Transformer winding optimization method and device, equipment and storage medium
Through sandwich structure winding design and copper wire optimization, the problem of substandard transformer heat dissipation is solved, the transformer performance is improved and the life is extended, making it suitable for a variety of application scenarios.
Patent Information
- Application Number
- CN202511005164.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-21
- Publication Date
- 2025-10-17
AI Technical Summary
In existing transformer designs, the winding frame hardware cannot be changed, resulting in substandard heat dissipation performance, affecting transformer performance and life.
A sandwich-structured winding design is adopted, with the inner layer using thicker copper wire for two-layer dense winding, and the outer layer using thinner copper wire for single-layer dense winding. Combined with the insulation layer setting, the wire diameter ratio and number of strands are optimized to form a thick inner and thin outer design to improve heat dissipation and current density.
Significantly reduce transformer temperature, improve reliability and service life, and enhance high-frequency characteristics and energy transmission efficiency to meet different application requirements.
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Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of winding optimization of a transformer, and in particular to a winding optimization method, device, equipment and storage medium of a transformer. BACKGROUND
[0002] At present, the competition of transformers is increasingly accumulated, and the product update cycle is shortened. Through the conventional standard transformer design method, the designed transformer is finalized, and the winding frame and other hardware cannot be changed. In order to improve the performance of the transformer, the use of thinner winding often makes the heat dissipation performance of the transformer not up to standard, thereby resulting in the need for overall design of the transformer. SUMMARY
[0003] The present application provides a winding optimization method, device, equipment and storage medium of a transformer, which is used to improve the performance of the transformer and improve the heat dissipation capacity of the transformer on the basis of maintaining the winding frame.
[0004] In a first aspect, an embodiment of the present application provides a winding optimization method of a transformer, which comprises: using a first copper wire to tightly wrap two layers of the winding frame of the transformer to form a first primary winding; using two second copper wires to tightly wrap a single layer of the first primary winding to form a first secondary winding and a second secondary winding; using a third copper wire to tightly wrap a single layer of the first secondary winding and the second secondary winding to form a second primary winding, the ratio of the wire diameter of the first copper wire to the wire diameter of the third copper wire ranges from 1.1 to 1.4, and the number of strands of the first copper wire is the same as the number of strands of the second copper wire.
[0005] In some embodiments, the method further comprises: selecting a copper wire with a wire diameter of TIW0.8 and a number of strands of 2 as the first copper wire; selecting a copper wire with a wire diameter of TIW0.7 and a number of strands of 2 as the second copper wire.
[0006] In some embodiments, the method further comprises: selecting an enameled Liz wire with a wire diameter of UEW0.10 and a number of strands of 180 as the third copper wire.
[0007] In some embodiments, the method further comprises: taking a first end of the first primary winding as a first primary lead; connecting a second end of the first primary winding and a first end of the second primary winding and taking them as a second primary lead; taking a second end of the second primary winding as a third primary lead. The first primary side pin, the second primary side pin and the third primary side pin are current input terminals of the transformer.
[0008] In some embodiments, the method further comprises: The first end of the first secondary side winding is a first secondary side pin; The second end of the first secondary side winding and the first end of the second secondary side winding are connected and serve as a second secondary side pin; The second end of the second secondary side winding is a third secondary side pin; The first secondary side pin, the second secondary side pin and the third secondary side pin are current output terminals of the transformer.
[0009] In some embodiments, a 3TS insulation layer is arranged between the two layers of the first primary side winding, between the first primary side winding and the first secondary side winding and the second secondary side winding, and between the first secondary side winding and the second secondary side winding and the second primary side winding.
[0010] In a second aspect, the embodiments of the present application provide a transformer, which is implemented by the winding optimization method of any one of the embodiments of the present application.
