Gujing has overcome the challenge of rod-type inductors: pressure testing tooling has achieved breakthroughs in mass production for automotive industry customers

I.Customer needs and industry pain points

The 2x10 rod-type inductors used by customers in the automotive industry, due to their tiny size (2mm×10mm), have extremely high requirements for product reliability: a single inductor must withstand a force of over 2.5kg to completely eliminate the issue of coil and magnetic core detachment. Traditional full inspection methods have two major pain points:

1. Manual defect detection: Manual testing is prone to uneven stress, and prolonged testing can easily injure fingers, leading to deviations in detection results;

2. Cost pressure: The cost of manual full inspection is high, making it difficult to accommodate mass production demands.

II. Valley View Solution: Customized Pressure Testing Tooling

Addressing the aforementioned issues, the GJ team has developed a pressure testing tooling through multiple process adjustments. The main advantages are as follows:

1. Accurate force control design: The tooling adopts a mechanical structure to ensure that the applied force remains stable at over 2.5kg, meeting the stringent standards of customers. Additionally, the contact surface is made of high-hardness wear-resistant material to avoid damage to the inductive surface.

2. Efficiency of pressure test tooling inspection: Replacing manual operations, it shortens the inspection time for individual inductors, significantly enhancing inspection efficiency;

3. Cost optimization: Reduce reliance on manual labor, reduce the cost of single batch testing by over 60%, and adapt to the scale effect of mass production.

III. Mass production verification and industry value

1. Customer verification results: After multiple verifications through small-scale trial production, the rate of coil and magnetic core detachment has been reduced to 0% in the installation and use of inductors at the customer's end after tooling testing, fully meeting reliability requirements;

2. Mass production implementation: Currently, the client has officially initiated mass production, and the Gujing tooling solution has become the standard testing process for this model of inductor;

3. Significance of technological breakthrough: In the field of micro inductors, the technological contradiction of "small size + high reliability" has been resolved through tooling innovation, providing a reproducible solution for the large-scale production of automotive electronic components.

IV. Summary of Gujing's Technological Capabilities

This breakthrough demonstrates the significant competitiveness of Gujing in inductor manufacturing:

1. Customized R&D capability: Quick response to customers' special needs, with the design-to-implementation cycle shortened to 1/3 of traditional solutions;

2. Precision manufacturing experience: With deep expertise in micro inductor technology, we have mastered the entire chain of technology, including material selection and structural design;

3. Automotive-grade quality standard: Using tooling as a carrier, integrate the "zero defect" requirement into the mass production process, in compliance with industry certification specifications such as IATF 16949 for automotive electronics.

Through the innovation of pressure testing tooling, Gujing not only addressed the pain points of individual customers but also facilitated breakthroughs in the application of micro inductors in high-reliability scenarios, providing a technical template for the intelligent production of automotive electronic components. If you are facing inductor process challenges, feel free to reach out to us. Perhaps the next "industry requirement" will be jointly created by us!