Optimized winding method of transformer

Abstract

The invention relates to an optimized winding method of a transformer, which comprises steps 1 to 7, in the step 2, two strands are wound from a second pin of a framework, the two strands are uniformly and densely wound by one layer around a winding groove of the framework at the same time to form a first-layer winding ring, then, the initial position of a second insulating tape is pre-attached to the outer side of the first-layer winding ring, and at the moment, the first-layer winding ring and the second-layer winding ring are wound by one layer at the same time; the tail ends of the two strands of wires are located on the outer side of the initial position of a second insulating tape, then the tail ends of the two strands of wires are hung on a third pin of the framework, and finally two circles of second insulating tape are wound to wrap the first layer of winding circle; the winding efficiency and the product yield are greatly improved, the labor cost is reduced, a sleeve is omitted before the wire is hung on the fourth pin, the winding efficiency is further improved, and the labor cost is further reduced.

Description

Technical Field

[0001] The invention relates to the technical field of transformer winding methods, and in particular to an optimized transformer winding method. Background Art

[0002] A high-frequency transformer is a power transformer whose operating frequency exceeds the medium frequency. It is mainly used as a high-frequency switching power supply transformer in a high-frequency switching power supply. It can also be used as a high-frequency inverter power supply transformer in a high-frequency inverter power supply and a high-frequency inverter welding machine.

[0003] The high-frequency transformer includes a skeleton, a magnetic core, a primary winding and a secondary winding. The magnetic core is arranged on the skeleton. The primary winding and the secondary winding are both wound around the magnetic core. It is the circuit part of the transformer and is usually wound with insulated copper wire or aluminum wire. The skeleton includes a winding shaft, connecting terminals of the primary winding and connecting terminals of the secondary winding. The connecting terminals can be used as the starting and winding ends of the winding.

[0004] The existing winding method of high-frequency transformer has the following defects: after the two strands of wire starting from the second pin of the skeleton are densely wound in one layer, a certain length of tail wire needs to be reserved at the end of the two strands of wire to be wound on the winding shaft of the automatic winding machine, which results in the need to loosen the reserved tail wire for manual winding when the winding circle is formed later, which greatly affects the winding efficiency and has high labor costs. Manual winding will cause large errors in the winding, which in turn affects the yield of the transformer.

[0005] Therefore, in the patent application of the present invention, the applicant carefully studied a new technical solution to solve the above problems. Summary of the invention