[0011] The embodiments of the present application provide a winding optimization method of a transformer, which comprises: using a first copper wire to tightly adhere to a winding frame of the transformer to perform two-layer dense winding and form a first primary side winding; using two second copper wires to respectively tightly adhere to the first primary side winding to perform single-layer dense winding and form a first secondary side winding and a second secondary side winding; and using a third copper wire to tightly adhere to the first secondary side winding and the second secondary side winding to perform single-layer dense winding and form a second primary side winding, wherein the ratio of the diameter of the first copper wire to the diameter of the third copper wire ranges from 1.1 to 1.4, and the number of strands of the first copper wire is the same as the number of strands of the second copper wire. In the above method, the first primary side winding with a larger diameter is arranged in the inner layer, so as to reduce the current density and copper loss, thereby reducing the temperature of the inner layer, and the second primary side winding with high loss is arranged in the outer layer, so as to directly utilize the high-efficiency heat dissipation of the surface of the transformer, and the double effects are combined to inhibit the overall temperature rise. BRIEF DESCRIPTION OF DRAWINGS
[0012] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced as follows. Obviously, the drawings in the following description are some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without creative labor.
[0013] Figure 1 A cross-sectional view of a transformer is provided for an embodiment of the present application; Figure 2 A schematic block diagram of a winding optimization method of a transformer is provided for an embodiment of the present application; Figure 3 A parameter table of a winding is provided for an embodiment of the present application; Figure 4 A connection diagram of a winding is provided for an embodiment of the present application. DETAILED DESCRIPTION
[0014] The technical solutions in the embodiments of the present application will be clearly and completely described with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the protection scope of the present application.
[0015] The flowchart shown in the drawings is only an example and does not necessarily include all the contents and operations / steps, nor does it necessarily need to be executed in the order described. For example, some operations / steps can be further divided, combined or partially merged, so the actual execution order can be changed according to the actual situation.
[0016] It should also be understood that the terms used in the present application are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the present application specification and the appended claims, unless otherwise clear from the context, the singular forms "a", "an" and "the" are intended to include the plural forms.
[0017] It should be further understood that the term "and / or" used in the present application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes these combinations.
[0018] Please refer to Figure 1 , Figure 1 A cross-sectional view of a transformer is provided for an embodiment of the present application. As shown in Figure 1 , the transformer includes a first primary winding N1A, a second primary winding N1B, a first secondary winding N2, a second secondary winding N3 and a winding frame. The transformer is a sandwich structure, and the first primary winding N1A and the second primary winding N1B sandwich the first secondary winding N2 and the second secondary winding N3. The first primary winding N1A is close to the bottom of the winding slot of the winding frame, which is the inner layer, and correspondingly, the second primary winding N1B is the outer layer.
[0019] Please refer to Figure 2 ,Figure 2 is a schematic flow chart of a winding optimization method of a transformer provided by an embodiment of the present application. As shown in the figure, the specific steps of the winding optimization method of the transformer include S101-S103. Figure 2
[0020] S101, two layers of tight winding are performed on the winding frame of the transformer by using the first copper wire to form the first primary winding N1A.
[0021] For example, the first copper wire should be selected to have a relatively large diameter (such as 0.8*2 specification), because the first primary winding N1A is located in the inner layer of the winding frame, and the heat dissipation condition is relatively poor. The heat needs to be transferred to the surface of the transformer through multiple layers of thermal resistance for dissipation. The use of a relatively large diameter can effectively reduce the resistance value of the copper wire, thereby reducing the transmission loss and the amount of heat generated. At the same time, the tight winding method ensures the compactness of the winding and good coupling degree. The design of two layers of tight winding not only meets the required number of turns, but also facilitates the uniform distribution of magnetic flux through the layered winding method. This design of using thick wire in the inner layer can significantly improve the overall temperature rise performance of the transformer and prolong the service life.
[0022] S102, two second copper wires are used to perform single-layer tight winding respectively close to the first primary winding N1A to form the first secondary winding N2 and the second secondary winding N3.
