An automated chamfering method and system for planar transformer PCB winding boards
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-14
- Publication Date
- 2026-08-14
AI Technical Summary
[0004]现有技术中，PCB绕组板的倒角加工多采用传统手工工艺，先通过斜口钳人工剪断连接板与边框的连接筋，再用砂纸手工打磨实现倒角，该加工方式存在诸多缺陷：其一，加工一致性极差，完全依赖操作人员的操作经验和手法，倒角的尺寸、外观平整度难以统一控制，产品良率波动大；其二，加工效率低下，纯手工作业耗时耗力，成为平面变压器PCB绕组板规模化生产中的关键瓶颈；其三，综合加工成本高昂，不仅需要投入大量人工成本，还易因人工操作不当导致绕组板开裂、变形，造成材料报废，同时斜口钳、砂纸等耗材的持续消耗也进一步增加了生产成本；其四，存在严重的质量隐患，斜口钳的挤压剪切方式易使绕组板侧断面产生分层裂纹，影响绕组板的结构强度和电气绝缘性能，后续使用过程中易出现短路、接触不良等故障
本发明利用锣切加工自身产生的粉尘作为临时“夹具”，配合预设的预留连接点，实现了无专用夹具情况下工件的牢固固定，构思巧妙，摒弃了传统定位方式对绕组板导电结构的损伤风险，同时简化了设备要求，降低了设备投入成本。
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Figure CN122560147A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of printed circuit board processing technology, specifically relating to an automated chamfering method and system for a planar transformer PCB winding board. Background Technology
[0002] Planar transformers are widely used in various electronic devices such as power adapters, new energy power control, and power supply modules for electronic equipment due to their advantages such as miniaturization, low profile, high power density, low leakage inductance, and excellent heat dissipation. As the core power conversion component of the planar transformer, the PCB winding board's processing precision directly determines the assembly effect and performance of the planar transformer.
[0003] Due to structural design requirements, the PCB winding board of a planar transformer must have smooth, burr-free edges. Furthermore, no additional process edges can be added during manufacturing, and NPTH holes cannot be added within a single PCB for router positioning. Using conventional pins to position the router within a single PCB can easily damage the metal layer inside the PTH holes, posing quality risks to subsequent winding coil soldering and lead-in copper pin assembly. Additionally, the edges of the PCB winding board must be chamfered after molding to meet both assembly compatibility and electrical safety requirements.
[0004] In existing technologies, the chamfering of PCB winding boards is mostly done manually. First, the connecting ribs between the connecting plate and the frame are manually cut using diagonal pliers, and then the chamfer is achieved by hand sanding. This processing method has many drawbacks: First, the processing consistency is extremely poor, relying entirely on the operator's experience and technique. The size and smoothness of the chamfer are difficult to control uniformly, resulting in large fluctuations in product yield. Second, the processing efficiency is low; purely manual operation is time-consuming and labor-intensive, becoming a key bottleneck in the large-scale production of planar transformer PCB winding boards. Third, the overall processing cost is high, requiring not only a large investment in labor costs but also being prone to cracking and deformation of the winding board due to improper manual operation, leading to material scrap. The continuous consumption of consumables such as diagonal pliers and sandpaper further increases production costs. Fourth, there are serious quality risks; the squeezing and shearing method of the diagonal pliers can easily cause delamination cracks on the side cross-section of the winding board, affecting the structural strength and electrical insulation performance of the winding board, and easily leading to short circuits, poor contact, and other faults during subsequent use. Summary of the Invention
[0005] The purpose of this invention is to provide an automated chamfering method and system for planar transformer PCB winding boards, addressing the technical problems described in the background art.
[0006] The technical solution of the present invention: An automated chamfering method for a planar transformer PCB winding board includes the following steps: S1: Create a router program based on the design file of the planar transformer PCB winding board. In the router program, a pre-reserved connection point is set between the starting point and the ending point of the machining path of the winding board outline. S2: Fix the planar transformer PCB winding board onto the processing workbench. Based on the router program, use the main router cutter to perform router cutting of the main outline of the winding board. During the processing, adjust the dust collection device to keep the dust generated by cutting in the cutting stroke gap. Utilize the combined effect of the retained dust and the reserved connection points to fix the planar transformer PCB winding board to be processed onto the substrate board. S3: After completing the main outline milling, replace it with a precision milling cutter with a diameter smaller than the main milling cutter. Use a lower feed speed than the main outline milling to precisely cut the reserved connection points and complete the separation and chamfering of the planar transformer PCB winding board.
