A transformer coil turns detection system and method

Abstract

This invention relates to a transformer coil turns detection system and method, belonging to the field of transformer technology. The system includes a detection fixture, which comprises a fixture body, a compression mechanism, a platform assembly, and a PCB functional board. The fixture body is made of bakelite and includes an openable lower half, terminals, and a plug-in interface. The compression mechanism, mounted on the fixture body, includes a first slide rail, a clamping plate, and a push-pull clamping device. The platform assembly includes a first platform plate, a second platform plate, a spring, and a spring pin. The first platform plate has a slot for the transformer, the spring pin is disposed on the second platform plate, and the spring is disposed between the first and second platform plates. The spring is used to separate the transformer leads and the spring pin in the uncompressed state. The PCB functional board, integrated within the fixture body, includes a power conversion circuit, a transformer drive circuit, a multi-channel voltage detection circuit, an MCU control module, and an LCD display module.

Description

Technical Field

[0001] This invention belongs to the field of transformer technology, and in particular relates to a transformer coil turns detection system and method. Background Technology

[0002] In the field of transformer manufacturing, the accuracy of the number of coil turns is a core parameter determining the transformer's performance. Traditional testing methods generally employ manual visual counting or indirect measurement based on an LCR bridge. The former suffers from low efficiency and susceptibility to human error, while the latter is limited by technical bottlenecks such as unstable contact impedance and insufficient high-frequency response. This is particularly pronounced in the testing of miniature high-frequency transformers (e.g., in 100kHz applications), where poor pin contact leads to signal distortion, making it difficult for conventional testing equipment to accurately capture secondary voltage changes caused by minute differences in the number of turns. Furthermore, existing testing devices generally suffer from poor tooling compatibility and complex testing procedures, failing to meet the stringent requirements of modern production lines for testing efficiency, accuracy, and traceability. Summary of the Invention

[0003] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a transformer coil turns detection system and method. This system realizes rapid and accurate detection of transformer turns, effectively solving the problems of contact impedance drift, high-frequency response distortion, and high dependence on manual operation that exist in traditional methods.

[0004] In a first aspect, the present invention provides a transformer coil turns detection system, comprising: a detection fixture, wherein the detection fixture includes a fixture body, a compression mechanism, a platform assembly, and a PCB functional board; wherein the fixture body is made of bakelite material and includes an openable lower half, terminals, and a plug-in interface; the compression mechanism is mounted on the fixture body and includes a first slide rail, a clamping plate, and a push-pull clamping device, wherein the push-pull clamping device drives the clamping plate to move vertically along the first slide rail via a handle, and the push-pull clamping device has a self-locking function; the platform assembly is connected to the fixture body by a plug-in connection and includes a first platform plate, a second platform plate, a spring, and spring pins; the first platform plate has a transformer slot, and the spring pins are disposed on the second platform plate, wherein the number and position of the spring pins are related to the transformer coil turns. The transformer pins correspond, and the spring is disposed between the first and second carrier plates. The spring is used to separate the transformer pins and the spring pins in the uncompressed state. The PCB functional board is integrated into the fixture body and includes a power conversion circuit, a transformer drive circuit, a multi-channel voltage detection circuit, an MCU control module, and an LCD display module. The power conversion circuit is used to convert the 24V input voltage to 3.3V and 15V. The transformer drive circuit is used to generate a square wave signal with a frequency of 100kHz and a duty cycle of 50% to be input into the primary coil of the transformer. The MCU control module is used to collect voltage data through an ADC and compare it with a preset number of turns in the data storage to obtain a comparison result. The LCD display module is used to display the comparison result.

[0005] Furthermore, the first slide rail is fixed to the tooling body by plugging in, and a sliding bearing is provided between the first slide rail and the clamping plate to restrict the clamping plate to move only in the vertical direction. The clamping plate is bolted to the push-pull clamping device.

[0006] Furthermore, the platform assembly also includes a second slide rail and a PCB terminal block. The second slide rail is used to constrain the movement of the first platform plate and the second platform plate. The PCB terminal block is connected to the spring pin by welding. The PCB terminal block is connected to the multi-channel voltage detection circuit through terminal blocks.

[0007] Furthermore, the tooling body is provided with holes, through which the second slide rail, the PCB wiring board and the spring pin extend into the tooling body.

