A flying wire winding process method based on electronic transformer

Abstract

The present invention relates to a flying wire winding process for electronic transformers, belonging to the technical field of transformers. The process comprises (A) a preparation step; (B) winding 1; (C) winding 2 to winding n; (D) winding n+1; (E) pin arrangement; (F) flying wire tinning / pin welding; and (G) outer glue coating of the wire package. The present invention has the following beneficial effects: the first and subsequent windings are wound in a center-tapped segmented winding manner, and the wire ends are then twisted, welded, and secured with protection, thereby avoiding the risk of damage to the reserved wire during turnover and straightening of the enameled wire during winding. The process also improves winding efficiency and facilitates the use of automated equipment. Manual winding efficiency is increased by 30%, while automated winding efficiency is increased by over 60%, meeting the market demand for large-scale use.

Description

Technical Field

[0001] The invention relates to a flying wire winding process method based on an electronic transformer, belonging to the technical field of transformers. Background Art

[0002] Typically, an electronic transformer consists of a bobbin, coils, and an iron core. The bobbin has a center hole, onto which the coils are wound, and the iron core is inserted from both sides of the bobbin into the center hole. During the initial production of an electronic transformer, the bobbin is inserted into the winding spool mold of the transformer winding machine. The primary and secondary coils are then wound around the bobbin using a rotary motion. Once winding is complete, the iron core is inserted into the coil package as required and secured.

[0003] In general, a single-output power supply has a transformer with three or more windings: a primary winding Np, a secondary winding Ns, and an auxiliary power winding Nb. The winding method of clamping the primary and the secondary increases the effective coupling area of ​​the primary and secondary windings, greatly reduces the leakage inductance of the transformer, and reduces the voltage spike. This reduces the voltage stress of the MOSFET and, at the same time, the common-mode interference current caused by the MOSFET and the heat sink, thereby improving EMI. Since a secondary winding is added in the middle of the primary, the interlayer distributed capacitance of the transformer primary is reduced. The reduction in interlayer capacitance reduces parasitic oscillations in the circuit, which can also reduce the voltage and current stress of the MOSFET and the secondary rectifier tube, thereby improving EMI.

[0004] This process uses a sandwich flying wire winding process, with the order Np / 2, Ns, Np / 2, and Nb. The original winding method for the product is as follows: After winding N1 is completed, a certain length of flying wire is reserved using a winding block and coiled together. Subsequent winding steps are then performed (before each winding step, the coiled flying wire needs to be secured to the winding shaft to facilitate winding). The final winding is then wound using the reserved wire from the first winding, straightened, and then wound. During the winding process, because the remaining windings are included, the coiled flying wire needs to be secured separately, increasing labor intensity and reducing efficiency. When the reserved wire is removed, the enameled wire is easily tangled and damaged, posing a risk of flying wire damage and product quality risks. Summary of the Invention

[0005] In order to overcome the shortcomings of the above-mentioned prior art, the present invention provides a flying wire winding process method based on an electronic transformer, in which the primary winding is wound in a center-tapped segmented winding manner, and then the wire tail and wire head are twisted and welded together and fixed, and a sleeve is used for insulation protection. While ensuring product quality, it facilitates the use of automated production equipment and improves production efficiency.

[0006] The present invention is achieved through the following technical solution: a method for winding a flying wire of an electronic transformer, comprising: (A) a preparation process; (B) winding 1; (C) winding 2 to winding n; (D) winding n+1; (E) pin arrangement; (F) flying wire tinning / pin welding; (G) outer glue coating of the wire package; the specific steps are as follows:

[0007] (A) Preparation: Use a tube cutter to cut the Teflon tube;

[0008] (B) Winding 1: First, press the reset button on the winding machine; pass one enameled wire through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding machine's winding shaft mold, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, the tail wire is led out from the top side of the bobbin, leaving some wire length. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0009] (C) Winding 2 - Winding n: First, press the reset button of the winding machine; pass the enameled wire through the magnetic bead, through the felt on the wire clamp, and pull it to the side of the winding shaft mold. Insert the skeleton into the winding shaft mold of the winding machine. After the enameled wire is passed through the casing, the lead wire is hung at the beginning of the skeleton wire. Press the start / stop button of the winding machine, and the winding machine will wind evenly in a clockwise direction. After the winding machine stops, the enameled wire and the casing are hung at the end of the skeleton wire. Use small scissors to cut the enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0010] (D) Winding n+1: First, press the reset button of the winding machine; pass one enameled wire through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding shaft mold of the winding machine, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, the tail wire is led out from the top side of the bobbin, leaving some wire length. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0011] (E) Pin Arrangement: Twist the flying wires at the top of the frame together to the sleeve position, and use side cutters to cut off the excess part at a certain distance from the sleeve; use toothless pliers to twist the leads to the corresponding pins, cut off the excess part and press the leads down close to the base of the pins;