[0007] In step S2, the dust collection method of the dust collection device is to reduce the dust collection force near the processing point, or remove the dust collection port near the processing point, or directly shut off the dust collection pipeline corresponding to the processing point.
[0008] In step S3, the diameter of the precision cutting auger is 0.8mm-1.0mm, and the feed speed for precisely cutting the reserved connection point is 0.3m / min.
[0009] In step S2, when the thickness of a single board of the planar transformer PCB winding board to be processed is less than 1.0 mm, a pad is placed on the surface of the planar transformer PCB winding board before performing this step.
[0010] In step S1, the cutting point is set at the right angle point of the outer shape of the planar transformer PCB winding board, and the right angle point is the right angle structure at the four corners of the winding board edge.
[0011] In step S1, when creating the router program, the positioning holes at the four corners of the planar transformer PCB winding board are selected as the machining positioning reference.
[0012] In step S2, the diameter of the main milling cutter is 1.6mm, and the machining quadrant for the main outline milling is the first quadrant.
[0013] It includes a CNC milling machine, which is equipped with a dust collection device and a control unit. The control unit is electrically connected to the CNC milling machine; the dust collection device is signal connected to the control unit; the control unit stores a milling tape program containing the machining path of the reserved connection point.
[0014] The CNC milling machine is equipped with a main milling cutter and a precision milling cutter.
[0015] The suction power and suction port position of the dust collection device are adjustable, and the suction ports are distributed around the processing area of the processing workbench.
[0016] The beneficial effects of this invention are: This invention utilizes the dust generated during the milling process as a temporary "clamp," along with pre-set connection points, to achieve secure fixation of the workpiece without a dedicated clamp. The ingenious design eliminates the risk of damage to the conductive structure of the winding board caused by traditional positioning methods, while also simplifying equipment requirements and reducing equipment investment costs.
[0017] This invention integrates the two separate processes of manual cutting and hand polishing in traditional processes into a continuous automated equipment processing in a single clamping. From the main outline cutting to the precision cutting of the connection points and the chamfering, no manual intervention is required, eliminating the impact of human operation on product quality and greatly improving the consistency of chamfering processing.
[0018] This invention, through the precise control of a CNC milling machine and the step-by-step processing of a dedicated milling cutter, ensures that the chamfer dimensional tolerance of the winding board is controlled within ±0.1mm, resulting in a smooth, burr-free chamfer surface. Simultaneously, the milling method replaces the traditional squeezing and shearing with diagonal pliers, fundamentally avoiding the problems of delamination and cracking on the side cross-section of the winding board. This guarantees the structural strength and electrical insulation performance of the winding board, reducing potential quality risks in subsequent assembly and use.
[0019] The automated processing mode of this invention significantly shortens the processing time of a single winding board, improving processing efficiency by more than 80% compared to traditional manual processes, thus meeting the needs of large-scale production. At the same time, it reduces labor input, avoids material scrap caused by manual operation, and the consumption of consumables such as sandpaper and diagonal pliers is almost zero, reducing the overall production cost. In addition, the optimized milling path reduces tool idle time, significantly reduces milling tool wear, and increases tool life, further reducing the cost of processing consumables.