[0006] The present invention aims to overcome the deficiencies in the above-mentioned prior art, and its main purpose is to provide an optimized winding method for a transformer, which greatly improves the winding efficiency and product yield, reduces labor costs, and eliminates the bushing before hanging the wire on the fourth pin, further improving the winding efficiency and reducing labor costs.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme: An optimized winding method for a transformer comprises the following steps: Step 1: Wrap a circle of the first insulating tape around the winding groove of the frame; Step 2: Start two strands of wire from the second tube pin of the skeleton, and wind the two strands of wire evenly and densely around the winding groove of the skeleton at the same time to form a first layer of winding rings. Then, pre-attach the starting position of the second insulating tape to the outside of the first layer of winding rings. At this time, the ends of the two strands of wire are located outside the starting position of the second insulating tape. Then, hang the ends of the two strands of wire on the third tube pin of the skeleton, and finally wind two turns of the second insulating tape to cover the first layer of winding rings. Step 3: Start one strand of wire from the 10th and 11th pins of the skeleton respectively, and wind the two strands of wire evenly and densely around the winding groove of the skeleton at the same time to form a second winding circle. Then, pre-attach the starting position of the third insulating tape to the outside of the second winding circle. At this time, the ends of the two strands of wire are located outside the starting position of the third insulating tape. Then, hang the ends of the two strands of wire on the 7th and 8th pins of the skeleton respectively, and finally wind two turns of the third insulating tape to cover the second winding circle. Step 4: Start two strands of wire from the third tube pin of the skeleton, and wind the two strands of wire evenly and densely around the winding groove of the skeleton at the same time to form a third layer of winding ring. Then, pre-attach the starting position of the fourth insulating tape to the outside of the third layer of winding ring. At this time, the ends of the two strands of wire are located outside the starting position of the fourth insulating tape. Then, hang the ends of the two strands of wire on the first tube pin of the skeleton, and finally wind two turns of the fourth insulating tape to cover the third layer of winding ring. Step 5: A strand of wire is started from the 12th tube pin of the skeleton, and one strand of wire is wound around the winding groove of the skeleton twice to form a fourth layer of winding coil. Then, the starting position of the fifth insulating tape is pre-attached to the outside of the fourth layer of winding coil. At this time, the end of one strand of wire is located outside the starting position of the fifth insulating tape. Then, the end of one strand of wire is hung on the 10th tube pin of the skeleton, and finally, two turns of the fifth insulating tape are wound to cover the fourth layer of winding coil. Step 6: Start two strands of wire from the 5th tube pin of the skeleton, and wind the two strands of wire evenly and densely around the winding groove of the skeleton at the same time to form a fifth winding circle. Then, pre-attach the starting position of the sixth insulating tape to the outside of the fifth winding circle. At this time, the ends of the two strands of wire are located outside the starting position of the sixth insulating tape. Then, hang the ends of the two strands of wire on the 4th tube pin of the skeleton, and finally wind two turns of the sixth insulating tape to cover the fifth winding circle. Step 7: First, solder all the wires hanging on the 3rd pin of the frame to the 3rd pin, and then cut off the part of the 3rd pin of the frame that is not soldered.

[0008] As a preferred solution, in step 2, one layer consists of 7 turns.

[0009] As a preferred solution, in step 3, one layer consists of 6 turns.

[0010] As a preferred solution, in step 4, one layer consists of 7 turns.

[0011] As a preferred solution, in step 6, one layer consists of 6 turns.

[0012] As a preferred solution, in steps 2 to 6, a first sleeve is firstly sleeved on the corresponding strand, and then the wire is started on the corresponding pin of the skeleton.

[0013] As a preferred solution, in steps 2 to 5, the ends of the corresponding strands are first sleeved with the second sleeve and then hung on the corresponding pins of the frame.

[0014] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, after the two strands of wire starting from the second tube pin of the skeleton are tightly wound for one layer, the ends of the two strands of wire are changed to be hung on the third tube pin of the skeleton, instead of reserving a preset length of tail wire to be wound on the winding shaft of the automatic winding machine, thereby avoiding the need to loosen the reserved tail wire wound on the winding shaft and then manually wind it to form a third layer of winding circle, greatly improving the winding efficiency and product yield, reducing labor costs, and eliminating the casing before hanging the wire on the fourth tube pin, further improving the winding efficiency and reducing labor costs.

[0015] In order to more clearly illustrate the structural features and effects of the present invention, it is described in detail below in conjunction with the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the winding principle of the transformer according to the embodiment of the present invention; Figure 2 is a cross-sectional schematic diagram of a transformer according to an embodiment of the present invention; Figure 3 is a flow chart of step 1 of an embodiment of the present invention; Figure 4 is a flow chart of step 2 of an embodiment of the present invention; Figure 5 is a flow chart of step 3 of an embodiment of the present invention; Figure 6 is a flow chart of step 4 of an embodiment of the present invention; Figure 7 is a flow chart of step 5 of an embodiment of the present invention; Figure 8 is a flow chart of step 6 of an embodiment of the present invention; Fig. 9 It is a flowchart of step 7 of an embodiment of the present invention.

