A transformer structure and manufacturing process

Abstract

The present application relates to a transformer structure and manufacturing process, belonging to the technical field of transformers. It includes 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. A bottom plate is installed at the bottom of the lower magnetic core; the outer parts of 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 and extend to the bottom. 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. By completely covering the outside of the upper magnetic core middle column and the lower magnetic core middle column of the upper magnetic core and the lower magnetic core with insulating tape and extending it all the way to the bottom of the magnetic core, the present application completely avoids the magnetic core and the winding, thus meeting the customer's high-voltage insulation problem.

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:

[0005] 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

[0006] The purpose of this application is to provide a transformer structure to solve the problems raised in the above background technology.

[0007] 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.

[0008] 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.

[0009] 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.

[0010] By adopting the above technical solution, the insulating tape can be made not easy to fall off and better insulation can be achieved.

[0011] Preferably, the tape base film is closely attached to the bottom of the inner cavity of the upper magnetic core or the lower magnetic core and extends to both inner walls of the cavity.

[0012] By adopting the above technical solution, the winding and the magnetic core are better separated, resulting in better insulation effect.

[0013] Preferably, back glue is provided on both inner walls of the inner cavities of the upper magnetic core and the lower magnetic core, and the bottom of the back glue is connected to the outer edge of the tape base film.

[0014] By adopting the above technical solution, by connecting the back glue to the outer edge of the tape base film, the winding and the magnetic core are better separated, improving the insulation effect.

[0015] In a second aspect, the manufacturing process of a transformer structure provided by the present application adopts the following technical solution: It includes the following steps:

[0016] S1 First, place the lower magnetic core on the positioning component;

[0017] S2 Wind and cover the insulating tape on the middle column of the lower magnetic core of the lower magnetic core so that the middle column of the magnetic core is completely covered with the insulating tape and extends all the way to the bottom of the magnetic core;

[0018] S3 Position the covered insulating tape through the positioning component;

[0019] S4 Install the coil winding on the middle column of the lower magnetic core covered with the insulating tape on the outside;

[0020] S5 Synchronously cover the insulating tape on the middle column of the upper magnetic core of the upper magnetic core, and buckle the upper magnetic core on the lower magnetic core to complete the installation work.

[0021] By adopting the above technical solution, the insulating tape can completely cover the middle columns of the upper magnetic core and the lower magnetic core of the upper magnetic core and the lower magnetic core, so as to isolate the coil winding from the upper magnetic core and the lower magnetic core, thereby achieving a higher insulation effect.

[0022] Preferably, the positioning component includes a support base plate, a support platform, a first positioning block, a second positioning block, a first mounting seat, a second mounting seat, a central rod, a pushing block, a first pushing rod, a second pushing rod, a rotating sleeve and a handle. The support platform is mounted on the support base plate, and the first mounting seat and the second mounting seat are respectively mounted on both sides of the support platform. The first positioning block and the second positioning block are respectively rotatably connected to the inner sides of the first mounting seat and the second mounting seat. The central rod is mounted in the middle of the support platform, and the bottom of the central rod is connected to the support base plate. The pushing block is rotatably connected to the middle of the central rod. The first pushing rod and the second pushing rod respectively abut against both sides of the pushing block. The first pushing rod and the second pushing rod respectively pass through both sides of the support platform and extend out to abut against the bottoms of the first positioning block and the second positioning block. The bottom of the pushing block is connected to the rotating sleeve, and the bottom of the rotating sleeve is rotatably connected to the upper end of the support base plate. A handle is mounted on one side of the support base plate.

[0023] By adopting the above technical solution, the positioning component is provided, so that when insulating tapes are wound and covered on the middle columns of the upper magnetic core and the lower magnetic core, the insulating tapes can be positioned from both sides, so that the insulating tapes are not easily loosened, which is convenient for subsequent coil winding installation to be more convenient and efficient, and improves the quality of transformer production.

[0024] Preferably, the first positioning block and the second positioning block are symmetrically arranged, and the upper ends of both are arc surfaces.

[0025] By adopting the above technical solution, the insulating tapes are positioned from both sides by the symmetric first positioning block and second positioning block, so that they are not easily loosened, and the arc surface setting can prevent the insulating tapes from being worn.

[0026] Preferably, the front and rear sides of the pushing block gradually protrude outwards towards both sides.

[0027] By adopting the above technical solution, after the pushing block is rotated clockwise, the first pushing rod and the second pushing rod can be pushed outwards. When the pushing block is rotated counterclockwise, the first pushing rod and the second pushing rod lose the thrust, and under the elastic reset of the spring, the lower ends of the first positioning block and the second positioning block push the first pushing rod and the second pushing rod back.

[0028] Preferably, the handle extends out of the opening on one side of the lower part of the support platform.

[0029] By adopting the above technical solution, it is convenient for the user to push the handle.

[0030] Preferably, springs are elastically connected between the upper ends of the first positioning block and the second positioning block and the support platform.

