Winding method of transformer
Through the CNC winding machine and sandwich winding method, the electromagnetic interference problem caused by uneven coil arrangement and looseness is solved, and more balanced electromagnetic interaction and more stable transformer performance are achieved.
Patent Information
- Application Number
- CN202411745404.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-02
- Publication Date
- 2025-03-21
AI Technical Summary
In the existing winding method of transformer coils, uneven and loose coil arrangement leads to changes in the magnetic field distribution, increasing electromagnetic interference, and affecting the normal operation of the transformer.
The CNC winding machine is used for automatic winding, and the skeleton is wound in multiple layers through sandwich winding to ensure that each layer of coil is closely fit, and the winding of each coil is accurately completed through preset winding parameters.
The electromagnetic interaction between the coil layers is achieved more balanced, the generation of electromagnetic interference is reduced, the stability of the transformer is improved, and the problems of uneven coil arrangement and looseness caused by insufficient experience or improper operation during manual winding are avoided.
Smart Images
Figure CN119673661A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of transformer production, and in particular to a transformer winding method. Background Art
[0002] With the rapid development of modern science and technology, the relationship between electronic equipment and people's life and work is becoming increasingly close. Among them, high-frequency power transformation plays a vital role in the field of electronic equipment and communications. It can efficiently transform voltage and current, making the matching between power supply and load more accurate.
[0003] At present, most of the traditional transformer coil winding methods adopt the manual winding method. The staff manually winds the wire tightly around the transformer frame to realize the production of the transformer. However, during the manual winding process of the above-mentioned transformer coil, due to the limitation of the staff's experience, the coil on the transformer has problems such as uneven arrangement and looseness, which leads to changes in the distribution of the magnetic field, aggravates the skin effect of the transformer, and then generates electromagnetic interference, affecting the normal operation of the transformer.
[0004] Therefore, a transformer winding method is urgently needed to solve the above problems. Summary of the invention
[0005] Based on the above, the purpose of the present invention is to provide a transformer winding method to solve the problems of uneven arrangement and looseness of the coils on the transformer in the existing manual winding method, which causes the distribution of the magnetic field to change and aggravates the problem of electromagnetic interference.
[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions:
[0007] A transformer winding method comprises the following steps:
[0008] S1. Place the frame on the CNC winding machine;
[0009] S2, winding the first copper wire at the PIN end of the skeleton in one direction and around the skeleton for the first time, and winding at least two layers on the outer surface of the skeleton, and performing a tail wire processing on the PIN end of the skeleton, so that the first copper wire is closely fitted to the skeleton;
[0010] S3, using multiple groups of second copper wires to perform a second winding on the surface of the coil completed by the first winding. This winding requires multiple groups of second copper wires to be laid in parallel on the surface of the first layer of wire groups. The winding area of the second copper wires accounts for 60% of the surface of the first layer of wire groups. It is necessary to ensure that the first wire end and the tail wire end of the second copper wire do not cross, and the PIN end of the skeleton is processed with the tail wire, so that the second copper wire and the skeleton are closely fitted;
[0011] S4, using multiple sets of third copper wires to perform a third winding on the surface of the coil after the second winding is completed. This winding requires multiple sets of third copper wires to be laid in parallel on the surface of the second layer of wire groups, and the multiple sets of third copper wires are repeatedly wound two layers starting from the PIN end of the skeleton, and the PIN end of the skeleton is not processed by the tail wire;
[0012] S5, using multiple groups of fourth copper wires to perform a fourth winding on the surface of the coil after the third winding is completed. This winding requires multiple groups of fourth copper wires to be laid in parallel on the surface of the third layer of wire groups, and the PIN end of the skeleton is not processed by tail wire;
[0013] S6. Use the fifth copper wire to perform the fifth winding on the surface of the coil after the fourth winding is completed. This winding requires the fifth copper wire to be laid in the center on the surface of the fourth layer of wire group, and the PIN end of the skeleton is processed with a tail wire;
[0014] S7. Assemble the wound magnetic cores neatly and carry out impregnation treatment in a vacuum environment. Dry the impregnated products in an oven and conduct quality inspection on the products.