[0012] (F) Flying wire tinning / pin soldering: Place the twisted flying wire into the tin pot and tin it up to the sleeve; dip the pin into the flux up to the twisting point and place it into the tin pot to solder the pins on both sides;

[0013] (G) Glue wrapping of wire package: first press the reset button of the winding machine; insert the skeleton into the winding shaft mold of the winding machine, and pass the flying wire through the sleeve, which should completely cover the stranded wire; press the start / stop button of the winding machine, and the winding machine will glue the flying wire in a clockwise direction. After the winding machine stops, use small scissors to cut the tape; remove the wire package from the winding shaft mold.

[0014] The reserved wire lengths of the winding 1 in step (B) and the winding n+1 in step (D) are 15-25 mm.

[0015] Use side cutting pliers to cut off the excess part of the sleeve of the (E) pin at 3-4 mm.

[0016] The beneficial effects of the present invention are as follows: the present invention winds the first and subsequent windings in a center-tapped segmented winding manner, and then twists and welds the wire ends to fix them and protect them, thereby avoiding the risk of damage to the reserved wire during turnover and straightening of the reserved wire during the winding process of the enameled wire. At the same time, the winding efficiency is improved, and the use of automated equipment is facilitated. The manual winding efficiency is increased by 30%, and the automated winding efficiency is increased by more than 60%, meeting the large-scale use needs in the market. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention will be further described below with reference to the accompanying drawings and examples.

[0018] Figure 1 It is a flow chart of Example 1 of the present invention. DETAILED DESCRIPTION

[0019] Example 1 of a flying wire winding process method for an electronic transformer, a TS-EI33LD transformer, the specific steps are as follows:

[0020] (A) Preparation: Use a tube cutter to cut the Teflon tube. Apply a layer of 0.025*17 polyimide tape before wrapping the frame.

[0021] (B) Figure 1 Winding N1.1 shown in B: First, press the reset button of the winding machine; pass one enameled wire (enameled wire QA-1 / 180*℃φ0.4) through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding shaft mold of the winding machine, and after passing the enameled wire through the casing, hang the lead wire at the beginning of the bobbin wire, with the lead wire hanging on pin No. 2; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, leave the tail wire A 15-25mm from the top side of the bobbin. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0022] (C) Winding N2-N7: First, press the reset button of the winding machine; pass the enameled wire through the magnetic bead, pull it to the side of the winding shaft mold through the felt on the wire clamp, insert the bobbin into the winding shaft mold of the winding machine, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind evenly in a clockwise direction. After the winding machine stops, hang the enameled wire and the casing at the end of the bobbin wire as the lead wire. Cut the enameled wire with small scissors and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0023] (D) Figure 1 Winding N1.2 shown in D: First, press the reset button of the winding machine; pass one enameled wire (enameled wire QA-1 / 180*℃φ0.4) through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding shaft mold of the winding machine, and hang the lead wire at position A at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, the tail wire is led out from the top side of the bobbin, leaving 15-25mm for the lead wire. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0024] (E) Pin arrangement: Twist the reserved wires A of the N1.1 and N1.2 windings together to the sleeve position. Use side cutters to cut off the excess part 3-4mm away from the sleeve. Use toothless pliers to twist the leads to the corresponding pins, cut off the excess part and press the leads down close to the base of the pins.

[0025] (F) Figure 1 Tinning of flying leads / pin soldering as shown in F: Place the twisted flying leads in a tin pot and tin them up to the sleeve. Dip the pins into flux and apply it to the twisting point. Place them in the tin pot and solder the pins on both sides. Twist the reserved wires A of the N1.1 and N1.2 windings and solder them. Cover the soldering points with 14#15mm Teflon sleeves to prevent them from being exposed. Fold the wires back and wrap them inside. Cover the outside with two layers of 0.025*17 polyimide tape.

[0026] (G) Glue wrapping of wire package: first press the reset button of the winding machine; insert the skeleton into the winding shaft mold of the winding machine, and pass the flying wire through the sleeve, which should completely cover the stranded wire; press the start / stop button of the winding machine, and the winding machine will glue the flying wire in a clockwise direction. After the winding machine stops, use small scissors to cut the tape; remove the wire package from the winding shaft mold.

