A power magnetic core common mode inductor and a manufacturing method thereof

Abstract

The application discloses a power magnetic core common mode inductor and a preparation method thereof, and belongs to the technical field of electronic component manufacturing, and comprises a winding execution unit, a magnetic circuit assembly unit and a material flow transfer module, wherein the winding execution unit comprises a main shaft rotating motor and a wire arranging servo module, the magnetic circuit assembly unit comprises a servo press and a glue injection nozzle, and the material flow transfer module is connected with the winding execution unit and the magnetic circuit assembly unit. The scheme physically increases the average distance of interlayer conductors through staggered span actions, changes the distribution direction of electric field vectors, effectively reduces the parasitic capacitance between windings, directly improves the high-frequency characteristics of the common mode inductor, expands the high-frequency impedance bandwidth, and enables the common mode inductor to more effectively inhibit high-frequency noise transmission.

Description

Technical Field

[0001] This invention relates to the field of electronic component manufacturing, specifically to a power magnetic core common-mode inductor and its preparation method. Background Technology

[0002] With the rapid development of power electronics technology and modern electronic equipment, the demand for electromagnetic interference suppression components is increasing. As a key filtering component, the electrical performance consistency and high-frequency characteristics of the power core common-mode inductor directly affect the stability and reliability of the entire device.

[0003] Currently, the fabrication of power core common-mode inductors mainly relies on manual labor or semi-automatic equipment. In traditional production processes, technicians or equipment typically first wind wires onto an insulating frame. After the winding is complete, the frame is transferred to the next process for core assembly and fixation. During the winding stage, the wires usually rely on natural tension to fall into the grooves of the lower wires for close arrangement. In the assembly stage, mechanical clamps are used to close the core body, and glue or other methods are used for fixation, ultimately completing the finished product.

[0004] However, this traditional manufacturing method has significant limitations. First, due to the relatively fragmented processes, semi-finished products are easily damaged or contaminated during manual or simple mechanical handling, affecting product quality. Second, although traditional winding methods involve close arrangement, in high-frequency applications, this close arrangement often leads to excessive distributed capacitance between windings, severely deteriorating the high-frequency impedance characteristics of the device and making it unable to effectively suppress high-frequency noise. More importantly, existing processing methods struggle to actively control parasitic parameters during core assembly. Due to stress release and elastic rebound phenomena in materials, the inductance value often drifts unpredictably after the assembly pressure is removed, making it difficult for the final product's electrical parameters to accurately fall within the target range. This results in poor product consistency, low yield, and problems often only being discovered during the finished product testing stage, leading to a waste of materials and time.

[0005] Therefore, optimizing the manufacturing process to ensure high-frequency characteristics while solving the problems of inductance drift and poor process consistency has become an urgent issue to be addressed in this field.

[0006] The information disclosed in the background section above is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0007] The purpose of this invention is to provide a power core common-mode inductor and its fabrication method to solve the problems mentioned in the background art.

[0008] The technical solution of the present invention includes:

[0009] S1. A winding execution unit, a magnetic circuit assembly unit, and a material transfer module are set up. The winding execution unit includes a spindle rotary motor and a wire laying servo module. The magnetic circuit assembly unit includes a servo press and a glue injection nozzle. The material transfer module connects the winding execution unit and the magnetic circuit assembly unit.

[0010] S2. Install the split insulating frame onto the main spindle rotary motor, start the wire winding servo module to wind the wire, and perform a staggered crossing action when winding the interlayer wire, so that the upper layer wire is spatially offset from the valley position of the lower layer wire.

[0011] S3. The wound split insulating skeleton is transferred to the magnetic circuit assembly unit through the material flow module, and the first magnetic core, the second magnetic core and the fine adjustment shim are installed. The servo press is started to push the first magnetic core and the second magnetic core closer to each other and clamp the fine adjustment shim.

[0012] S4. Real-time acquisition of the feed pressure value of the servo press, calculation of the process locking inductance value based on the preset pressure and inductance rebound drift mapping relationship, and adjustment of the press head position of the servo press until the measured inductance value is equal to the process locking inductance value.

