Manufacturing high reliability weapon grade transformers in small lots
Sandia has used flyback transformers for many years, primarily to charge capacitors for capacitive discharge units. Important characteristics of the transformer design are to meet inductance, turns ratio, and high voltage breakdown requirements as well as not magnetically saturating during each energy transfer cycle. Sandia has taken over production responsibility for magnetic components from a previous GE/LM, General Electric/Lockheed Martin, facility in Florida that produced {approximately} 50 K units per year. Vanguard Electronics is working with Sandia to transfer many of these designs to Vanguard`s small manufacturing facility in Gardena, CA. The challenge is to achieve the required high reliability and meet all the other electrical requirements with such small quantities of parts, {approximately} 100 per year. DOE requirements include high reliability {le} 3 failures per 10,000 components per 20 years while meeting numerous other environmental requirements. The basic design and prove-in required four lots of preproduction parts, extensive environmental testing, and numerous design changes. The manufacturing problems that affected performance of the transformer will be presented. These include encapsulation voids and core alignment. Also, some extended life test data that predicts long term reliability of newly produced transformers versus older designs will be compared.
- Research Organization:
- Sandia National Labs., Passive Devices/Interconnects Dept., Albuquerque, NM (United States)
- Sponsoring Organization:
- USDOE, Washington, DC (United States)
- DOE Contract Number:
- AC04-94AL85000
- OSTI ID:
- 674582
- Report Number(s):
- SAND-98-1459C; CONF-981007-; ON: DE98007216; BR: DP0401014; TRN: AHC29820%%34
- Resource Relation:
- Conference: EEIC/EMCW conference, Cincinnati, OH (United States), 6-8 Oct 1998; Other Information: PBD: [1998]
- Country of Publication:
- United States
- Language:
- English
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