[0008] Furthermore, the platform assembly is provided with a positioning pin, and the tooling body is provided with a positioning hole corresponding to the positioning pin, and the positioning pin is inserted into the positioning hole for fixation.

[0009] Furthermore, the transformer drive circuit includes: a DC-DC power supply chip for stepping down the 24V power supply to 15V; and a resonant chip, which forms an oscillation network with the MOSFET.

[0010] Furthermore, each voltage detection circuit in the multi-channel voltage detection circuit includes: a filter and rectification module composed of diodes and electrolytic capacitors; and a voltage follower composed of dual operational amplifiers, which inputs the voltage divider signal to the pin of the ADC in the MCU control module.

[0011] Furthermore, the data storage includes pre-stored turns, permissible error parameters, and drive parameters for different types of transformers.

[0012] Furthermore, the LCD display module communicates with the PCB functional board via an FPC connector, and the displayed content also includes the transformer model and the detection voltage values ​​of each channel.

[0013] A second aspect of the present invention provides a method for detecting the number of turns in a transformer coil, comprising: selecting an appropriate platform assembly and placing the transformer in a slot on the first platform plate of the platform assembly; pushing and pulling the handle of a pressing mechanism to make the pressing plate in the compression mechanism press against the transformer and lock itself; the PCB functional board outputting a 100kHz square wave to drive the primary coil and simultaneously acquiring eight sets of secondary coil voltages; the MCU control module calculating the actual turns ratio and comparing it with a preset value, and displaying the comparison result through an LCD display module.

[0014] The beneficial effects of this invention are as follows:

[0015] The present invention discloses a transformer coil turns detection system and method. The system comprises: a detection fixture, which includes a fixture body, a compression mechanism, a platform assembly, and a PCB functional board. The fixture body is made of bakelite and includes an openable lower half, terminals, and a plug-in interface. The compression mechanism, mounted on the fixture body, includes a first slide rail, a clamping plate, and a push-pull clamping device. The platform assembly includes a first platform plate, a second platform plate, a spring, and a spring pin. The first platform plate has a slot for the transformer, the spring pin is disposed on the second platform plate, and the spring is disposed between the first and second platform plates. The spring is used to separate the transformer leads and the spring pin in an uncompressed state. The PCB functional board, integrated within the fixture body, includes a power conversion circuit, a transformer drive circuit, a multi-channel voltage detection circuit, an MCU control module, and an LCD display module. This transformer coil turns detection system can quickly determine whether the coil turns meet process requirements, replacing traditional manual sampling or offline testing equipment, enabling full inspection or high-frequency sampling, and significantly improving product consistency. Meanwhile, the system's high compatibility can reduce the cost of repeated equipment investment when factories produce multiple models. Attached Figure Description

[0016] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts. It is obvious that the drawings described below are merely some embodiments of the present invention, and those skilled in the art can obtain other drawings based on these drawings.

[0017] Figure 1 This is a schematic diagram of a testing fixture according to an embodiment of the present invention;

[0018] Figure 2 This is a schematic diagram of the tooling body according to an embodiment of the present invention;

[0019] Figure 3 This is a schematic diagram of a compression mechanism according to an embodiment of the present invention;

[0020] Figure 4 This is a schematic diagram of a platform assembly according to an embodiment of the present invention;

[0021] Figure 5 This is a schematic diagram of a PCB functional board according to an embodiment of the present invention;

[0022] Figure 6 This is a schematic diagram of a PCB functional board according to an embodiment of the present invention;

[0023] Figure 7 This is a schematic diagram of a transformer drive circuit according to an embodiment of the present invention;

[0024] Figure 8 This is a schematic diagram of a multi-channel voltage detection circuit according to an embodiment of the present invention;

[0025] Figure 9 This is a schematic diagram of an LCD display module according to an embodiment of the present invention;

[0026] Figure 10 This is a schematic diagram of a power conversion circuit according to an embodiment of the present invention;

[0027] Figure 11 This is a flowchart of a transformer coil turns detection method according to an embodiment of the present invention.