[0013] S5. Keep the position and pressure of the servo press unchanged, control the glue injection nozzle to inject adhesive into the magnetic core mating gap, and release the pressure after the adhesive has cured.

[0014] Preferably, the misalignment crossing action in step S2 includes:

[0015] The spindle rotation motor is controlled to maintain a specific angular displacement, while the wire servo module is controlled to drive the wire nozzle to move rapidly along the axial direction by a distance that is not an integer multiple of the wire diameter, forming an interlayered arrangement.

[0016] Preferably, the step after S2 and before S3 includes:

[0017] S2.1 Control the spindle rotary motor to rotate to the test zero position and lock it, and use the Kelvin test clamp to contact the two ends of the coil;

[0018] S2.2 Measure the self-resonant frequency of the current winding. If the self-resonant frequency is lower than the preset target value, instruct the wiring servo module to increase the axial sparsity of the subsequent windings.

[0019] Preferably, the construction of the pressure-inductance rebound drift mapping relationship in step S4 includes:

[0020] Select a sample and apply gradient pressure. Record the real-time inductance value at each pressure value and the final inductance value after the pressure is removed. Calculate the inductance difference before and after the pressure is removed and establish a functional mapping relationship between the applied pressure value and the inductance rebound loss after the pressure is removed.

[0021] Preferably, the method for calculating the process lock inductance value in step S4 is as follows:

[0022] The expected inductor springback loss corresponding to the current feed pressure value is retrieved from the database. The target inductor value is then subtracted from the expected inductor springback loss to obtain the process-locked inductor value.

[0023] A power core common-mode inductor, comprising:

[0024] Overall rack base;

[0025] A winding execution unit is disposed on one side of the overall frame base and is used to construct windings on the split insulating frame;

[0026] A magnetic circuit assembly unit, mounted on the overall frame base, is used to assemble the magnetic core and adjust the magnetic reluctance parameters;

[0027] The material transfer module connects the winding execution unit and the magnetic circuit assembly unit, and is used to transfer the semi-finished skeleton;

[0028] An impedance feedback detection unit is mounted on the overall frame base and is used to detect high-frequency electrical parameters.

[0029] Preferably, the winding execution unit includes:

[0030] The main spindle rotation motor is fixed to the overall frame base, and its output shaft is equipped with a pneumatic three-jaw chuck;

[0031] The cable servo module includes a linear guide pair parallel to the center line of the main shaft and a ball screw transmission mechanism, and the cable servo module is equipped with a wire nozzle;

[0032] The cable servo module establishes an electronic cam relationship with the spindle rotary motor.

[0033] Preferably, the magnetic circuit assembly unit includes:

[0034] The mounting and positioning base is fixed to the overall frame base and is provided with a contoured groove.

[0035] A servo press is inverted and mounted directly above the assembly positioning base. The end of the press head of the servo press is integrated with a feed force closed-loop monitoring sensor and a contour buffer block.

[0036] The glue dispensing nozzle is mounted on an electric slide, which is located on the side wall of the servo press.

[0037] Preferably, the impedance feedback detection unit includes:

[0038] The Kelvin test clip is located on the radial side of the winding execution unit, and its driving mechanism is a double guide rod cylinder. The extension and retraction direction of the double guide rod cylinder is perpendicular to the spindle rotation center line.

[0039] The LCR digital bridge is connected to the Kelvin test clip.

[0040] Preferably, the split-type insulating frame includes:

[0041] The main frame has an I-shaped structure with rectangular through holes between the two side plates.

[0042] Layered limiting grooves are machined on the outer surface of the main skeleton body and are spiral in shape;

[0043] An isolation baffle is located at the axial center of the main frame body.

[0044] This invention provides an improved version of a power core common-mode inductor and its fabrication method, which has the following improvements and advantages compared with the prior art:

[0045] 1. The staggered crossing action of this scheme physically increases the average distance between the interlayer conductors and changes the distribution direction of the electric field vector, thereby effectively reducing the parasitic capacitance between windings. This directly improves the high-frequency characteristics of the common-mode inductor, expands its high-frequency impedance bandwidth, and enables it to more effectively suppress the transmission of high-frequency noise.

