Multi-color twisting and winding process for transformer

Abstract

The invention discloses a multi-wire twisting and winding process for a transformer. The multi-wire twisting and winding process comprises the steps of S1, preparation before winding, S2, a twisted wire pretreatment process, S3, a twisted wire overall winding process, S4, an ending and wire tail fixing process, S5, a branch wire leading-out and welding process and S6, post-treatment and inspection. In the step S1, the specific process comprises the following steps: S11, determining the number of output paths, the rated current of each path and the corresponding wire diameter according to the design specification of the transformer / inductor; and S12, the number of strands of the stranded wires is strictly equal to the number of output paths. According to the transformer multi-wire twisting winding process, multiple winding operations are combined into one time, the frequency of wire changing, wire clamping and positioning is reduced, the transformer multi-wire twisting winding process is particularly suitable for automatic winding equipment, the production efficiency is greatly improved, the process deviation is eliminated, and the deviation of the winding process is mainly improved, for example, the winding positions are different, the winding is crossed, and the winding quality is improved. And the output voltage is not consistent due to factors such as non-uniform density.

Description

Technical Field

[0001] This invention relates to the technical field of multi-output electromagnetic devices, and in particular to a transformer multi-wire stranding winding process. Background Technology

[0002] Currently, existing multi-output switching power supply transformers or coupled inductors require a high degree of consistency in the secondary output voltages. However, the traditional winding method involves winding each output winding separately and sequentially. This method has inherent drawbacks: the later-wound windings are located outside the earlier-wound windings, resulting in different distances between each winding and the magnetic core, inconsistent leakage inductance, and difficulty in ensuring that the trajectory, tension, and tightness of each winding are completely consistent during manual or mechanical winding.

[0003] Tiny gaps or intersections can lead to differences in inductance. Due to the inconsistency in the physical location and distribution, the coupling tightness between each winding and the primary winding varies, resulting in deviations in the adjustment characteristics of the output voltage under dynamic loads. Traditional improvement methods, such as precise mechanical control and complex winding sequences (e.g., "sandwich winding"), are either too costly or have limited effectiveness, and cannot fundamentally guarantee the consistency of parallel multi-output. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a multi-wire stranding winding process for transformers.

[0005] The objective of this invention is achieved through the following technical solution: A transformer multi-wire stranding winding process includes: S1 preparation before winding, S2 stranded wire pretreatment process, S3 overall stranded wire winding process, S4 tailing and wire end fixing process, S5 branching and welding process, and S6 post-processing and inspection. In step S1, the specific process includes the following steps: S11, based on the transformer / inductor design specifications, determine the number of output paths, the rated current of each path, and the corresponding wire diameter; S12, the number of strands in the stranded wire is strictly equal to the number of output paths, and a unique insulating varnish color is assigned to each strand, such as: output path 1 - red, output path 2 - yellow, output path 3 - blue. Based on the total diameter of the wire bundle and the required flexibility, the optimal stranding pitch is determined experimentally, with a suggested range of 8-15 times the outer diameter of the stranded wire bundle. The stranding direction (S-direction or Z-direction) must be consistent; S13, obtain or customize stranded wire reels conforming to the above specifications, inspect the wire appearance, and confirm that there is no insulation damage and the color is correct.

[0006] In step S2, the specific process includes the following steps: S21, placing the stranded wire spool in an oven at 70-80°C for 2-4 hours to remove any moisture that may be absorbed inside the wire, to prevent bubbles from forming during subsequent impregnation, and to improve insulation strength; S22, installing the stranded wire spool onto a winding machine, allowing the wire bundle to pass through an adjustable tension control system, and initially setting the unwinding tension to 20-50 cN according to the total diameter of the stranded wire bundle; In step S3, the specific process includes the following steps: S31, fixing the ends of the stranded wire harness to the starting pin of the skeleton with a special fixing clip or welding plate to ensure that the fixing is firm and that all N strands of wire are well electrically connected; S32, starting the winding machine, winding the entire stranded wire harness as a single, integrated winding unit, the winding machine spindle rotates according to the preset number of turns T, and the wire guide precisely guides the wire according to the total outer diameter of the stranded wire harness; In one embodiment, in step S3, since the N strands are physically twisted together and occupy the exact same spatial path on the core or frame, each turn simultaneously winds one turn for all N outputs.

[0007] In one embodiment, in step S3, the operator or vision system needs to monitor in real time to ensure that the twisted wire harness is in the winding process: there is no accidental untwisting, the wires are evenly laid out, there is no crossing, overlapping or excessive gaps, and the tension value is stable within the preset range.