[0028] Figure label:

[0029] 1. Fixture body; 11. Openable lower half; 12. Terminal block; 13. Plug-in interface; 14. Hinge; 15. Lock; 2. Compression mechanism; 21. First slide rail; 22. Pressure plate; 23. Push-pull pressure device; 3. Platform assembly; 31. First platform plate; 32. Second platform plate; 33. Spring; 34. Spring pin; 35. Transformer slot; 36. Second slide rail; 37. PCB terminal block; 38. Positioning pin; 4. PCB functional board; 41. Power conversion circuit; 42. Transformer drive circuit; 43. Multi-channel voltage detection circuit; 44. MCU control module; 45. LCD display module; 46. Data storage; 47. Button and encoder circuit; 5. Handle. Detailed Implementation

[0030] To enable those skilled in the art to better understand the technical solutions in the embodiments of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0031] Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concepts disclosed in this invention.

[0032] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "installed," "connected," and "linked" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0033] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention. Rather, they are merely examples of methods and systems consistent with some aspects of the invention as detailed in the appended claims.

[0034] This invention proposes a transformer coil turns detection system and method. Specifically, an embodiment of the transformer coil turns detection system and method of this invention is described below with reference to the accompanying drawings.

[0035] like Figure 1-5 As shown, the transformer coil turns detection system includes: a detection fixture, which comprises a fixture body 1, a compression mechanism 2, a platform assembly 3, and a PCB functional board 4.

[0036] The tool body 1 is made of bakelite material and includes an openable lower half 11, a terminal block 12 and a plug-in interface 13.

[0037] The compression mechanism 2 is installed on the tooling body 1 and includes a first slide rail 21, a pressure plate 22 and a push-pull type pressure device 23. The push-pull type pressure device 23 drives the pressure plate 22 to move vertically along the first slide rail 21 through the handle 5, and the push-pull type pressure device 23 has a self-locking function.

[0038] The platform assembly 3 is connected to the tooling body 1 by a plug-in connection and includes a first platform plate 31, a second platform plate 32, a spring 33 and a spring pin 34. The first platform plate 31 is provided with a transformer slot 35. The spring pin 34 is disposed on the second platform plate 32. The number and position of the spring pin 34 correspond to the pins of the transformer. The spring 33 is disposed between the first platform plate 31 and the second platform plate 32. The spring 33 is used to separate the transformer pins and the spring pin 34 when not compressed.

[0039] The PCB functional board 4, integrated within the fixture body 1, includes a power conversion circuit 41, a transformer drive circuit 42, a multi-channel voltage detection circuit 43, an MCU control module 44, and an LCD display module 45. The power conversion circuit 41 converts the 24V input voltage to 3.3V and 15V. The transformer drive circuit 42 generates a square wave signal with a frequency of 100kHz and a duty cycle of 50% to be input into the primary coil of the transformer. The MCU control module 44 acquires voltage data via an ADC and compares it with a preset number of turns in the data storage 46 to obtain the comparison result. The LCD display module 45 displays the comparison result.

[0040] Based on the aforementioned transformer coil turns detection system, it is possible to quickly determine whether the number of coil turns meets process requirements, replacing traditional manual sampling or offline testing equipment. This enables full inspection or high-frequency sampling, significantly improving product consistency. Furthermore, the system's high compatibility reduces the repeated equipment investment costs for factories producing multiple models.

[0041] In an embodiment of the present invention, the lower half 11 of the tooling body 1 is openable, that is, the lower half 11 can be opened to facilitate circuit wiring and storage of accessories. The lower half 11 can be opened by a hinge 14, and can be locked by a latch 15 after the lower half 11 is closed.

[0042] In an embodiment of the present invention, the first slide rail 21 is fixed to the tooling body 1 by a plug-in connection. A sliding bearing is provided between the first slide rail 21 and the clamping plate 22 to restrict the clamping plate 22 to move only in the vertical direction. The clamping plate 22 is bolted to the push-pull clamping device 23. That is, when in use, the handle 5 is turned to control the clamping plate 22 to move downward and press against the transformer placed on the platform.

[0043] Among them, the push-pull clamp 23 has a self-locking function, which can be fixed in place when the preset position is reached.

[0044] In an embodiment of the present invention, the platform assembly 3 further includes a second slide rail 36 and a PCB terminal block 37. The second slide rail 36 is used to constrain the movement of the first platform plate 31 and the second platform plate 32. The PCB terminal block 37 is connected to the spring pin 34 by welding. The PCB terminal block 37 is connected to the multi-channel voltage detection circuit 43 through the terminal block.