[0046] 2. This solution transforms the invisible mechanical stress release process into a calculable inductance compensation amount. By pre-setting the rebound amount, it ensures that after the adhesive cures and the pressure is removed, the physical structure of the product rebounds precisely to offset the reserved parameters, so that the final inductance value falls accurately on the target center value, thus solving the problem of inductance value drift.

[0047] 3. This solution establishes a dynamic adjustment strategy based on real-time feedback. By adjusting the physical spacing of subsequent windings, it offsets the capacitance deviation of earlier windings. This proactive correction mechanism not only avoids direct scrapping but also corrects the electrical parameters of the entire product, significantly improving the first-pass yield of the process. Furthermore, highly integrated automated collaboration constructs a continuous workflow, eliminating uncertainties caused by manual intervention and ensuring manufacturing consistency from winding construction to magnetic circuit closure. Attached Figure Description

[0048] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0049] Figure 1This is a structural schematic diagram of a split insulating frame, a first magnetic core, a second magnetic core, and a fine-tuning shim;

[0050] Figure 2 This is a schematic diagram of the winding execution unit and its overall connection structure;

[0051] Figure 3 This is a schematic diagram of the impedance feedback detection unit;

[0052] Figure 4 This is a structural schematic diagram of the magnetic circuit assembly unit;

[0053] Figure 5 This is a schematic diagram of the process flow of the method of the present invention.

[0054] In the diagram: 100, split insulating frame; 110, frame body; 120, layered limiting groove; 130, isolation baffle; 210, first magnetic core; 220, second magnetic core; 230, fine-tuning shim; 300, winding execution unit; 310, spindle rotary motor; 320, wiring servo module; 330, pressure sensor; 400, impedance feedback detection unit; 410, Kelvin test clip; 420, LCR digital bridge; 510, servo press; 520, glue nozzle. Detailed Implementation

[0055] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0056] Example 1

[0057] Please see Figure 1-5 This invention provides a method for fabricating a power core common-mode inductor, comprising:

[0058] S1. A winding execution unit 300, a magnetic circuit assembly unit, and a material transfer module are set up. The winding execution unit 300 includes a spindle rotary motor 310 and a wire laying servo module 320. The magnetic circuit assembly unit includes a servo press 510 and a glue injection nozzle 520. The material transfer module connects the winding execution unit 300 and the magnetic circuit assembly unit.

[0059] S2. Install the split insulating frame 100 onto the spindle rotary motor 310, start the wire winding servo module 320 to wind the wire, and perform a staggered crossing action when winding the interlayer wire, so that the upper layer wire is spatially offset from the valley position of the lower layer wire.

[0060] S3. The wound split insulating skeleton 100 is transferred to the magnetic circuit assembly unit through the material flow module, and the first magnetic core 210, the second magnetic core 220 and the fine adjustment shim 230 are installed. The servo press 510 is started to push the first magnetic core 210 and the second magnetic core 220 closer to each other and clamp the fine adjustment shim 230.

[0061] S4. Real-time acquisition of the feed pressure value of the servo press 510, calculation of the process locking inductance value based on the preset pressure and inductance springback drift mapping relationship, and adjustment of the press head position of the servo press 510 until the measured inductance value is equal to the process locking inductance value.

[0062] S5. Keep the position and pressure of the servo press 510 unchanged, control the glue injection nozzle 520 to inject adhesive into the magnetic core mating gap, and release the pressure after the adhesive has cured.