[0031] By adopting the above technical solution, by arranging springs between the first positioning block and the second positioning block and the support platform, the lower ends of the first positioning block and the second positioning block can be reset through the springs after losing the thrust, which is convenient for the quick picking and placing of the transformer.

[0032] In summary, the present application includes at least one of the following beneficial technical effects of the transformer structure and manufacturing process:

[0033] 1. In the present application, by completely covering the upper magnetic core column of the upper magnetic core and the lower magnetic core column of the lower magnetic core with insulating tape and extending it all the way to the bottom of the magnetic core, the magnetic core and the winding are completely avoided, thus meeting the customer's high-voltage insulation problem;

[0034] 2. In the present application, the tape base of the insulating tape is closely attached to the bottom of the inner cavity of the upper magnetic core or the lower magnetic core and extends to both inner walls, better separating the winding and the magnetic core and making the insulation effect better;

[0035] 3. In the manufacturing process of the present application, a positioning component is used to position the insulating tape wound and covered on the upper magnetic core column and the lower magnetic core column, so that the insulating tape is not prone to loosening and shifting, facilitating the subsequent installation of the coil winding and improving the manufacturing efficiency and quality of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 is a schematic diagram of the overall structure of the present application;

[0037] Figure 2 is a schematic top view structure diagram of the present application;

[0038] Figure 3 is an exploded structure schematic diagram of the present application;

[0039] Figure 4 is a schematic diagram of the insulating tape structure of the present application;

[0040] Figure 5 is a schematic diagram of the overall structure of the positioning component of the present application;

[0041] Figure 6 is a schematic diagram of the internal structure of the positioning component of the present application;

[0042] Figure 7 is a schematic top view structure diagram of the pushing block of the present application.

[0043] Description of the reference numerals: 1. Upper magnetic core; 2. Lower magnetic core; 3. Upper magnetic core column; 4. Lower magnetic core column; 5. Insulating tape; 6. Coil winding; 7. Bottom plate; 51. Tape cap; 52. Tape base; 1a. Adhesive; 8. Support bottom plate; 9. Support platform; 10. Positioning block one; 11. Positioning block two; 12. Mounting seat one; 13. Mounting seat two; 14. Central rod; 15. Pushing block; 16. Pushing rod one; 17. Pushing rod two; 18. Rotating sleeve; 19. Handle; 20. Spring. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0044] The following is combined with the attached Figure 1 - Attached Figure 7, a further detailed description of the present application is given.

[0045] A transformer structure, referring to Figures 1-3 , includes an upper magnetic core 1 and a lower magnetic core 2. An upper magnetic core middle column 3 and a lower magnetic core middle column 4 are respectively provided in the upper magnetic core 1 and the lower magnetic core 2. A bottom plate 7 is installed at the bottom of the lower magnetic core 2; an insulating tape 5 is covered outside 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 and extends to the bottom. 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 outside.

[0046] Referring to Figure 4 , the 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 wound and covered with the insulating tape 5 and extend to the bottom, so that the magnetic core and the winding are completely avoided, thus meeting the customer's high-voltage insulation problem. And the tape cap 51 is closely attached to the outside of the upper magnetic core middle column 3 or the lower magnetic core middle column 4, which can make the insulating tape 5 not easy to fall off and can better perform insulation.

[0047] Among them, the tape bottom film 52 is closely attached to the bottom of the inner cavity of the upper magnetic core 1 or the lower magnetic core 2 and extends to both inner walls of the cavity, better separating the winding and the magnetic core, making the insulation effect better. Adhesive tapes 1a are provided on both inner walls of the inner cavities of the upper magnetic core 1 and the lower magnetic core 2, and the bottom of the adhesive tape 1a is connected to the outer edge of the tape bottom film 52. By using the connection between the adhesive tape 1a and the outer edge of the tape bottom film 52, the winding and the magnetic core are better separated, improving the insulation effect.

[0048] A manufacturing process of a transformer structure includes the following steps:

[0049] S1 First, place the lower magnetic core 2 on the support table 9 of the positioning component;

[0050] S2 Then wind and cover the insulating tape 5 outside the lower magnetic core middle column 4 of the lower magnetic core 2, 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 closely attached to the outside of the upper magnetic core middle column 3 or the lower magnetic core middle column 4;

[0051] S3 Position the insulating tape 5 through the positioning component to make the insulating tape 5 not easy to loosen and shift;

[0052] S4 Align the middle slot of the coil winding 6 with the lower magnetic core middle column 4 covered with the insulating tape 5 outside and then install it;

[0053] S5 then synchronously covers the insulating tape 5 on the upper magnetic core middle column 3 of the upper magnetic core 1, and reversely buckles the upper magnetic core 1 on the lower magnetic core 2 to complete the installation work.

[0054] As can be seen from the above steps, the insulating tape 5 is completely covered on the upper magnetic core middle column 3 of the upper magnetic core 1 and the lower magnetic core middle column 4 of 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.