[0017] Description of Figure Numbers: 10. Frame 101, winding groove 11. Pin 1 12. Pin 2 13. Pin 3 14. Pin 4 15. Pin 5 16. Pin 7 17, 8th pin 18, 10th pin 19, 11th pin 20, 12th pin 21. First insulating tape 22. Second insulating tape 23. Third insulation tape 24. Fourth insulation tape 25. Fifth insulating tape 26. Sixth insulating tape DETAILED DESCRIPTION

[0018] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0019] like Figures 1 to 9 As shown, an optimized winding method for a transformer includes the following steps: Step 1: If Figure 3 As shown, a circle of the first insulating tape 21 is wound around the winding groove 101 of the frame 10; Step 2: If Figure 4 As shown, two strands of wire are started from the second pin 12 of the frame 10, and the two strands of wire are evenly and densely wound around the winding groove 101 of the frame 10 to form a first layer of winding turns. It should be noted that this layer is 7 turns.

[0020] Next, the starting position of the second insulating tape 22 is pre-attached to the outside of the first layer of winding. At this time, the ends of the two strands are located outside the starting position of the second insulating tape 22. The ends of the two strands are then hung at right angles on the third pin 13 of the frame 10. Finally, two turns of the second insulating tape 22 are wound to cover the first layer of winding. Step 3: If Figure 5 As shown, two strands of wire are respectively started from the 10th and 11th pins 18 and 19 of the frame 10, and the two strands of wire are evenly and densely wound around the winding groove 101 of the frame 10 to form a second layer of winding turns. It should be noted that this layer is 6 turns.

[0021] Next, the starting position of the third insulating tape 23 is pre-attached to the outside of the second layer of winding. At this time, the ends of the two strands are located outside the starting position of the third insulating tape 23. The ends of the two strands are then hung at right angles on the seventh pin 16 and the eighth pin 17 of the frame 10, respectively. Finally, two turns of the third insulating tape 23 are wound to cover the second layer of winding. Step 4: Figure 6 As shown, two strands of wire are started from the third pin 13 of the frame 10, and the two strands of wire are evenly and densely wound around the winding groove 101 of the frame 10 to form a third layer of winding turns. It should be noted that this layer is 7 turns.

[0022] Next, the starting position of the fourth insulating tape 24 is pre-attached to the outside of the third layer of winding. At this time, the ends of the two strands are located outside the starting position of the fourth insulating tape 24. The ends of the two strands are then hung at right angles on the first pin 11 of the frame 10. Finally, two turns of the fourth insulating tape 24 are wound to cover the third layer of winding. Step 5: Figure 7 As shown, a strand of wire is started from the 12th pin 20 of the frame 10, and the strand of wire is wound around the winding groove 101 of the frame 10 twice at intervals to form a fourth layer of winding coils. Next, the starting position of the fifth insulating tape 25 is pre-attached to the outside of the fourth winding circle. At this time, the end of one strand is located outside the starting position of the fifth insulating tape 25. Then, the end of one strand is hung at a right angle to the 10th pin 18 of the frame 10. Finally, two turns of the fifth insulating tape 25 are wound to cover the fourth winding circle. Step 6: Figure 8 As shown, two strands of wire are started from the fifth pin 15 of the frame 10, and the two strands of wire are evenly and densely wound around the winding groove 101 of the frame 10 to form a fifth layer of winding turns. It should be noted that this layer is 6 turns.

[0023] Next, the starting position of the sixth insulating tape 26 is pre-attached to the outside of the fifth winding circle. At this time, the ends of the two strands of wire are located outside the starting position of the sixth insulating tape 26. The ends of the two strands of wire are then hung at right angles on the fourth pin 14 of the frame 10. Finally, two turns of the sixth insulating tape 26 are wound to cover the fifth winding circle. Step 7: Fig. 9 As shown, all the wires hung on the third pins 13 of the frame 10 are first welded to the third pins 13 by soldering, and then the part of the third pins 13 of the frame 10 that is not welded is cut off.

[0024] In this embodiment, in steps 2 to 6, the first sleeve is firstly sleeved on the corresponding strand, and then the thread is started on the corresponding pin of the frame 10. In steps 2 to 5, the end of the corresponding strand is firstly sleeved with a second sleeve and then hung on the corresponding pin of the frame 10.

