A fully automated high-power flat wire inductor

Abstract

This utility model discloses a fully automated high-power flat wire inductor, comprising: an upper insulating shell, a lower insulating shell below the upper insulating shell, a bracket between the upper and lower insulating shells, and slots engaging on the upper and lower sides of the bracket, the slots being located inside the upper and lower insulating shells; and a coil wound on the outer side of the bracket. This fully automated high-power flat wire inductor, through a clamping mechanism, ensures significantly improved winding compactness during the flat wire winding process, thereby increasing short-circuit withstand capability. It also features an easy-to-install mechanism, allowing for quick installation of the coil assembly and insulating shell, improving installation efficiency and facilitating disassembly. Furthermore, a protective mechanism effectively protects the flat wire joints, preventing damage from collisions during transportation.

Description

Technical Field

[0001] This utility model relates to the field of reactor technology, specifically to a high-power flat wire inductor that is wound in a fully automated manner. Background Technology

[0002] Flat wire inductors are inductors that use flat copper wire as a conductor. Because of their flat cross-section, these wires can better adapt to a variety of compact installation environments. Their structure includes a coil section and a lead section. Currently, there are many types of fully automated winding high-power flat wire inductors available on the market, but they still have some drawbacks.

[0003] For example, Chinese utility model patent CN222168112U discloses a high-power flat wire vertically wound hollow inductor, in which the coil assembly adopts multi-strand hollow wire spiral three-dimensional winding. The use of multi-strand hollow wire can increase the effective heat dissipation area of ​​the coil, while reducing the volume and weight of the reactor. The multi-strand vertical winding of the coil can effectively reduce the proximity effect and improve the electrical performance of the product. The coil is directly fixed by the coil insulation fixing frame, which improves manufacturing and use efficiency; it is suitable for fully automated equipment operation.

[0004] The existing technologies mentioned above have the following technical problems: gaps are generated during the automated winding of flat wires, which reduces the compactness of the windings and makes it impossible to quickly install the coil assembly with the insulating shell, indicating a design deficiency. In addition, the flat wire inductor has a connecting pin on the outside. If the connecting pin is not protected during transportation, it will be damaged. Therefore, we propose a fully automated high-power flat wire inductor to solve the problems mentioned above. Utility Model Content

[0005] The purpose of this invention is to provide a fully automated high-power flat wire inductor to solve the problems mentioned in the background art. Currently, when using fully automated flat wire inductors, gaps are generated between the wires during the automated winding process, which reduces the compactness of the winding and makes it impossible to quickly install the coil assembly with the insulating shell. The design has shortcomings. In addition, the flat wire inductor has a connecting pin on the outside. If the connecting pin is not protected during transportation, it will be damaged.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a high-power flat wire inductor with fully automated winding, comprising:

[0007] An upper insulating shell is provided below the upper insulating shell, and a bracket is provided between the upper and lower insulating shells. The upper and lower sides of the bracket are engaged with slots, which are located inside the upper and lower insulating shells. A coil is wound around the outside of the bracket.

[0008] Also includes:

[0009] The bracket is symmetrically provided with clamping mechanisms on its outer left and right sides to increase the short-circuit resistance of the coil.

[0010] Preferably, the clamping mechanism symmetrically arranged on the left and right sides of the bracket includes a connecting frame, a first spring and a clamping plate. The connecting frame is symmetrically installed on the left and right sides of the bracket, and the first spring is symmetrically installed on the inner side of the middle part of the connecting frame. The clamping plate is fixedly connected to the inner side of the first spring, and the coil is tightly attached to the inner side of the clamping plate.

[0011] Preferably, the lower part of the upper insulating shell is symmetrically and equidistantly equipped with locking pins, and the lower part of the locking pins is engaged with locking holes, which are symmetrically and equidistantly located inside the lower insulating shell.

[0012] Preferably, fixing blocks are rotatably installed on the upper left and right sides of the lower insulating shell, and the fixing blocks are tightly fitted with the lower left and right sides of the upper insulating shell, and the fixing blocks are fixedly connected to the upper insulating shell by bolts.

[0013] Preferably, the upper insulating shell and the lower insulating shell are provided with protective covers on their front sides, and the upper and lower sides of the outer side of the protective covers are tightly fitted with limit strips.

[0014] Preferably, a second spring is fixedly connected to the rear side of the limiting strip.

[0015] Preferably, the upper and lower rear sides of the second spring are fixedly connected to the interior of the upper insulating shell and the lower insulating shell, respectively.

[0016] Compared with the prior art, the beneficial effects of this utility model are as follows: This fully automated high-power flat wire inductor, by setting a clamping mechanism, can ensure that the flat wire will greatly improve the compactness of the winding during the winding process, thereby increasing the short-circuit resistance. At the same time, it is set with an easy installation mechanism, which can quickly install the coil assembly and the insulating shell, improving the installation efficiency and facilitating disassembly. Furthermore, it is set with a protective mechanism, which can effectively protect the flat wire joints and ensure that the flat wire joints will not be damaged by collisions during transportation.