[0045] There are four second slide rails 36, which are respectively set at the four corners of the bottom of the second platform plate 32.

[0046] The spring 33 is disposed between the first carrier plate 31 and the second carrier plate 32. The spring 33 is used to separate the transformer pins and the spring needle 34 when not compressed, thereby preventing electrical short circuits.

[0047] In embodiments of the present invention, the platform assembly 3 can be determined based on the shape and size of the transformer; that is, different transformers correspond to different platform assemblies 3.

[0048] In an embodiment of the present invention, the tooling body 1 is provided with holes, through which the second slide rail 36, PCB wiring board 37 and spring pin 34 extend into the tooling body 1.

[0049] In an embodiment of the present invention, the platform assembly 3 is provided with a positioning pin 38, and the tooling body 1 is provided with a positioning hole corresponding to the positioning pin 38, and the positioning pin 38 is inserted into the positioning hole for fixation.

[0050] In an embodiment of the present invention, the schematic diagram of the PCB functional board 4 can be as follows: Figure 6 As shown, the power conversion circuit 41 connects to a 24V voltage and reduces it to 3.3V and then 15V. The 3.3V powers the chips in the MCU control module 44, button and encoder circuit 47, data storage 46, LCD display module 45, and multi-channel voltage detection circuit 43. The 15V powers the transformer drive circuit. At the start of detection, the 15V voltage is processed by the transformer drive circuit into a square wave power supply with an amplitude of 15V, a frequency of 100kHz, and a duty cycle of 50%, which is then input to the primary coil of the transformer. Under the power supply, the magnetic flux of the primary coil increases... When the voltage changes, the secondary coil induces an unknown power signal with the same frequency and duty cycle. This unknown power signal is filtered and rectified by a multi-channel voltage detection circuit, and the voltage is output to the ADC peripheral of the MCU control module to complete voltage acquisition. After the voltage acquisition is completed, the MCU control module 44 communicates with the data storage chip through the IIC protocol to obtain the preset number of turns of each coil in the data storage. The software algorithm calculates the set induced voltage of the secondary coil, compares it with the detected voltage, obtains the comparison result, and displays the comparison result on the LCD display module 45.

[0051] The circuit includes buttons and an encoder. The buttons are 4-pin (i.e., buttons with four pins), single-pole single-throw (SPST) tactile buttons. The encoder is used to control the selection of the transformer model.

[0052] In an embodiment of the present invention, the transformer drive circuit 42 includes: a DC-DC power supply chip for stepping down a 24V power supply to 15V; and a resonant chip, which forms an oscillation network with a MOSFET.

[0053] For example, such as Figure 7 As shown, V1 is a DC-DC power supply chip, and IC2 is a resonant chip. V1 transforms the 24V power supply to 15V. One path of this 15V is stepped down to approximately 10V via a 5.1V Zener diode to power IC2. The other path is directly connected to the center tap of the transformer's primary winding, serving as the drive power supply. Together with MQ1 and MQ2, they form an oscillation network to control the output of the secondary coil of the transformer, producing a square wave power signal with a voltage of 15V, a frequency of 100kHz, and a duty cycle of 50%.

[0054] For example, in Figure 7In the circuit diagram: 1) Power input and conversion: Input power: 24V DC (e.g., from an external power source or battery). V1 steps down the 24V to 15V, dividing it into two paths: First path (power supply): further stepped down to 10V through a 5.1V Zener diode to power IC2. Second path (drive): directly connected to the center tap of the primary coil of the transformer, serving as the drive power source. 2) Oscillation signal generation: IC2 acts as a resonant chip, generating a 100kHz square wave signal with a 50% duty cycle. MOSFET drive (MQ1, MQ2): The output signal of IC2 controls the alternating switching of the two MOSFETs (MQ1, MQ2), forming a push-pull drive circuit that converts the 15V DC to a high-frequency AC signal, inputting it to the primary coil of the transformer. 3) Transformer operation: Primary coil: the center tap is connected to GND, and both ends are connected to 15V. Secondary coil: the induced voltage is related to the number of turns. For example, if the primary coil has 5 turns and the secondary coil has 15 turns, then the voltage induced in the secondary coil is equal to 15V / 5 (turns) * 15 (turns) = 45V.

