, indicating that it is installed in place; Step 4, install the magnetic core: the upper magnetic core includes a top plate, an upper middle column and an upper side plate, the upper middle column is integrally extended downward from the center of the bottom of the top plate, and the upper side plates are integrally extended downward from the left and right sides of the top plate respectively; the upper middle column of the upper magnetic core extends downward into the first through hole of the top copper sheet and continues to extend downward, but does not reach the first through hole of the bottom copper sheet; Step 5, install the lower magnetic core: the lower magnetic core includes a bottom plate, a lower middle column and a lower side plate, the lower middle column is integrally extended upward from the center of the top of the bottom plate, and the lower side plates are integrally extended upward from the left and right sides of the bottom plate respectively; first, turn the semi-finished product installed in step 4 upside down so that the top of the upper magnetic core is placed downward, and then extend the lower middle column of the lower magnetic core downward into the first through hole of the copper sheet and continue to extend downward until the lower middle column and the upper middle column are bonded and spliced ​​into the middle column, and the lower side plate of the lower magnetic core and the upper side plate of the upper magnetic core are bonded and spliced ​​into the side plate; Step 6: drip insulating glue on the front and rear ends of the side panels respectively, and glue the insulating glue to fix the upper side panel and the lower side panel. At the same time, glue the copper sheet to the side panel.

2. The method for manufacturing a server power transformer according to claim 1, characterized in that: The first wire end and the second wire end of the flat coil are reserved with extended sections for fitting an identification protection tube, and the first wire end and the second wire end both extend from the left and right spacings on the rear side of the flat coil; after winding is completed, glue is applied to the upper and / or lower sides of the coil body to fix the size of the coil body, and then the ends of the first wire end of all the flat coils are peeled and the cores are exposed to be gathered into a first common terminal, and the ends of the second wire end of all the flat coils are peeled and the cores are exposed to be gathered into a second common terminal, and the first common terminal and the second common terminal are formed by winding the core wires into bundles and then covering them with solder.

3. The method for manufacturing a server power transformer according to claim 2, characterized in that: The rear end of the annular body of the copper sheet is integrally extended with a widened portion, and the widened portion protrudes beyond the rear end of the upper magnetic core. The left and right sides of the widened portion are positioned with the inner wall surface of the upper side plate of the upper magnetic core or are glued and connected for positioning. In addition, a gap is formed between the two adjacent widened portions above and below for the extended extension section to extend and position. The extended extension section extends out from the gap, and the subsequent extended extension section is restricted by the limiting effect of the widened portion when bending, so as to prevent the connection between the extended extension section and the ring body from being pulled loose due to force.

4. The method for manufacturing a server power transformer according to claim 3, characterized in that: The insulating adhesive bonds and fixes the widened portion to the side plate.

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