Transformer structure and manufacturing process

Abstract

The invention relates to a transformer structure and a manufacturing process, and relates to the technical field of transformers, the transformer structure comprises an upper magnetic core and a lower magnetic core, the middle parts of the upper magnetic core and the lower magnetic core are respectively provided with an upper magnetic core middle column and a lower magnetic core middle column, and the bottom of the lower magnetic core is provided with a bottom plate; an upper magnetic core middle column and a lower magnetic core middle column of the upper magnetic core and the lower magnetic core are covered with insulating rubber tapes and extend to the bottom, and coil windings are installed on the upper magnetic core middle column and the lower magnetic core middle column which are covered with the insulating rubber tapes. The upper magnetic core middle column and the lower magnetic core middle column of the upper magnetic core and the lower magnetic core are completely coated with the insulating tape and extend to the bottoms of the magnetic cores, so that the magnetic cores are completely kept away from the winding, and the high-voltage insulation problem of customers is solved.

Description

Technical Field

[0001] The present application relates to the technical field of transformers, and in particular to a transformer structure and manufacturing process. Background Art

[0002] At present, the existing transformer structure has an irregular structure because the coil winding is directly assembled on the magnetic core, that is, the middle column and the bottom are connected at a right angle, which makes it difficult for the insulating material to completely cover the surface. The magnetic core is exposed or a discharge gap appears at the connection position between the root of the middle column and the bottom of the magnetic core. When the winding and the magnetic core have higher insulation withstand voltage requirements, it is difficult to meet them.

[0003] The existing technology usually adopts the following solutions: 1. Increasing the thickness of the insulating gasket to raise the coil winding and increase the distance between the winding and the magnetic core to meet the requirement, but sacrificing the winding space and increasing the cost; 2. Wrapping the inner circle of the coil winding with a layer of insulating tape before assembling; 3. Reducing the insulation withstand voltage.

[0004] The above prior art has the following problems: Solution 1 is to increase the distance between the winding and the magnetic core to meet the insulation conditions, but it sacrifices the winding space; Solution 2 is to increase insulation on the inner ring of the coil, but the operation process is difficult; Solution 3 is for the client to actively reduce the insulation withstand voltage, which cannot be met if there are higher insulation withstand voltage requirements. Summary of the invention

[0005] The purpose of this application is to provide a transformer structure to solve the problems raised in the above background technology.

[0006] In the first aspect, a transformer structure provided in the present application adopts the following technical solution: it includes an upper magnetic core and a lower magnetic core, wherein an upper magnetic core middle column and a lower magnetic core middle column are respectively provided in the middle of the upper magnetic core and the lower magnetic core, and a bottom plate is installed at the bottom of the lower magnetic core; the upper magnetic core middle column and the lower magnetic core middle column of the upper magnetic core and the lower magnetic core are covered with insulating tape on the outside and extend to the bottom, and the coil winding is installed on the upper magnetic core middle column and the lower magnetic core middle column covered with insulating tape on the outside, and the insulating tape includes a tape cap and a tape bottom film, the tape cap covers the outside of the upper magnetic core middle column or the lower magnetic core middle column, and the bottom of the tape cap is integrally connected with the tape bottom film, and the tape bottom film covers the bottom of the inner cavity of the upper magnetic core or the lower magnetic core.

[0007] By adopting the above technical solution, the upper core middle column and the lower core middle column of the upper core and the lower core are respectively wrapped with insulating tape and extended to the bottom, so that the core and the winding are completely avoided, thereby meeting the customer's high-voltage insulation problem.

[0008] Preferably, the tape cap is tightly fitted to the outer portion of the upper magnetic core middle column or the lower magnetic core middle column.

[0009] By adopting the above technical solution, the insulating tape can be prevented from falling off and can perform better insulation.

[0010] Preferably, the tape bottom film is tightly fitted to the bottom of the inner cavity of the upper magnetic core or the lower magnetic core, and extends to the two walls of the inner cavity.

[0011] By adopting the above technical solution, the winding and the magnetic core can be better separated, so that the insulation effect is better.