[0015] As a preferred solution for a transformer winding method, the skeleton PIN end is nine groups of PIN pins arranged circumferentially at the bottom end of the skeleton, namely the first PIN pin, the second PIN pin, the third PIN pin, the fourth PIN pin, the fifth PIN pin, the sixth PIN pin, the seventh PIN pin, the eighth PIN pin and the ninth PIN pin.
[0016] As a preferred solution for a transformer winding method, in S2, the number of first copper wires is one, and a copper wire with a diameter of 0.5 mm is used. The head wire of the first copper wire is first hung on the first PIN needle, and is closely wound thirty-two times back and forth on the outer surface of the skeleton to form a first layer wire group with two layers, and the tail wire of the first copper wire is hung on the second PIN needle.
[0017] As a preferred solution of a transformer winding method, in S3, the number of the second copper wires is five, the copper wires have a diameter of 0.15 mm, and the five second copper wires are closely wound six times in the first layer wire group near the PIN end.
[0018] As a preferred solution for a transformer winding method, the first wire of the second copper wire is first hung on the sixth PIN pin, and the tail wire of the second copper wire is hung from the inside of the fifth PIN pin to ensure that the first wire and the tail wire of the second copper wire do not cross.
[0019] As a preferred solution for a transformer winding method, in S4, the number of third copper wires is two, and a copper wire with a diameter of 0.5 mm is used. The two third copper wires are respectively wound flatly and densely in two layers on the second layer wire group from the PIN end. The two third copper wires in each layer need to be wound five times on the second layer wire group, and the tail wires of the third copper wires are not hung after winding.
[0020] As a preferred solution of a transformer winding method, in S5, the number of fourth copper wires is three, the copper wires with a diameter of 0.15 mm are used, and the three fourth copper wires are closely wound six times in the third layer wire group near the PIN end.
[0021] As a preferred solution of a transformer winding method, in S6, the number of the fifth copper wire is one, a copper wire with a diameter of 0.5 mm is used, and the fifth copper wire is wound seven times in the center of the fourth layer wire group.
[0022] As a preferred solution for a transformer winding method, after the fifth layer of wire group is wound to form a magnetic core, three tinned wires with a diameter of 0.15 mm are hung on the fifth PIN needle, one end of the tinned wire is connected to the fifth PIN needle, and the other end of the tinned wire is connected to the magnetic core.
[0023] As a preferred solution for a transformer winding method, in S7, the magnetic core needs to be immersed in impregnation oil in a vacuum environment of 72-76 cmHg. During the immersion, the impregnation oil needs to immerse all the wire packages of the magnetic core and soak for 5-10 minutes. During the immersion process, the PIN pins on the magnetic core cannot be stained with the impregnation oil. After the immersion is completed, the magnetic core is dried and tested.
[0024] The beneficial effects of the present invention are:
[0025] The transformer coil is wound on the frame by sandwich winding method. The first layer wire group and the fifth layer wire group wound by S2 and S6 are used as the primary winding, and the third layer wire group wound by S4 is used as the secondary winding. The winding method of the primary winding sandwiching the secondary winding makes the electromagnetic interaction between the primary winding and the secondary winding more balanced. The potential difference between the coil layers is reduced by reasonable layout according to the preset winding parameters, which effectively avoids the magnetic field interference problem caused by unreasonable winding layout and greatly reduces the generation of electromagnetic interference. In addition, the third layer wire group wound by S3 and S5 is used as the secondary winding. The second-layer wire group and the fourth-layer wire group serve as shielding layers, effectively blocking the intrusion of external electromagnetic interference and suppressing the propagation of internal electromagnetic interference, further reducing the generation of electromagnetic interference and improving the stability of transformer use. At the same time, the automatic winding is carried out by the CNC winding machine, which can accurately complete the winding of each coil according to the preset winding parameters, such as wire diameter, number of turns, winding spacing, etc., to improve the accuracy and consistency of coil winding and avoid problems such as uneven coil arrangement and looseness caused by lack of experience or improper operation during manual winding. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Figure 1 A schematic diagram of a process flow of a transformer winding method provided by the present invention;
[0027] Figure 2A schematic diagram of the process of step 3 provided by the present invention;
[0028] Figure 3 The flowchart of step 6 provided by the present invention is shown in FIG. DETAILED DESCRIPTION
[0029] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.
