Frameless induction transformer and winding method thereof

Abstract

The invention discloses a frameless induction transformer and a winding method thereof, and relates to the technical field of frameless induction transformers, the frameless induction transformer comprises a coil main body, the coil main body is wound on a positioning mechanism, the end part of the coil main body is fixed on a winding roller, and the winding roller is fixed on the coil main body. An electric wire on the winding roller sequentially penetrates through a take-up hole in the take-up mechanism to be wound and fixed to the positioning mechanism, the winding roller is arranged on a support in a sleeving mode, and the support is fixedly connected to the winding device body. Through the arrangement of the positioning mechanism, the distance between the arc-shaped plates can be positioned, the inner diameter of a wound electric wire can be positioned, coils of different strands or coils of the same strand can be wound according to different inner diameters, inductors of different inductance values can be obtained, and the positioning mechanism is easy to operate and convenient for operators to use.

Description

Technical Field

[0001] The invention relates to the technical field of frameless inductor transformers, and in particular to a frameless inductor transformer and a winding method thereof. Background Art

[0002] Compared with traditional transformers, skeleton-free inductor transformers have larger space utilization and lower cost. They are usually composed of coils and magnetic cores. The coils are directly wound on the magnetic cores without additional skeletons to support and fix the coils. Since there is no skeleton, the coils can be wound more tightly on the magnetic cores, which can achieve higher inductance values ​​in the same space, or achieve specific inductance requirements in a smaller space, which is conducive to the miniaturization and integrated design of electronic equipment. The coils are in direct contact with the magnetic cores, and the heat can be more directly transferred to the magnetic cores and then dissipated through the magnetic cores. Compared with the structure with skeletons, it may have better heat dissipation effect to a certain extent. However, if the design is improper, the heat dissipation may be poor due to the tight winding of the coils. Without the skeleton component, the material cost and production process may be reduced. Especially for large-scale production, the cost advantage may be more obvious, so skeleton-free inductors are slowly occupying the market and are loved by more audiences. The production process of skeleton-free inductors is different from the traditional winding method. The middle winding roller needs to be removed, and the inner diameter after removal is not easy to determine, and it is easy to cause problems such as difficult winding and difficult forming.

[0003] The existing winding method of the frameless inductor is to wind it on a winding column, and the inner diameter of the winding is fixed and cannot be flexibly adjusted, and it is not easy to remove the material after winding.

[0004] For example, the publication number CN118398356A discloses an assembled frameless insulated power inductor transformer and electronic equipment. In the patent, the inductor transformer includes a magnetic core shell, a magnetic core column and a winding. A winding cavity is arranged in the magnetic core shell, and the winding cavity has an inner cavity wall. An insulating layer is arranged on at least part of the inner cavity wall and the outer wall of the magnetic core shell; the magnetic core column is arranged in the winding cavity, and the magnetic core column and the insulating layer are arranged at intervals; the winding is sandwiched between the magnetic core column and the insulating layer, and the winding is arranged around the magnetic core column, without the need for traditional The skeleton structure can fix the winding; an insulating layer is arranged on the inner wall to contact the winding to avoid electrical contact between the winding and the core shell, which is beneficial to enhancing the performance stability of the inductor transformer; the insulating layer on the outer wall can also increase the insulation performance between the inductor and other electronic devices; compared with the traditional complex skeleton structure, the insulating layer has a smaller volume, which is beneficial to the miniaturization of the inductor transformer, while the inner diameter of the coil is fixed when it is wound and cannot be flexibly changed, and cannot better adapt to the production of coils of different sizes;

[0005] For example, a high-power sunken frameless high-frequency transformer and a PFC inductor module combination disclosed in publication number CN221632391U includes two PFC inductors, an upper protective frame and a lower protective frame. The PFC inductor includes a coil and a magnetic core. A placement groove is provided in the lower protective frame. The outer wall of the magnetic core is covered with insulating paper. The coil is wound on the outside of the insulating paper. Slots are provided at both ends of the lower protective frame. A plug-in plate is fixedly provided on the upper protective frame. The lower protective frames of the two PFC inductors are fixedly connected by a connecting block. The outer sliding sleeves of the two lower protective frames are provided with a pin positioning plate. The connecting block is close to the pin fixing plate. One end is provided with an adjusting column slot, in which an adjusting column fixedly connected to a pin positioning plate is arranged, and a knob for controlling the movement of the adjusting column is arranged on the connecting block. The utility model adopts insulating paper as a coil support, and pulls out the lead wire of the winding body as a pin, so as to make full use of the magnetic core winding, increase the magnetic flux density, and improve the product power. The pin positioning plate is slidingly arranged to make the product body sink, and reduce the space occupancy rate of the product. However, the inner diameter of the coil in the coil winding method of the inductor is still a fixed inner diameter, and the inner diameter of the coil cannot be adjusted according to customer needs, and it is not truly skeleton-free.