[0012] Preferably, adhesive backing is provided on both walls of the inner cavities of the upper magnetic core and the lower magnetic core, and the bottom of the adhesive backing is connected to the outer edge of the tape bottom film.

[0013] By adopting the above technical solution, the backing glue is connected to the outer edge of the tape bottom film, so that the group and the magnetic core are better separated and the insulation effect is improved.

[0014] In a second aspect, the present application provides a transformer structure manufacturing process using the following technical solution: comprising the following steps: S1 first places the lower magnetic core on the positioning assembly; S2 wraps the insulating tape around the middle column of the lower magnetic core so that the middle column of the magnetic core is completely covered with the insulating tape and extends to the bottom of the magnetic core; S3 positions the covering insulating tape through a positioning component; S4 installs the coil winding on the middle column of the lower magnetic core covered with insulating tape on the outside; S5 simultaneously covers the insulating tape on the middle column of the upper magnetic core, and turns the upper magnetic core upside down on the lower magnetic core to complete the installation work.

[0015] By adopting the above technical solution, the insulating tape can be completely covered on the upper magnetic core middle column and the lower magnetic core middle column of the upper magnetic core and the lower magnetic core, so as to isolate the coil winding and the upper magnetic core and the lower magnetic core, thereby achieving a higher insulation effect.

[0016] Preferably, the positioning assembly includes a supporting base plate, a supporting platform, a positioning block 1, a positioning block 2, a mounting seat 1, a mounting seat 2, a center rod, a pushing block, a pushing rod 1, a pushing rod 2, a rotating sleeve and a handle, the supporting base plate is installed with the supporting base plate, the mounting seat 1 and the mounting seat 2 are respectively installed on both sides of the supporting base plate, the inner sides of the mounting seat 1 and the mounting seat 2 are respectively rotatably connected with the positioning block 1 and the positioning block 2, the center rod is installed in the middle of the supporting platform, and the bottom of the center rod is connected to the supporting base plate, the middle of the center rod is rotatably connected with the pushing block, the two sides of the pushing block are respectively abutted with the pushing rod 1 and the pushing rod 2, the pushing rod 1 and the pushing rod 2 are respectively movable through the two sides of the supporting platform and extend to abut the bottom of the positioning block 1 and the positioning block 2, the bottom of the pushing block is connected with the rotating sleeve, the bottom of the rotating sleeve is rotatably connected to the upper end of the supporting base plate, and a handle is installed on one side of the supporting base plate.

[0017] By adopting the above technical solution and setting a positioning component, the insulating tape can be positioned from both sides when the insulating tape is wrapped around the upper magnetic core middle column and the lower magnetic core middle column, so that the insulating tape is not easy to loosen, so that the subsequent coil winding installation is more convenient and efficient, thereby improving the quality of transformer manufacturing.

[0018] Preferably, the positioning block 1 and the positioning block 2 are symmetrically arranged, and the upper ends of both are arc surfaces.

[0019] By adopting the above technical solution, the insulating tape is positioned from both sides by the symmetrical positioning block 1 and the positioning block 2, so that it is not easy to loosen, and the setting of the arc surface can prevent the insulating tape from being worn.

[0020] Preferably, the front and rear sides of the pushing block gradually protrude outwards.

[0021] By adopting the above technical solution, after the pushing block is rotated clockwise, the pushing rod 1 and the pushing rod 2 can be pushed outward. When the pushing block is rotated counterclockwise, the pushing rod 1 and the pushing rod 2 lose the thrust. Under the elastic reset of the spring, the lower ends of the positioning block 1 and the positioning block 2 push the pushing rod 1 and the pushing rod 2 back.

[0022] Preferably, the handle extends out of an opening on one side of the lower portion of the support platform.

[0023] By adopting the above technical solution, it is convenient for the user to push the handle.

[0024] Preferably, a spring is elastically connected between the upper ends of the positioning block 1 and the positioning block 2 and the support platform.