[0020] This invention, by adjusting the length of the reserved connection point, adding a backing plate, and replacing the precision cutting cutter with different specifications, can be adapted to the chamfering processing of various planar transformer PCB winding boards with thicknesses of 0.5mm-2.0mm. It solves the problems of difficult fixing and low chamfering accuracy in the processing of ultra-thin and thick winding boards, and has strong processing versatility. Attached Figure Description
[0021] Figure 1 This is a process operation flow chart of the present invention; Figure 2 This is a schematic diagram of delamination cracks at the cross-section of the winding plate in this invention. Figure 1 ; Figure 3 This is a schematic diagram of delamination cracks at the cross-section of the winding plate in this invention. Figure 2 ; Figure 4 This is a schematic diagram of the gong belt path design in this invention; Figure 5 This is a partially enlarged schematic diagram of the dust fixation mechanism in this invention. Detailed Implementation
[0022] refer to Figures 1-5 An automated chamfering method for a planar transformer PCB winding board includes the following steps: S1: Create a router program based on the design file of the planar transformer PCB winding board. In the router program, a pre-reserved connection point is set between the starting point and the ending point of the machining path of the winding board outline. The cutting point is located at the right angle of the outer shape of the planar transformer PCB winding board, and the right angle is the right angle structure at the four corners of the winding board edge.
[0023] When creating the router program, the positioning holes at the four corners of the planar transformer PCB winding board are used as the machining positioning reference.
[0024] In this invention, the length of the reserved connection point is 1.3mm-2.5mm, and the thicker the planar transformer PCB winding board, the shorter the length of the reserved connection point.
[0025] The specific operations of this step are as follows: Based on the design file of the planar transformer PCB winding board, a routing program is created in CAM software. The positioning holes at the four corners of the planar transformer PCB winding board are selected as the machining positioning reference to avoid damage to the conductive structure of the planar transformer PCB winding board during the positioning process. In the routing program, a pre-reserved connection point is preset between the starting point and the ending point of the machining path of the planar transformer PCB winding board. The length of the pre-reserved connection point is 1.3mm to 2.5mm. The thicker the planar transformer PCB winding board, the shorter the length of the pre-reserved connection point. The starting point is preferably set at the right angle point of the planar transformer PCB winding board, and this right angle point is at the right angle structure of the four corners of the winding board edge to improve machining positioning accuracy.
[0026] S2: Fix the planar transformer PCB winding board onto the processing workbench. Based on the router program, use the main router cutter to perform router cutting of the main outline of the winding board. During the processing, adjust the dust collection device to keep the dust generated by cutting in the cutting stroke gap. Utilize the combined effect of the retained dust and the reserved connection points to fix the planar transformer PCB winding board to be processed onto the substrate board. The dust collection method of the controlled dust collection device is to reduce the dust collection force near the processing point, or remove the dust collection port near the processing point, or directly shut off the dust collection pipeline corresponding to the processing point.
[0027] When the thickness of a single board of the planar transformer PCB winding board to be processed is less than 1.0mm, a pad is placed on the board surface of the planar transformer PCB winding board before performing this step.
[0028] The diameter of the main milling cutter is 1.6mm, and the machining quadrant for the main outer profile milling is the first quadrant.
[0029] The specific operation of this step is as follows: Main outline cutting and dust-assisted fixation: The planar transformer PCB winding board is fixed on the processing worktable. Based on the completed routing program, a main router 4 with a diameter of 1.6mm is used to cut the main outline of the winding board along the processing path in the first quadrant. During the processing, by adjusting the dust collection device, the suction power near the processing point is reduced, the dust collection port near the processing point is removed, or the local dust collection pipeline corresponding to the processing point is closed. This allows a large amount of dust generated by the cutting to be retained and filled in the cutting stroke gap. By utilizing the frictional accumulation effect of the retained dust and the physical support of the reserved connection points, the planar transformer PCB winding board to be processed is firmly fixed to the board substrate, preventing the winding board from shifting or falling off during the processing.
[0030] If the thickness of a single board of the planar transformer PCB winding board to be processed is less than 1.0mm, before performing this step, waste drilled paper pads should be placed on the surface of the winding board to increase the dust adhesion area, improve the dust-assisted fixing effect, and avoid fixing failure due to the board being too thin or insufficient dust retention.
[0031] S3: After completing the main outline milling, replace it with a precision milling cutter with a diameter smaller than the main milling cutter. Use a lower feed speed than the main outline milling to precisely cut the reserved connection points and complete the separation and chamfering of the planar transformer PCB winding board.
[0032] The diameter of the precision cutting auger is 0.8mm-1.0mm, and the feed speed for precisely cutting the reserved connection point is 0.3m / min.