[0025] The key point of the design of the present invention is that after the two strands of wire from the second pin of the skeleton are tightly wound for one layer, the ends of the two strands of wire are hung on the third pin of the skeleton instead of winding the tail wire of a preset length on the winding shaft of the automatic winding machine, thereby avoiding the need to loosen the reserved tail wire wound on the winding shaft and then manually wind it to form a third layer of winding circle, greatly improving the winding efficiency and product yield, reducing labor costs, and omitting the sleeve before hanging the wire on the fourth pin, further improving the winding efficiency and reducing labor costs. .

[0026] The above description is only a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any slight modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. An optimized winding method for a transformer, characterized in that: The following steps are included: Step 1: Wrap a circle of the first insulating tape around the winding groove of the frame; Step 2: Start two strands of wire from the second pin of the bobbin and wind them evenly and densely around the bobbin's winding groove to form the first layer of winding. Next, pre-attach the starting position of the second insulating tape to the outside of the first layer of winding. At this time, the ends of the two strands of wire are located outside the starting position of the second insulating tape. Then, hang the ends of the two strands of wire on the third pin of the bobbin and finally wrap two turns of the second insulating tape to cover the first layer of winding. Step 3: Start one strand of wire from the 10th and 11th pins of the bobbin, and wind both strands evenly and densely around the bobbin's winding groove to form a second layer of winding. Next, pre-attach the starting position of the third insulating tape to the outside of the second layer of winding. At this time, the ends of the two strands are located outside the starting position of the third insulating tape. Then, hang the ends of the two strands of wire on the 7th and 8th pins of the bobbin, respectively. Finally, wrap two turns of the third insulating tape to cover the second layer of winding. Step 4: Start two strands of wire from the third pin of the bobbin and wind them evenly and densely around the bobbin's winding groove to form a third layer of winding. Next, pre-attach the starting position of the fourth insulating tape to the outside of the third layer of winding. At this time, the ends of the two strands of wire are located outside the starting position of the fourth insulating tape. Then, hang the ends of the two strands of wire on the first pin of the bobbin and finally wrap two turns of the fourth insulating tape to cover the third layer of winding. Step 5: Start with one strand of wire from the 12th pin of the bobbin. Wind one strand of wire around the bobbin's winding groove twice with sparse intervals to form the fourth layer of winding. Next, pre-attach the starting position of the fifth insulating tape to the outside of the fourth layer of winding. At this time, the end of one strand of wire is located outside the starting position of the fifth insulating tape. Then, hang the end of one strand of wire on the 10th pin of the bobbin. Finally, wrap two turns of the fifth insulating tape to cover the fourth layer of winding. Step 6: Start two strands of wire from the fifth pin of the bobbin and wind them evenly and densely around the bobbin's winding groove to form the fifth layer of winding. Next, pre-attach the starting position of the sixth insulating tape to the outside of the fifth layer of winding. At this time, the ends of the two strands of wire are located outside the starting position of the sixth insulating tape. Then, hang the ends of the two strands of wire on the fourth pin of the bobbin and finally wrap two turns of the sixth insulating tape to cover the fifth layer of winding. Step 7: First, solder all the wires hanging on the 3rd pin of the frame to the 3rd pin, and then cut off the part of the 3rd pin of the frame that is not soldered.

2. The optimized winding method for a transformer according to claim 1, characterized in that: In step 2, one layer is 7 circles.

3. The optimized winding method for a transformer according to claim 1, wherein: In step 3, one layer is 6 circles.

4. The optimized winding method for a transformer according to claim 1, wherein: In step 4, one layer is 7 circles.

5. The optimized winding method for a transformer according to claim 1, wherein: In step 6, one layer is 6 turns.

6. The optimized transformer winding method according to claim 1, wherein: In steps 2 to 6, firstly, a first sleeve is placed on the corresponding strand, and then the strands are started on the corresponding pins of the frame.

7. The optimized transformer winding method according to claim 1, characterized in that: In steps 2 to 5, the ends of the corresponding strands are first sleeved with the second sleeve and then hung on the corresponding pins of the frame.

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