[0063] In this embodiment, addressing the problems of poor core assembly consistency, inability to actively control parasitic parameters, and inductance value drift caused by stress release during inductor fabrication in existing manual or semi-automatic equipment processes, this power core common-mode inductor fabrication method constructs a continuous workflow from winding construction to magnetic circuit closure through highly integrated automated unit collaboration. The winding execution unit 300, in cooperation with the spindle rotary motor 310 and the wiring servo module 320, not only completes the basic winding but also introduces a misalignment crossing action between layers, breaking the interlayer capacitance accumulation effect caused by traditional tight wiring. The material transfer module, acting as a connecting hub, transfers the wound, split-type insulating skeleton 100 to the magnetic circuit assembly unit without damage, avoiding mechanical damage or contamination that may be introduced by manual transfer. The magnetic circuit assembly unit utilizes the high-precision force control characteristics of the servo press 510, combined with the compressibility of the fine-tuning shim 230. The fine-tuning shim 230 is preferably made of an insulating composite material with a specific elastic modulus, such as polyamide. An imide film or FR-4 epoxy resin fiberglass board is used to ensure the recoverability of physical deformation and insulation performance, and an adjustable physical air gap is established during the closing process of the first magnetic core 210 and the second magnetic core 220. In particular, the pressure and inductor rebound drift mapping relationship is introduced to transform the invisible mechanical stress release process into a calculable inductance compensation amount. The rebound amount is pre-funded by locking the inductance value in the process. Before the fast-curing adhesive is injected into the dispensing nozzle 520 and fixed, the system is already in a pre-stress equilibrium state. After the pressure is removed, the product parameters accurately fall back to the target range, realizing deterministic manufacturing of the electrical performance of the common mode inductor.

[0064] The misaligned crossing action in step S2 includes:

[0065] The spindle rotation motor 310 is controlled to maintain a specific angular displacement, while the wire servo module 320 is controlled to drive the wire nozzle to move rapidly along the axial direction by a distance that is not an integer multiple of the wire diameter, forming an interlayered arrangement.

[0066] This action constructs a ridge-arrangement model, which forces the upper conductor to be positioned above the line connecting the tangent points of the two lower conductors rather than in the valley. This increases the geometric distance between the centers of the interlayer conductors from d and the conductor diameter to the geometrically combined distance of d and the thickness of the interlayer insulating medium, significantly reducing the parasitic capacitive coupling strength caused by the proximity effect.

[0067] In this embodiment, the execution of the misalignment crossing action relies on the precise linkage between the spindle rotary motor 310 and the wire servo module 320. In traditional winding processes, the upper layer wire often naturally falls into the valley formed by the lower layer wire, resulting in a minimized interlayer distance, which in turn increases the interlayer distributed capacitance and deteriorates high-frequency characteristics. This method controls the spindle rotary motor 310 to precisely hover at a specific angular displacement. The spindle rotary motor 310 model can be, for example, the Yaskawa SGM7J series. The circumferential position of the skeleton is locked, at which point the wire servo module 320 drives the wire nozzle along the... The skeleton is forced to offset axially, and the offset amount is set to a non-integer multiple of the conductor diameter. For example, the axial movement distance of the conductor nozzle is controlled to be 0.5 times the conductor diameter, so that the upper conductor is precisely positioned above the tangent point of the two lower conductors, forcing the upper conductor to cross the valley of the lower conductor and straddle the ridge of the two lower conductors. This interlayer staggered arrangement physically increases the average distance between the conductors, changes the distribution direction of the electric field vector, effectively reduces the parasitic capacitance between windings, thereby expanding the high-frequency impedance bandwidth of the power common-mode inductor and suppressing the transmission of high-frequency noise.

[0068] The period after step S2 and before step S3 includes:

[0069] S2.1 Control the spindle rotation motor 310 to rotate to the test zero position and lock it, and use the Kelvin test clamp 410 to contact the two ends of the coil;

[0070] S2.2 Measure the self-resonant frequency of the current winding. If the self-resonant frequency is lower than the preset target value, instruct the wiring servo module 320 to increase the axial sparsity of the subsequent windings.

[0071] In this embodiment, to address the issue of delayed finished product consistency screening, intermediate-state quality control is introduced during the winding stage. The spindle rotary motor 310 rotates to the test zero position and locks, ensuring that the coil pins are accurately aligned with the testing station. The Kelvin test clamp 410, driven by a dual-guide-rod cylinder (e.g., an SMC cylinder), extends and stably contacts both ends of the coil, eliminating contact resistance interference. The LCR digital bridge 420, such as the Tonghui TH283X series, measures the self-resonant frequency of the current winding using an excitation signal. This parameter directly reflects the magnitude of the winding's distributed capacitance. If the self-resonant frequency is lower than the preset target value, it indicates that the current distributed capacitance is too large and the high-frequency performance is insufficient. Instead of directly scrapping the product, the system instructs the wiring servo module 320 to increase the axial sparsity in subsequent windings, i.e., to increase the ratio of the wiring speed to the spindle speed, thereby increasing the physical spacing between the coil turns.