[0030] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.
[0031] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.
[0032] In the description of this embodiment, terms such as "up", "down", "left", and "right" and other orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.
[0033] In the description of the present invention, unless otherwise specified, the meaning of "plurality" is two or more than two. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.
[0034] In one embodiment of the present invention, Figure 1-3 As shown, a transformer winding method is provided, comprising the following steps:
[0035] S1. Prepare the corresponding winding items, such as the winding skeleton and the copper wires of different sizes required for winding. After the preparation is completed, the skeleton is placed on the CNC winding machine; the CNC winding machine is also used for automatic winding. Compared with manual winding, the accuracy and consistency of coil winding are improved, and the problems of uneven coil arrangement and looseness caused by lack of experience or improper operation during manual winding are avoided.
[0036] In this embodiment, the skeleton PIN end is nine groups of PIN pins arranged circumferentially at the bottom end of the skeleton, namely the first PIN pin, the second PIN pin, the third PIN pin, the fourth PIN pin, the fifth PIN pin, the sixth PIN pin, the seventh PIN pin, the eighth PIN pin and the ninth PIN pin.
[0037] S2. Wrap the first copper wire for the first time along one direction at the PIN end of the skeleton and around the skeleton, and wrap at least two layers on the outer surface of the skeleton, and perform tail wire processing on the PIN end of the skeleton, so that the first copper wire and the skeleton form a tight fit; the first layer of wire group after winding is used as the primary winding, and every time a layer of coil is densely wound, the surface of the coil needs to be wrapped with insulating tape, and the wrapping area of the insulating tape can be the same width as the middle part of the skeleton.
[0038] The number of the first copper wire is one, and a copper wire with a diameter of 0.5 mm is used. The first wire of the first copper wire is first hung on the first PIN needle, and is closely wound thirty-two times back and forth on the outer surface of the frame to form a first layer of wire group with two layers, and the tail wire of the first copper wire is hung on the second PIN needle. The first copper wire is hung on the first PIN needle and closely wound thirty-two times to form a two-layer wire group, thereby enhancing the mechanical strength of the coil, and the electromagnetic leakage is reduced by the close fit between the first copper wire and the frame, thereby providing a stable electromagnetic environment for the primary winding.
[0039] S3. Use multiple groups of second copper wires to perform a second winding on the surface of the coil completed by the first winding. This winding requires multiple groups of second copper wires to be laid in parallel on the surface of the first layer of wire groups. The winding area of the second copper wire accounts for 60-70% of the surface of the first layer of wire groups, preferably 60% of the winding area. It is necessary to ensure that the head and tail ends of the second copper wires do not cross, and the tail wire end of the skeleton PIN is processed so that the second copper wire and the skeleton form a tight fit; the second layer of wire groups after winding is used as a shielding layer, and the surface of the second layer of wire groups needs to be wrapped with insulating tape, and the wrapping area of the insulating tape is the same width as the middle of the skeleton. By setting the head and tail wires not to cross, the interference of the VCC voltage and the voltage on the capacitor are reduced, thereby reducing the generation of electromagnetic interference.