[0025] By adopting the above technical solution, a spring is arranged between the positioning block 1, the positioning block 2 and the support platform, so that the lower ends of the positioning block 1 and the positioning block 2 can be reset by the spring after losing thrust, which is convenient for quick removal and placement of the transformer.

[0026] In summary, the present application includes at least one of the following transformer structures and manufacturing processes with beneficial technical effects: 1. This application completely covers the upper core middle column and the lower core middle column of the upper core and the lower core with insulating tape and extends it to the bottom of the core, so that the core and the winding are completely avoided, thereby meeting the customer's high-voltage insulation problem; 2. The tape bottom sheet of the insulating tape of the present application is tightly attached to the bottom of the inner cavity of the upper magnetic core or the lower magnetic core, and extends to the two walls of the inner cavity, so as to better separate the winding and the magnetic core, and achieve better insulation effect; 3. In the manufacturing process of the present application, a positioning component is used to position the insulating tape wrapped around the upper magnetic core center column and the lower magnetic core center column, so that the insulating tape is not easy to loosen or deviate, which facilitates the subsequent installation of the coil winding and improves the manufacturing efficiency and quality of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the overall structure of this application; Figure 2 It is a top view structural schematic diagram of the present application; Figure 3 It is a schematic diagram of the explosion structure of the present application; Figure 4 It is a schematic diagram of the insulating tape structure of the present application; Figure 5 It is a schematic diagram of the overall structure of the positioning component of the present application; Figure 6 It is a schematic diagram of the internal structure of the positioning component of the present application; Figure 7 It is a schematic diagram of the top view structure of the push block of the present application.

[0028] Explanation of the reference numerals in the accompanying drawings: 1. upper magnetic core; 2. lower magnetic core; 3. middle column of the upper magnetic core; 4. middle column of the lower magnetic core; 5. insulating tape; 6. coil winding; 7. bottom plate; 51. tape cap; 52. tape bottom film; 1a. adhesive backing; 8. supporting bottom plate; 9. supporting platform; 10. positioning block one; 11. positioning block two; 12. mounting seat one; 13. mounting seat two; 14. center rod; 15. pushing block; 16. pushing rod one; 17. pushing rod two; 18. rotating sleeve; 19. handle; 20. spring. DETAILED DESCRIPTION

[0029] The following is combined with Figure 1 -Attached Figure 7 , further details of this application are given.

[0030] A transformer structure, referring to Figure 1-Figure 3 , including an upper magnetic core 1 and a lower magnetic core 2, wherein an upper magnetic core middle column 3 and a lower magnetic core middle column 4 are respectively provided in the middle of the upper magnetic core 1 and the lower magnetic core 2, and a base plate 7 is installed at the bottom of the lower magnetic core 2; the upper magnetic core middle column 3 and the lower magnetic core middle column 4 of the upper magnetic core 1 and the lower magnetic core 2 are covered with insulating tape 5 on the outside and extend to the bottom, and the coil winding 6 is installed on the upper magnetic core middle column 3 and the lower magnetic core middle column 4 covered with insulating tape 5 on the outside.

[0031] Reference Figure 4The insulating tape 5 includes a tape cap 51 and a tape bottom film 52. The tape cap 51 covers the outside of the upper magnetic core middle column 3 or the lower magnetic core middle column 4, and the bottom of the tape cap 51 is integrally connected with the tape bottom film 52. The tape bottom film 52 covers the bottom of the inner cavity of the upper magnetic core 1 or the lower magnetic core 2. The upper magnetic core middle column 3 and the lower magnetic core middle column 4 of the upper magnetic core 1 and the lower magnetic core 2 are respectively wrapped with the insulating tape 5 and extended to the bottom, so that the magnetic core and the winding are completely avoided, thereby meeting the customer's high-voltage insulation problem, and the tape cap 51 is tightly fitted with the outer side of the upper magnetic core middle column 3 or the lower magnetic core middle column 4, which can prevent the insulating tape 5 from falling off and can better insulate.

