A method of winding a transformer winding
By calculating the number of turns and layers of the winding, and by adopting staggered winding and optimized lead wire methods, the problems of uneven transformer winding and wasted space were solved, thereby improving the winding performance and power density.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- NORTH CHINA UNIVERSITY OF TECHNOLOGY
- Filing Date
- 2021-12-03
- Publication Date
- 2026-06-19
Smart Images
Figure CN116313497B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of transformers, and in particular, to a method for winding transformer windings. Background Technology
[0002] A transformer typically consists of a primary coil, a secondary coil, and a magnetic core, and changes voltage based on the principle of electromagnetic induction. The primary and secondary coils are also known as the primary winding and secondary winding, respectively. Because of the use of electromagnetic induction, the winding method of the primary and secondary windings affects the performance of the transformer.
[0003] For magnetic cores, there is a certain limit to the maximum number of turns that can be wound in a single layer. However, in actual use, the number of turns required is far greater than the maximum allowable number of turns, so layered winding is necessary. However, there are no fixed rules for current winding methods. For example, if the maximum allowable number of turns per layer is 10, and a total of 91 turns are required, one could use a method where the first 9 turns are wound with 10 layers each, and the last turn is wound with 1 layer. Because the last layer has far fewer turns than the other layers, winding is inconvenient and prone to misalignment, resulting in an uneven transformer winding with poor performance and high leakage inductance. Furthermore, common winding layer arrangements include layered winding and sandwich winding. Layered winding produces transformers with high leakage inductance, failing to meet the requirements of some operating conditions, while sandwich winding produces transformers with low leakage inductance, requiring series inductors in some cases to meet operational needs. Additionally, arbitrarily winding a transformer without considering the number of turns results in winding leads and leads being distributed on the top and bottom sides of the transformer, wasting space and reducing power density. Summary of the Invention
[0004] To overcome the shortcomings of existing technologies, this invention provides a method for winding transformer windings. This method addresses the problem of uneven turns per layer caused by layered winding methods, which leads to winding misalignment, resulting in uneven transformer windings, poor performance, and excessive leakage inductance. The provided winding layer arrangement method can control transformer leakage inductance without requiring external series inductors. The winding lead method also addresses the issues of wasted space and low power density to some extent.
[0005] The technical solution adopted by this invention to solve its technical problem is:
[0006] A method for winding a transformer winding includes the following steps:
[0007] Step (1): Obtain the number of turns to be wound and the maximum allowable number of turns per layer;
[0008] Step (2): When the number of turns to be wound is not an integer multiple of the maximum allowable number of turns per single layer, the number of turns to be wound and the number of layers at the location of each turn are calculated using the following set of equations based on the number of turns to be wound and the maximum allowable number of turns per single layer:
[0009] n = xm + y(m+1)
[0010] x + y = c
[0011] Where n is the number of turns to be wound, a is the maximum allowed number of turns, c is the smallest integer greater than or equal to n / a, m is the number of turns to be wound per layer (the largest integer less than or equal to n / c), x is the number of layers with m turns, and y is the number of layers with m+1 turns.
[0012] Furthermore, when the number of winding layers in the primary winding is greater than or equal to 3 and the number of winding layers in the secondary winding is greater than or equal to 2, the primary and secondary windings are interleaved at each turn position, wherein the interleaving includes:
[0013] The innermost and outermost layers of the winding are wound as a primary winding;
[0014] The secondary winding is divided into two parts, which are wound separately next to the innermost and outermost layers.
[0015] The remaining primary winding is wound between two secondary windings;
[0016] The process of dividing the secondary winding into two parts includes:
[0017] When the number of layers at each turn of the secondary winding is even, the secondary winding is divided into two equal parts.
[0018] When the number of layers at each turn of the secondary winding is odd, the difference between the number of layers in one part and the number of layers in the other part of the secondary winding is 1.