[0040] The number of the second copper wires is five, and the copper wires are 0.15-0.2 mm in diameter, preferably 0.15 mm in diameter, and the five second copper wires are wound six times in the first layer of wires near the PIN end. At the same time, the first wire of the second copper wire is first hung on the sixth PIN pin, and the tail wire of the second copper wire is hung from the inside of the fifth PIN pin to ensure that the first wire and the tail wire of the second copper wire do not cross. By winding the five second copper wires six times in the first layer of wires near the PIN end, electromagnetic interference is effectively reduced. At the same time, the first wire and the tail wire of the second copper wire are wound without crossing, further reducing the generation of electromagnetic interference.
[0041] S4. Use multiple groups of third copper wires to perform a third winding on the surface of the coil after the second winding is completed. This winding requires multiple groups of third copper wires to be laid in parallel on the surface of the second layer of wire groups, and multiple groups of third copper wires are repeatedly wound from the PIN end of the skeleton for two layers, and the PIN end of the skeleton is not processed with tail wires; the third layer of wire group after winding is completed is a coil layer with two layers both wound from the PIN end of the skeleton, which serves to form a secondary winding, and every time a layer of coil is wound, it is necessary to wrap the surface of the coil with insulating tape, and the wrapping area of the insulating tape can be the same width as the middle part of the skeleton.
[0042] Among them, the number of the third copper wires is two, and the copper wire with a diameter of 0.5mm is used. The two third copper wires are respectively wound flatly and densely on the second layer wire group from the PIN end for two layers, and the two third copper wires in each layer need to be wound five times on the second layer wire group, and the tail wires of the third copper wires are not hung after winding. The third layer wire group after winding can effectively reduce the leakage inductance, thereby reducing the generation of electromagnetic interference. At the same time, by not hanging the tail wire of the third copper wire, it is convenient to wind the subsequent coil layer, simplify the winding steps, and after the subsequent winding steps are completed, the tail wire of the third copper wire of the inner layer is hung on the ninth PIN pin and the tail wire of the third copper wire of the outer layer is hung on the eighth PIN pin.
[0043] S5. Use multiple groups of fourth copper wires to perform the fourth winding on the surface of the coil after the third winding. This winding requires multiple groups of fourth copper wires to be laid in parallel on the surface of the third layer of wire groups, and the tail wires of the skeleton PIN end are not processed. The fourth layer of wire groups after winding is used to form a shielding layer, and the surface of the fourth layer of wire groups needs to be wrapped with insulating tape. The wrapping area of the insulating tape is the same width as the middle of the skeleton. By not hanging the tail wire of the fourth copper wire, the winding of the subsequent coil layer is facilitated, the winding steps are simplified, and the tail wire of the fourth copper wire is folded back into the wire package after the subsequent winding steps are completed.
[0044] Among them, the number of the fourth copper wires is three, and the copper wire with a diameter of 0.15mm is used, and the three fourth copper wires are closely wound six times in the third layer wire group near the PIN end. By closely winding the three fourth copper wires six times in the third layer wire group near the PIN end, electromagnetic interference is effectively reduced and the use stability of the transformer is improved.
[0045] S6. Use the fifth copper wire to perform a fifth winding on the surface of the coil after the fourth winding is completed. This time, the fifth copper wire needs to be laid centrally on the surface of the fourth layer wire group, and the PIN end of the skeleton is processed with a tail wire. The fifth layer wire group after winding is used as the primary winding, and the surface of the fifth layer wire group needs to be wrapped with insulating tape. The wrapping area of the insulating tape can be the same width as the middle of the skeleton.
[0046] Among them, the number of the fifth copper wire is one, and the copper wire with a diameter of 0.5 mm is used. The fifth copper wire is wound seven times in the center of the fourth layer of wires. The sandwich winding method of the primary winding sandwiching the secondary winding is adopted between the first layer of wires, the third layer of wires and the fifth layer of wires, so as to reduce the generation of electromagnetic interference and improve the stability of the transformer.