[0072] Increasing axial sparsity directly reduces the coil density per unit length, thus lowering the total distributed capacitance between coils. According to the self-resonant frequency formula... Decreasing the capacitance C will directly increase the self-resonant frequency. This corrects the deviation caused by the earlier windings;

[0073] This dynamic adjustment strategy based on real-time feedback reduces the coupling area between the windings to offset the capacitance deviation of the early windings, actively corrects the electrical parameters of the entire product, and improves the first-pass yield of the process.

[0074] The construction of the pressure-inductor rebound drift mapping relationship in step S4 includes:

[0075] Select a sample and apply gradient pressure. Record the real-time inductance value at each pressure value and the final inductance value after the pressure is removed. Calculate the inductance difference before and after the pressure is removed and establish a functional mapping relationship between the applied pressure value and the inductance rebound loss after the pressure is removed.

[0076] The construction process specifically includes: Step 1, applying pressure at a constant speed to the preset maximum value and recording the three-dimensional data of pressure-displacement-inductance according to the set step size; Step 2, maintaining the pressure at each pressure step for a set time to eliminate the creep effect and recording the steady-state inductance value; Step 3, quickly unloading the pressure and recording the final inductance value after standing; Step 4, using the least squares method to fit the nonlinear compensation curve between the holding pressure value and the inductance loss, i.e., the holding pressure value minus the final value.

[0077] In this embodiment, the construction of the pressure-inductance rebound drift mapping relationship is the data foundation for achieving precise air gap control. Due to the nonlinear elastic hysteresis characteristics of the fine-tuning shim 230 and the skeleton material, such as polyetheretherketone, the magnetic core assembly will experience a slight rebound after the external force is removed from the servo press 510, resulting in an increase in the air gap and a decrease in the inductance value. By pre-selecting samples, the servo press 510 applies gradient pressure from low to high, and records the real-time inductance value at each pressure step, the inductance value under pressure holding state, and the final inductance value after pressure removal, i.e., the inductance value in the free state. Through the acquisition and difference calculation of a large number of data points, the system fits a function curve between the applied pressure value and the inductance rebound loss after force removal. This mapping relationship digitizes the complex material mechanical behavior, enabling the system to accurately predict the inductance change after force removal based on the current pressure reading during the production process, providing a quantitative feedforward compensation basis for process control.

[0078] The method for locking the inductance value in step S4 is as follows:

[0079] The database is used to retrieve the expected inductor springback loss corresponding to the current feed pressure value. The target inductor value is then subtracted from the expected inductor springback loss to obtain the process lock inductor value.

[0080] The process lock-in inductance value is a preset overshoot target value. Its physical meaning is that this value is equal to the final target inductance value plus the inductance lost due to the slight expansion of the air gap caused by the release pressure. It aims to compensate for the subsequent mechanical relaxation by over-tightening during the process.

[0081] In this embodiment, the logic for calculating the inductance value aims to overcome parameter deviations caused by elastic aftereffects. During the magnetic circuit assembly process, the servo press 510 provides real-time feedback on the current feed pressure value. The control system retrieves the corresponding expected inductance rebound loss from the pre-stored database based on this pressure value. Considering that the inductance value will inevitably decrease due to the increase in air gap after the force is released, the system subtracts this expected decrease from the target inductance value required in the product specification. When the drift is negative, it is algebraically added to obtain a process-locked inductance value that is more stringent than the target value and usually has a larger inductance. The servo press 510 is adjusted until the measured inductance value converges to the process-locked inductance value, which means that although the product is in an over-compressed state, a certain rebound margin has been reserved. When the process flows to the point where the glue cures and the force is released, the rebound of the physical structure exactly offsets the reserved parameter margin, so that the inductance value of the final product falls precisely on the target center value.

[0082] Example 2

[0083] Please see Figure 1-4 A power core common-mode inductor, comprising:

[0084] Overall rack base;

[0085] The winding execution unit 300 is located on one side of the overall frame base and is used to construct windings on the split insulating frame 100.

