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When a wireless charging pad stops working or emits a faint hum, the cause is often a damaged coil or misalignment after a drop or disassembly. Begin by unplugging the unit and removing the outer shell to access the internal electronics. Inspect the coil housing for cracks, burns, or corrosion, and document the orientation of each coil part before removal. Use a non-conductive tool to lift the coil assembly carefully, avoiding any metal contact that could cause short circuits. Take clear photos from multiple angles for reference. Verify that the charging coil sits flat within its ferrite shield and that no foreign debris obstructs the gap between transmitter and receiver surfaces.

Next, source a compatible replacement coil kit that matches the original specifications, including the coil turns, wire gauge, and insulating coating. It is crucial to select components rated for the same wattage and frequency as the original device. Before installation, inspect the new coil for hidden defects, such as micro-cracks or loose windings, and test continuity with a multimeter. Align the coil precisely with the ferrite core or shield, ensuring there is uniform spacing around the circumference. Secure it with adhesive or mounts designed for minimal thermal expansion. Reassemble the unit loosely to verify that the coil remains centered and does not contact nearby metal parts.

After the coil is installed, perform a preliminary electrical test to confirm there is no short or open circuit. Use a regulated power source at a low voltage to power the transmitter stage and monitor current draw for stability. If the current spikes or the device overheats rapidly, recheck the coil alignment and insulation. A small gap between coils is essential for proper field coupling; too tight a fit can cause eddy currents that degrade performance, while too wide a gap reduces charging efficiency. Document any observed irregularities and compare them against the original design tolerances. A calibrated test rig can reproduce real-world charging distances for consistent results.

With basic electrical checks complete, you should evaluate the physical coil spacing using a precise spacer gauge. The goal is to mirror the manufacturer’s recommended air gap, typically a few tenths of a millimeter. Place the gauge between the transmitter coil and the ferrite shield while the power is off, then adjust the coil position until the gap is uniform all around. Re-test continuity and inspect for any shift when gently tapping the assembly. After confirming mechanical accuracy, reconnect the power supply and perform a light, iterative charging test at several positions and orientations. Observe the charging indicator and measure input efficiency at standard load conditions.

Once the coil geometry is verified, perform a series of controlled load tests to gauge practical performance. Place a compatible receiving pad or device on the transmitter and measure the charging rate over a fixed period. Note any drop in watts as you rotate or shift the device by small angles, which indicates nonuniform field distribution. If the output fluctuates beyond expected tolerance, re-check the alignment again and examine the ferrite shield for cracks. Additionally, ensure there are no nearby metal objects that could distort the magnetic field during operation. Document results carefully to establish a reliable baseline for future repairs.

A comprehensive evaluation also includes thermal monitoring during charging. Use an infrared thermometer or thermal camera to map hotspot formation along the coil and shield borders. Excessive heat in one area can point to partial misalignment or insufficient coupling. If heat concentrates near solder joints or connectors, inspect those areas for loose connections or damaged insulation. Ensure that any adhesives used do not exude fumes that could degrade coil performance over time. Finally, perform a fatigue test by simulating repeated charging cycles to confirm long-term stability.

In addition to electrical and thermal checks, verify the magnetic field pattern using a simple field probe or smartphone-based app that detects coil resonance. This cross-verification helps confirm that the transmitter and receiver coils are properly in phase and spaced. If misalignment is detected, small incremental adjustments can restore optimal coupling without disassembling major components. Maintain careful notes about the exact adjustments made and the corresponding performance changes. Over time, repeated checks help ensure that the coil assembly remains within tolerance despite handling or minor mechanical shifts during use.

Practical alignment testing also involves real-world compatibility. Try charging different compatible devices at several angles and distances to ensure stable transfer across a range of scenarios. Record the initial charging rate, peak rate, and any intermittent pauses. If certain devices hold a charge poorly, re-evaluate the coil gap and shielding to identify whether a targeted adjustment is needed. Protect the electrical connections from vibration with proper strain relief and ensure that connectors do not rub against the housing. A consistent, repeatable test protocol yields dependable results.

Safety remains a priority during repairs, especially when handling live components. Always disconnect power before handling coils or shields, and wear appropriate eye protection to guard against solder splashes. Use rotatable clamps to hold parts steady rather than fingers that could slip. When soldering, use flux with good residue management to avoid conductive residues near the coil. After each adjustment, verify there are no exposed metal edges that could contact the coil or shield. Finally, re-check insulation resistance with a megohmmeter to confirm that there is no breakdown, especially in high-humidity environments.

After completing the mechanical and electrical refinements, reassemble the unit with care. Secure the outer shell tightly to protect internal components and maintain proper spacing around the coil. Replace any worn gaskets or seals that could affect positioning or shielding performance. Run a full power cycle test from zero to full charge while monitoring for unexpected shutdowns or audible arcing. If the unit behaves unusually, backtrack through your alignment steps and revisit each one until the device meets safety and efficiency standards. A thorough wrap-up ensures dependable operation.

The final verification should include a documented performance dossier for future reference. Compile a comparison between pre-repair and post-repair metrics, including resistance, inductance, and resonance frequency if available. Provide a summary of observed improvements in charging speed, heat distribution, and stability under different loads. Include maintenance notes that highlight recurring trouble spots and suggested intervals for rechecking coil spacing. A clear record helps technicians quickly troubleshoot similar devices later and supports warranty requirements. If problems persist, consider reviewing the original design documents or consulting the manufacturer’s service manual to ensure compatibility and safety.

To close, maintain a proactive maintenance routine that keeps coils aligned. Periodically inspect the ferrite shield for cracks and replace any aging adhesive that may shift components. Avoid placing metal accessories near the charging pad during use, which can disturb the field and degrade efficiency. Train technicians to follow identical testing protocols to preserve consistency across repairs. By embracing precise spacing, careful alignment, and thorough testing, the repaired wireless charger can deliver reliable energy transfer and safe operation for many charging cycles.