Intelligent correction method and equipment for magnetic core assembly of miniature transformer

Abstract

The invention is suitable for the technical field of transformer magnetic core correction, and particularly relates to an intelligent correction method and equipment for miniature transformer magnetic core assembly, and the method comprises the steps: when a transformer equipped with a magnetic core is in place, a control device controls a no-load experiment device to apply a first voltage, and detects the first no-load information of the transformer; when the first no-load information does not reach the standard, the control device controls the no-load experiment device to apply a second voltage and detects second no-load information of the transformer; when the second no-load information reaches the standard, controlling a no-load experiment device to measure the saturation magnetic flux of the magnetic core, determining an air gap thickness value according to the saturation magnetic flux, and controlling an air gap thickness device to adjust the air gap thickness of the magnetic core in the transformer according to the air gap thickness value; and when the second no-load information does not reach the standard, replacing the magnetic core of the transformer and then re-executing the step 1 to the step 3. According to the method, the problem that an existing miniature transformer manufacturing method cannot automatically determine the appropriate air gap thickness can be solved.

Description

Technical Field

[0001] This application belongs to the field of transformer core correction technology, and particularly relates to intelligent correction methods and equipment for assembling micro transformer cores. Background Technology

[0002] A transformer can be divided into two main parts: the magnetic core and the windings. The core function of the transformer is to provide a path with high permeability and low reluctance, confining the magnetic flux generated by the primary winding (primary coil) within it as much as possible and efficiently transmitting it to the secondary winding (secondary coil). When the magnetic core is damaged or has poor insulation, resulting in a defective core, problems such as leakage flux, localized overheating, or severe vibration will occur during transformer operation, making the transformer unable to operate. This problem can be solved by replacing the magnetic core. In micro transformers, the magnetic core is smaller, and the smaller the magnetic core, the smaller its energy storage capacity. This may cause magnetic saturation during normal operation, leading to a sharp increase in excitation current and severe distortion. The magnetic field also dissipates from the magnetic core, greatly increasing leakage flux and making it impossible to maintain normal electrical characteristics. An air gap can be added to the magnetic core to improve its energy storage capacity and thus solve the problem. However, if the air gap thickness is too large, the magnetic field will be exposed from the air gap, which will increase leakage flux. Therefore, determining the appropriate thickness of the air gap is very important.

[0003] In existing micro transformer manufacturing methods, it is impossible to determine the appropriate air gap thickness, making it difficult to apply the core opening air gap technology. Since the rated capacity of a micro transformer is directly proportional to the maximum magnetic flux of the core (the maximum magnetic flux of a core without an air gap is much smaller than that of a core with an air gap), the rated capacity of existing micro transformers is very small. Therefore, there is an urgent need for an intelligent core assembly correction method that can automatically determine the appropriate air gap thickness of the transformer core. Summary of the Invention

[0004] This application provides a method and device for intelligent correction of micro transformer core assembly, which can solve the problem that existing micro transformer manufacturing methods cannot automatically determine the appropriate air gap thickness.

[0005] In a first aspect, embodiments of this application provide a smart correction method for assembling a miniature transformer core, applied to a core correction device. The core correction device includes an no-load testing apparatus, an air gap thickness device, and a control device. The no-load testing apparatus is used to perform no-load tests on the transformer, and the air gap thickness device is used to control the thickness of the air gap within the core. The method includes: Step 1: When the transformer with the assembled magnetic core is in place, the control device controls the no-load test device to apply a first voltage and detect the first no-load information of the transformer; wherein, the first voltage is the rated voltage, and the first no-load information includes the first no-load loss and the first no-load current; Step 2: When the first no-load information fails to meet the standard, the control device controls the no-load test device to apply a second voltage and detect the second no-load information of the transformer; wherein, the second voltage is less than the rated voltage, and the second no-load information includes the second no-load loss and the second no-load current; Step 3: When the second no-load information meets the standard, the no-load test device is controlled to measure the saturation magnetic flux of the core, and the air gap thickness value is determined according to the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the core inside the transformer according to the air gap thickness value. When the second no-load information does not meet the standard, the core of the transformer is replaced and steps 1 to 3 are repeated.

[0006] The technical solutions described in this application embodiment have at least the following technical effects: The intelligent correction method for assembling the core of a miniature transformer provided in this application firstly involves the control device applying a first voltage and detecting the first no-load information of the transformer when the transformer with the assembled core is in place. This step applies the rated voltage to the transformer and detects the no-load loss, enabling the identification of transformers with substandard electrical characteristics and the separation of transformers with abnormalities. Secondly, if the first no-load information is substandard, the control device applies a second voltage and detects the second no-load information of the transformer. This step performs a secondary test on the abnormal transformers separated in the first step. Specifically, the secondary test applies a second voltage lower than the rated voltage to the transformer and re-detects the no-load loss, allowing the identification of whether the abnormality is due to a fault in the core itself or magnetic saturation. Corresponding correction operations can then be performed for both types of faults and magnetic saturation. Then, when the second no-load information meets the standard, the no-load test device is controlled to measure the saturation magnetic flux of the core, and the air gap thickness value is determined based on the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the core inside the transformer according to the air gap thickness value. In this step, abnormal transformers that pass the second test are specifically addressed. Passing the second test means that the core itself is not faulty, i.e., the problem is magnetic saturation of the core. Therefore, the saturation magnetic flux of the core is measured, and the air gap thickness value is determined based on the saturation magnetic flux. Then, the corresponding thickness of the air gap is opened on the core to correct the abnormality of the core. Next, when the second no-load information does not meet the standard, the core of the transformer is replaced, and steps one to three are repeated. In this step, abnormal transformers that fail the second test are specifically addressed. Failing the second test means that the abnormality comes from a fault in the core itself (such as core damage or deformation, or insufficient core insulation). Therefore, a new core is replaced, and the process restarts from step one to correct the core abnormality. In this method, the transformer is first tested to determine whether its electrical characteristics are qualified. If it is not qualified, a second test is conducted to determine the cause of the failure. Different processing steps are taken for the two causes of magnetic core failure and magnetic core saturation to correct the abnormality of the magnetic core. Finally, the corrected transformer and magnetic core are fixed and packaged. This method can solve the problem that existing micro transformer manufacturing methods cannot automatically determine the appropriate air gap thickness.