[0047] Furthermore, after the fifth layer of wire group is wound, the tail of the third copper wire of the inner layer is hung on the ninth PIN and the tail of the third copper wire of the outer layer is hung on the eighth PIN, and the tail of the fourth copper wire is folded back into the wire package to obtain the magnetic core, and the magnetic core is encapsulated with insulating tape, and three tinned wires with a diameter of 0.15 mm are hung on the fifth PIN, one end of the tinned wire is connected to the fifth PIN, and the other end of the tinned wire is connected to the magnetic core. Among them, the fifth PIN and the magnetic core are tested by a multimeter to ensure that the two groups are well conductive, otherwise it will be classified as a defective product.
[0048] S7. Assemble the wound magnetic core neatly and carry out impregnation treatment in a vacuum environment. The impregnated product is dried in an oven and quality tested. After the product is dried, first check whether the magnetic core is loose. If the magnetic core is not loose, use the safety instrument to test the first, third and fifth wire groups in the magnetic core, that is, the primary and secondary windings, to ensure that the transformer meets the production requirements.
[0049] The magnetic core needs to be immersed in impregnation oil in a vacuum environment of 72-76cmHg. During the immersion, the impregnation oil needs to immerse all the wire packages of the magnetic core for 5-10 minutes, preferably 6 minutes. During the immersion process, the PIN pins on the magnetic core cannot be stained with the impregnation oil. After the immersion is completed, the magnetic core is dried and tested. The wire packages of the magnetic core need to be completely immersed in the impregnation oil to ensure the insulation performance of each layer of the wire group, and to prevent the PIN pins from being stained with the impregnation oil, so as to protect the PIN pins and improve the production quality of the transformer.
[0050] The transformer coil is wound on the frame by sandwich winding method. The first layer wire group and the fifth layer wire group wound by S2 and S6 are used as the primary winding, and the third layer wire group wound by S4 is used as the secondary winding. The winding method of the primary winding sandwiching the secondary winding makes the electromagnetic interaction between the primary winding and the secondary winding more balanced. The potential difference between the coil layers is reduced by reasonable layout according to the preset winding parameters, which effectively avoids the magnetic field interference problem caused by unreasonable winding layout and greatly reduces the generation of electromagnetic interference. In addition, the third layer wire group wound by S3 and S5 is used as the secondary winding. The second-layer wire group and the fourth-layer wire group serve as shielding layers, effectively blocking the intrusion of external electromagnetic interference and suppressing the propagation of internal electromagnetic interference, further reducing the generation of electromagnetic interference and improving the stability of transformer use. At the same time, the automatic winding is carried out by the CNC winding machine, which can accurately complete the winding of each coil according to the preset winding parameters, such as wire diameter, number of turns, winding spacing, etc., to improve the accuracy and consistency of coil winding and avoid problems such as uneven coil arrangement and looseness caused by lack of experience or improper operation during manual winding.
[0051] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention is disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with the profession can make some changes or modifications to equivalent embodiments of equivalent changes by using the technical contents disclosed above without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent changes and modifications made to the above embodiments according to the technology of the present invention are within the scope of the technical solution of the present invention without departing from the content of the technical solution of the present invention.