[0027] The specific parameters are shown in Table 1:

[0028]

[0029] Table 1

[0030] Example 2, TS-EE13MA6 transformer, the specific steps are as follows:

[0031] (A) Preparation: Use a tube cutter to cut the Teflon tube;

[0032] (B) Winding NP1: First, press the reset button on the winding machine; pass one enameled wire (enameled wire QA-1 / 180*℃φ0.2) through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding machine's winding shaft mold, and after passing the enameled wire through the casing, hang the lead wire at the beginning of the bobbin wire, with the lead wire hanging on pin 2; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, leave the lead wire greater than 15mm from the top side of the bobbin. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0033] (C) Winding N1-N3: First, press the reset button of the winding machine; pass the enameled wire through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding shaft mold of the winding machine, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind evenly in a clockwise direction. After the winding machine stops, hang the enameled wire and the casing at the end of the bobbin wire as the lead wire. Cut the enameled wire with small scissors and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0034] (D) Winding NP2: First, press the reset button on the winding machine; pass one enameled wire (enameled wire QA-1 / 180*℃φ0.2) through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding machine's winding shaft mold, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, the tail wire is led out from the top side of the bobbin, leaving the lead wire larger than 15mm. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0035] (E) Pin arrangement: Twist the reserved wires of NP1 and NP2 windings together to the sleeve position, and use side cutters to cut off the excess part 3-4mm away from the sleeve; use toothless pliers to twist the leads to the corresponding pins, cut off the excess part and press the leads down close to the base of the pins;

[0036] (F) Flying Wire Tinning / Pin Soldering: Place the twisted flying wires in a tin pot and tin them up to the sleeve. Dip the pins into flux and solder them to the twist point. Place them in the tin pot and solder the pins on both sides. Twist the reserved wires of the NP1 and NP2 windings and solder them. Cover the soldering points with 17# Teflon sleeves to prevent them from being exposed. Then fold the wires inside and wrap them with two layers of 0.025*8 polyimide tape.

[0037] (G) Glue wrapping of wire package: first press the reset button of the winding machine; insert the skeleton into the winding shaft mold of the winding machine, and pass the flying wire through the sleeve, which should completely cover the stranded wire; press the start / stop button of the winding machine, and the winding machine will glue the flying wire in a clockwise direction. After the winding machine stops, use small scissors to cut the tape; remove the wire package from the winding shaft mold.

[0038] The specific parameters are shown in Table 2:

[0039]

[0040] NP1 / 2 winding reserved wire twisted solder, hard point outer cover 17# Teflon casing protection must not be exposed, then fold the wire inside, and cover with 2 layers of 0.025*8 polyimide tape.

[0041] Table 2

[0042] Example 3, TS-EE16CA transformer, the specific steps are as follows:

[0043] (A) Preparation: Use a tube cutter to cut the Teflon tube;

[0044] (B) Winding NP1: First, press the reset button on the winding machine. Pass one enameled wire (enameled wire QA-1 / 155*℃ 2*φ0.2) through the magnetic bead and pull it through the felt on the wire clamp to the side of the winding spool mold. Insert the bobbin into the winding machine's winding spool mold. After the enameled wire is sleeved, hang the lead wire at the beginning of the bobbin wire, with the lead wire hanging on pin 2. Press the start / stop button on the winding machine to wind the wire evenly in a clockwise direction. After the winding machine stops, leave the lead wire F1 10±1mm from the top side of the bobbin. Use scissors to cut one enameled wire and cover the wire package with glue. Remove the wire package from the winding spool mold.

[0045] (C) Winding N1-N3: First, press the reset button of the winding machine; pass the enameled wire through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding shaft mold of the winding machine, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind evenly in a clockwise direction. After the winding machine stops, hang the enameled wire and the casing at the end of the bobbin wire as the lead wire. Cut the enameled wire with small scissors and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0046] (D) Winding NP2: First, press the reset button on the winding machine; pass one enameled wire (enameled wire QA-1 / 155*℃2*φ0.2) through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding machine's winding shaft mold, and after the enameled wire is inserted into the casing, hang the lead wire at the F2 position at the beginning of the bobbin wire; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, the tail wire is led out from the top side of the bobbin, leaving 10±1mm for the lead wire. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold;

[0047] (E) Pin arrangement: Twist the reserved wires of NP1 and NP2 windings together to the sleeve position, and use side cutters to cut off the excess part 3-4mm away from the sleeve; use toothless pliers to twist the leads to the corresponding pins, cut off the excess part and press the leads down close to the base of the pins;

[0048] (F) Flying Wire Tinning / Pin Soldering: Place the twisted flying wires in a tin pot and tin them up to the sleeve. Dip the pins into flux and solder them to the twist point. Place them in the tin pot and solder the pins on both sides. Twist the reserved wires of the NP1 and NP2 windings and solder them. Cover the soldering points with 14# Teflon sleeves to prevent them from being exposed. Then fold the wires inside and wrap them with 1.5 layers of 0.025*9 polyimide tape.