[0007] Secondly, embodiments of this application provide a magnetic core correction device, applied to a magnetic core correction equipment. The magnetic core correction equipment includes an no-load test device, an air gap thickness device, and a control device. The no-load test device is used to perform no-load tests on a transformer, and the air gap thickness device is used to control the thickness of the air gap inside the magnetic core. The device includes: The first detection unit is used to control the no-load test device to apply a first voltage and detect the first no-load information of the transformer when the transformer with the assembled magnetic core is in place; wherein, the first voltage is the rated voltage, and the first no-load information includes the first no-load loss and the first no-load current; The second detection unit is used to control the no-load test device to apply a second voltage and detect the second no-load information of the transformer when the first no-load information fails to meet the standard; wherein the second voltage is less than the rated voltage, and the second no-load information includes the second no-load loss and the second no-load current. The air gap thickness determination unit is used to control the no-load test device to measure the saturation magnetic flux of the magnetic core when the second no-load information meets the standard, and to determine the air gap thickness value based on the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the magnetic core inside the transformer based on the air gap thickness value. When the second no-load information does not meet the standard, the transformer core is replaced and the first detection unit, the second detection unit, and the air gap thickness determination unit are run again.

[0008] Thirdly, embodiments of this application provide a magnetic core calibration device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that the processor executes the computer program to implement the method described in any of the first aspects above.

[0009] Fourthly, embodiments of this application provide a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any of the first aspects above.

[0010] Fifthly, embodiments of this application provide a computer program product that, when run on a core correction device, causes the core correction device to execute the intelligent correction method for assembling the core of a miniature transformer as described in any of the first aspects.

[0011] It is understood that the beneficial effects of the second to fifth aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1This is a flowchart illustrating an embodiment of the intelligent correction method for assembling a miniature transformer core provided in this application. Figure 2 This is a schematic diagram of a no-load test scenario in the intelligent correction method for assembling a micro transformer core provided in an embodiment of this application; Figure 3 This is a schematic diagram of the magnetic core correction device provided in the embodiments of this application; Figure 4 This is a schematic diagram of the magnetic core correction device provided in the embodiments of this application. Detailed Implementation

[0014] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0015] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0016] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0017] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrases "if determined" or "if detected [the described condition or event]" may be interpreted, depending on the context, as meaning "once determined," "in response to determination," "once detected [the described condition or event]," or "in response to detection [the described condition or event]."

[0018] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0019] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0020] In related technologies, existing micro transformer manufacturing methods cannot determine a suitable air gap thickness, making it difficult to apply core air gap technology. Since the rated capacity of a micro transformer is directly proportional to the maximum magnetic flux of the core (the maximum magnetic flux of a core without an air gap is much smaller than that of a core with an air gap), the rated capacity of existing micro transformers is very small. Therefore, existing micro transformer manufacturing methods have the problem of not being able to automatically determine a suitable air gap thickness.

[0021] To address the aforementioned problems, this application provides an intelligent correction method for the assembly of a miniature transformer core. In this method, firstly, when the transformer with its core assembled is in place, a control device controls a no-load testing device to apply a first voltage and detect the transformer's first no-load information. In this step, applying the rated voltage to the transformer and detecting the no-load loss allows for the identification of transformers with substandard electrical characteristics, thus separating transformers with abnormalities. Secondly, when the first no-load information is substandard, the control device controls the no-load testing device to apply a second voltage and detect the transformer's second no-load information. In this step, the abnormal transformer separated in the first step undergoes a secondary test. Specifically, the secondary test involves applying a second voltage, lower than the rated voltage, to the transformer and re-detecting the no-load loss. This allows for the identification of whether the abnormality is due to a fault in the core itself or magnetic saturation of the core, enabling corresponding correction operations for both types of faults and magnetic saturation. Then, when the second no-load information meets the standard, the no-load test device is controlled to measure the saturation magnetic flux of the core, and the air gap thickness value is determined based on the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the core inside the transformer according to the air gap thickness value. In this step, abnormal transformers that pass the second test are specifically addressed. Passing the second test means that the core itself is not faulty, i.e., the problem is magnetic saturation of the core. Therefore, the saturation magnetic flux of the core is measured, and the air gap thickness value is determined based on the saturation magnetic flux. Then, the corresponding thickness of the air gap is opened on the core to correct the abnormality of the core. Next, when the second no-load information does not meet the standard, the core of the transformer is replaced, and steps one to three are repeated. In this step, abnormal transformers that fail the second test are specifically addressed. Failing the second test means that the abnormality comes from a fault in the core itself (such as core damage or deformation, or insufficient core insulation). Therefore, a new core is replaced, and the process restarts from step one to correct the core abnormality. In this method, the transformer is first tested to determine whether its electrical characteristics are qualified. If it is not qualified, a second test is conducted to determine the cause of the failure. Different processing steps are taken for the two causes of magnetic core failure and magnetic core saturation to correct the abnormality of the magnetic core. Finally, the corrected transformer and magnetic core are fixed and packaged. This method can solve the problem that existing micro transformer manufacturing methods cannot automatically determine the appropriate air gap thickness.

