Flexible coil current transformer and production method thereof

A coil current and transformer technology, applied in the manufacture of inductors, inductors/transformers/magnets, transformer/inductor coils/windings/connections, etc. problem, to achieve the effect of easy and fast installation

Inactive Publication Date: 2012-10-24
SHENZHEN CHUANGYIN TECH
8 Cites 9 Cited by

AI-Extracted Technical Summary

Problems solved by technology

[0004] At present, the traditional electromagnetic current transformer also has a method of opening an air gap on the iron core magnetic circuit. By increasing the reluctance and reducing the residual magnetism, it will not be saturated when the tra...
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Method used

The advantage of low-pressure injection molding: 1. injection pressure is extremely low, without damaging internal coil; 2. curing time is fast (5~10S); 3. injection temperature is low (180 ℃~200 ℃); 4. sealing is good; 5 .Low-pressure molds can use aluminum molds, and the corresponding cost is also low; so choosing this low-pressure injection molding method can effectively ensure the electrical performance and structural requirements of the flexible coil.
[0031] The compensation turn is a loop, and the enameled wire wound in step B is a large turn. Since the return line is connected in series with the large turn in the opposite direction, and the return line and the large turn are located on the same plane, therefore, for the interference perpendicular to the coil and the eccentricity of the primary current-carrying conductor, the induced potential generated in the large turn and the return line The directions are opposite and the sizes are approximately equal to cance...
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Abstract

The invention provides a flexible coil current transformer and a production method thereof. The method comprises the following steps: processing silicone rubber composite into a flexible skeleton; winding enamelled wires on the flexible skeleton; winding compensating turns on the flexible skeleton; letting the primary sides of the wound enamelled wires go through the rated current for test; arranging an insulating layer on the tested and qualified flexible skeleton with the enamelled wires; arranging a shielding layer on the outer part of the insulating layer; welding an output shielding wire on one end of the shielding layer; retesting output signals of a coil; and arranging a low-voltage injection insulating protective layer on the outer part of the shielding layer. The flexible coil current transformer provided by the invention is flexible in structure, can be opened and also can be measured randomly in small space without breaking circuits. The installation is simple and rapid, and the output signals can be rapidly connected to an oscilloscope, a data recorder or a multimeter through a connector.

Application Domain

Technology Topic

Materials processingCurrent transformer +6

Image

  • Flexible coil current transformer and production method thereof

Examples

  • Experimental program(1)