[0017] 1. The device is equipped with a bracket, a coil, and a clamping plate. The coil is wound around the outside of the bracket, and the clamping plates are symmetrically arranged on the left and right sides of the outside of the coil. The clamping plates are fixedly connected to the outside of the clamping plates for support. The first spring has elasticity and can push the clamping plates to fit tightly against the coil during the coil winding process, thereby improving the compactness of the coil winding.

[0018] 2. It is equipped with an upper insulating shell and a lower insulating shell. The inner side of the upper insulating shell and the lower insulating shell are provided with a locking groove. The locking groove can be firmly connected with the upper and lower sides of the bracket. At the same time, the locking pin installed at the bottom of the upper insulating shell will engage with the locking hole provided at the top of the lower insulating shell. This allows the upper insulating shell and the lower insulating shell to be quickly installed on the outside of the bracket.

[0019] 3. It is equipped with fixing blocks and bolts. The fixing blocks are symmetrically rotated on the left and right sides of the outside of the lower insulating shell. After the upper and lower insulating shells are engaged, the fixing blocks can be rotated upward and inward to fit tightly against the left and right sides of the outside of the upper insulating shell. By inserting the bolts into the fixing blocks and tightening them inside the upper insulating shell, the stability of the installation of the upper and lower insulating shells can be further enhanced.

[0020] 4. A limit bar is provided. The lead is located on the front side of the coil, and the limit bar is installed on the front side of the upper insulating shell and the bracket to effectively protect the lead.

[0021] 5. A limit strip and a second spring are provided. The limit strip is tightly connected to the upper and lower sides of the outside of the protective cover. The back of the limit strip is fixedly connected to the second spring. The upper and lower sides of the back of the second spring are fixedly connected to the inside of the upper and lower insulating shells, respectively. Since the second spring has elasticity, it is convenient to pull the limit strip and to disassemble the protective cover. Attached Figure Description

[0022] Figure 1 This is a perspective structural diagram of the present invention;

[0023] Figure 2 This is a perspective view of the protective cover, limiting strip, and second spring connection structure of this utility model.

[0024] Figure 3 This is a perspective view of the connection structure of the upper insulating shell, bracket, and coil of this utility model;

[0025] Figure 4 This is a perspective view of the connection structure of the connecting frame, the first spring, and the clamping plate of this utility model.

[0026] Figure 5 This is a perspective view of the connection structure of the upper insulating shell, locking pin, and locking hole of this utility model;

[0027] Figure 6 This is a perspective structural diagram of the lower insulating shell, fixing block, and bolt connection of this utility model.

[0028] In the diagram: 1. Upper insulating shell; 2. Bracket; 3. Coil; 4. Connecting frame; 5. First spring; 6. Pressing plate; 7. Lower insulating shell; 8. Engaging pin; 9. Engaging hole; 10. Fixing block; 11. Bolt; 12. Slot; 13. Protective cover; 14. Limiting strip; 15. Second spring. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] Please see Figures 1-6 This utility model provides a technical solution:

[0031] To address the problems existing in the prior art, this embodiment provides the following technical solution: a fully automated high-power flat wire inductor with an upper insulating shell 1; a clamping mechanism located on the left and right sides of the coil 3, which can clamp and limit the coil 3 during automated winding, thereby improving the compactness of the coil 3 winding; an easy-to-install mechanism located between the upper insulating shell 1 and the lower insulating shell 7, which facilitates quick installation and connection of the upper insulating shell 1 and the lower insulating shell 7 to the bracket 2, improving installation efficiency and facilitating disassembly; and a protective mechanism located on the front side of the upper insulating shell 1 and the lower insulating shell 7, which can effectively protect the connecting feet located on the front side of the coil 3.

[0032] like Figure 4 , Figure 5 and Figure 6As shown, the bracket 2 is connected by aligning the upper and lower sides of the bracket 2 with the slots 12 inside the upper insulating shell 1 and the lower insulating shell 7. At the same time, the upper insulating shell 1 is symmetrically provided with locking pins 8 on the lower left and right sides, and the lower insulating shell 7 is symmetrically provided with locking holes 9 on the inner left and right sides. The locking pins 8 and locking holes 9 will also be connected by locking. The fixing blocks 10 are installed by rotating the fixing blocks 10 on the outer left and right sides of the lower insulating shell 7. The fixing blocks 10 can be rotated upward and inward to fit against the outer side of the upper insulating shell 1. Then, the bolts 11 are inserted into the fixing blocks 10 and tightened inside the upper insulating shell 1. This strengthens the fixed connection between the upper insulating shell 1 and the lower insulating shell 7. At this time, the bracket 2 is firmly installed between the upper insulating shell 1 and the lower insulating shell 7.