[0022] The intelligent correction method for assembling the magnetic core of the miniature transformer provided in this application embodiment can be applied to a magnetic core correction device. In this case, the magnetic core correction device is the execution subject of the intelligent correction method for assembling the magnetic core of the miniature transformer provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of magnetic core correction device.

[0023] For example, a magnetic core calibration device may include an unloaded testing device, an air gap thickness device, and a control device, wherein the control device is communicatively connected to the unloaded testing device and the air gap thickness device. The unloaded testing device may include a voltage source, a voltmeter, and an ammeter. The voltage source is connected to the primary winding of the transformer, the voltmeter is connected to the secondary winding of the transformer, and the ammeter is connected to the primary winding circuit. The unloaded testing device is used to perform unloaded tests. The air gap thickness device may include three robotic arms and a device for generating air gaps of custom thickness. Two robotic arms are used to insert or remove the magnetic core from both sides of the transformer, and the remaining robotic arm is used to attach air gaps in the middle of the magnetic core (if the magnetic core is a common EE or EI type, air gaps of the same thickness are set at the three connection points). The air gap generation device may be a quantitative cutter used to cut air gaps of different thicknesses from a strip of material (the cross-section of the strip is the same as the cross-section at the magnetic core connection point). The control device can control the unloaded testing device to perform unloaded tests on different transformers, and the control device can also control the air gap thickness device to set air gaps of different thicknesses at the magnetic core connection points.

[0024] The control device can be a microcontroller, microprocessor, mobile phone, tablet computer, laptop computer, netbook, desktop computer, computer, laptop computer, etc.

[0025] To better understand the intelligent correction method for assembling micro transformer cores provided in this application, the specific implementation process of the intelligent correction method for assembling micro transformer cores provided in this application will be described below by way of example.

[0026] Figure 1 This paper presents a schematic flowchart of a smart calibration method for assembling a miniature transformer core, provided in an embodiment of this application. The smart calibration method for assembling a miniature transformer core includes: S100, Step 1: When the transformer with the assembled magnetic core is in place, the control device controls the no-load test device to apply a first voltage and detect the first no-load information of the transformer; wherein, the first voltage is the rated voltage, and the first no-load information includes the first no-load loss and the first no-load current.

[0027] It is understandable that after the transformer with the magnetic core is in place, the control device sends a first detection signal. The no-load test device responds to this signal by performing a no-load test on the transformer. Specifically, a rated voltage at the rated frequency is applied to the terminals of one winding of the transformer while the other windings are open-circuited (the rated voltage is obtained from the instruction manual of this transformer specification). The effective power of the transformer and the effective value of the current passing through that winding are then detected, i.e., the first no-load loss and the first no-load current. The first no-load information (first no-load loss and first no-load current) reflects the overall condition of the magnetic core and can verify whether there are any defects in the magnetic core. The specific circuit diagram is as follows: Figure 2 As shown, Figure 2 The left winding is the primary winding, which contains a power supply and an ammeter. The right winding is the secondary winding, which contains a voltmeter and an oscilloscope. Figure 2 The first no-load current is measured by an ammeter, and the waveform of the first no-load current is displayed on an oscilloscope. The first no-load current is multiplied by the voltage measured by a voltmeter to obtain the first no-load loss.

[0028] S200, Step 2: When the first no-load information does not meet the standard, the control device controls the no-load test device to apply the second voltage and detect the second no-load information of the transformer; wherein, the second voltage is less than the rated voltage, and the second no-load information includes the second no-load loss and the second no-load current.

[0029] It is understandable that the first no-load current / rated current in the first no-load information is calculated as the percentage of no-load current. Then, the percentage of no-load current and the first no-load loss are compared with the standard value. When both are within the standard range, the transformer core is considered to meet the standard; otherwise, it does not. When the first no-load information does not meet the standard, it means that the core has a defect and does not meet the required electrical performance. There are two reasons for this situation: one is that the core itself has a defect, such as core breakage or partial lack of insulation; the other is magnetic saturation within the core. Therefore, it is necessary to conduct another test to distinguish between these two situations.

[0030] When the first no-load information meets the standard, it means that the electrical performance of the transformer meets the requirements and no further correction steps are needed.

[0031] When the first no-load information fails to meet the standard, the control device sends a second detection signal. The no-load test device responds to this signal by performing a second test on the transformer. Specifically, a second voltage at the rated frequency is applied to the terminals of one winding of the transformer while the other windings are open-circuited. The effective power of the transformer and the effective value of the current passing through that winding are then detected (i.e., the rated voltage in the first no-load test is replaced by the second voltage). This yields the second no-load information, which includes the second no-load loss and the second no-load current. The second voltage must be less than the rated voltage, ideally half or less, to prevent magnetic core saturation when the second voltage is sufficiently low.

[0032] In one possible implementation, in step S200, the standard value of the first no-load loss and the rated current of the in-situ transformer are recorded in the core correction device; the method further includes: S210, divide the first no-load current by the rated current to obtain the no-load current percentage.