[0049] (G) Glue wrapping of wire package: first press the reset button of the winding machine; insert the skeleton into the winding shaft mold of the winding machine, and pass the flying wire through the sleeve, which should completely cover the stranded wire; press the start / stop button of the winding machine, and the winding machine will glue the flying wire in a clockwise direction. After the winding machine stops, use small scissors to cut the tape; remove the wire package from the winding shaft mold.

[0050] The specific parameters are shown in Table 3:

[0051]

[0052] Flying wires F1 and F2 are twisted and soldered. The solder joints are covered with 14# Teflon sleeves for protection and must not be exposed. The wires are then folded back and wrapped inside. The solder joints are covered with 1.5 layers of 0.025*9 polyester tape.

[0053] Table 3

[0054] The present invention eliminates the winding of reserved wires and the fixing of flying wires in each process. The reserved wires are first hung to a fixed position, and finally the two reserved wires are twisted and welded, and then folded back into the wire package after insulation protection, which is convenient for production using automated winding equipment.

Claims

1. A flying wire winding process method for an electronic transformer, characterized in that: The process includes (A) preparation; (B) winding 1; (C) winding 2 to winding n; (D) winding n+1; (E) pin arrangement; (F) flying lead tinning / pin welding; (G) wire wrapping and adhesive coating. The specific steps are as follows: (A) Preparation process: Use a tube cutter to cut the Teflon tube; (B) Winding 1: First, press the reset button on the winding machine; pass one enameled wire through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding machine's winding shaft mold, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, the tail wire is led out from the top side of the bobbin, leaving some wire length. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold; (C) Winding 2 - Winding n: First press the reset button of the winding machine; pass the enameled wire through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the skeleton into the winding shaft mold of the winding machine, and hang the lead wire at the beginning of the skeleton wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind evenly in a clockwise direction. After the winding machine stops, hang the enameled wire and the casing at the end of the skeleton wire as the lead wire. Cut the enameled wire with small scissors and cover the wire package with glue; remove the wire package from the winding shaft mold; (D) Winding n+1: First, press the reset button on the winding machine; pass one enameled wire through the magnetic bead, pull it through the felt on the wire clamp to the side of the winding shaft mold, insert the bobbin into the winding machine's winding shaft mold, and hang the lead wire at the beginning of the bobbin wire after passing the enameled wire through the casing; press the start / stop button of the winding machine, and the winding machine will wind the wire evenly in a clockwise direction. After the winding machine stops, the tail wire is led out from the top side of the bobbin, leaving some wire length. Use scissors to cut one enameled wire and cover the wire package with glue; remove the wire package from the winding shaft mold; (E) Pin arrangement: Twist the flying wires at the top of the frame together to the sleeve position, and use side cutters to cut off the excess part at a certain distance from the sleeve; use toothless pliers to twist the leads to the corresponding pins, cut off the excess part and press the leads down close to the base of the pins; (F) Flying wire tinning / pin soldering: Place the twisted flying wire into the tin pot and tin it to the sleeve; dip the pin into the flux to the twisting point and place it into the tin pot to solder the pins on both sides; (G) Glue wrapping of wire package: first press the reset button of the winding machine; insert the skeleton into the winding shaft mold of the winding machine, and pass the flying wire through the sleeve. The sleeve must completely cover the stranded wire; press the start / stop button of the winding machine, and the winding machine will glue the flying wire in a clockwise direction. After the winding machine stops, use small scissors to cut the tape; remove the wire package from the winding shaft mold.

2. The method for winding a flying wire of an electronic transformer according to claim 1, wherein: The reserved wire lengths of the plurality of wire lengths in the step (B) winding 1 and the step (D) winding n+1 are 15-25 mm.

3. The method for winding a flying wire of an electronic transformer according to claim 1, wherein: Use side cutting pliers to cut off the excess part of the sleeve 3-4mm away from the (E) pin.

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