Optimized winding method for transformers

Abstract

This invention relates to an optimized winding method for transformers, comprising steps 1 to 7. In step 2, two strands of wire are started from the second pin of the frame and simultaneously wound evenly and densely around the winding slot of the frame to form a first winding loop. Next, the starting position of the second insulating tape is pre-attached to the outside of the first winding loop, at which point the ends of the two strands are located outside the starting position of the second insulating tape. Then, the ends of the two strands are hung on the third pin of the frame, and finally, two turns of the second insulating tape are wrapped to cover the first winding loop. This method greatly improves winding efficiency and product yield, reduces labor costs, and eliminates the need for a sleeve before hanging the wires on the fourth pin, further improving winding efficiency and reducing labor costs.

Description

Technical Field

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

[0002] High-frequency transformers are power transformers that operate at frequencies exceeding intermediate frequencies. They are mainly used in high-frequency switching power supplies as high-frequency switching power supply transformers, and can also be used in high-frequency inverter power supplies and high-frequency inverter welding machines as high-frequency inverter power supply transformers.

[0003] A high-frequency transformer includes a frame, a magnetic core, a primary winding, and a secondary winding. The magnetic core is located on the frame, and both the primary and secondary windings are wound on the magnetic core, forming the circuit part of the transformer. They are usually made of insulated copper or aluminum wire. The frame includes a winding shaft, connection terminals for the primary winding, and connection terminals for the secondary winding. The connection terminals can be used as the starting and ending points of the winding.

[0004] The existing winding method for high-frequency transformers has the following drawbacks: After the two strands starting from the second pin of the bobbin are tightly wound in one layer, a certain length of tail wire needs to be reserved at the end of the two strands and wound on the winding shaft of the automatic winding machine. As a result, when forming the winding loop later, it is necessary to loosen the reserved tail wire and manually wind the transformer, which greatly affects the winding efficiency, increases labor costs, and causes large errors in winding due to manual winding, thus affecting the yield of the transformer.

[0005] Therefore, in this patent application, the applicant has carefully researched a new technical solution to solve the above problems. Summary of the Invention

[0006] The present invention addresses the shortcomings of the prior art by providing an optimized winding method for transformers, which significantly improves winding efficiency and product yield, reduces labor costs, and eliminates the need for bushings before the fourth pin, further improving winding efficiency and reducing labor costs.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] An optimized winding method for a transformer includes the following steps:

[0009] Step 1: Wrap a loop of the first insulating tape around the winding groove of the skeleton;

[0010] Step 2: Starting from the second pin of the skeleton, take two strands of wire and wrap them evenly and tightly around the winding groove of the skeleton to form the first layer of winding. Next, 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 skeleton. Finally, wrap two turns of the second insulating tape to cover the first layer of winding.

[0011] Step 3: Take one strand of wire from the 10th and 11th pins of the skeleton, and simultaneously wrap both strands evenly and tightly around the winding groove of the skeleton to form a second layer of winding. Next, 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 on the 7th and 8th pins of the skeleton respectively. Finally, wrap two turns of the third insulating tape to cover the second layer of winding.

[0012] Step 4: Starting from the third pin of the skeleton, take two strands of wire and wrap them evenly and tightly around the winding groove of the skeleton to form a third layer of winding. Next, 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 skeleton. Finally, wrap two turns of the fourth insulating tape to cover the third layer of winding.

[0013] Step 5: Start with one strand of wire from the 12th pin of the skeleton. Wrap the wire around the winding groove of the skeleton two loose turns to form the fourth layer of winding coil. Next, attach the starting position of the fifth insulating tape to the outside of the fourth layer of winding coil. At this time, the end of the wire is located outside the starting position of the fifth insulating tape. Then hang the end of the wire on the 10th pin of the skeleton. Finally, wrap two turns of the fifth insulating tape to cover the fourth layer of winding coil.

[0014] Step 6: Starting from the 5th pin of the skeleton, take two strands of wire and wrap them evenly and tightly around the winding groove of the skeleton to form the fifth layer of winding. Next, 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 4th pin of the skeleton. Finally, wrap two turns of the sixth insulating tape to cover the fifth layer of winding.

[0015] Step 7: First, solder all the wires attached to the third pin of the skeleton to the third pin using solder, and then cut off the unsoldered parts of the third pin of the skeleton.

[0016] As a preferred option, in step 2, one layer consists of 7 rings.

[0017] As a preferred option, in step 3, one layer consists of 6 rings.

[0018] As a preferred option, in step 4, one layer consists of 7 loops.