[0055] In an embodiment of the present invention, each voltage detection circuit in the multi-channel voltage detection circuit 43 includes: a filter and rectification module composed of diodes and electrolytic capacitors; and a voltage follower composed of dual operational amplifiers, which inputs the voltage divider signal to the pin of the ADC in the MCU control module.

[0056] For example, such as Figure 8 As shown, D2 is a diode, E2 is a 22uF / 50V electrolytic capacitor, and IC3 is a dual operational amplifier. According to the transformer's working principle, the voltage signal induced in the secondary coil is still a square wave power signal. D2 and E2 form a filter circuit to filter the square wave signal into a smooth DC voltage signal. R34 and R39 form a voltage divider circuit. The voltage across R39 passes through a voltage follower formed by IC3 and is connected to the pin of the ADC in the MCU control module. The algorithm calculates the voltage induced in the secondary coil. R19 and R25 form a voltage divider circuit, providing 1V. This voltage is connected to the non-inverting input of another operational amplifier in IC3 and MQ3 to form a constant current load, with a current of 1V / R44 = 1mA. A total of 8 sets of these circuits are designed on the functional board, allowing simultaneous measurement of 8 sets of voltage data.

[0057] For example, in such Figure 8The circuit diagram shown is divided into the following stages: 1) Signal Input Stage: The secondary coil of the transformer induces a square wave voltage signal (AC), which serves as the input signal source for the circuit. 2) Rectification and Filtering Stage: D2 (diode): performs half-wave rectification on the square wave signal, converting the AC signal into a pulsating DC signal. E2 (22μF / 50V electrolytic capacitor): works with the diode to form a filter circuit, smoothing the pulsating DC signal and outputting a stable DC voltage. 3) Voltage Divider and Detection Stage: R34 and R39: form a voltage divider circuit, proportionally reducing the filtered DC voltage to suit the MCU's ADC input range. Dual Operational Amplifier (IC3): buffers the voltage across R39 before outputting, ensuring high impedance input and low impedance output, avoiding the voltage divider circuit being affected by the MCU's ADC input impedance. MCU's ADC Pin: detects the signal output from the voltage follower and calculates the induced voltage value of the secondary coil using an algorithm. 4) Constant Current Load Control (Another Op-Amplifier): R19 and R25 form a voltage divider circuit to generate a 1V reference voltage, which is connected to the non-inverting input of the other op-amp in IC3. MQ3 (MOSFET or other load device): forms a constant current circuit with the op-amp for stabilizing load conditions or calibration purposes. 5) Multiplexing: The entire circuit design has 8 identical structures, allowing simultaneous detection of 8 independent voltage signals, suitable for multi-channel data acquisition scenarios.

[0058] In an embodiment of the present invention, the data storage 46 pre-stores the number of turns, allowable error parameters, and driving parameters of different types of transformers.

[0059] In an embodiment of the present invention, the LCD display module 45 communicates with the PCB function board through an FPC connector, wherein the display content also includes the transformer model and the detection voltage value of each channel.

[0060] For example, such as Figure 9 As shown, Q2 is an NPN transistor, and its base is connected to the MCU control module through a current-limiting resistor R13 to control the power supply to the LCD screen. J1 is an FPC connector, which connects to the LCD screen from the bottom.

[0061] For example, in such Figure 10The circuit diagram of the power conversion circuit shown starts with a 24V DC input, which is the initial voltage source for the entire power conversion circuit (i.e., the input power process). The 24V input is connected to a DC-DC power supply chip (V2), which steps down the 24V to 5V. V2 has high conversion efficiency and is suitable for scenarios with large voltage drops. The 5V output may pass through a filter capacitor (not marked in the diagram, but usually present) to stabilize the voltage (i.e., the first stage of voltage reduction). The 5V output is connected to an LDO power supply chip (V3), which steps down the 5V to 3.3V to power low-power devices such as MCUs and EEPROMs. V3 is characterized by low output noise and is suitable for powering sensitive devices (i.e., the second stage of voltage reduction). The 3.3V directly supplies MCUs (such as microcontrollers), EEPROMs, and other components that require stable low voltage. The 5V may power other peripheral circuits (i.e., output distribution).