[0006] Therefore, it is necessary to invent a frameless inductor transformer and a winding method thereof to solve the above problems. Summary of the invention

[0007] The object of the present invention is to provide a frameless inductor transformer and a winding method thereof, so as to solve the problem that the inner diameter of the coil cannot be fixed when winding the coil in the prior art.

[0008] In order to achieve the above-mentioned object, the present invention provides the following technical solution: a frameless inductor transformer comprises a coil body, the coil body is wound on a positioning mechanism, the end of the coil body is fixed on a winding roller, the wire on the winding roller passes through the wire taking-up hole on the wire taking-up mechanism in turn and is wound and fixed with the positioning mechanism, the winding roller is sleeved on a bracket, and the bracket is fixedly connected to the winding device body;

[0009] The invention discloses a winding method for a frameless inductor transformer, comprising a winding device body and a motor, wherein a pedal is installed on the winding device body, a fixing rod is connected to the bottom of the pedal, a push rod is arranged through the fixing rod, the positioning mechanism comprises a latch, a straight rod and a tapered rod are fixedly connected to the latch, a plurality of tapered rubber sleeves are fixedly connected to the straight rod, a plurality of slide grooves are provided on the tapered rod, a rotating rod is installed on the shaft of the motor, a slot is provided in the rotating rod, an arc plate is connected in the rotating rod through a moving rod, and a roller is connected to the other end of the moving rod.

[0010] Preferably, a cutting mechanism is further provided on the main body of the winding device, and the cutting mechanism comprises a cylinder, a lifting rod is connected to the cylinder, and the end of the lifting rod is in contact with the bottom surface of the slice.

[0011] Preferably, the cutting mechanism is further provided with a slide rail, which is arranged in a horizontal direction and perpendicular to the winding device body, and the cutting mechanism is arranged directly below the positioning mechanism.

[0012] Preferably, the coil body is made of multiple strands of electric wire wound on a positioning mechanism, the diameter of the coil body can be positioned according to the distance between the positioning mechanisms, and the number of strands of the coil body can be adjusted according to the positioning mechanisms.

[0013] Preferably, the position and diameter of the slot correspond to the straight rod, and the distances between the multiple conical rubber sleeves are equal.

[0014] Preferably, the plurality of slide grooves are distributed in a circular array on the tapered rod and have the same length, and the length of the plurality of slide grooves is smaller than the length of the tapered rod.

[0015] Preferably, the rollers on the plurality of moving rods are all in contact with the surface of the slide groove.

[0016] Preferably, the arc-shaped plates are distributed in a circular array about the rotating rod.

[0017] In the above technical solution, the technical effects and advantages provided by the present invention are:

[0018] 1. Through the setting of the positioning mechanism, the distance between multiple arc plates can be positioned, and the inner diameter of the wound wire can be positioned. According to the different inner diameters, coils with different or the same number of strands can be wound to obtain inductors with different inductances. The positioning mechanism is easy to operate and convenient for operators to use;

[0019] 2. Through the setting of the cutting mechanism, the wound coil can be cut short in time, without the need for extra cutting tools and cutting operations, which saves the completion time of the entire inductor and improves the operating efficiency;

[0020] 3. By setting up multiple arc plates, the initial inner diameter of the coil is fixed, and the position of the unwound coil is fixed until the winding is completed. The inner diameter of the coil is fixed, and coils with various inner diameters can be wound, which makes it convenient to take out the material after the winding is completed. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0022] Figure 2 It is a three-dimensional structural schematic diagram of the wire taking-up mechanism of the present invention;

[0023] Figure 3 Schematic diagram of the three-dimensional structure of the positioning mechanism of the present invention

[0024] Figure 4 It is a schematic diagram of the three-dimensional structure of the tapered rod of the present invention;

[0025] Figure 5 It is a three-dimensional exploded view of the latch of the present invention;

[0026] Figure 6 is a three-dimensional cross-sectional view of the curved plate of the present invention;

[0027] Figure 7 For the present invention Figure 6 A is an enlarged structural diagram;

[0028] Figure 8 It is a three-dimensional structural schematic diagram of the cutting mechanism of the present invention.