[0008] In one embodiment, step S4 specifically includes the following steps: S41, when the preset number of turns T is reached, the winding machine stops, and the end of the stranded wire bundle is fixed to the termination pin of the bobbin in the same way as the starting wire. It is also necessary to ensure that all N strands of wire participate in the connection.

[0009] In one embodiment, step S5 specifically includes the following steps: S51, carefully separate the fixed wire ends and the untied wire ends of the twisted wire bundle, and accurately lead each wire to its corresponding, designed PCB pad or transformer pin according to the color code. S52. Use a soldering iron or wave soldering machine to solder the wires of each color to their corresponding positions.

[0010] In one embodiment, step S6 specifically includes the following steps: S61, using a multimeter to perform a circuit test to confirm that the resistance of each winding is normal and there is no short circuit; S62, placing the entire winding into a vacuum impregnation tank, then removing it for curing, and using a turns ratio tester or an inductance tester to test the finished product.

[0011] Compared with the prior art, the present invention has at least the following advantages: The present invention provides a transformer multi-wire stranding winding process that combines multiple winding operations into one, reducing the number of wire changes, clamping, and positioning operations. It is particularly suitable for automated winding equipment, significantly improving production efficiency and eliminating process deviations. It mainly improves the winding process deviations, such as the inconsistent output voltage caused by factors such as different winding positions, winding crossings, and uneven density. Multi-colored wires make the winding leads very easy to identify, reducing the probability of misconnection during production and facilitating later quality inspection and maintenance. Attached Figure Description

[0013] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0014] Figure 1 This is a schematic diagram of the two-color winding structure of the present invention (wire harness A or B is a single strand or twisted wire). Figure 2 This is a schematic diagram of the transformer structure of the present invention. Detailed Implementation

[0016] To facilitate understanding of the present invention, a more comprehensive description will be given below with reference to the accompanying drawings. The drawings illustrate preferred embodiments of the invention.

[0017] A transformer multi-wire stranded winding process includes: S1 preparation before winding, S2 stranded wire pretreatment process, S3 overall stranded wire winding process, S4 tailing and wire tail fixing process, S5 wire branching and welding process, and S6 post-processing and inspection. In step S1, the specific process includes the following steps: S11. Based on the design specifications of the transformer / inductor, determine the number of output channels, the rated current of each channel, and the corresponding wire diameter. S12. The number of strands in the stranded wire is strictly equal to the number of output paths. A unique insulation color is assigned to each strand of wire, such as: output path 1 - red, output path 2 - yellow, output path 3 - blue. Based on the total diameter of the wire harness and the required flexibility, the optimal stranding pitch is determined through experiments. The recommended range is 8-15 times the outer diameter of the wire harness after stranding. The stranding direction, whether S-direction or Z-direction, must be consistent. S13. Obtain or customize stranded wire spools that meet the above specifications, check the appearance of the wires, and confirm that there is no damage to the insulation and the color is correct.

[0018] In step S2, the specific process includes the following steps: S21. Place the stranded wire spool in an oven at 70-80°C for 2-4 hours to remove any moisture that may have been absorbed inside the wire, prevent air bubbles from forming during subsequent impregnation, and improve insulation strength. S22. Install the stranded wire spool onto the winding machine, so that the wire harness passes through an adjustable tension control system (usually including a ceramic tensioner and a spring buffer mechanism). According to the total diameter of the stranded wire harness, set the initial unwinding tension to 20-50cN. It should be noted that it is important to ensure that the tension is constant and moderate during winding. Excessive tension will cause the winding to deform and the wire to stretch, while insufficient tension will cause the winding to become loose.

[0019] In step S3, the specific process includes the following steps: S31. Secure the ends of the stranded wire harness to the starting pins of the frame using a special fixing clip or soldering plate to ensure a firm fixation and that all N-strand wires are properly electrically connected. S32. Start the winding machine and wind the entire stranded wire bundle as a single, integrated winding unit. The main shaft of the winding machine rotates according to the preset number of turns T, and the wire guide precisely guides the wire according to the total outer diameter of the stranded wire bundle. In one embodiment, in step S3, since the N strands have been physically twisted together, they occupy the exact same spatial path on the magnetic core or frame, and each turn simultaneously winds one turn for all N outputs.

[0020] In one embodiment, in step S3, the operator or vision system needs to monitor in real time to ensure that the stranded wire harness is in the winding process as follows: there is no accidental untwisting, the wires are evenly laid out, there is no crossing, overlapping or excessive gaps, and the tension value is stable within the preset range.

[0021] In one embodiment, step S4 specifically includes the following steps: S41. Once the preset number of turns T is reached, the winding machine stops, and the end of the stranded wire bundle is fixed to the termination pin of the bobbin in the same way as the starting wire. It is also necessary to ensure that all N strands are involved in the connection.