[0033] The specific operation of this step is as follows: Precision cutting and chamfering of reserved connection points: After the main outline of the winding board is cut, the precision cutting cutter with a diameter smaller than the main cutting cutter is replaced by an automatic tool changer. The diameter of the precision cutting cutter is preferably 0.8mm-1.0mm. The connection point is precisely cut along the processing path of the reserved connection point at a feed speed of 0.3m / min (lower than the feed speed of the main outline cutting), so that the planar transformer PCB winding board is separated from the substrate. At the same time, the chamfering of the edge of the winding board is achieved through precision cutting to ensure that the chamfered surface is smooth and burr-free.
[0034] A system for automating the chamfering of a planar transformer PCB winding board includes a CNC milling machine, which is equipped with a dust extraction device and a control unit. The control unit is electrically connected to the CNC milling machine. The dust extraction device is signal-connected to the control unit. The control unit stores a milling program containing a pre-reserved connection point processing path.
[0035] The control unit is electrically connected to the CNC milling machine and is used to send processing instructions to the CNC milling machine, control the CNC milling machine to perform the main outline milling and reserved connection point fine cutting processing actions step by step, and can adjust the processing parameters and processing path at the same time. The dust collection device is connected to the control unit via signal. Its suction power and suction port position can be adjusted by the control unit. It is used to adjust the dust collection effect during the main shape cutting stage, so that the cutting dust is retained in the cutting stroke gap to achieve dust fixation. During the fine cutting stage, normal dust collection can be restored to clean up the processing dust in time. The CNC milling machine is equipped with a main milling cutter and a precision milling cutter, which are used to replace the precision milling cutter according to the instructions of the control unit after the main outline is milled, so as to realize continuous processing. The suction power and suction port position of the dust collection device are adjustable, and the suction ports are distributed around the processing area of the processing workbench.
[0036] The processing worktable is a plate used to fix the PCB winding board of the planar transformer. The processing worktable is equipped with a positioning structure that adapts to the positioning holes at the four corners of the PCB winding board of the planar transformer, so as to ensure the accuracy and stability of the plate positioning.
[0037] In this invention, the suction ports are evenly distributed around the processing area of the processing workbench, and each suction port is equipped with an independent on / off valve, which can control the on / off of the suction port in a certain area according to processing needs, and precisely regulate the suction effect of the processing point.
[0038] The following two implementation examples illustrate this application: Example 1: Automated chamfering of a 1.2mm thick planar transformer PCB winding board. The specific steps are as follows: 1. Preliminary preparation: Import the design file of the winding board into the CAM software, create the router program, select the positioning holes at the four corners of the winding board as the machining positioning reference, set the cutting point 0.3mm above the right angle point of the upper left corner of the winding board, preset a 2.0mm long reserved connection point between the cutting point and the cutting end point of the outer shape machining path, and compile the precision cutting program of the reserved connection point into the router program separately; 2. Equipment debugging: Import the programmed winding tape into the control unit, fix the winding board to the processing worktable through the positioning structure, replace the main milling cutter of the CNC milling machine with a ∅1.6mm milling cutter, close the dust suction port of the dust collection device corresponding to the processing point, and only retain the weak suction of the surrounding suction port to ensure that most of the cutting dust is retained in the processing area. 3. Main outline milling: The control unit sends instructions to the CNC milling machine, which performs main outline milling along the processing path in the first quadrant. The dust generated during the milling process fills the cutting gap and, together with the 2.0mm reserved connection point, fixes the winding board to the substrate without displacement or falling off. 4. Precision cutting of connection points: After the main outline is cut, the control unit instructs the automatic tool changer to replace the main milling cutter with a precision milling cutter of ∅0.8mm. The CNC milling machine precisely cuts off the reserved connection points at a feed speed of 0.3m / min, completing the separation of the winding board from the substrate and the chamfering process; at the same time, the dust collection device resumes normal dust collection and cleans up the processing dust. 5. Finished product inspection: The edges of the winding board after processing are chamfered smoothly without burrs, delamination, cracks, deformation and other defects. The chamfer dimensional tolerance is controlled within ±0.1mm, which fully meets the assembly and use requirements of the planar transformer.
