Hall current sensors, as the main core components in control and transmission systems, play a crucial role in the overall stability of equipment and are widely used in various industries such as variable frequency speed regulation, battery testing, power supply, servo, welding machine power supply, photovoltaic inverter, wind power inverter, reactive power compensation, electroplating, rectification, locomotives, etc.

The product process of a current sensor is cumbersome and involves numerous steps. Here are some basic steps to provide a good understanding of the current sensor and facilitate its selection.

1. PCB chip placement processing for circuit boards

The current sensor PCB board mounting machining center uniformly performs mounting, which has the advantages of high accuracy, small error, and high efficiency.

2. Welding of other PCB components

After the placement machine is processed, some remaining components that cannot be completed by the placement machine are welded manually, such as terminals, potentiometer and other components. After the welding is completed, visual inspection by the welding personnel shows whether there are any missing components or welding errors.

3. Initial assembly of current sensor

Weld the two outgoing wires of the coil to the corresponding positions on the circuit board, and sequentially embed the magnetic core and circuit board into the casing.

4. Initial debugging

After assembly is completed, the initial debugging inspection is carried out by the debugging personnel. Before gluing, this step is very important, mainly checking whether the product is good. If there is a welding error on the PCB board or the number of coils wound is incorrect, it can be replaced in a timely manner. After debugging, measure after gluing.

5. Gluing

After the initial product adjustment, if there are no problems, use a fully automatic glue injection machine for one-time glue injection. Do not perform secondary glue injection, and after glue injection, place it in a high-temperature box to fully release the bubbles inside the glue under high temperature conditions and avoid quality problems caused by bubbles.

6. Secondary testing

After the glue injection is completed, and before high and low temperatures, a secondary test is conducted. The main purpose of the secondary test is to increase the current from 0 to 1000A, and increase it every 50A or 100A.

7. High and low temperature, aging test

After the product undergoes secondary testing, the current sensor needs to undergo various tests such as high temperature, low temperature, vibration, power aging, and room temperature aging. The high temperature needs to be increased to 100 degrees Celsius, and the low temperature needs to be increased to minus 40 degrees Celsius. The vibration test is generally according to the customer's requirements (railway, coal mine, vehicle, and wind power generally have this requirement).

8. Appearance beautification

After various experiments, the product will be beautified by the staff to remove the glue on the shell and terminals.

9. Factory inspection

After the product has been beautified, it needs to undergo a secondary inspection after Z. Following the same process as the secondary inspection, the current should be set from 0 to 1000A, increasing every 50A or 100A, and the waveform and corresponding time chart of each stage should be viewed.

10. Marking

After various inspections and tests, the product is then marked with a laser marking machine.

11. Packaging

After the product has undergone various inspections and tests, it must be packaged using pearl cotton with a reasonable design to prevent transportation vibration, and equipped with inspection reports, packing lists, and instructions.