[0033] It is understandable that, under ideal conditions, the current in the transformer coil is 0 when the transformer is unloaded. However, due to heat loss or iron loss in the magnetic core, the first no-load current is always greater than 0. The rated current of a transformer is a fixed value. Dividing the detected first no-load current by the rated current gives the no-load current percentage. The no-load current percentage reflects the percentage of transformer losses relative to the rated power. Generally, 3.5% is used as the dividing line. When the no-load current percentage is greater than 3.5%, the loss ratio is considered too high, meaning the magnetic core is unqualified.

[0034] S220: The first no-load information meets the standard only when the percentage of no-load current is less than the preset threshold and the first no-load loss is within the standard range; otherwise, the first no-load information does not meet the standard.

[0035] It is understandable that the percentage of no-load current reflects the proportion of loss relative to rated power, while the first no-load loss reflects the actual value of energy loss, most of which is converted into heat loss. Therefore, the standard value of the first no-load loss depends on the size of the magnetic core and its heat dissipation performance. When the magnetic core is larger and the heat dissipation is better, the standard value of the first no-load loss will also be larger. Only when the power loss percentage meets the requirements and the actual value of loss also meets the requirements can it be said that the transformer performance corresponding to the first no-load information meets the standards; otherwise, it does not meet the standards.

[0036] This setup allows the transformer's first no-load information to undergo two checks: the loss ratio and the actual loss value. Only when both checks meet the requirements is the transformer's performance deemed to be up to standard, thus improving the rationality of determining whether the first no-load information meets the standards.

[0037] S300, when the second no-load information meets the standard, the no-load test device is controlled to measure the saturation magnetic flux of the core and determine the air gap thickness value based on the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the core inside the transformer based on the air gap thickness value. When the second no-load information does not meet the standard, the core of the transformer is replaced and steps one to three are repeated.

[0038] It is understandable that, similar to the steps in step S200 for determining whether the first no-load information meets the standard, when the second no-load information meets the standard (the standard values ​​for the two tests are different), it means that the first test failed while the second test passed. Therefore, the magnetic core itself is not the problem; the abnormality is due to magnetic core saturation. The solution is to add an air gap shim to the magnetic core. The function of the air gap is to increase the magnetic reluctance of the magnetic core, thereby increasing the upper limit of magnetic saturation and solving the magnetic saturation problem. Specifically, the saturation magnetic flux of the magnetic core is measured, and the air gap thickness value is determined based on the saturation magnetic flux. The air gap thickness device selects air gap shims of different thicknesses based on the air gap thickness value and attaches them inside the magnetic core. Conversely, when the second no-load information fails to meet the standard, it means that both the first and second tests fail. Therefore, the abnormality is due to a defect in the magnetic core itself. The solution is to replace the magnetic core with a new one using the air gap thickness device, and after replacing the transformer's magnetic core, start again from step one (S100) of this method.

[0039] The above-mentioned measurement of the saturation magnetic flux of the magnetic core and determination of the air gap thickness based on the saturation magnetic flux are as follows: Under magnetic saturation, the no-load loss increases sharply and nonlinearly with the increase of the voltage applied to the primary winding of the transformer. Under non-magnetic saturation, the no-load loss is linearly proportional to the voltage on the primary winding. Therefore, the main goal of the solution is to ensure that the transformer with the rated voltage is also in a non-magnetic saturation state. This is achieved by increasing the magnetic reluctance of the magnetic core through the air gap, making the magnetic core more difficult to saturate, i.e., at least satisfying Rg×Φg>Ug (Rg refers to the total magnetic reluctance, Φg refers to the saturation magnetic flux in the magnetic core, and Ug is the rated magnetomotive force), where Ug is the rated magnetomotive force. Under no-load conditions, the transformer's voltage is constant: Ug = number of turns in the primary winding n × current I in the primary winding. Φg depends only on the core material and cross-sectional area (transformers of the same specification have the same Φg). Therefore, the power supply voltage on the primary winding can be increased uniformly from the second voltage to the rated voltage, while constantly monitoring the no-load loss. When the no-load loss suddenly increases non-linearly and sharply, it means the core has reached magnetic saturation (the derivative of the no-load loss with respect to time can be calculated; when the derivative continuously exceeds a preset threshold within a certain time period, it is considered magnetic saturation). The core's Φg can then be calculated using the voltage E0 applied to the primary winding when magnetic saturation is just achieved. Let f be the frequency of E0, and n be the number of turns in the primary winding. Therefore, after determining Ug and Φg, the minimum value of Rg, Rgmin, can be obtained, and Rgmin = Rg1 + Rg2 (Rg1 is the reluctance of the magnetic core, and Rg2 is the reluctance of the air gap). Then, according to the reluctance formula: Rg = ( It is the length of the magnetic circuit. Where is the permeability, and S is the cross-sectional area of ​​the magnetic circuit. (where S is a constant), the permeability of the magnetic core and the permeability of the air gap gasket Substituting the cross-sectional area S1 of the magnetic circuit into the magnetic reluctance formula, we can obtain... and The value ( It is the maximum value of the magnetic circuit length of the magnetic core. (This is the minimum magnetic circuit length of the air gap), and the air gap thickness can be... ×a, where a is a constant greater than 1, to provide some margin to prevent magnetic saturation caused by signal peaks. In practical applications, because the value of Rg1 is much smaller than Rg2, Rg1 and Rg2 can be directly ignored. .

