Transformer framework
By designing a transformer skeleton including magnetic core mounting holes, winding bobbins, bases and cylindrical structures, the automatic production of transformers in high-power EV switching power supplies is realized, solving the problems of large leakage inductance and complex process, and reducing production costs.
Patent Information
- Application Number
- CN202422025834.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-21
- Publication Date
- 2025-07-25
- Estimated Expiration
- 2034-08-21
AI Technical Summary
In the high-power EV switching power supply, the use of ordinary enameled wires leads to large leakage inductance and high losses. The existing winding process is complex and costly, making it difficult to achieve automatic installation of flat lines.
A transformer skeleton including magnetic core mounting holes, winding spools, bases, top baffles and cylindrical structures is designed. The primary winding is wound on a special fixture and then connected in parallel, and the secondary winding is connected in series on the winding spool. During the winding process, the primary winding is avoided to achieve automated production.
Automatic production of flat wire windings is achieved, reducing production costs and improving production efficiency, and avoiding the need for additional tape and retaining walls.
Smart Images
Figure CN223155790U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of switching power transformers, in particular to a transformer skeleton. Background Technique
[0002] In high-power EV switching power supplies, the transformer is a key power device. Due to the large input current, if ordinary enameled wire is used for the primary side, it is necessary to select enameled wire with a relatively thick wire diameter. It is not easy to wind the thick wire diameter smoothly and form a shape, resulting in large parasitic parameters such as leakage inductance, which in turn leads to large transformer losses and high temperature. To solve this problem, the current method is to use flat wires stacked in multiple layers for the primary side winding. To reduce parasitic parameters such as leakage inductance, the transformer winding usually adopts the sandwich winding method of alternating stacking of the secondary side and the primary side. The spaced primary and secondary windings need to be isolated by taping. In this way, for each layer wound, it is necessary to remove the tape from the winding shaft for taping isolation. The process is complex, time-consuming and laborious, resulting in high transformer costs. At the same time, flat wires are not easy to form and install. Therefore, there is an urgent need for a transformer skeleton to solve this problem.
[0003] In order to solve the problems in the actual production of transformers and achieve automated production, the utility model provides a transformer skeleton. Content of the Utility Model
[0004] The technical problem to be solved by the utility model is to provide a transformer skeleton.
[0005] The technical solution adopted by the utility model to solve the above technical problems is as follows:
[0006] A transformer skeleton, characterized in that it includes a magnetic core installation hole penetrating the upper and lower main bodies, a winding shaft, a base, a top baffle, and two cylindrical structures with one side open. The two cylindrical structures are spaced between the base and the top baffle and are connected to the winding shaft to form a winding area for three secondary windings of the transformer. The flat area inside the cylindrical structure is the installation area for the primary winding of the transformer. There is an inlet wire groove and an outlet wire groove on the outer wall of the other side.
[0007] The two primary windings of the transformer are wound with flat wires on a special fixture, and the inlet ends and the outlet ends are respectively combined together and then welded through a soldering furnace, and then respectively clamped into the two cylindrical structures to complete the parallel connection and installation of the flat wire windings.
[0008] The three secondary windings of the transformer are sequentially wound in series on the winding posts through the inlet wire groove and the outlet wire groove, and the winding completely avoids the flat wire winding on the primary side, and automated production can be realized.
[0009] Furthermore, the base extends horizontally to both sides to form a primary side base and a secondary side base. The primary side base and the secondary side base are each provided with a baffle vertically downward on both sides and in the middle. The side opening toward the cylindrical structure is the primary side base, and a concave wire clamping groove is provided in the top area of the middle baffle and the adjacent areas on both sides.
[0010] Furthermore, the side of the base that is closed toward the cylindrical structure is a secondary base, wherein the top area of the middle baffle and the adjacent areas on both sides each have a U-shaped wire clamping groove, and the adjacent areas on both sides are pre-buried with a vertically downward pin.
[0011] Furthermore, the interior of the winding shaft is a magnetic core mounting hole, which passes through the transformer skeleton body from top to bottom and is used to mount the magnetic core.
[0012] Furthermore, the shapes and directions of the inlet and outlet grooves are set according to the thickness and direction of the winding wires.
[0013] Furthermore, the transformer frame is integrally formed and made of plastic.
[0014] The technical effects achieved by the utility model relative to the existing structural design are:
[0015] The secondary winding of the transformer frame provided by the utility model completely avoids the flat wire winding of the primary side, does not require additional isolation tape and retaining wall, can realize automated production, and solves the installation problem of the flat wire winding, improves production efficiency and reduces production costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 The utility model provides a transformer skeleton axonometric Figure 1 ;
[0017] Figure 2 The utility model provides a transformer skeleton axonometric Figure 2 ;
[0018] Figure 3 It is a front view of the primary side of the transformer skeleton provided by the utility model;
[0019] Figure 4 It is an exploded diagram of the transformer skeleton and winding provided by the utility model;
[0020] Figure 5 A side view of the transformer skeleton after winding provided by the utility model;
[0021] Figure 6 The utility model provides an axonometric diagram of a transformer skeleton after winding. DETAILED DESCRIPTION
[0022] The preferred embodiments of the present invention are given below in conjunction with the accompanying drawings to illustrate the technical solution of the present invention in detail.