[0023] For example, the secondary winding is divided into two independent windings (N2 and N3), which can not only realize the functions of multiple output or center tap, but also realize different output voltage configurations through reasonable connection method. The winding method close to the first primary winding N1A ensures good coupling coefficient, reduces leakage inductance, and improves energy transmission efficiency. This design also helps to reduce the distributed capacitance between the windings and improve the high-frequency characteristics of the transformer, and is particularly suitable for high-frequency applications such as switching power supplies.
[0024] S103, the third copper wire is used to perform single-layer tight winding close to the first secondary winding N2 and the second secondary winding N3 to form the second primary winding N1B, and the ratio of the diameter of the first copper wire to the diameter of the third copper wire is in the range of 1.1-1.4, and the number of strands of the first copper wire is the same as the number of strands of the second copper wire.
[0025] For example, the second primary winding N1B (N1B) at the outermost layer uses a thinner wire diameter (such as 0.7*2 specification), although the current density is higher and the loss is larger, but since it is at the outermost layer of the winding frame, it has the best heat dissipation condition, and the heat can be directly dissipated to the surrounding environment without the need to pass through multiple layers of thermal resistance. The ratio range of the wire diameter of the first copper wire and the third copper wire is set to 1.1-1.4, which is an optimized design. The ratio ensures that the overall volume of the inner and outer windings will not be too large, and in the case of not changing the winding frame, the performance of the transformer can be improved and the heat dissipation index can be achieved, and the optimization of loss distribution is also realized. This "thick inside and thin outside" design cleverly uses the principle of heat conduction: the thick wire with small heat generation is placed in the inner layer with poor heat dissipation condition, and the thin wire with large heat generation is placed in the outer layer with good heat dissipation condition, thereby optimizing the overall temperature rise. The actual measurement data shows that this design can reduce the temperature of the transformer by about 5 degrees, significantly improving the reliability and service life of the transformer.
[0026] The embodiment of the present application provides a winding optimization method of a transformer, which comprises the following steps: adopting a first copper wire to tightly perform two-layer dense winding on a winding frame of the transformer to form a first primary winding N1A; adopting two second copper wires to respectively tightly perform single-layer dense winding on the first primary winding N1A to form a first secondary winding N2 and a second secondary winding N3; and adopting a third copper wire to tightly perform single-layer dense winding on the first secondary winding N2 and the second secondary winding N3 to form a second primary winding N1B, wherein the ratio range of the wire diameter of the first copper wire and the wire diameter of the third copper wire is 1.1-1.4, and the number of strands of the first copper wire is the same as the number of strands of the second copper wire. In the above method, the first primary winding N1A with a larger wire diameter is arranged in the inner layer, so that the current density and the copper loss are reduced, thereby reducing the temperature of the inner layer, and the second primary winding N1B with high loss is arranged in the outer layer, so that the high-efficiency heat dissipation of the surface of the transformer is directly utilized, and the overall temperature rise is cooperatively inhibited.
[0027] In order to more clearly introduce the technical scheme of the present application, the technical scheme of the present application will be introduced through specific embodiments below. It should be noted that the specific embodiments are used to expand the description of the technical scheme of the present application, and are not intended to limit the present application.
[0028] Please refer to Figure 3 , Figure 3 The parameter table of the winding provided by the embodiment of the present application is shown.
[0029] In some embodiments, as shown in Figure 3 , the method further comprises: selecting a copper wire with a wire diameter of TIW0.8 and a number of strands of 2 as the first copper wire; and selecting a copper wire with a wire diameter of TIW0.7 and a number of strands of 2 as the second copper wire.
[0030] For example, the first copper wire is selected as a copper wire with a line diameter of TIW 0.8 and a strand number of 2. The selection takes into account the regulatory requirements and performance optimization. TIW represents triple insulated wire, which has excellent electrical insulation performance and can meet the regulatory electrical insulation distance requirements between the primary and secondary sides without additional insulation measures. The line diameter of 0.8 mm is relatively thick, which can effectively reduce the current density and transmission loss of the first primary winding N1A. The triple insulation structure generally includes a basic insulation layer, a reinforced insulation layer, and a protective insulation layer, each of which has independent insulation functions, so that sufficient insulation strength can be ensured even if one of the layers is damaged. This design allows the transformer winding slot to be free of additional retaining walls, simplifying the structural design of the transformer and reducing manufacturing costs. At the same time, although the thicker line diameter occupies more winding space, reasonable winding layout and optimization design can still meet the assembly requirements of the magnetic core.