[0029] Description of reference numerals:

[0030] 1. Winding device body; 2. Motor; 3. Pedal; 301. Fixed rod; 302. Push rod; 4. Cutting mechanism; 401. Cylinder; 402. Lifting rod; 403. Slicer; 404. Slide rail; 5. Bracket; 6. Winding roller; 7. Take-up mechanism; 701. Take-up hole; 9. Positioning mechanism; 901. Latch; 902. Straight rod; 903. Conical rubber sleeve; 904. Conical rod; 905. Slide groove; 906. Rotating rod; 907. Slot; 908. Arc plate; 909. Moving rod; 910. Roller. DETAILED DESCRIPTION

[0031] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0032] 2. The present invention provides Figure 1-8 A frameless inductor transformer is shown, comprising a coil body 10, the coil body 10 is wound on a positioning mechanism 9, the end of the coil body 10 is fixed on a winding roller 6, the wires on the winding roller 6 pass through the wire-receiving holes 701 on the wire-receiving mechanism 7 in sequence and are wound and fixed with the positioning mechanism 9, the winding roller 6 is sleeved on a bracket 5, the bracket 5 is fixedly connected to the winding device body 1, the wires on the winding roller 6 are evenly wound on the positioning mechanism 9, and the wires are cut after winding multiple strands, so as to obtain a frameless coil transformer;

[0033] The invention discloses a winding method for a frameless inductor transformer, comprising a winding device body 1 and a motor 2, wherein a pedal 3 is installed on the winding device body 1, a fixed rod 301 is connected to the bottom of the pedal 3, a push rod 302 is provided through the fixed rod 301, the push rod 302 is pushed out from the fixed rod 301 to contact with a switch 201 on the motor 2, and the motor 2 drives the intermittent rotation of a positioning mechanism 9, the positioning mechanism 9 comprises a latch 901, a straight rod 902 and a tapered rod 904 are fixedly connected to the latch 901, a plurality of tapered rubber sleeves 903 are fixedly connected to the straight rod 902, a plurality of slide grooves 905 are provided on the tapered rod 904, the tapered rod 904 can be inserted into a rotating rod 906, the rotating rod 906 is installed on the shaft of the motor 2, a slot 907 is provided in the rotating rod 906, an arc plate 908 is connected to the rotating rod 906 through a moving rod 909, and a roller 910 is connected to the other end of the moving rod 909.

[0034] Before multiple strands of wires are wound around the positioning mechanism 9, the pin 901 can be inserted into the rotating rod 906, and the arc plate 908 can be pushed outward to a suitable distance, so that a coil of a fixed diameter can be wound. The straight rod 902 on the pin 901 is continuously pushed into the slot 907, and multiple gears are achieved under the action of the conical rubber sleeve 903.

[0035] A cutting mechanism 4 is also provided on the winding device body 1, and the cutting mechanism 4 includes a cylinder 401, and a lifting rod 402 is connected to the cylinder 401, and the end of the lifting rod 402 is in contact with the bottom surface of the slice 403. A slide rail 404 is also provided on the cutting mechanism 4, and the slide rail 404 is arranged in a horizontal direction and perpendicular to the winding device body 1. The cutting mechanism 4 is arranged directly below the positioning mechanism 9.

[0036] The function of the cutting mechanism 4 is to cut the wound coil. The slice 403 is lifted by the lifting rod 402, and the blade on the top of the slice 403 is set upward, so that one end of the coil can be pressed down to cut the coil.

[0037] The coil body 10 is made of multiple strands of electric wire wound on the positioning mechanism 9. The diameter of the coil body 10 can be positioned according to the distance between the positioning mechanism 9. The number of strands of the coil body 10 can be adjusted according to the positioning mechanism 9. The position and diameter of the slot 907 correspond to the straight rod 902, and the distances between the multiple conical rubber sleeves 903 are equal. The multiple slide grooves 905 are distributed in a circular array on the conical rod 904, and the lengths are equal. The lengths of the multiple slide grooves 905 are less than the length of the conical rod 904.

[0038] The rollers 910 on the plurality of moving rods 909 are all in contact with the surface of the slide groove 905 , and the arc plates 908 are distributed in a circular array about the rotating rod 906 .

[0039] Working principle of the present invention:

[0040] Refer to the instruction manual Figure 1-3 When using the present invention, firstly, the latch 901 on the positioning mechanism 9 is inserted into the rotating rod 906, and the straight rod 902 is inserted into the position of the slot 907. The deeper the straight rod 902 is inserted, the larger the diameter of the wound coil becomes (according to the setting of equal distances between the multiple conical rubber sleeves 903, the equal spacing of the conical rubber sleeves 903, and the special shape of the conical rubber sleeves 903 and the friction of the rubber, the depth of insertion into the rotating rod 906 can be better controlled).