[0086] The magnetic circuit assembly unit, located on the overall frame base, is used to assemble the magnetic core and adjust the magnetic reluctance parameters;

[0087] The material transfer module connects the winding execution unit 300 and the magnetic circuit assembly unit, and is used to transfer the semi-finished skeleton;

[0088] In this embodiment, the material flow module preferably adopts a multi-axis articulated robot, whose end effector integrates pneumatic fingers that match the shape of the skeleton, enabling multi-degree-of-freedom spatial grasping and placement from the winding station to the assembly station.

[0089] Impedance feedback detection unit 400 is mounted on the overall frame base and is used to detect high-frequency electrical parameters.

[0090] In this embodiment, the overall layout of the device is based on a cast or welded integral frame base, ensuring the geometric accuracy benchmark of all moving parts; the winding execution unit 300 is arranged on one side of the base, focusing on building a winding structure with specific electric field characteristics on the split insulating skeleton 100; the magnetic circuit assembly unit is located in another functional area of ​​the base, responsible for assembling the magnetic core with the wound skeleton, and adjusting the magnetic reluctance parameters through mechanical compression to correct the inductance; the material flow module, such as a single-axis linear robot arm working with pneumatic fingers, physically connects the above two units, undertaking the automated transfer task of the semi-finished skeleton, reducing manual intervention; the impedance feedback detection unit 400 is integrated inside the equipment, capable of intervening at key process nodes, contacting product pins to obtain real-time high-frequency electrical parameters; the units work together to deeply integrate mechanical action and electrical detection, realizing closed-loop parameter manufacturing of common mode inductors from raw materials to finished products.

[0091] The winding execution unit 300 includes:

[0092] The main spindle rotation motor 310 is fixed to the overall frame base, and its output shaft is equipped with a pneumatic three-jaw chuck;

[0093] The cable servo module 320 includes a linear guide pair parallel to the spindle centerline and a ball screw transmission mechanism. The cable servo module 320 is equipped with a wire nozzle.

[0094] Among them, the cable servo module 320 establishes an electronic cam relationship with the spindle rotary motor 310.

[0095] In this embodiment, the core of the winding execution unit 300 lies in the precise synthesis of motion trajectory. The spindle rotary motor 310, using a servo motor with a high-resolution encoder, is fixed to the base and firmly clamps the skeleton through a pneumatic three-jaw chuck on the output shaft, providing the main rotational motion and high-rigidity indexing lock at any angle. The wire laying servo module 320 uses a linear guide pair parallel to the spindle centerline and a ball screw transmission mechanism to drive the wire nozzle mounted on it to perform axial reciprocating motion. The relationship between the wire laying servo module 320 and the spindle rotary motor 310 is not a simple speed follow, but rather a strict electronic cam relationship is established. The controller directly maps the target position of the wire laying axis according to the real-time angular position of the spindle by looking up a table or calculating a function. This control architecture ensures that no matter how the spindle speed fluctuates, the axial displacement of the wire nozzle always maintains a definite geometric correspondence with the skeleton rotation angle, thereby ensuring the trajectory accuracy of precision wire laying and misalignment crossing actions.

[0096] The magnetic circuit assembly unit includes:

[0097] The mounting and positioning base is fixed to the overall frame base and has a contoured groove;

[0098] The servo press 510 is mounted upside down on top of the assembly positioning base. The end of the press head of the servo press 510 integrates a feed force closed-loop monitoring sensor and a contour buffer block.

[0099] The dispensing nozzle 520 is mounted on an electric slide, which is located on the side wall of the servo press 510.

[0100] In this embodiment, the magnetic circuit assembly unit ensures assembly accuracy through a rigid structure; the assembly positioning base is fixed to the base, and the contoured groove on it matches the negative tolerance of the skeleton shape, limiting the horizontal freedom of the component; the servo press 510 is inverted and mounted directly above the base, and its press head integrates a pressure sensor 330, such as an S-shaped tension / compression sensor and a contoured buffer block made of polyurethane, which can provide real-time feedback on minute changes in assembly pressure and prevent the brittle magnetic core from breaking under pressure; the glue nozzle 520 is mounted on an electric slide on the side wall, such as a module driven by a small lead screw stepper motor, and can be controlled to move to the magnetic core mating gap for glue dispensing during the press's pressure holding period; this layout allows the pressing, inspection, and glue dispensing processes to be completed in the same station and under the same clamping state, eliminating positioning errors caused by multiple clamping and ensuring the stability of the magnetic core air gap and the reliability of the glue after curing.