[0031] In some embodiments, as shown in Figure 3 the method further includes selecting a third copper wire as an enameled litz wire with a line diameter of UEW 0.10 and a strand number of 180.
[0032] For example, UEW represents polyurethane enameled wire, which has good heat resistance and electrical performance. The single-strand line diameter of 0.10 mm combined with the design of 180 strands forms a typical litz wire structure. This multi-strand thin wire design can effectively suppress the skin effect during high-frequency operation, as the diameter of each thin wire is much smaller than the skin depth, and the current can be uniformly distributed throughout the conductor cross section. The design of 180 strands not only provides sufficient conductor cross-sectional area to carry the secondary current, but also reduces the influence of proximity effect through the twisted structure of the thin wires. Another advantage of litz wire is its good flexibility, which facilitates winding and molding. Compared with the triple insulated wire used in the primary side, the use of enameled wire in the secondary side can reduce the thickness of the insulation layer and improve the window utilization rate.
[0033] Referring to Figure 4 , Figure 4 a connection diagram of a winding provided by an embodiment of the present application is shown.
[0034] In some embodiments, as shown in Figure 4 the method further includes connecting the first end of the first primary winding N1A as a first primary pin PIN1; connecting the second end of the first primary winding N1A and the first end of the second primary winding N1B as a second primary pin N1; and connecting the second end of the second primary winding N1B as a third primary pin PIN2; wherein the first primary pin PIN1, the second primary pin N1, and the third primary pin PIN2 are all current input terminals of the transformer.
[0035] Exemplarily, the design of connecting the two ends of the first primary winding N1A and the two ends of the second primary winding N1B to form a three-primary-pin structure provides flexible input configuration options. This connection actually connects the first primary winding N1A and the second primary winding N1B through an intermediate tap to form a primary structure with a center tap. The second primary pin N1 acts as the center tap, and various operating modes can be achieved: in some applications, the center tap can be used to implement double-tube forward, push-pull, and other topological structures; in other applications, different connection methods can be used to switch the input voltage (such as 110V / 220V automatic switching). This design also helps to balance the current distribution of the two primary windings, especially under asymmetric load conditions. By reasonably designing the turn ratio of the two primary windings, different voltage transformation ratios can be achieved. At the same time, this segmented primary design helps to reduce the distributed capacitance of the winding and improve the high-frequency characteristics of the transformer. In practical applications, the three-primary-pin design also facilitates PCB layout, and the pin positions can be arranged flexibly according to the specific circuit topology.
[0036] In some embodiments, as shown in FIG. 7, the method further includes: connecting the first end of the first secondary winding N2 as a first secondary pin PIN7; connecting the second end of the first secondary winding N2 and the first end of the second secondary winding N3 as a second secondary pin PIN10; and connecting the second end of the second secondary winding N3 as a third secondary pin PIN9; wherein the first secondary pin PIN7, the second secondary pin PIN10, and the third secondary pin PIN9 are current output terminals of the transformer. Figure 4
[0037] Exemplarily, the secondary winding adopts a three-pin structure similar to the primary winding, and the center tap configuration is formed by connecting the specific ends of the first secondary winding N2 and the second secondary winding N3. This design is of great significance in switching power supply applications, especially in cases where symmetrical positive and negative output or full-wave rectification is required. The center-tapped secondary structure can cooperate with two rectifier diodes to achieve full-wave rectification, which has lower conduction voltage drop and higher efficiency compared to bridge rectification. In some applications, the first secondary winding N2 and the second secondary winding N3 can provide independent outputs, and multi-output functions can be achieved through different rectification and filtering circuits. This design also helps to reduce output ripple, as the two secondary windings can work alternately, and the pulsation frequency of the output current is twice the switching frequency. The secondary pin as a current output terminal, its connection method directly affects the output characteristics. By reasonably designing the turn ratio and connection method of the two secondary windings, different output voltage combinations can be achieved. At the same time, the center tap structure also helps to reduce common-mode noise and improve the EMC performance of the power supply. The flexibility of this design allows the same transformer to adapt to different application requirements.