[0041] Refer to the instruction manual Figure 4-7 When using the present invention, after the depth of the conical rubber sleeve 903 is positioned, the slide groove 905 on the conical rod 904 will contact the roller 910 on the moving rod 909, pushing the moving rod 909 and the arc plate 908 outward, and the outward push of the arc plate 908 can wind an inductor with a larger diameter;

[0042] Refer to the instruction manual Figure 8 When using the present invention, after the position of the arc plate 908 on the positioning mechanism 9 is fixed, winding begins, and the end of the wire on the winding roller 6 on the bracket 5 is pulled out, and passed through the take-up mechanism 7 and the take-up hole 701 in turn, so that the wire is fixed at multiple points and will not deviate, and can be stably wound within the range, and the wire is wound onto the arc plate 908 in turn. When the winding is completed, the slice 403 is lifted, the wire is pressed down hard, and cut off, and finally the pin 901 is taken out from the rotating rod 906. When taking it out, the arc plate 908 will be retracted toward the center of the rotating rod 906, and the wound coil is easier to remove from the arc plate 908.

Claims

1. A frameless inductor transformer, comprising a coil body (10), characterized in that: The coil body (10) is wound on the positioning mechanism (9), the end of the coil body (10) is fixed on the winding roller (6), the wire on the winding roller (6) passes through the wire taking-up hole (701) on the wire taking-up mechanism (7) in turn and is wound and fixed with the positioning mechanism (9), the winding roller (6) is sleeved on the bracket (5), and the bracket (5) is fixedly connected to the winding device body (1); The invention discloses a winding method for a frameless inductor transformer, comprising a winding device body (1) and a motor (2), wherein a pedal (3) is installed on the winding device body (1), a fixing rod (301) is connected to the bottom of the pedal (3), a push rod (302) is arranged in the fixing rod (301), a positioning mechanism (9) comprises a latch (901), a straight rod (902) and a tapered rod (904) are fixedly connected to the latch (901), a plurality of tapered rubber sleeves (903) are fixedly connected to the straight rod (902), a plurality of slide grooves (905) are provided on the tapered rod (904), a rotating rod (906) is installed on the shaft of the motor (2), a slot (907) is provided in the rotating rod (906), an arc plate (908) is connected in the rotating rod (906) via a moving rod (909), and a roller (910) is connected to the other end of the moving rod (909).

2. The method for winding a frameless inductor transformer according to claim 1, characterized in that: The winding device body (1) is also provided with a cutting mechanism (4), and the cutting mechanism (4) comprises a cylinder (401), and a lifting rod (402) is connected to the cylinder (401), and the end of the lifting rod (402) contacts the bottom surface of the slice (403).

3. The method for winding a frameless inductor transformer according to claim 2, characterized in that: The cutting mechanism (4) is also provided with a slide rail (404), the slide rail (404) is arranged in a horizontal direction and is perpendicular to the winding device body (1), and the cutting mechanism (4) is arranged directly below the positioning mechanism (9).

4. The frameless inductor transformer according to claim 1, characterized in that: The coil body (10) is made of multiple strands of electric wire wound on a positioning mechanism (9). The diameter of the coil body (10) can be positioned according to the distance between the positioning mechanisms (9), and the number of strands of the coil body (10) can be adjusted according to the positioning mechanisms (9).

5. The frameless inductor transformer according to claim 4, characterized in that: The wire taking-up mechanism (7) is arranged to be inclined, and the inclination angle of the wire taking-up mechanism (7) is fixed; the wire taking-up hole (701) is arranged on opposite sides of the wire taking-up mechanism (7), and the wire taking-up hole (701) is elliptical.

6. The method for winding a frameless inductor transformer according to claim 1, characterized in that: The position and diameter of the slot (907) correspond to those of the straight rod (902), and the distances between the multiple conical rubber sleeves (903) are equal.

7. The method for winding a frameless inductor transformer according to claim 6, characterized in that: The multiple slide grooves (905) are distributed in a circular array on the tapered rod (904) and have the same length. The length of the multiple slide grooves (905) is smaller than the length of the tapered rod (904).

8. The method for winding a frameless inductor transformer according to claim 7, characterized in that: The rollers (910) on the plurality of moving rods (909) are all in contact with the surface of the slide groove (905).

9. The method for winding a frameless inductor transformer according to claim 8, characterized in that: The arc-shaped plates (908) are distributed in a circular array about the rotating rod (906).

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