Claims
1. A transformer winding method, characterized in that: The following steps are involved: S1. Place the frame on the CNC winding machine; S2, winding the first copper wire at the PIN end of the skeleton in one direction and around the skeleton for the first time, and winding at least two layers on the outer surface of the skeleton, and performing a tail wire processing on the PIN end of the skeleton, so that the first copper wire is closely fitted to the skeleton; S3, using multiple groups of second copper wires to perform a second winding on the surface of the coil completed by the first winding. This winding requires multiple groups of second copper wires to be laid in parallel on the surface of the first layer of wire groups. The winding area of the second copper wires accounts for 60% of the surface of the first layer of wire groups. It is necessary to ensure that the first wire end and the tail wire end of the second copper wire do not cross, and the PIN end of the skeleton is processed with the tail wire, so that the second copper wire and the skeleton are closely fitted; S4, using multiple sets of third copper wires to perform a third winding on the surface of the coil after the second winding is completed. This winding requires multiple sets of third copper wires to be laid in parallel on the surface of the second layer of wire groups, and the multiple sets of third copper wires are repeatedly wound two layers starting from the PIN end of the skeleton, and the PIN end of the skeleton is not processed by the tail wire; S5, using multiple groups of fourth copper wires to perform a fourth winding on the surface of the coil after the third winding is completed. This winding requires multiple groups of fourth copper wires to be laid in parallel on the surface of the third layer of wire groups, and the PIN end of the skeleton is not processed by tail wire; S6. Use the fifth copper wire to perform the fifth winding on the surface of the coil after the fourth winding is completed. This winding requires the fifth copper wire to be laid in the center on the surface of the fourth layer of wire group, and the PIN end of the skeleton is processed with a tail wire; S7. Assemble the wound magnetic cores neatly and carry out impregnation treatment in a vacuum environment. Dry the impregnated products in an oven and conduct quality inspection on the products.
2. The transformer winding method according to claim 1, characterized in that: The skeleton PIN end is nine groups of PIN needles arranged circumferentially at the bottom end of the skeleton, namely the first PIN needle, the second PIN needle, the third PIN needle, the fourth PIN needle, the fifth PIN needle, the sixth PIN needle, the seventh PIN needle, the eighth PIN needle and the ninth PIN needle.
3. The transformer winding method according to claim 2, characterized in that: In S2, the number of the first copper wire is one, and a copper wire with a diameter of 0.5 mm is used. The head wire of the first copper wire is first hung on the first PIN needle, and is tightly wound back and forth thirty-two times on the outer surface of the skeleton to form a first layer wire group with two layers, and the tail wire of the first copper wire is hung on the second PIN needle.
4. The transformer winding method according to claim 2, characterized in that: In S3, the number of the second copper wires is five, the copper wires have a diameter of 0.15 mm, and the five second copper wires are closely wound six times in the first layer wire group near the PIN end.
5. The transformer winding method according to claim 4, characterized in that: The first line of the second copper wire is first hung on the sixth PIN needle, and the tail line of the second copper wire is hung from the inner side of the fifth PIN needle to ensure that the first line and the tail line of the second copper wire do not cross.
6. The transformer winding method according to claim 2, characterized in that: In S4, the number of the third copper wires is two, and the copper wire with a diameter of 0.5 mm is used. The two third copper wires are respectively wound flatly and densely on the second layer wire group from the PIN end. The two third copper wires in each layer need to be wound five times on the second layer wire group, and the tail wires of the third copper wires are not hung after winding.
7. The transformer winding method according to claim 2, characterized in that: In S5, the number of fourth copper wires is three, and the copper wires with a diameter of 0.15 mm are used. The three fourth copper wires are closely wound six times in the third layer wire group near the PIN end.
8. The transformer winding method according to claim 2, characterized in that: In S6, the number of the fifth copper wire is one, and a copper wire with a diameter of 0.5 mm is used. The fifth copper wire is wound seven times in the center of the fourth layer wire group.
9. The transformer winding method according to claim 8, characterized in that: After the fifth layer of wire group is wound to form a magnetic core, three tinned wires with a diameter of 0.15 mm are hung on the fifth PIN needle. One end of the tinned wire is connected to the fifth PIN needle, and the other end of the tinned wire is connected to the magnetic core.
10. The transformer winding method according to claim 2, characterized in that: In S7, the magnetic core needs to be immersed in impregnation oil in a vacuum environment of 72-76cmHg. During the immersion, the impregnation oil needs to immerse all the wire packages of the magnetic core for 5-10 minutes. During the immersion process, the PIN pins on the magnetic core cannot be stained with the impregnation oil. After the immersion is completed, the magnetic core is dried and tested.