[0019] As a preferred option, in step 6, one layer consists of 6 rings.

[0020] As a preferred option, in steps 2 to 6, the first sleeve is first installed on the corresponding strand, and then the wire is started on the corresponding pin of the skeleton.

[0021] As a preferred embodiment, in steps 2 to 5, the end of the corresponding strand is first fitted with a second sleeve and then hung on the corresponding foot of the skeleton.

[0022] Compared with the prior art, the present invention has obvious advantages and beneficial effects. Specifically, it mainly involves the two strands of wire starting from the second pin of the bobbin being wound tightly in one layer, and then the ends of the two strands are instead hung on the third pin of the bobbin, instead of leaving a pre-set length of tail wire to be wound on the winding shaft of the automatic winding machine. This avoids the need to loosen the pre-set tail wire wrapped on the winding shaft and then manually wind the wire to form a third layer of winding, which greatly improves winding efficiency and product yield, and reduces labor costs. Moreover, the sleeve is eliminated before hanging the wire on the fourth pin, further improving winding efficiency and reducing labor costs.

[0023] To more clearly illustrate the structural features and effects of the present invention, a detailed description is provided below in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the winding principle of a transformer according to an embodiment of the present invention;

[0025] Figure 2 This is a cross-sectional schematic diagram of a transformer according to an embodiment of the present invention;

[0026] Figure 3 This is a flowchart illustrating step 1 of an embodiment of the present invention;

[0027] Figure 4 This is a flowchart illustrating step 2 of an embodiment of the present invention;

[0028] Figure 5 This is a flowchart illustrating step 3 of an embodiment of the present invention;

[0029] Figure 6 This is a flowchart illustrating step 4 of an embodiment of the present invention;

[0030] Figure 7 This is a flowchart illustrating step 5 of an embodiment of the present invention;

[0031] Figure 8This is a flowchart illustrating step 6 of an embodiment of the present invention;

[0032] Figure 9 This is a flowchart illustrating step 7 of an embodiment of the present invention.

[0033] Explanation of icon numbers:

[0034] 10. Skeleton 101. Winding groove

[0035] 11. Pin 1 12. Pin 2

[0036] 13. Pin 3 14. Pin 4

[0037] 15. Pin 5 16. Pin 7

[0038] 17. Pin 8 18. Pin 10

[0039] 19. Pin 11 20. Pin 12

[0040] 21. First insulating tape 22. Second insulating tape

[0041] 23. Third insulating tape 24. Fourth insulating tape

[0042] 25. Fifth insulating tape 26. Sixth insulating tape Detailed Implementation

[0043] The present invention will now be further described with reference to the accompanying drawings and specific embodiments.

[0044] like Figures 1 to 9 As shown, an optimized winding method for a transformer includes the following steps:

[0045] Step 1: As Figure 3 As shown, a first insulating tape 21 is wrapped around the winding groove 101 of the skeleton 10;

[0046] Step 2: As Figure 4 As shown, two strands of wire are started from the second pin 12 of the skeleton 10 and simultaneously wound evenly and densely around the winding groove 101 of the skeleton 10 to form the first layer of winding loops. It should be noted that this layer consists of 7 turns.

[0047] 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. Then, the ends of the two strands are hung at right angles on the third pin 13 of the frame 10. Finally, the second insulating tape 22 is wrapped around the first layer of winding to cover it.

[0048] Step 3: As Figure 5As shown, a strand of wire is started from each of the 10th pin 18 and the 11th pin 19 of the skeleton 10, and the two strands are simultaneously wound evenly and densely around the winding groove 101 of the skeleton 10 to form a second layer of winding. It should be noted that this layer consists of 6 turns.

[0049] 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. Then, the ends of the two strands are hung at right angles on the 7th pin 16 and the 8th pin 17 of the frame 10 respectively. Finally, the third insulating tape 23 is wrapped around the second layer of winding two times to cover it.

[0050] Step 4: As Figure 6 As shown, two strands of wire are started from the third pin 13 of the skeleton 10 and simultaneously wound evenly and densely around the winding groove 101 of the skeleton 10 to form a third layer of winding. It should be noted that this layer consists of 7 turns.

[0051] 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. Then, the ends of the two strands are hung at right angles on the first pin 11 of the frame 10. Finally, the fourth insulating tape 24 is wrapped around the third layer of winding two times to cover it.

[0052] Step 5: As Figure 7 As shown, starting from pin 20 of the 12th pin of the skeleton 10, one strand of wire is loosely wound around the winding groove 101 of the skeleton 10 twice to form the fourth layer of winding coil.