[0032] Among them, the tape film 52 is tightly fitted on the bottom of the inner cavity of the upper magnetic core 1 or the lower magnetic core 2, and extends to the two walls of the inner cavity, so as to better separate the winding and the magnetic core, so as to achieve better insulation effect. The two walls of the inner cavity of the upper magnetic core 1 and the lower magnetic core 2 are both provided with backing glue 1a, and the bottom of the backing glue 1a is connected to the outer edge of the tape film 52. By using the backing glue 1a to connect to the outer edge of the tape film 52, the winding and the magnetic core can be better separated, thereby improving the insulation effect.

[0033] A manufacturing process of a transformer structure comprises the following steps: S1 first places the lower magnetic core 2 on the support platform 9 of the positioning assembly; S2 then wraps the outer part of the lower magnetic core middle column 4 of the lower magnetic core 2 with the insulating tape 5, so that the magnetic core middle column is completely covered with the insulating tape 5 and extends to the bottom of the magnetic core, and the tape cap 51 is tightly fitted with the outer part of the upper magnetic core middle column 3 or the lower magnetic core middle column 4; S3 positions the covering insulating tape 5 by means of a positioning assembly so that the insulating tape 5 is not easily loosened or deviated; S4 aligns the middle slot of the coil winding 6 with the lower magnetic core middle column 4 covered with insulating tape 5 on the outside and then installs it; S5 then covers the upper magnetic core middle column 3 of the upper magnetic core 1 with the insulating tape 5 , and then turns the upper magnetic core 1 upside down on the lower magnetic core 2 to complete the installation work.

[0034] It can be seen from the above steps that the insulating tape 5 is completely covered on the upper magnetic core middle column 3 and the lower magnetic core middle column 4 of the upper magnetic core 1 and the lower magnetic core 2 to isolate the coil winding 6 from the upper magnetic core 1 and the lower magnetic core 2, thereby achieving a higher insulation effect.

[0035] Reference Figure 5-Figure 7The positioning assembly includes a supporting base plate 8, a supporting platform 9, a positioning block 10, a positioning block 2 11, a mounting seat 12, a mounting seat 2 13, a center rod 14, a pushing block 15, a push rod 16, a push rod 2 17, a rotating sleeve 18 and a handle 19. A supporting base plate 9 is installed on the supporting base plate 8. Mounting seats 12 and 13 are respectively installed on both sides of the supporting base plate 9. The inner sides of the mounting seats 12 and 13 are respectively rotatably connected with the positioning block 10 and the positioning block 2 11. A center rod 14 is installed in the middle of the supporting base plate 9, and the bottom of the center rod 14 is connected to the supporting base plate 8. The middle of the center rod 14 is rotatably connected with a pushing block 15. Push rods 16 and 17 are respectively abutted on both sides of the pushing block 15. Push rods 16 and 17 respectively run through both sides of the supporting base plate 9 and extend out to abut against the bottoms of the positioning blocks 10 and 11. Then, a rotating sleeve 18 is connected to the bottom of the pushing block 15, and the bottom of the rotating sleeve 18 is rotatably connected to the upper end of the supporting base plate 8. A handle 19 is installed on one side of the supporting base plate 8, and the handle 19 extends out of an opening on one side of the lower part of the supporting platform 9, which is convenient for the user to push the handle 19. A spring 20 is elastically connected between the upper ends of the positioning blocks 10 and 11 and the supporting platform 9. A spring 20 is arranged between the positioning blocks 10 and 11 and the supporting platform 9, so that the lower ends of the positioning blocks 10 and 11 can be reset by the spring 20 after losing thrust, which is convenient for quick placement of the transformer. A positioning component is arranged, and when the insulating tape 5 is wrapped around the upper magnetic core middle column 3 and the lower magnetic core middle column 4, the insulating tape 5 can be positioned from both sides, so that the insulating tape 5 is not easy to loosen and is cheap, so that the subsequent installation of the coil winding 6 is more convenient and efficient, thereby improving the quality of transformer manufacturing.