[0019] Furthermore, it also includes:
[0020] When the number of layers in both the primary and secondary windings is odd, the primary winding starts from the top of the magnetic core and the secondary winding starts from the bottom of the magnetic core.
[0021] When both the primary and secondary windings are even numbers, the primary winding starts from the bottom of the magnetic core, and the secondary winding starts from the top of the magnetic core.
[0022] When the number of primary windings is even and the number of secondary windings is odd, both the primary and secondary windings are wound from the bottom of the magnetic core.
[0023] When the primary winding has an odd number of windings and the secondary winding has an even number of windings, both the primary and secondary windings are wound from the top of the magnetic core.
[0024] Beneficial effects:
[0025] This application provides a method for winding transformer windings. First, the number of turns to be wound and the maximum allowable number of turns are obtained. Then, based on these numbers, the required number of turns per layer and the layer distribution are calculated. Finally, winding is performed based on the calculation results. Using this method, the maximum difference in the number of turns per layer is one, thus solving the problem of misalignment during winding. It offers advantages such as uniform and smooth winding, low leakage inductance, and good transformer performance. The winding layer arrangement method proposed in this application can control leakage inductance within a certain range, which has significant application value in some situations. The winding lead method in this technical solution solves, to some extent, the problems of wasted space and low power density. Attached Figure Description
[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0027] Figure 1 This is a schematic diagram of a transformer winding layering method provided in an embodiment of the present invention;
[0028] Figure 2 This is a schematic diagram of a winding layer arrangement method provided in an embodiment of the present invention;
[0029] Figure 3 This is a schematic diagram of a transformer winding lead method provided in an embodiment of the present invention. Detailed Implementation
[0030] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of the present invention will be described in detail below with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0031] This invention provides a method for layering transformer windings, comprising the following steps:
[0032] Step (1): Obtain the number of turns to be wound and the maximum allowable number of turns per layer;
[0033] Step (2): When the number of turns to be wound is not an integer multiple of the maximum allowable number of turns per single layer, the number of winding layers and the number of turns per layer are calculated using the following set of equations based on the number of turns to be wound and the maximum allowable number of turns per single layer:
[0034] n = xm + y(m+1)
[0035] x + y = c
[0036] Where n is the number of turns to be wound, a is the maximum allowed number of turns, c is the smallest integer greater than or equal to n / a, m is the number of turns to be wound per layer (the largest integer less than or equal to n / c), x is the number of layers with m turns, and y is the number of layers with m+1 turns.
[0037] like Figure 1 As shown, a winding with m turns has x layers, and a winding with (m+1) turns has y layers. For example, if the number of turns to be wound is 76, and the maximum allowable number of turns per layer is 10, according to the provided equations, c is 8, m is 9, x is 4, and y is 4. Therefore, a winding with 9 turns has 4 layers, and a winding with 10 turns has 4 layers.
[0038] This scheme allows for the determination of the number of winding layers and the number of turns per layer, ensuring that the number of layers is minimized while the maximum difference in the number of turns per layer is 1, thus achieving convenient winding and smooth winding.
[0039] In one embodiment, the present invention proposes a winding layer arrangement method. After determining the number of layers of the primary and secondary windings, when the number of winding layers of the primary winding is greater than or equal to 3 and the number of winding layers of the secondary winding is greater than or equal to 2, the primary and secondary windings are interleaved at each turn position; the innermost and outermost layers of the winding are wound as primary windings; the secondary windings are divided into two parts and wound in positions adjacent to the innermost and outermost layers respectively; the remaining primary windings are wound between the two parts of the secondary windings.
[0040] When the number of layers at each turn of the secondary winding is even, the secondary winding is divided into two equal parts; when the number of layers at each turn of the secondary winding is odd, the difference between the number of layers in one part and the number of layers in the other part of the secondary winding is 1.