[0101] The impedance feedback detection unit 400 includes:

[0102] Kelvin test clip 410 is located on the radial side of winding execution unit 300. Its drive mechanism is a double guide rod cylinder. The extension and retraction direction of the double guide rod cylinder is perpendicular to the spindle rotation center line.

[0103] The LCR digital bridge 420 is connected to the Kelvin test clip 410.

[0104] In this embodiment, the impedance feedback detection unit 400 solves the contact reliability problem of online measurement; the Kelvin test clamp 410, using a four-wire measurement fixture, is arranged radially on the side of the winding execution unit 300. Its drive mechanism uses a high-rigidity double-guide rod cylinder, with the cylinder's extension and retraction direction perpendicular to the spindle centerline; when testing is required, the cylinder drives the test clamp to feed radially in a straight line, and with the spindle's zero-position locking, the test clamp's jaws precisely engage the coil pins; the LCR digital bridge 420 connects to the test clamp. This LCR digital bridge 420 has a frequency scanning function, which can automatically identify the frequency point when the phase angle is zero, i.e., the self-resonant frequency, by scanning the impedance-frequency curve, and apply a high-frequency excitation signal at the moment of contact and read the feedback; the guiding structure of the double-guide rod cylinder ensures the position repeatability of the test clamp during repeated advance and retreat, avoiding contact resistance fluctuations caused by contact position offset, thereby ensuring the authenticity and repeatability of the measurement of small inductance and high-frequency parameters.

[0105] The split-type insulating frame 100 includes:

[0106] The main frame is 110, with an I-shaped structure and rectangular through holes between the two side plates;

[0107] The layered limiting groove 120 is machined on the outer surface of the skeleton body 110 and is spiral in shape;

[0108] The isolation baffle 130 is located at the axial center of the main frame 110.

[0109] In this embodiment, the split insulating frame 100 serves as the core process carrier, and its structure directly contributes to the improvement of electrical performance. The frame body 110 is injection molded from high-performance engineering plastics such as polyetheretherketone (PEEK) and has an I-shaped structure. The rectangular through holes between the two side plates provide a precise installation space for the magnetic core. Spiral layered limiting grooves 120 are machined on the outer surface of the frame body 110. The geometric dimensions of these grooves are strictly matched with the wire diameter, forcing the wire to fall into a predetermined trajectory like a thread, preventing the wire from becoming disordered under high tension winding. The isolation baffle 130 is located at the axial center, physically dividing the winding area into two independent spaces, forcibly isolating the input and output windings, and blocking the surface creepage path. This structural design not only improves the withstand voltage level of the product, but also ensures the uniqueness of the position of each coil turn through physical limiting, providing a stable geometric basis for the subsequent control of electric field distribution and adjustment of leakage inductance parameters.

[0110] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for fabricating a power magnetic core common-mode inductor, characterized in that, include: S1. A winding execution unit (300), a magnetic circuit assembly unit, and a material transfer module are set up. The winding execution unit (300) includes a spindle rotary motor (310) and a wire laying servo module (320). The magnetic circuit assembly unit includes a servo press (510) and a glue injection nozzle (520). The material transfer module connects the winding execution unit (300) and the magnetic circuit assembly unit. S2. Install the split insulating frame (100) on the main spindle rotary motor (310), start the wire winding servo module (320) to wind the wire, and perform a staggered crossing action when winding the interlayer wire, so that the upper layer wire is spatially offset from the valley position of the lower layer wire. S3. The wound split insulating skeleton (100) is transferred to the magnetic circuit assembly unit through the material transfer module, and the first magnetic core (210), the second magnetic core (220) and the fine adjustment shim (230) are installed. The servo press (510) is started to push the first magnetic core (210) and the second magnetic core (220) closer to each other and clamp the fine adjustment shim (230). S4. Real-time acquisition of the feed pressure value of the servo press (510), calculation of the process locking inductance value according to the preset pressure and inductance springback drift mapping relationship, and adjustment of the pressure head position of the servo press (510) until the measured inductance value is equal to the process locking inductance value. S5. Keep the position and pressure of the servo press (510) unchanged, control the glue injection nozzle (520) to inject adhesive into the magnetic core mating gap, and release the pressure after the adhesive has cured. The period following step S2 and before step S3 includes: S2.1 Control the spindle rotary motor (310) to rotate to the test zero position and lock it, and use the Kelvin test clamp (410) to contact the two ends of the coil; S2.2 Measure the self-resonant frequency of the current winding. If the self-resonant frequency is lower than the preset target value, instruct the wiring servo module (320) to increase the axial sparsity of the subsequent winding.