[0036] Among them, the positioning block 10 and the positioning block 2 11 are symmetrically arranged, and the upper ends of both are arc surfaces. The symmetrical positioning block 10 and the positioning block 2 11 position the insulating tape 5 from both sides, making it difficult to loosen, and the setting of the arc surface can prevent the insulating tape 5 from being worn.

[0037] Among them, the front and rear sides of the pushing block 15 gradually protrude outward. After the pushing block 15 is rotated clockwise, the pushing rod 16 and the pushing rod 2 17 can be pushed outward. When the pushing block 15 is rotated counterclockwise, the pushing rod 16 and the pushing rod 2 17 lose their thrust, and under the elastic reset of the spring 20, the lower ends of the positioning blocks 10 and 11 push the pushing rod 16 and the pushing rod 2 17 back.

[0038] The implementation principle of the positioning assembly is as follows: after the lower magnetic core 2 is placed on the support platform 9 of the positioning assembly, the insulating tape 5 is wound around the middle column 4 of the lower magnetic core. At this time, the handle 19 is pushed from right to left, and the rotating sleeve 18 rotates clockwise on the center rod 14. At the same time, the pushing block 15 is synchronously driven to rotate clockwise. After the pushing block 15 rotates clockwise, the pushing rod 1 16 and the pushing rod 2 17 are pushed outward, and the bottom of the positioning block 10 and the positioning block 2 11 are pushed out by the pushing rod 1 16 and the pushing rod 2 17. The positioning block 10 , the positioning block 10 and the positioning block 11 rotate on the mounting seat 12 and the mounting seat 13, so that the upper ends of the positioning blocks 10 and 11 move inward to clamp and position the insulating tape 5 to prevent the lower insulation 5 from loosening and falling off. After the handle 19 is pushed in the reverse direction, the rotating sleeve 18 and the pushing block 15 rotate counterclockwise. At this time, the elastic reset of the spring 20 pushes the upper ends of the positioning blocks 10 and 11 outward, and the lower ends are retracted to push the push rod 16 and the push rod 17 back inward, so that the magnetic core can be easily taken in and placed for the next positioning work.

[0039] It should be noted that the push block 15 can rotate about 90 degrees to push the push rod 16 and the push rod 2 17 to the positioning block 10 and the positioning block 2 11 to be clamped.

[0040] The present application provides a transformer structure and manufacturing process, by completely covering the upper magnetic core middle column 3 and the lower magnetic core middle column 4 of the upper magnetic core 1 and the lower magnetic core 2 with insulating tape 5 and extending it to the bottom of the magnetic core, the magnetic core and the winding are completely avoided, thereby meeting the customer's high-voltage insulation problem; the tape base film 52 of the insulating tape 5 is tightly fitted with the bottom of the inner cavity of the upper magnetic core 1 or the lower magnetic core 2, and extends to the two walls of the inner cavity, so as to better separate the winding and the magnetic core, so as to achieve better insulation effect; in the manufacturing process of the present application, a positioning component is used to position the insulating tape 5 wrapped around the upper magnetic core middle column 3 and the lower magnetic core middle column 4, so that the insulating tape 5 is not easy to loosen or deviate, which is convenient for the subsequent installation of the coil winding 6, and improves the manufacturing efficiency and quality of the transformer.

[0041] The embodiments of this specific implementation are all preferred embodiments of the present application, and are not intended to limit the protection scope of the present application. The same components are represented by the same figure marks. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A transformer structure, comprising an upper magnetic core (1) and a lower magnetic core (2), wherein an upper magnetic core middle column (3) and a lower magnetic core middle column (4) are respectively provided in the middle of the upper magnetic core (1) and the lower magnetic core (2), and a bottom plate (7) is installed at the bottom of the lower magnetic core (2); It is characterized in that The invention also comprises an insulating tape (5), wherein the upper magnetic core middle column (3) and the lower magnetic core middle column (4) of the upper magnetic core (1) and the lower magnetic core (2) are covered with the insulating tape (5) on the outside and extend to the bottom, and the coil winding (6) is installed on the upper magnetic core middle column (3) and the lower magnetic core middle column (4) covered with the insulating tape (5) on the outside, and the insulating tape (5) comprises a tape cap (51) and a tape bottom film (52), wherein the tape cap (51) covers the outside of the upper magnetic core middle column (3) or the lower magnetic core middle column (4), and the bottom of the tape cap (51) is integrally connected with the tape bottom film (52), and the tape bottom film (52) covers the bottom of the inner cavity of the upper magnetic core (1) or the lower magnetic core (2).