[0062] According to the transformer coil turns detection system of this embodiment, the cooperation between the slide rails (first slide rail 21, second slide rail 36) and the sliding bearing ensures the vertical movement accuracy of the clamping plate 22 and the platform assembly 3, avoiding poor contact caused by misalignment. The self-locking clamping device 23 fixes the clamping force, ensuring stable contact between the spring pin 34 and the transformer pin, reducing the impact of contact resistance on measurement accuracy. The plug-in design of the platform assembly 3 (positioning pin 38 and positioning hole) allows for adaptation to transformers of different sizes / shapes, and combined with the encoder, it allows for quick switching of preset parameters, significantly reducing changeover time. Eight independent voltage detection circuits (filtered rectification + voltage follower) can process multiple sets of secondary coil signals in parallel, avoiding timing errors caused by time-division detection.

[0063] A 100kHz high-frequency square wave drive (resonant chip + MOSFET) improves the signal-to-noise ratio of the secondary induced voltage and reduces low-frequency interference. A filter circuit (diode + 22μF capacitor) combined with a voltage follower suppresses high-frequency ripple, ensuring the stability of the DC signal acquired by the ADC. A power conversion circuit isolates the 24V input from the low-voltage logic circuit (3.3V), reducing power supply noise interference to sensitive modules (such as the ADC). A constant current load design (1mA through R44) ensures constant load conditions during secondary coil induced voltage measurement, avoiding errors introduced by load fluctuations. The MCU control module acquires the actual voltage via the ADC and compares it with the pre-stored turns-voltage mapping in the memory chip, using allowable error parameters for automatic judgment, reducing manual calculation errors. A spring separates the spring pin from the lead when not compressed, preventing accidental power-on before testing that could cause short circuits or equipment damage. The high insulation and high-temperature resistance of the bakelite fixture body 1 ensure operational safety. Independent modules such as the PCB functional board 4 and the stage assembly 3 are connected via plug-in / soldering, allowing for direct replacement in case of damage without requiring overall repair. The lower half 11 of the main body 1 of the tooling can be quickly opened and closed through the hinge 14 and the latch 15, which facilitates the internal circuit inspection or replacement of parts.

[0064] In an embodiment of the present invention, a method for detecting the number of turns in a transformer coil is also proposed, such as... Figure 11 As shown, the method for detecting the number of turns in a transformer coil includes:

[0065] S110, Select the appropriate platform assembly and place the transformer in the slot of the first platform plate in the platform assembly.

[0066] S120, push and pull the handle of the pressing mechanism to make the pressing plate in the compression mechanism press against the transformer and self-lock.

[0067] The S130 PCB functional board outputs a 100kHz square wave to drive the primary coil and simultaneously acquires 8 sets of secondary coil voltages.

[0068] The simultaneous acquisition of voltages from 8 sets of secondary coils can be understood as the tooling having the ability to detect transformers with 8 sets of secondary coils. If a transformer only has 6 sets of secondary coils, then the voltages of the 6 sets of secondary coils will be detected separately.

[0069] S140, the MCU control module calculates the actual turns ratio and compares it with the preset value, and displays the comparison result through the LCD display module.

[0070] According to the transformer principle, the ratio of the number of turns in the primary coil to the number of turns in the secondary coil is equal to the ratio of the voltage in the primary coil to the voltage in the secondary coil.

[0071] For example, a transformer has one primary coil and three secondary coils. The MCU stores the known number of turns for each of the primary and secondary coils. The input primary coil voltage is fixed and known. During detection, the ratio of the voltage of the first secondary coil to the input primary coil voltage is calculated, and it is determined whether this ratio equals the ratio of the number of turns in the primary coil to the number of turns in the first secondary coil. Then, the ratio of the voltage of the second secondary coil to the primary coil is calculated, and it is determined whether this ratio equals the ratio of the number of turns in the primary coil to the number of turns in the second secondary coil. Finally, the ratio of the voltage of the third secondary coil to the primary coil is calculated, and it is determined whether this ratio equals the ratio of the number of turns in the primary coil to the number of turns in the third secondary coil. The resulting comparison is then displayed on an LCD display module.

[0072] The applicant of this invention has provided a detailed description of the embodiments of the invention in conjunction with the accompanying drawings. However, those skilled in the art should understand that the above embodiments are merely preferred embodiments of the invention. The detailed description is only intended to help readers better understand the spirit of the invention and is not intended to limit the scope of protection of the invention. On the contrary, any improvements or modifications made based on the inventive spirit of the invention should fall within the scope of protection of the invention.