[0040] It is important to note that the shape of the magnetic core affects the calculation of reluctance. For example, EI and EE type magnetic cores have two magnetic circuits and three connection points, which means two air gap reluctances are connected in parallel and then in series with the remaining air gap reluctance. According to the parallel resistance formula, the reluctance of a single air gap is = Rg2 × 2 / 3. Therefore, after determining Rg2, multiply it by 2 / 3 before calculating. The magnetic reluctance of the magnetic core is very small, so this error can be ignored (the magnetic core is equivalent to a wire, and the air gap is equivalent to a resistor).

[0041] In one possible implementation, in step S300, measuring the saturation magnetic flux of the magnetic core includes: S310: Obtain the saturation magnetic flux density and cross-sectional area of ​​the magnetic core material, and obtain the theoretical value of the saturation magnetic flux based on the saturation magnetic flux density and cross-sectional area.

[0042] It is understandable that the saturation magnetic flux density of the same material is only related to temperature. Therefore, the temperature during processing should be kept constant, and then the saturation magnetic flux density of the core material at this constant temperature should be determined. If the core is of type EE or EI, the main magnetic circuit of the core is the middle magnetic circuit of the core, and its cross-sectional area is also the cross-sectional area of ​​the core. Multiply the saturation magnetic flux density by the cross-sectional area of ​​the core to obtain the theoretical value of the saturation magnetic flux.

[0043] S320, based on the theoretical value of saturation magnetic flux, obtains the theoretical value of saturation voltage, and the core correction equipment adjusts the power supply voltage of the transformer to the theoretical value of saturation voltage.

[0044] This is understandable, according to the formula relating magnetic flux and voltage: E is the maximum voltage amplitude, f is the voltage frequency, and n is the number of coil turns. It is the magnetic flux. The theoretical value of the saturation voltage E_saturation is calculated. The core correction equipment adjusts the power supply voltage of the transformer to the theoretical value of the saturation voltage.

[0045] S330 collects the transformer's no-load current and calculates the first distortion rate.

[0046] It is understandable that after the transformer's power supply voltage is adjusted to E_saturation, the transformer's no-load current is collected, and the first distortion rate of the no-load current is calculated. Distortion rate = IH is the harmonic RMS value of the no-load current, IL is the fundamental RMS value of the no-load current, and the distortion rate reflects the degree to which the no-load current deviates from the sine wave.

[0047] S340, if the first distortion rate is greater than the first threshold, the core correction device uniformly decreases the power supply voltage of the transformer until the first distortion rate is less than the first threshold, and records the power supply voltage at this time as the actual value of the saturation voltage; if the first distortion rate is less than the first threshold, the core correction device uniformly increases the power supply voltage of the transformer until the first distortion rate is greater than or equal to the first threshold, and records the power supply voltage at this time as the actual value of the saturation voltage.

[0048] It is understandable that a first threshold is set. If the first distortion rate is greater than the first threshold, it means that the transformer is magnetically saturated, and the power supply voltage needs to be reduced to find the saturation voltage. Therefore, the core correction equipment uniformly reduces the power supply voltage of the transformer until the first distortion rate is less than the first threshold, and records the power supply voltage at this time as the actual value of the saturation voltage. If the first distortion rate is less than the first threshold, it means that the transformer is not yet saturated, and the power supply voltage needs to be increased to find the saturation voltage. Therefore, the core correction equipment uniformly increases the power supply voltage of the transformer until the first distortion rate is greater than or equal to the first threshold, and records the power supply voltage at this time as the actual value of the saturation voltage.

[0049] This setting allows the initial value of the power supply voltage to be closer to the actual saturation voltage, thereby reducing the time required to measure the saturation voltage.

[0050] S350, the saturation flux of the magnetic core is obtained based on the actual value of the saturation voltage.

[0051] This is understandable, based on the formula relating magnetic flux and voltage: The saturation flux of the magnetic core is calculated.

[0052] This setup allows for obtaining the saturation flux of the magnetic core as quickly as possible.

[0053] S400 sends an encapsulation signal. In response to the encapsulation signal, the magnetic core inside the transformer is fixed before the transformer is encapsulated.

[0054] Understandably, after resolving the core's abnormality, the core calibration equipment sends a packaging signal. In response to this signal, the core and transformer are then fully packaged to obtain the finished transformer. The packaging method could involve first wrapping the core with tape to secure it, and then encapsulating the transformer with a product casing.

[0055] This setup first identifies transformers with substandard electrical characteristics through an initial inspection. Then, a second inspection is conducted on these substandard transformers to determine whether the failure is due to core loss or core saturation. Different processing steps are then implemented for each cause to resolve the transformer problem. Finally, the processed transformers are packaged to obtain the finished transformer. This approach solves the problem of existing micro-transformer manufacturing methods being unable to automatically determine the appropriate air gap thickness.

[0056] Optionally, it can be applied to a mixed-line production line that simultaneously processes multiple transformers of the same shape but different specifications, with different specifications of transformers having different color characteristics; the method also includes: S510 collects the color characteristics of the in-place transformer before sending the first detection signal.

[0057] It's understandable that multiple production lines producing transformers of different specifications can be combined during transformer manufacturing. However, for model and processing compatibility, transformers of different specifications should have the same body shape. Therefore, core calibration equipment should be used on these combined production lines that simultaneously process multiple transformers of the same body shape but different specifications. Furthermore, different specifications of transformers should have different color characteristics; for example, if there are three specifications, there are three color characteristics to distinguish them. Moreover, the core calibration equipment needs to pre-record the corresponding electrical data and color characteristics of these three specifications of transformers.