[0022] In one embodiment, step S5 specifically includes the following steps: S51. Carefully separate the twisted wire bundle with the fixed wire ends and the untied wire ends, and accurately lead each wire to its corresponding PCB pad or transformer pin according to the color code. S52. Using a soldering iron or wave soldering, solder the wires of each color to their corresponding positions. It should be noted that this design completely eliminates the risk of incorrect connections due to wire harness tangles, greatly improving production first-pass yield and reliability.

[0023] In one embodiment, step S6 specifically includes the following steps: S61. Use a multimeter to test the circuit and confirm that the resistance of each winding is normal and there is no short circuit. S62. Place the entire winding into a vacuum impregnation tank, then remove and cure. Test the finished product using a turns ratio tester or an inductance tester. It should be noted that the stranded structure facilitates the penetration and uniform distribution of the varnish, resulting in better overall insulation and mechanical strength. Finally, the finished product can be tested using a turns ratio tester or an inductance tester. The turns ratio error and inductance deviation between each output winding should be less than 0.5%, significantly better than the typical deviation of 2-5% in traditional step-by-step winding processes.

[0024] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A multi-wire stranded winding process for a transformer, characterized in that, include: S1 Preparation before winding, S2 Pre-treatment process of stranded wire, S3 Overall winding process of stranded wire, S4 Ending and fixing process of wire end, S5 Branching and welding process, S6 Post-treatment and inspection. In step S1, the specific process includes the following steps: S11, according to the design specifications of the transformer / inductor, determine the number of output paths, the rated current of each path, and the corresponding wire diameter; S12, the number of strands in the stranded wire is strictly equal to the number of output paths, and a unique insulation varnish color is assigned to each strand, such as: output path 1 - red, output path 2 - yellow, output path 3 - blue. Based on the total diameter of the wire harness and the required flexibility, the optimal stranding pitch is determined through experiments. The recommended range is 8-15 times the outer diameter of the stranded wire harness. The stranding direction, whether S-direction or Z-direction, must be consistent; S13, obtain or customize stranded wire reels that meet the above specifications, check the appearance of the wire, and confirm that there is no damage to the insulation and the color is correct.

2. In step S2, the specific process includes the following steps: S21. Place the stranded wire spool in an oven at 70-80°C for 2-4 hours to remove any moisture that may have been absorbed inside the wire, preventing air bubbles from forming during subsequent impregnation and improving insulation strength; S22. Install the stranded wire spool onto the winding machine, allowing the wire bundle to pass through an adjustable tension control system. Based on the total diameter of the stranded wire bundle, initially set the unwinding tension to 20-50 cN; In step S3, the specific process... The process includes the following steps: S31, fixing the ends of the stranded wire harness to the starting pins of the bobbin using a special fixing clip or welding disc, ensuring a firm fixation and that all N strands are properly electrically connected; S32, starting the winding machine and winding the entire stranded wire harness as a single, integrated winding unit, with the winding machine spindle rotating at a preset number of turns T, and the wire guide precisely guiding the wires according to the total outer diameter of the stranded wire harness; According to claim 1, a transformer multi-strand winding process is characterized in that, in step S3, since the N strands have been physically stranded, they occupy the same spatial path on the magnetic core or frame, and each turn simultaneously winds one turn for all N outputs.

3. The transformer multi-wire stranding winding process according to claim 1, characterized in that, In step S3, the operator or vision system needs to monitor in real time to ensure that the twisted wire harness is in the winding process as follows: there is no accidental untwisting, the wires are evenly laid out, there is no crossing, overlapping or excessive gaps, and the tension value is stable within the preset range.

4. The transformer multi-wire stranding winding process according to claim 1, characterized in that, In step S4, the specific process includes the following steps: S41, when the preset number of turns T is reached, the winding machine stops and the end of the stranded wire bundle is fixed to the termination pin of the skeleton in the same way as the starting wire.

5. Similarly, it is necessary to ensure that all N-strand wires are involved in the connection.

6. The transformer multi-wire stranding winding process according to claim 1, characterized in that, In step S5, the specific process includes the following steps: S51, carefully separate the fixed wire ends and the untied wire ends of the twisted wire bundle, and accurately lead each wire to its corresponding PCB pad or transformer pin according to the color code; S52, use a soldering iron or wave soldering to solder the wires of each color to their corresponding positions.

7. The transformer multi-wire stranding winding process according to claim 1, characterized in that, In step S6, the specific process includes the following steps: S61, use a multimeter to perform a circuit test to confirm that the resistance of each winding is normal and there is no short circuit; S62, put the entire winding into a vacuum impregnation tank, then take it out for curing, and use a turns ratio tester or an inductance tester to test the finished product.

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