[0073] Furthermore, the functional units in the various embodiments of the present invention can be integrated into a processing module, or each unit can exist physically separately, or two or more units can be integrated into a module. The integrated module can be implemented in hardware or as a software functional module. If the integrated module is implemented as a software functional module and sold or used as an independent product, it can also be stored in a computer-readable storage medium.

[0074] The storage medium mentioned above can be a read-only memory, a disk, or an optical disk, etc. Although embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of the present invention.

[0075] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the embodiments of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the protection scope of the present invention.

Claims

1. A transformer coil turns detection system, characterized in that, include: The testing fixture includes a fixture body, a compression mechanism, a stage assembly, and a PCB functional board. The main body of the tooling is made of bakelite material and includes an openable lower half, terminals and plug-in interfaces; The compression mechanism is installed on the tooling body and includes a first slide rail, a pressure plate and a push-pull pressure device. The push-pull pressure device drives the pressure plate to move vertically along the first slide rail through a handle, and the push-pull pressure device has a self-locking function. The platform assembly is connected to the tooling body by a plug-in connection and includes a first platform plate, a second platform plate, a spring, and spring pins. The first platform plate has a slot for a transformer, and the spring pins are disposed on the second platform plate. The number and position of the spring pins correspond to the pins of the transformer. The spring is disposed between the first platform plate and the second platform plate and is used to separate the pins of the transformer from the spring pins when not compressed. The PCB functional board, integrated within the fixture body, includes a power conversion circuit, a transformer drive circuit, a multi-channel voltage detection circuit, an MCU control module, and an LCD display module. The power conversion circuit converts a 24V input voltage to 3.3V and 15V. The transformer drive circuit generates a square wave signal with a frequency of 100kHz and a duty cycle of 50% to be input into the primary coil of the transformer. The MCU control module acquires voltage data via an ADC and compares it with a preset number of turns stored in the data to obtain a comparison result. The LCD display module displays the comparison result. The first slide rail is fixed to the tooling body by plugging in, and a sliding bearing is provided between the first slide rail and the clamping plate to restrict the clamping plate to move only in the vertical direction. The clamping plate is bolted to the push-pull clamping device. The platform assembly further includes a second slide rail and a PCB terminal block. The second slide rail is used to constrain the movement of the first platform plate and the second platform plate. The PCB terminal block is connected to the spring pin by welding. The PCB terminal block is connected to the multi-channel voltage detection circuit through terminal blocks. The lower part is opened by a hinge and locked by a latch after it is closed. The tooling body has holes, through which the second slide rail, PCB wiring board and spring pin extend into the tooling body; The platform assembly is provided with a positioning pin, and the tooling body is provided with a positioning hole corresponding to the positioning pin. The positioning pin is inserted into the positioning hole for fixation.

2. The transformer coil turns detection system according to claim 1, characterized in that, The transformer drive circuit includes: DC-DC power supply chip, used to step down 24V power supply to 15V; The resonant chip, together with the MOSFET, forms an oscillation network.

3. The transformer coil turns detection system according to claim 1, characterized in that, Each voltage detection circuit in the multi-channel voltage detection circuit includes: A filter and rectifier module consisting of diodes and electrolytic capacitors; A voltage follower, consisting of a dual operational amplifier, inputs a voltage divider signal to the pin of the ADC in the MCU control module.

4. The transformer coil turns detection system according to claim 1, characterized in that, The data storage contains pre-stored information on the number of turns, permissible error parameters, and drive parameters for different types of transformers.

5. The transformer coil turns detection system according to claim 1, characterized in that, The LCD display module communicates with the PCB functional board via an FPC connector, and the displayed content also includes the transformer model and the detection voltage values ​​of each channel.

6. A method for detecting the number of turns in a transformer coil, the method being applicable to the transformer coil turns detection system according to any one of claims 1-5, characterized in that, include: Select the appropriate platform assembly and place the transformer in the slot of the first platform plate in the platform assembly; Push or pull the handle of the pressing mechanism so that the pressing plate in the compression mechanism abuts against the transformer and locks itself; The PCB functional board outputs a 100kHz square wave to drive the primary coil and simultaneously acquires 8 sets of secondary coil voltages. The MCU control module calculates the actual turns ratio and compares it with a preset value, then displays the comparison result on the LCD display module.

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