Analysis of several components of switching power supply that "seriously affect the cost"!

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Analysis of several components of switching power supply that "seriously affect the cost"! [Copy link]

1The Impact of Custom Inductors on Cost

Common-mode inductors are essential EMC components for switching power supplies. However, whether the common-mode inductor has a base will directly affect your production costs. The problem lies in the base. If there is no base, the worker must have manually inserted it. And because the angle of the pin is not necessarily straight, it may take several insertions to insert it, which seriously affects the production schedule and production costs. However, if it is a standard part produced by a large company such as Wruth, it is possible to achieve machine insertion. The cost is also very different.

2The impact of transformer flying leads and safety skeletons on processing costs

The flying leads of transformers are also a point that seriously affects the cost of power supply. Because the flying lead transformers are not only expensive for custom-made transformers, but also expensive for installation and production costs, after all, this is a solution that requires manual plug-in. It is for this reason that only super compact high-performance power supply solutions will use the flying lead transformer design. Of course, modern IT products have much higher space requirements than cost demands, so flying lead transformers are still very common.

If possible, using a safety transformer bobbin can avoid the use of flying wires, but it will waste some space. You can't have your cake and eat it too. It depends on your values when designing the power supply.

3The installation cost of the power heat sink

This is a common To220 package transistor, but if you want to install a heat sink for it, you will need the following parts.

Insulation cap, insulation pad, heat sink, screw, gasket, spring ring.

Then there is a special man-hour to install this transistor. This is the fundamental reason why I am very reluctant to use independent MOS tubes and add heat sinks in low-cost solutions. If PCB heat dissipation can be used, PCB heat dissipation must be used. The cost is high.

4Insulation baffle

As the name implies, it is a plastic insulator used to isolate electronic components and increase the voltage resistance of the power supply.

Don't underestimate these things. Although the unit price of these things is not high, they are very time-consuming.

If you look at it the other way around, you will understand that the shape of this baffle is very peculiar. You can never buy ready-made goods without custom-making. It is definitely not cost-effective for most companies to have such financial resources to make a mold to make a baffle for small batches of products. However, the charging head of Xiaomi 6 uses such a custom-made baffle. Let's calculate the cost. He is really generous and tolerant.

5The right to speak on pricing

You can completely copy the board and then buy all the components on it. But the price you can negotiate with the supplier will definitely not be better than Apple's. I believe you can understand this, so the whole price is actually a mystery. For industrial products, clearly marked prices are a joke.

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