[0038] In some embodiments, 3TS insulation layers are arranged between the two layers of the first primary winding N1A, between the first primary winding N1A and the first secondary winding N2 and the second secondary winding N3, and between the first secondary winding N2 and the second secondary winding N3 and the second primary winding N1B.
[0039] For example, 3TS represents 3 Tape Spiral, which is a reliable insulation method formed by spiral winding of multiple layers of tape. The insulation layer arranged between the two layers of the first primary winding N1A is mainly to improve the interlayer voltage distribution, reduce the interlayer capacitance, and prevent interlayer breakdown. The 3TS insulation layer arranged between the primary and secondary windings is a key measure to meet the regulatory requirements, ensuring that the primary and secondary windings have sufficient electrical isolation strength to withstand the specified voltage test. This insulation design not only considers the normal working voltage, but also considers factors such as transient overvoltage and long-term aging. The thickness and material selection of the 3TS insulation layer are carefully designed to ensure insulation strength and control overall thickness to avoid affecting the assembly of the magnetic core. At the same time, reasonable insulation layer arrangement also helps to improve the heat conduction path of the transformer, although it increases the thermal resistance, but through the optimization of material selection and thickness control, its impact can be minimized. This strict insulation design ensures that the transformer can meet the requirements of various regulatory standards.
[0040] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of various equivalent modifications or replacements within the technical scope disclosed in the present application, and these modifications or replacements should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.
Claims
1. A method for optimizing transformer windings, characterized in that the method comprises: A first copper wire is wound closely around the winding frame of the transformer in two layers to form a first primary winding; Two second copper wires are respectively wound tightly in a single layer around the first primary winding to form a first secondary winding and a second secondary winding; A third copper wire is tightly wound in a single layer around the first secondary winding and the second secondary winding to form a second primary winding. The ratio of the diameter of the first copper wire to the diameter of the third copper wire is as follows: 1.1-1.4, the number of strands of the first copper wire is the same as the number of strands of the second copper wire.
2. The transformer winding optimization method according to claim 1, wherein: The method further comprises: A copper wire with a wire diameter of TIW0.8 and a strand number of 2 is selected as the first copper wire; A copper wire with a wire diameter of TIW0.7 and a strand number of 2 is selected as the second copper wire.
3. The transformer winding optimization method according to claim 1, wherein: The method further comprises: An enameled Litz wire with a wire diameter of UEW0.10 and a strand number of 180 is selected as the third copper wire.
4. The transformer winding optimization method according to claim 1, wherein: The method further comprises: Using the first end of the first primary winding as a first primary pin; Connecting the second end of the first primary winding and the first end of the second primary winding to serve as a second primary pin; Using the second end of the second primary winding as the third primary pin; The first primary pin, the second primary pin and the third primary pin are all current input terminals of the transformer.
5. The transformer winding optimization method according to claim 1, wherein: The method further comprises: Using the first end of the first secondary winding as a first secondary pin; Connecting the second end of the first secondary winding and the first end of the second secondary winding to serve as a second secondary pin; Using the second end of the second secondary winding as the third secondary pin; The first secondary pin, the second secondary pin and the third secondary pin are current output terminals of the transformer.
6. The transformer winding optimization method according to claim 1, wherein: A 3TS insulation layer is set between the two layers of the first primary winding, the 3TS insulation layer is set between the first primary winding and the first secondary winding and the second secondary winding, and the 3TS insulation layer is set between the first secondary winding, the second secondary winding and the second primary winding.
7. A transformer, characterized in that: The transformer is realized by the transformer winding optimization method according to any one of claims 1 to 6.