[0039] Example 2: Automated chamfering of an ultra-thin planar transformer PCB winding board with a thickness of 0.8mm. The specific steps are as follows: 1. Preliminary preparation: Same as in Example 1, create the roulette program and preset a 1.8mm long reserved connection point, and select the non-electroplated positioning holes at the four corners of the board edge as the positioning reference; 2. Board pretreatment: Cover the surface of the winding board with a layer of waste drilled paper pad to increase the dust adhesion area and improve the fixing effect; 3. Equipment debugging and processing: Same as in Example 1, close the dust suction port at the processing point, use a ∅1.6mm main milling cutter to perform main outline milling, and firmly fix the dust and reserved connection points. Subsequently, replace with a ∅1.0mm precision milling cutter and precision cut the connection points at a feed speed of 0.3m / min. 4. Finished product inspection: The ultra-thin winding board is free from deformation and cracks, with smooth chamfers and dimensional tolerances controlled within ±0.1mm, meeting the usage requirements.
Claims
1. An automated chamfering method for a planar transformer PCB winding board, characterized in that... Includes the following steps: S1: Create a router program based on the design file of the planar transformer PCB winding board. In the router program, a pre-reserved connection point is set between the starting point and the ending point of the machining path of the winding board outline. S2: Fix the planar transformer PCB winding board onto the processing workbench. Based on the router program, use the main router cutter to perform router cutting of the main outline of the winding board. During the processing, adjust the dust collection device to keep the dust generated by cutting in the cutting stroke gap. Utilize the combined effect of the retained dust and the reserved connection points to fix the planar transformer PCB winding board to be processed onto the substrate board. S3: After completing the main outline milling, replace it with a precision milling cutter with a diameter smaller than the main milling cutter. Use a lower feed speed than the main outline milling to precisely cut the reserved connection points and complete the separation and chamfering of the planar transformer PCB winding board.
2. The automated chamfering method for planar transformer PCB winding boards according to claim 1, characterized in that: In step S2, the dust collection method of the dust collection device is to reduce the dust collection force near the processing point, or remove the dust collection port near the processing point, or directly shut off the dust collection pipeline corresponding to the processing point.
3. The automated chamfering method for planar transformer PCB winding boards according to claim 1, characterized in that: In step S3, the diameter of the precision cutting auger is 0.8mm-1.0mm, and the feed speed for precisely cutting the reserved connection point is 0.3m / min.
4. The automated chamfering method for planar transformer PCB winding boards according to claim 1, characterized in that: In step S2, when the thickness of a single board of the planar transformer PCB winding board to be processed is less than 1.0 mm, a pad is placed on the surface of the planar transformer PCB winding board before performing this step.
5. The automated chamfering method for planar transformer PCB winding boards according to claim 1, characterized in that: In step S1, the cutting point is set at the right angle point of the outer shape of the planar transformer PCB winding board, and the right angle point is the right angle structure at the four corners of the winding board edge.
6. The automated chamfering method for planar transformer PCB winding boards according to claim 1, characterized in that: In step S1, when creating the router program, the positioning holes at the four corners of the planar transformer PCB winding board are selected as the machining positioning reference.
7. The automated chamfering method for planar transformer PCB winding boards according to claim 1, characterized in that: In step S2, the diameter of the main milling cutter is 1.6mm, and the machining quadrant for the main outline milling is the first quadrant.
8. A system for implementing the automated chamfering method for planar transformer PCB winding boards according to any one of claims 1-7, characterized in that: It includes a CNC milling machine, which is equipped with a dust collection device and a control unit. The control unit is electrically connected to the CNC milling machine; the dust collection device is signal connected to the control unit; the control unit stores a milling tape program containing the machining path of the reserved connection point.
9. The system according to claim 8, characterized in that: The CNC milling machine is equipped with a main milling cutter and a precision milling cutter.
10. The system according to claim 8, characterized in that: The suction power and suction port position of the dust collection device are adjustable, and the suction ports are distributed around the processing area of the processing workbench.