Example Embodiment

[0022] In order to better understand the technical solutions of the present invention, the embodiments provided by the present invention will be described in detail below with reference to the accompanying drawings.
[0023] The embodiment of the present invention provides a flexible coil current transformer, such as figure 1 As shown, it includes:
[0024] The wire body, the output shielded wire 106, the plastic lock catch 107 and the integrating amplifier 108, the wire body includes a flexible frame 101, an enameled wire 102, an insulating layer 103, a shielding layer 104, and a low-voltage injection molded insulating protective layer 105, in which:
[0025] The flexible skeleton is wound with enameled wire, the enameled wire is wound with an insulating layer, the insulating layer is provided with a shielding layer, the shielding layer is provided with a low-voltage injection molded insulating protective layer, and the connecting end of the wire body is provided with Plastic lock, the shielding layer of the line body is connected to the integrating amplifier through the output shielding line.
[0026] The present invention also provides a method for manufacturing a flexible coil current transformer, which includes the steps:
[0027] A. The silicone rubber composite material is processed into a flexible skeleton; since the induced voltage of the coil is proportional to the cross-section of the single-turn coil, in order to reduce the influence of temperature on the coil skeleton, a silicone rubber composite material with a low expansion coefficient is used. The expansion coefficient is as low as 1.2×10-5/℃, the working temperature range is -50~180℃, and the silicone rubber has excellent compression resistance, ensuring the consistency of the coil section under different environments, and at the same time meeting flexibility And a certain mechanical strength, the hardness is controlled at 60 Shao degrees, and the silicone rubber is used to form a flexible skeleton with an outer diameter of Φ8.5mm.
[0028] B. Winding the enameled wire on the flexible frame: fix one end of the flexible frame to the head of the winding machine shaft, and fix the other end on the concentric bearing tooling, adjust the strength of the two ends of the frame, and wind the enameled wire.
[0029] For winding coils on a flexible skeleton, the parallel winding machine provided by the prior art is difficult to meet the winding demand. It is necessary to use a spiral winding machine or modify the existing parallel winding machine. Here, the parallel winding The machine is equipped with a concentric bearing tooling to meet the winding needs. First, fix one end of the flexible frame on the head of the winding machine shaft, fix the other end of the flexible frame on the concentric bearing tooling, adjust the strength of the two ends of the frame, and start Winding, enameled wire adopts Φ0.10mm QZ-2/155 polyurethane enameled copper wire, the winding coefficient is controlled at 1.15, to ensure that there is a certain gap between the turns, and the coils should be evenly distributed so that the coils can be bent into a circle later When looping, the turns will not be stacked to form a symmetrical distribution. At this time, the induced potentials generated in the two symmetrical small turns are equal in magnitude and opposite in direction, and the two cancel each other, which can effectively suppress the interference parallel to the coil and the current-carrying conductor Eccentric interference.
[0030] C. Winding compensation turns on the flexible skeleton;
[0031] The compensation turn is a loop, and the enameled wire wound in step B is a large turn. Since the loop and the large turns are connected in series in the opposite direction, and the loop and the large turns are in the same plane, the induced electric potential generated in the large turns and loops for interference perpendicular to the coil and the eccentricity of the primary current-carrying conductor The directions are opposite, the sizes are approximately equal, and they cancel each other out, so the winding compensation turn structure of the coil can well compensate the magnetic field interference. Weld the large wire turns embedded in the flexible skeleton with the beginning of the loop, and the lead end of the loop is drawn from the head end of the loop and the end of the large loop, so that the loop is reversed by one turn inside the coil to compensate The role of.
[0032] D. Test the primary side of the winding enameled wire through the rated current; pass the primary side of the coil of the wound enameled wire through the rated current, and test the signal value of the secondary output terminal with a 6 and a half high precision voltmeter to meet the design requirements .
[0033] E. Install an insulating layer on the flexible frame with enameled wire that has passed the test; the flexible coil that has passed the test in step D is half-stacked (TP1) polytetrafluoroethylene (PTFE) insulation tape on the periphery of the coil. The specification of vinyl fluoride tape is: 15mmx0.1mm, temperature resistance 180℃.
[0034] F. Set a shielding layer outside the insulating layer; in order to avoid the influence of the coupling capacitance of the alternating electric field on the coil magnetic field, the flexible coil must be shielded, the shielding layer must be reliably grounded, and a metal shielding layer for low-frequency alternating electric fields must be used. For high-frequency alternating electric fields, high-resistivity materials are required. Therefore, semiconductor composite paper with higher resistivity is used, and the semiconductor composite paper is wrapped around 1/3 of the coil in one layer, and 7 pieces of Φ0 are wrapped at the same time as the shielding layer. .12 Tinned copper wire W2 connects the semiconductor composite paper turns together, and at the same time, it is led out and welded together with the shielding layer of the output shielding wire and grounded.
[0035] G. Soldering an output shielding wire to one end of the shielding layer;
[0036] H. Retest the output signal of the coil, the test process is the same as step D;
[0037] I. A low-voltage injection-molded insulating protective layer is arranged outside the shielding layer. To meet the requirements of external insulation and protection of the flexible coil, it is necessary to wrap the flexible coil with an insulating layer and adopt low-pressure injection molding. Compared with sleeve wrapping, low-pressure injection molding protects the coil more reliably. The flexible coil is completely sealed and die-casted. In plastic, its frequent bending, opening and closing service life is longer.
[0038] Advantages of low-pressure injection molding: 1. Very low injection pressure, no damage to the internal coil; 2. Fast curing time (5~10S); 3. Low injection temperature (180℃~200℃); 4. Good sealing; 5. Low pressure The mold can be an aluminum mold, and the corresponding cost is low; therefore, this low-pressure injection molding method can effectively ensure the electrical performance and structural requirements of the flexible coil.
[0039] Process flow of low pressure injection molding of flexible coil: The equipment adopts low pressure injection molding machine, the temperature parameters before injection: the temperature of the glue tank is 185℃, the temperature of the injection nozzle is 190℃, and the temperature of the hose is 185℃; put the wound and wrapped coil into the injection mold Adjust the position, close the mold, and the injection time is 12s to ensure that the glue can fill the injection space. There will be no undesirable phenomena such as dissatisfaction, air bubbles, etc., holding pressure 0.2Mpa, holding pressure time 8s, cooling time 30s, cooling is completed, mold is opened, and the finished product is taken out.
[0040] The above provides a detailed introduction to the flexible coil current transformer and its manufacturing method provided by the embodiments of the present invention. For those of ordinary skill in the art, according to the ideas of the embodiments of the present invention, the specific implementation and application scope will be discussed. There are changes. In summary, the content of this specification should not be construed as limiting the present invention.
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Description & Claims & Application Information

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