[0053] Next, the starting position of the fifth insulating tape 25 is pre-attached 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 25. Then, the end of one strand of wire is hung at a right angle on the 10th pin 18 of the frame 10. Finally, two turns of the fifth insulating tape 25 are wrapped to cover the fourth layer of winding.

[0054] Step 6: As Figure 8 As shown, starting from the fifth pin 15 of the skeleton 10, two strands of wire are simultaneously wound evenly and densely around the winding groove 101 of the skeleton 10 to form a fifth layer of winding. It should be noted that this layer consists of 6 turns.

[0055] Next, the starting position of the sixth insulating tape 26 is pre-attached to the outside of the fifth layer of winding. At this time, the ends of the two strands are located outside the starting position of the sixth insulating tape 26. Then, the ends of the two strands are hung at right angles on the fourth pin 14 of the frame 10. Finally, the sixth insulating tape 26 is wrapped around the fifth layer of winding twice to cover it.

[0056] Step 7: As Figure 9As shown, firstly, all the wires hanging on the third pin 13 of the skeleton 10 are soldered to the third pin 13, and then the unsoldered part of the third pin 13 of the skeleton 10 is cut off.

[0057] In this embodiment, in steps 2 to 6, a first sleeve is first fitted onto the corresponding strand, and then the thread is started on the corresponding pin of the skeleton 10. In steps 2 to 5, a second sleeve is first fitted onto the end of the corresponding strand, and then it is hung on the corresponding pin of the skeleton 10.

[0058] The key design feature of this invention is that, after the two strands of wire starting from the second pin of the bobbin are tightly wound in one layer, the ends of these two strands are instead hung on the third pin of the bobbin, instead of leaving a pre-set length of tail wire wrapped around the winding shaft of the automatic winding machine. This avoids the need to manually unwrap the tail wire wrapped around the winding shaft to form a third layer of winding, greatly improving winding efficiency and product yield, and reducing labor costs. Furthermore, the elimination of the sleeve before hanging the wire at the fourth pin further improves winding efficiency and reduces labor costs.

[0059] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. An optimized winding method for a transformer, characterized in that: The steps include the following: Step 1: Wrap a loop of the first insulating tape around the winding groove of the skeleton; Step 2: Starting from the second pin of the skeleton, take two strands of wire and wrap them evenly and tightly around the winding groove of the skeleton to form the first layer of winding. Next, 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 skeleton. Finally, wrap two turns of the second insulating tape to cover the first layer of winding. Step 3: Take one strand of wire from the 10th and 11th pins of the skeleton, and simultaneously wrap both strands evenly and tightly around the winding groove of the skeleton to form a second layer of winding. Next, 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 on the 7th and 8th pins of the skeleton respectively. Finally, wrap two turns of the third insulating tape to cover the second layer of winding. Step 4: Starting from the third pin of the skeleton, take two strands of wire and wrap them evenly and tightly around the winding groove of the skeleton to form a third layer of winding. Next, 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 skeleton. 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 skeleton. Wrap the wire around the winding groove of the skeleton two loose turns to form the fourth layer of winding coil. Next, attach the starting position of the fifth insulating tape to the outside of the fourth layer of winding coil. At this time, the end of the wire is located outside the starting position of the fifth insulating tape. Then hang the end of the wire on the 10th pin of the skeleton. Finally, wrap two turns of the fifth insulating tape to cover the fourth layer of winding coil. Step 6: Starting from the 5th pin of the skeleton, take two strands of wire and wrap them evenly and tightly around the winding groove of the skeleton to form the fifth layer of winding. Next, 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 4th pin of the skeleton. Finally, wrap two turns of the sixth insulating tape to cover the fifth layer of winding. Step 7: First, solder all the wires attached to the third pin of the skeleton to the third pin using solder, and then cut off the unsoldered parts of the third pin of the skeleton.

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

3. The optimized winding method for a transformer according to claim 1, characterized in that: In step 3, one layer consists of 6 loops.

4. The optimized winding method for a transformer according to claim 1, characterized in that: In step 4, one layer consists of 7 loops.

5. The optimized winding method for a transformer according to claim 1, characterized in that: In step 6, one layer consists of 6 circles.

6. The optimized winding method for a transformer according to claim 1, characterized in that: In steps 2 to 6, the first sleeve is first installed on the corresponding strand, and then the wire is started on the corresponding pin of the skeleton.

7. The optimized winding method for a transformer according to claim 1, characterized in that: In steps 2 to 5, the end of the corresponding strand is first fitted with a second sleeve and then hung on the corresponding foot of the skeleton.

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