[0033] Connecting brackets 4 are symmetrically installed on the left and right sides of the outside of bracket 2. First springs 5 ​​are symmetrically installed on the left and right sides of the inner side of connecting brackets 4. The clamping plate 6 is fixedly connected to the inner side of the first spring 5. Since the first spring 5 has elasticity, it can push the clamping plate 6 to clamp the coil 3 during the winding process, which can greatly improve the compactness of the coil 3 winding. At the same time, the magnetic core shape is changed to EQ type, which can realize the automation of winding under high current. The flat wire is wound and then assembled with the magnetic core, which increases the production efficiency by more than 40% and the power density by more than 30%.

[0034] like Figure 1 , Figure 2 and Figure 3 As shown, a protective cover 13 is provided on the front side of the upper insulating shell 1 and the lower insulating shell 7. The protective cover 13 can protect the connector installed on the front side of the coil 3. Since the upper and lower sides of the outer side of the protective cover 13 are tightly fitted with the limiting strip 14, and the rear side of the limiting strip 14 is fixedly connected to the second spring 15, the rear side of the second spring 15 is fixedly connected to the interior of the upper insulating shell 1 and the lower insulating shell 7 respectively. Since the second spring 15 is elastic, the limiting strip 14 can be pulled to separate it from the protective cover 13, so that the protective cover 13 can be taken out for easy connection of the connector.

[0035] The working principle of this fully automated high-power flat wire inductor is as follows: The upper insulating shell 1 and the lower insulating shell 7 can be quickly installed on the outside of the bracket 2, which can greatly improve the installation speed. At the same time, the coil 3 is set on the outside of the bracket 2, and the clamping plate 6 is symmetrically and tightly attached to the outside of the coil 3. Under the action of the first spring 5 set on the outside, the clamping plate 6 can press the coil 3, thereby improving the compactness of the coil 3 winding. Secondly, a protective cover 13 is set on the front side of the upper insulating shell 1 and the lower insulating shell 7. The protective cover 13 can effectively protect the connecting feet set on the front side of the coil 3.

[0036] Contents not described in detail in this specification are common knowledge to those skilled in the art. All standard parts used in this invention can be purchased commercially, and irregularly shaped parts can be custom-made according to the description and drawings. The specific connection methods for each part all employ conventional methods such as bolts, rivets, and welding, which are already mature in the prior art. The machinery, parts, and equipment all use conventional models from the prior art, and the circuit connections also employ conventional connection methods from the prior art, which will not be detailed here.

[0037] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-power flat wire inductor with fully automated winding, comprising: An upper insulating shell (1) is provided below the upper insulating shell (1), and a lower insulating shell (7) is provided between the upper insulating shell (1) and the lower insulating shell (7). A bracket (2) is provided between the upper insulating shell (1) and the lower insulating shell (7), and a slot (12) is engaged and connected on the upper and lower sides of the bracket (2). The slot (12) is opened inside the upper insulating shell (1) and the lower insulating shell (7). A coil (3) is wound on the outside of the bracket (2). Its characteristic is that it further includes: The bracket (2) is symmetrically provided on the left and right sides of the outside with a clamping mechanism to increase the resistance of the coil (3) to short circuit force.

2. The fully automated winding high-power flat wire inductor according to claim 1, characterized in that: The clamping mechanism symmetrically arranged on the left and right sides of the bracket (2) includes a connecting frame (4), a first spring (5) and a clamping plate (6). The connecting frame (4) is symmetrically installed on the left and right sides of the bracket (2), and the first spring (5) is symmetrically installed on the inner side of the middle part of the connecting frame (4). The clamping plate (6) is fixedly connected to the inner side of the first spring (5), and the coil (3) is tightly attached to the inner side of the clamping plate (6).

3. A fully automated wound high power flat wire inductor as claimed in claim 2, wherein: The upper insulating shell (1) is symmetrically and equally spaced on the left and right sides of the lower insulating shell (7), and the lower side of the locking pin (8) is engaged with a locking hole (9), and the locking hole (9) is symmetrically and equally spaced on the left and right sides of the lower insulating shell (7).

4. The fully automated winding high-power flat wire inductor according to claim 3, characterized in that: Fixing blocks (10) are rotatably installed on the upper left and right sides of the lower insulating shell (7), and the fixing blocks (10) are closely fitted with the lower left and right sides of the upper insulating shell (1), and the fixing blocks (10) and the upper insulating shell (1) are fixedly connected by bolts (11).

5. The fully automated wound high power flat wire inductor of claim 1, wherein: The upper insulating shell (1) and the lower insulating shell (7) are provided with protective covers (13) on their front sides, and the upper and lower sides of the protective cover (13) are tightly fitted with limit strips (14).

6. A fully automated wound high power flat wire inductor as claimed in claim 5, wherein: A second spring (15) is fixedly connected to the rear side of the limiting strip (14).

7. A fully automated wound high power flat wire inductor as claimed in claim 6, wherein: The upper and lower sides of the rear of the second spring (15) are fixedly connected to the interior of the upper insulating shell (1) and the lower insulating shell (7), respectively.

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