2. A transformer structure according to claim 1, characterized in that: The adhesive tape cap (51) is tightly fitted to the exterior of the upper magnetic core middle column (3) or the lower magnetic core middle column (4).

3. A transformer structure according to claim 1, characterized in that: The adhesive tape bottom film (52) is tightly fitted to the bottom of the inner cavity of the upper magnetic core (1) or the lower magnetic core (2), and extends to the two walls of the inner cavity.

4. A transformer structure according to claim 3, characterized in that: Both walls of the inner cavities of the upper magnetic core (1) and the lower magnetic core (2) are provided with backing glue (1a), and the bottom of the backing glue (1a) is connected to the outer edge of the tape bottom film (52).

5. A manufacturing process of a transformer structure, based on a transformer structure according to any one of claims 1 to 4, characterized in that: The steps include: S1 first places the lower magnetic core (2) on the positioning assembly; S2 wraps the insulating tape (5) around the lower magnetic core middle column (4) of the lower magnetic core (2), so that the insulating tape (5) is completely covered on the magnetic core middle column and extends all the way to the bottom of the magnetic core; S3 positions the covering insulating tape (5) by means of a positioning component; S4 installs the coil winding (6) on the lower magnetic core center column (4) whose exterior is covered with insulating tape (5); S5 simultaneously covers the insulating tape (5) on the upper magnetic core middle column (3) of the upper magnetic core (1), and turns the upper magnetic core (1) upside down on the lower magnetic core (2), thereby completing the installation work.

6. The manufacturing process of a transformer structure according to claim 5, characterized in that: The positioning assembly comprises a supporting base plate (8), a supporting platform (9), a positioning block 1 (10), a positioning block 2 (11), a mounting seat 1 (12), a mounting seat 2 (13), a center rod (14), a pushing block (15), a pushing rod 1 (16), a pushing rod 2 (17), a rotating sleeve (18) and a handle (19). The supporting base plate (8) is mounted with a supporting platform (9), and mounting seats 1 (12) and 2 (13) are mounted on both sides of the supporting platform (9). The inner sides of the mounting seats 1 (12) and 2 (13) are rotatably connected to the positioning block 1 (10) and the positioning block 2 (11). The middle of the supporting platform (9) is A center rod (14) is installed, and the bottom of the center rod (14) is connected to the support base plate (8). The middle part of the center rod (14) is rotatably connected to a push block (15). The two sides of the push block (15) are respectively abutted with a push rod 1 (16) and a push rod 2 (17). The push rod 1 (16) and the push rod 2 (17) are respectively movably passed through the two sides of the support platform (9) and extend to abut against the bottom of the positioning block 1 (10) and the positioning block 2 (11). The bottom of the push block (15) is connected to a rotating sleeve (18). The bottom of the rotating sleeve (18) is rotatably connected to the upper end of the support base plate (8). A handle (19) is installed on one side of the support base plate (8).

7. The manufacturing process of a transformer structure according to claim 6, characterized in that: The positioning block 1 (10) and the positioning block 2 (11) are symmetrically arranged, and the upper ends of both are arc surfaces.

8. A transformer structure and manufacturing process according to claim 6, characterized in that: The front and rear sides of the push block (15) gradually protrude outwards towards both sides.

9. A transformer structure and manufacturing process according to claim 6, characterized in that: The handle (19) extends out of an opening on one side of the lower portion of the support platform (9).

10. A transformer structure and manufacturing process according to claim 7, characterized in that: A spring (20) is elastically connected between the upper ends of the positioning block 1 (10) and the positioning block 2 (11) and the support platform (9).

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