[0041] like Figure 2As shown, the primary winding has 5 layers, and the secondary winding has 4 layers. The winding layer closest to the center post of the magnetic core (layer 1) and the winding layer furthest from the center post (layer 9) are the primary windings. Layers 2, 3, 7, and 8 are the secondary windings, and layers 4, 5, and 6 are the remaining primary winding layers. The innermost and outermost layers of the windings are the primary windings; the secondary windings are divided into two parts, each with two layers, arranged closely adjacent to the innermost and outermost layers; the remaining three layers of the primary windings are arranged between the two parts of the secondary windings.
[0042] The layer arrangement method proposed in this scheme can control the leakage inductance of the transformer within a certain range, making the leakage inductance parameters applicable.
[0043] In one embodiment, the present invention proposes a winding lead method in which, when the number of layers in both the primary and secondary windings is odd, the primary winding starts from the top of the magnetic core and the secondary winding starts from the bottom of the magnetic core; when the number of layers in both the primary and secondary windings is even, the primary winding starts from the bottom of the magnetic core and the secondary winding starts from the top of the magnetic core; when the number of layers in the primary winding is even and the number of layers in the secondary winding is odd, both the primary and secondary windings start from the bottom of the magnetic core; and when the number of layers in the primary winding is odd and the number of layers in the secondary winding is even, both the primary and secondary windings start from the top of the magnetic core.
[0044] like Figure 3 As shown, the primary side lead-in and lead-out wires are both at the bottom of the transformer, while the secondary side lead-in and lead-out wires are both at the top of the transformer, and can be led to the connected PCB board respectively. For example, when the primary winding has 75 turns and the secondary winding has 40 turns, the primary winding starts from the top and the primary winding lead-out wire is at the bottom of the transformer; the secondary winding starts from the top and the secondary winding lead-out wire is at the top of the transformer.
[0045] The winding lead method proposed in this scheme can make full use of space, which solves the problems of space waste and low power density to a certain extent.
Claims
1. A method of winding a transformer winding, characterized in that, Includes the following steps: Step (1): Obtain the number of turns to be wound and the maximum allowable number of turns per layer; Step (2): The number of turns to be wound is not an integer multiple of the maximum allowable number of turns per single layer. Based on the number of turns to be wound and the maximum allowable number of turns per single layer, the following set of equations is used to calculate the number of turns to be wound and the layer number at the location of each turn: n = xm + y(m + 1) x+y=c Where n is the number of turns to be wound, a is the maximum allowed number of turns, c is the smallest integer greater than or equal to n / a, m is the number of turns to be wound per layer, taking the largest integer less than or equal to n / c, x is the number of layers with m turns, and y is the number of layers with m+1 turns. After confirming the number of layers in the primary and secondary windings, the primary winding has more than 3 layers and the secondary winding has more than 2 layers. The primary and secondary windings are interleaved in each turn. The interleaved winding is as follows: The innermost and outermost layers of the winding are wound as a primary winding; The secondary winding is divided into two parts, which are wound separately next to the innermost and outermost layers. The remaining primary winding is wound between two secondary windings; The process of dividing the secondary winding into two parts includes: When the number of layers at each turn of the secondary winding is even, the secondary winding is divided into two equal parts. When the number of layers at each turn of the secondary winding is odd, the difference between the number of layers in one part and the number of layers in the other part of the secondary winding is 1. After confirming the number of layers in the primary and secondary windings, the specific winding lead method is as follows: When the number of layers in both the primary and secondary windings is odd, the primary winding starts from the top of the magnetic core and the secondary winding starts from the bottom of the magnetic core. When both the primary and secondary windings are even numbers, the primary winding starts from the bottom of the magnetic core, and the secondary winding starts from the top of the magnetic core. When the number of primary windings is even and the number of secondary windings is odd, both the primary and secondary windings are wound from the bottom of the magnetic core. When the primary winding has an odd number of windings and the secondary winding has an even number of windings, both the primary and secondary windings are wound from the top of the magnetic core.