2. The method for preparing a power magnetic core common-mode inductor according to claim 1, characterized in that, The misaligned crossing action in step S2 includes: The spindle rotation motor (310) is controlled to maintain a specific angular displacement, while the wire servo module (320) is controlled to drive the wire nozzle to move rapidly along the axial direction by a distance that is not an integer multiple of the wire diameter, forming an interlayer staggered arrangement.

3. The method for fabricating a power magnetic core common-mode inductor according to claim 1, characterized in that, The construction of the pressure-inductance rebound drift mapping relationship in step S4 includes: Select a sample and apply gradient pressure. Record the real-time inductance value at each pressure value and the final inductance value after the pressure is removed. Calculate the inductance difference before and after the pressure is removed and establish a functional mapping relationship between the applied pressure value and the inductance rebound loss after the pressure is removed.

4. The method for preparing a power magnetic core common-mode inductor according to claim 1, characterized in that, The method for calculating the process lockout inductance value in step S4 is as follows: The expected inductor springback loss corresponding to the current feed pressure value is retrieved from the database. The target inductor value is then subtracted from the expected inductor springback loss to obtain the process-locked inductor value.

5. A power core common-mode inductor, applied to the method for fabricating a power core common-mode inductor according to any one of claims 1 to 4, characterized in that, include: Overall rack base; A winding execution unit (300) is disposed on one side of the integral frame base and is used to construct windings on the split insulating frame (100); A magnetic circuit assembly unit, mounted on the overall frame base, is used to assemble the magnetic core and adjust the magnetic reluctance parameters; The material transfer module connects the winding execution unit (300) and the magnetic circuit assembly unit, and is used to transfer the semi-finished skeleton; An impedance feedback detection unit (400) is mounted on the overall frame base and is used to detect high-frequency electrical parameters.

6. A power core common-mode inductor according to claim 5, characterized in that, The winding execution unit (300) includes: A main spindle rotary motor (310) is fixed to the overall frame base, and its output shaft is equipped with a pneumatic three-jaw chuck. The cable servo module (320) includes a linear guide pair parallel to the center line of the main shaft and a ball screw transmission mechanism. The cable servo module (320) is equipped with a wire nozzle. The cable servo module (320) establishes an electronic cam relationship with the spindle rotary motor (310).

7. A power core common-mode inductor according to claim 5, characterized in that, The magnetic circuit assembly unit includes: The mounting and positioning base is fixed to the overall frame base and is provided with a contoured groove. A servo press (510) is inverted and mounted directly above the assembly positioning base. The end of the press head of the servo press (510) is integrated with a feed force closed-loop monitoring sensor and a contour buffer block. The glue dispensing nozzle (520) is mounted on an electric slide, which is located on the side wall of the servo press (510).

8. A power core common-mode inductor according to claim 5, characterized in that, The impedance feedback detection unit (400) includes: Kelvin test clip (410) is located on the radial side of the winding execution unit (300), and its driving mechanism is a double guide rod cylinder. The extension and retraction direction of the double guide rod cylinder is perpendicular to the rotation center line of the main shaft. The LCR digital bridge (420) is connected to the Kelvin test clip (410).

9. A power core common-mode inductor according to claim 5, characterized in that, The split-type insulating frame (100) includes: The main frame (110) has an I-shaped structure with rectangular through holes between the two side plates; A layered limiting groove (120) is machined on the outer surface of the skeleton body (110) and is spiral in shape; The isolation baffle (130) is located at the axial center of the main body of the skeleton (110).

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