[0058] Before sending the first detection signal, it is necessary to collect the color characteristics of the transformer in place to identify the transformer's specifications. This can be done by collecting the color characteristics of the transformer in place using a fixed camera.

[0059] S520: Based on color characteristics, transformers are grouped into different groups, and their corresponding rated voltages are obtained. Within the same group, steps one through three are performed only on the first transformer, and the obtained air gap thickness value is used as the inter-group shared thickness value. The remaining transformers in the same group perform step two. When the second no-load information obtained from step two meets the standard, the inter-group shared thickness value is used. If the second no-load information obtained from step two does not meet the standard, the transformer core is replaced, and step two is performed again until the second no-load information obtained from step two meets the standard, at which point the inter-group shared thickness value is used.

[0060] It is understandable that transformers are classified into different groups according to different color characteristics. Transformers in the same group are of the same specification, and then the rated voltage of the transformer of that specification is obtained. When the core correction equipment is used on a mixed production line that processes multiple transformers of the same shape but different specifications at the same time, and the main purpose is to quickly set the air gap for transformers of different specifications, the individual errors of transformers of the same specification can be ignored. Transformers of the same specification in the same group can use the same air gap thickness value, that is, the inter-group shared thickness value. The inter-group shared thickness value can be the air gap thickness value of the first transformer in a group to complete this method, while the other transformers in the group only perform step two of the method to determine whether the transformer core is qualified. When the second no-load information meets the standard (i.e., the core is qualified), the core correction equipment directly applies the inter-group shared thickness value to set the air gap of the transformer. When the second no-load information does not meet the standard (i.e., the core is unqualified), the transformer core is replaced and step two is repeated until the core is qualified. After the core is qualified, the core correction equipment also applies the inter-group shared thickness value to set the air gap of the transformer.

[0061] This setup allows the method to be applied to mixed-line production lines that simultaneously process multiple transformers of the same shape but different specifications, enabling the core correction equipment to quickly set air gaps for transformers of different specifications and accelerating transformer production efficiency.

[0062] Optionally, the color characteristics and rated voltage of each type of transformer are recorded in the control device, and after the color characteristics of the transformer are determined, the power supply voltage of the transformer can be automatically switched to the corresponding rated voltage.

[0063] It is understandable that when a core correction device is used on a mixed-line production line that processes multiple transformers of the same size but different specifications, the core correction device records the color characteristics and rated voltage of each transformer specification. It can match the color characteristics with the rated voltage one by one. After the color characteristics of the transformer are determined, the power supply voltage can be automatically changed to the corresponding rated voltage.

[0064] This setup allows the method to be applied to mixed-line production lines that simultaneously process multiple transformers of the same size but different specifications.

[0065] Optionally, the magnetic core type can be EE or EI; when the second no-load information is not up to standard, the method also includes: S610, after the core correction device replaces one side of the core, it resends the second detection signal and receives new second no-load information.

[0066] It's understandable that the commonly used types of magnetic cores are EE or EI. When the second no-load information fails to meet the standard, it means that the magnetic core itself is defective. In this case, there are three possible scenarios: the left magnetic core is defective but the right is qualified; the right magnetic core is defective but the left is qualified; or both magnetic cores are qualified. Therefore, it is necessary to conduct further testing for multiple possible scenarios to prevent replacing a defective, normal magnetic core and wasting resources.

[0067] First, have the core calibration device replace one side of the core, either the left or right side, and then resend the second detection signal and receive the new second no-load information.

[0068] S620: When the new second no-load information meets the standard, the saturation magnetic flux of the magnetic core is measured, and the air gap thickness value is determined based on the saturation magnetic flux. The magnetic core correction equipment adjusts the air gap thickness of the magnetic core inside the transformer based on the air gap thickness value. When the new second no-load information does not meet the standard, the other side of the magnetic core is replaced and the process restarts from the first step of the method.

[0069] It is understandable that after replacing one side of the magnetic core, new second no-load information is received again to determine whether the new second no-load information meets the standard. When the new second no-load information meets the standard, it means that the replaced magnetic core is qualified, so the subsequent steps of the execution method are carried out, namely, measuring the saturation magnetic flux of the magnetic core and determining the air gap thickness value based on the saturation magnetic flux. The magnetic core calibration equipment adjusts the air gap thickness of the magnetic core in the transformer according to the air gap thickness value. When the new second no-load information does not meet the standard, it means that the replaced magnetic core is still unqualified, so the magnetic core calibration equipment replaces the magnetic core on the other side, and then starts from the first step of the method again.

[0070] This design prevents the replacement of defective, normal magnetic cores, thus conserving magnetic core resources.

[0071] Optionally, the method also includes: The magnetic core correction equipment adds air gap pads with air gap thickness values ​​at multiple connection points of the magnetic cores on both sides.

[0072] It is understandable that core correction equipment sets air gap pads with air gap thickness values ​​at all connection points of the cores on both sides. For example, EE and EI type transformers have three connection points, so air gap pads with air gap thickness values ​​are set at all three connection points. The air gap pads can be special insulating pads such as epoxy resin, thermally conductive adhesive, Teflon film, and polyimide film.

[0073] This design makes the air gap of the magnetic core more stable and less prone to deformation.

[0074] Optionally, the method also includes: The magnetic core alignment equipment uses tape to fix the magnetic core.