[0023] as follows Figures 1 to 6 In the figure, the transformer skeleton includes a core mounting hole 10 that passes through the upper and lower main bodies, a winding shaft 20, a base 30, a top baffle 40 and two cylindrical structures 50 with one side opening. The two cylindrical structures 50 are spaced apart between the base 30 and the top baffle 40 and are interconnected with the winding shaft 20 to form a winding area 60 for the three secondary windings of the transformer. The flat area 70 formed inside the cylindrical structure is the installation area for the primary winding of the transformer.
[0024] The base 30 extends horizontally to both sides to form a primary base 31 and a secondary base 32. There is a baffle vertically downward on both sides and the middle of the primary base and the secondary base. The side open to the cylindrical structure is the primary base 31. The three baffles facing downward are 311, 312, and 313 respectively. The top area of the middle baffle 312 and the top area of the adjacent baffles have a concave wire clamping groove 314 and 315 respectively; the side of the base closed to the cylindrical structure is the secondary base 32. The three baffles facing downward are 321, 322, and 323 respectively. The top area of the middle baffle 322 and the top areas of the adjacent baffles 321 and 323 have a U-shaped wire clamping groove 324 and 325 respectively. A vertically downward pin 326 and 327 are pre-buried in the adjacent areas on both sides.
[0025] The outer walls of the closed sides of the two cylindrical structures 50 are each provided with a wire inlet groove 51, 52 and a wire outlet groove 53, 54, and the shapes and directions thereof are set according to the thickness and direction of the winding wire.
[0026] The two primary windings of the transformer are respectively wound with flat wires on a special jig. The incoming wire end and the outgoing wire end are respectively merged together and then welded in a tin furnace, and then respectively inserted into two cylindrical structures. The incoming wire end and the outgoing wire end are respectively inserted into the concave wire clamping grooves 314 and 315 to complete the parallel connection and installation of the flat wire windings; the three windings on the secondary side of the transformer are connected in series, and the initial winding is wound around the pin 326, and then wound upward on the winding shaft clockwise through the U-shaped wire clamping groove 324. After winding the required number of turns, the second and third windings of the secondary side of the transformer are respectively wound around the winding shaft clockwise through the incoming wire grooves 51 and 52, and the winding is wound back to the pin 327 through the outgoing wire grooves 53 and 54.
[0027] The above primary winding and secondary winding are completely isolated, and no additional tape and retaining wall are required, so that fully automated production can be realized, production efficiency is improved, and production costs are reduced.
[0028] Although the specific implementation cases of the present utility model have been described above, those skilled in the art should understand that these are only examples. Without departing from the principle and essence of the present utility model, various changes or modifications can be made to these implementation cases. Therefore, the protection scope of the present utility model is defined by the appended claims.
Claims
1. A transformer skeleton, characterized in that, It includes a magnetic core mounting hole that runs through the upper and lower bodies, a winding shaft, a base, a top baffle, and two cylindrical structures with one side open. The two cylindrical structures are spaced between the base and the top baffle and are connected to the winding shaft to form the winding area of the three secondary windings of the transformer. The flat area inside the cylindrical structure is the installation area of the primary winding of the transformer. There is an inlet groove and an outlet groove on the outer wall on the other side. The two primary windings of the transformer are wound on a special jig using flat wires, the incoming wire end and the outgoing wire end are respectively combined together and then soldered in a tin furnace, and then respectively inserted into two cylindrical structures to complete the parallel connection and installation of the flat wire windings; The three secondary windings of the transformer are sequentially wound in series on a winding shaft through an inlet groove and an outlet groove, and the winding completely avoids the flat wire winding of the primary side, thereby realizing automated production.
2. The transformer skeleton according to claim 1, wherein, The base extends horizontally to both sides to form a primary base and a secondary base. There is a baffle vertically downward on both sides and the middle of the primary base and the secondary base. The side facing the opening of the cylindrical structure is the primary base, and there is a concave wire clamping groove in the top area of the middle baffle and the adjacent areas on both sides.
3. The transformer skeleton according to claim 2, characterized in that, The side of the base that is closed toward the cylindrical structure is the secondary base, wherein the top area of the middle baffle and the adjacent areas on both sides each have a U-shaped wire groove, and the adjacent areas on both sides are pre-buried with a vertically downward pin.
4. A transformer skeleton according to claim 1, characterized in that, The interior of the winding shaft is a magnetic core mounting hole, which passes through the transformer skeleton body from top to bottom and is used for mounting the magnetic core.
5. A transformer skeleton according to claim 1, characterized in that, The shapes and directions of the inlet and outlet grooves are set according to the thickness and direction of the winding wires.
6. A transformer skeleton as described in claim 1, characterized in that, The transformer frame is integrally formed and made of plastic.