[0055] Refer to Figures 5-7 , the positioning component includes a support base plate 8, a support platform 9, a first positioning block 10, a second positioning block 11, a first mounting seat 12, a second mounting seat 13, a central rod 14, a pushing block 15, a first pushing rod 16, a second pushing rod 17, a rotating sleeve 18 and a handle 19. The support platform 9 is installed on the support base plate 8. The first mounting seat 12 and the second mounting seat 13 are respectively installed on both sides of the support platform 9. The first positioning block 10 and the second positioning block 11 are respectively rotatably connected to the inner sides of the first mounting seat 12 and the second mounting seat 13. The central rod 14 is installed in the middle of the support platform 9, and the bottom of the central rod 14 is connected to the support base plate 8. The middle of the central rod 14 is rotatably connected to the pushing block 15. The first pushing rod 16 and the second pushing rod 17 respectively abut against both sides of the pushing block 15. The first pushing rod 16 and the second pushing rod 17 respectively pass through both sides of the support platform 9 and extend out to abut against the bottoms of the first positioning block 10 and the second positioning block 11. The bottom of the pushing block 15 is connected to the 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. The handle 19 extends out of the lower opening on one side of the support 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 first positioning block 10 and the second positioning block 11 and the support platform 9. By arranging the spring 20 between the first positioning block 10 and the second positioning block 11 and the support platform 9, the lower ends of the first positioning block 10 and the second positioning block 11 can be reset through the spring 20 after losing the thrust, which is convenient for the quick taking and placing of the transformer. By setting the positioning component, when the insulating tape 5 is wound and covered on 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, which is convenient for the subsequent installation of the coil winding 6 to be more convenient and efficient, and improves the quality of transformer production.

[0056] Among them, the first positioning block 10 and the second positioning block 11 are symmetrically arranged, and the upper ends of both are arc surfaces. The symmetric first positioning block 10 and second positioning block 11 position the insulating tape 5 from both sides, making it not easy to loosen, and the arc surface setting can prevent the insulating tape 5 from being worn.

[0057] Among them, both the front and rear sides of the pushing block 15 gradually bulge outwards towards both sides. After the pushing block 15 rotates clockwise, the first pushing rod 16 and the second pushing rod 17 can be pushed outwards. When the pushing block 15 rotates counterclockwise, the first pushing rod 16 and the second pushing rod 17 lose the thrust, and under the elastic reset of the spring 20, the lower ends of the first positioning block 10 and the second positioning block 11 push the first pushing rod 16 and the second pushing rod 17 back.

[0058] The implementation principle of the positioning component is as follows: After the lower magnetic core 2 is placed on the support platform 9 of the positioning component, 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 central rod 14. At the same time, the pushing block 15 is synchronously driven to rotate clockwise. After the pushing block 15 rotates clockwise, the first pushing rod 16 and the second pushing rod 17 are pushed outwards. After the first pushing rod 16 and the second pushing rod 17 are pushed out, the bottoms of the first positioning block 10 and the second positioning block 11 are pushed out. The first positioning block 10 and the second positioning block 11 rotate on the first mounting seat 12 and the second mounting seat 13, and the upper ends of the first positioning block 10 and the second positioning block 11 move inwards to clamp and position the insulating tape 5, preventing the insulating tape 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, through the elastic reset of the spring 20, the upper ends of the first positioning block 10 and the second positioning block 11 are pushed outwards, and the lower ends retract to push the first pushing rod 16 and the second pushing rod 17 inwards, making it convenient to take and place the magnetic core for the next positioning work.

[0059] It should be noted that when the pushing block 15 rotates about 90 degrees, the first pushing rod 16 and the second pushing rod 17 can be pushed out to the clamping state of the first positioning block 10 and the second positioning block 11.

[0060] This 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 the insulating tape 5 and extending it to the bottom of the magnetic core, the magnetic core and the winding are completely avoided, thus meeting the customer's high-voltage insulation problem; the tape base film 52 of the insulating tape 5 is closely attached to the inner cavity bottom of the upper magnetic core 1 or the lower magnetic core 2 and extends to the two inner walls, better separating the winding and the magnetic core and making the insulation effect better; in the manufacturing process of this application, the positioning component is used to position the insulating tape 5 wound and covered on 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 and shift, facilitating the subsequent installation of the coil winding 6 and improving the manufacturing efficiency and quality of the transformer.

[0061] The embodiments of this specific implementation manner are all preferred embodiments of this application, and do not limit the protection scope of this application accordingly. The same components are denoted by the same reference numerals. Therefore, all equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. A manufacturing process of a transformer structure, 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 covers the insulating tape (5) on the upper magnetic core middle column (3) of the upper magnetic core (1) simultaneously, and turns the upper magnetic core (1) upside down on the lower magnetic core (2), thereby completing the installation work; 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 movable 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); The positioning block 1 (10) and the positioning block 2 (11) are symmetrically arranged, and the upper ends of both are arc surfaces; The front and rear sides of the push block (15) gradually protrude outwards to both sides; The handle (19) extends out of an opening on one side of the lower portion of the support platform (9); 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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