[0075] It is understandable that after setting the air gap, the magnetic core is wrapped and fixed with tape. Since the connection point of the magnetic core is located outside the winding, rotating the entire transformer will wrap and fix the magnetic core.

[0076] This setup allows for quick fixation of the magnetic core and stable air gap.

[0077] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0078] Corresponding to the intelligent correction method for assembling the magnetic core of the micro transformer described in the above embodiments, this application also provides a magnetic core correction device, the various units of which can realize the various steps of the intelligent correction method for assembling the magnetic core of the micro transformer. Figure 3 A structural block diagram of the magnetic core correction device provided in the embodiments of this application is shown. For ease of explanation, only the parts related to the embodiments of this application are shown.

[0079] Reference Figure 3 The device includes: The first detection unit is used to control the no-load test device to apply a first voltage and detect the first no-load information of the transformer when the transformer with the assembled magnetic core is in place; wherein, the first voltage is the rated voltage, and the first no-load information includes the first no-load loss and the first no-load current. The second detection unit is used to control the no-load test device to apply a second voltage and detect the second no-load information of the transformer when the first no-load information fails to meet the standard; wherein, the second voltage is less than the rated voltage, and the second no-load information includes the second no-load loss and the second no-load current. The air gap thickness determination unit is used to control the no-load test device to measure the saturation magnetic flux of the magnetic core when the second no-load information meets the standard, and to determine the air gap thickness value based on the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the magnetic core inside the transformer based on the air gap thickness value. When the second no-load information does not meet the standard, the transformer core is replaced and the first detection unit, the second detection unit, and the air gap thickness determination unit are run again.

[0080] It should be noted that the information interaction and execution process between the above-mentioned units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.

[0081] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units is used as an example. In practical applications, the above functions can be assigned to different functional units as needed, that is, the internal structure of the device can be divided into different functional units to complete all or part of the functions described above. The functional units in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0082] This application also provides a magnetic core correction device. Figure 4 This is a schematic diagram of the structure of a magnetic core correction device provided in one embodiment of this application. Figure 4 As shown, the control device 5 of the magnetic core correction equipment in this embodiment includes: at least one processor 50 ( Figure 4 Only one is shown in the image), at least one memory 51 ( Figure 4 (Only one is shown in the image) and a computer program 52 stored in the at least one memory 51 and executable on the at least one processor 50. When the processor 50 executes the computer program 52, it causes the control device 5 of the magnetic core correction device to perform the steps in any of the above embodiments of the intelligent correction method for assembling the magnetic core of the micro transformer, or causes the control device 5 of the magnetic core correction device to perform the functions of each unit in the above embodiments of the device.

[0083] Exemplarily, the computer program 52 may be divided into one or more units, which are stored in the memory 51 and executed by the processor 50 to complete this application. The one or more units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 52 in the control device 5 of the magnetic core correction equipment.

[0084] The control device 5 of the magnetic core calibration equipment can be a microcontroller, microprocessor, mobile phone, tablet computer, wearable device, vehicle-mounted device, laptop computer, ultra-mobile personal computer (UMPC), netbook, personal digital assistant (PDA), desktop computer, smart screen, smart TV, or handheld device with wireless communication capabilities. The control device 5 of the magnetic core calibration equipment may include, but is not limited to, a processor 50 and a memory 51. Those skilled in the art will understand that... Figure 4 This is merely an example of the control device 5 for a magnetic core calibration device and does not constitute a limitation on the control device 5 for a magnetic core calibration device. It may include more or fewer components than shown, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0085] The processor 50 can be a Central Processing Unit (CPU), or it can be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0086] In some embodiments, the memory 51 may be an internal storage unit of the control device 5 of the core calibration equipment, such as a hard disk or memory of the control device 5. In other embodiments, the memory 51 may be an external storage device of the control device 5, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the control device 5. Further, the memory 51 may include both internal and external storage units of the control device 5. The memory 51 is used to store the operating system, applications, bootloader, data, and other programs, such as the program code of the computer program. The memory 51 can also be used to temporarily store data that has been output or will be output.

[0087] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0088] This application provides a computer program product that, when run on a magnetic core calibration device, enables the magnetic core calibration device to perform the steps described in any of the above method embodiments.

[0089] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or some intermediate form. The computer-readable medium can include at least: any entity or device capable of carrying the computer program code to a magnetic core correction device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium. Examples include USB flash drives, portable hard drives, magnetic disks, or optical disks.

[0090] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0091] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0092] In the embodiments provided in this application, it should be understood that the disclosed intelligent correction method, core correction device, and core correction equipment for micro-transformer core assembly can be implemented in other ways. For example, the embodiments of the intelligent correction method, core correction device, and core correction equipment for micro-transformer core assembly described above are merely illustrative. For instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0093] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0094] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application 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. Such 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 this application, and should all be included within the protection scope of this application.

Claims

1. A method for intelligent correction of micro transformer core assembly, characterized in that, An application is made in a core calibration device, which includes an no-load testing apparatus, an air gap thickness device, and a control device. The no-load testing apparatus is used to perform no-load tests on a transformer, and the air gap thickness device is used to control the thickness of the air gap within the core. The method includes: Step 1: When the transformer with the assembled magnetic core is in place, the control device controls the no-load test device to apply a first voltage and detect the first no-load information of the transformer; wherein, the first voltage is the rated voltage, and the first no-load information includes the first no-load loss and the first no-load current; Step 2: When the first no-load information fails to meet the standard, the control device controls the no-load test device to apply a second voltage and detect the second no-load information of the transformer; wherein, the second voltage is less than the rated voltage, and the second no-load information includes the second no-load loss and the second no-load current; Step 3: When the second no-load information meets the standard, the no-load test device is controlled to measure the saturation magnetic flux of the core, and the air gap thickness value is determined according to the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the core inside the transformer according to the air gap thickness value. When the second no-load information does not meet the standard, the core of the transformer is replaced and steps 1 to 3 are repeated.

2. The intelligent correction method for assembling a micro transformer core as described in claim 1, characterized in that, The method is applied to a mixed-line production line that simultaneously processes multiple transformers of the same shape but different specifications, with the different specifications of transformers having different color characteristics; the method also includes: Before performing step one, the color characteristics of the in-situ transformer are collected; Based on the color characteristics, the transformers are divided into different groups, and their corresponding rated voltages are obtained. Within the same group, only the first transformer undergoes steps one through three, and the resulting air gap thickness value is used as the shared thickness value between groups. The remaining transformers in the same group undergo step two. When the second no-load information obtained from step two meets the standard, the shared thickness value between groups is used. If the second no-load information obtained from step two does not meet the standard, the transformer core is replaced, and step two is repeated until the second no-load information obtained from step two meets the standard, at which point the shared thickness value between groups is used.

3. The intelligent correction method for assembling a micro transformer core as described in claim 2, characterized in that, The control device records the color characteristics and rated voltage of each type of transformer, and after determining the color characteristics of the transformer, the power supply voltage of the transformer can be automatically changed to the corresponding rated voltage.

4. The intelligent correction method for assembling a micro transformer core as described in claim 1, characterized in that, The measurement of the saturation magnetic flux of the magnetic core includes: The saturation magnetic flux density and cross-sectional area of ​​the magnetic core material are obtained, and the theoretical value of the saturation magnetic flux is obtained based on the saturation magnetic flux density and the cross-sectional area. The theoretical value of saturation voltage is obtained based on the theoretical value of saturation magnetic flux, and the core correction device adjusts the power supply voltage of the transformer to the theoretical value of saturation voltage. Collect the no-load current of the transformer and calculate the first distortion rate; If the first distortion rate is greater than the first threshold, the core correction device uniformly reduces the power supply voltage of the transformer until the first distortion rate is less than the first threshold, and records the power supply voltage at this time as the actual value of the saturation voltage; if the first distortion rate is less than the first threshold, the core correction device uniformly increases the power supply voltage of the transformer until the first distortion rate is greater than or equal to the first threshold, and records the power supply voltage at this time as the actual value of the saturation voltage. The saturation flux of the magnetic core is obtained from the actual value of the saturation voltage.

5. The intelligent correction method for assembling a micro transformer core as described in claim 1, characterized in that, The standard value of the first no-load loss and the rated current of the in-situ transformer are recorded in the core correction equipment; the method further includes: Divide the first no-load current by the rated current to obtain the no-load current percentage; The first no-load information meets the standard only when the percentage of no-load current is less than a preset threshold and the first no-load loss is within the standard range; otherwise, the first no-load information does not meet the standard.

6. The intelligent correction method for assembling a micro transformer core as described in claim 1, characterized in that, The magnetic core is of type EE or EI; when the second no-load information is not up to standard, the method further includes: After the magnetic core correction device replaces one side of the magnetic core, it resends the second detection signal and receives new second no-load information. When the new second no-load information meets the standard, the saturation magnetic flux of the magnetic core is measured, and the air gap thickness value is determined based on the saturation magnetic flux. The magnetic core correction device adjusts the air gap thickness of the magnetic core inside the transformer based on the air gap thickness value. When the new second no-load information does not meet the standard, the other side of the magnetic core is replaced, and the process restarts from the first step of the method.

7. The intelligent correction method for assembling a micro transformer core as described in claim 1, characterized in that, The method further includes: The magnetic core correction device adds air gap pads with the air gap thickness value at multiple connection points of the magnetic cores on both sides.

8. The intelligent correction method for assembling a micro transformer core as described in claim 1, characterized in that, The method further includes: The magnetic core calibration device uses tape to fix the magnetic core.

9. A magnetic core calibration device, characterized in that, This is applied to a core calibration device, which includes an no-load testing device, an air gap thickness device, and a control device. The no-load testing device is used to perform no-load tests on transformers, and the air gap thickness device is used to control the thickness of the air gap inside the core. The device includes: The first detection unit is used to control the no-load test device to apply a first voltage and detect the first no-load information of the transformer when the transformer with the assembled magnetic core is in place; wherein, the first voltage is the rated voltage, and the first no-load information includes the first no-load loss and the first no-load current; The second detection unit is used to control the no-load test device to apply a second voltage and detect the second no-load information of the transformer when the first no-load information fails to meet the standard; wherein the second voltage is less than the rated voltage, and the second no-load information includes the second no-load loss and the second no-load current. The air gap thickness determination unit is used to control the no-load test device to measure the saturation magnetic flux of the magnetic core when the second no-load information meets the standard, and to determine the air gap thickness value based on the saturation magnetic flux. The air gap thickness device is then controlled to adjust the air gap thickness of the magnetic core inside the transformer based on the air gap thickness value. When the second no-load information does not meet the standard, the transformer core is replaced and the first detection unit, the second detection unit, and the air gap thickness determination unit are run again.

10. A magnetic core calibration device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method as described in any one of claims 1 to 8.

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