Transformer Winding Layout With Parallel Primary Sections for EMI Control
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Solution Overview
Problem
Transformers manufactured using traditional sandwich winding techniques exhibit poorer electromagnetic interference (EMI) performance, with EMI quasi-peak and average strength curves exceeding regulatory limits.
Innovation Solution
A transformer manufacturing method where the third and fourth winding wires are wound in parallel around the bobbin and then connected in series, forming a primary coil, while the second winding wire forms a secondary coil, thereby improving EMI performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional sandwich winding method is used, then the manufacturing process is simple, but the EMI performance is poor and exceeds regulatory limits
Solution Approach 1:
The primary coil is segmented into multiple separate winding wires (first, third, and fourth winding wires) instead of using a single continuous wire. These segmented wires are wound in specific patterns around the bobbin and connected to form the primary coil, which helps reduce electromagnetic interference while maintaining manufacturing simplicity
Solution Approach 2:
The winding structure employs a nested arrangement where the third and fourth winding wires are wound in parallel around the bobbin, and the first winding wire is wound separately. This nested winding pattern creates a compact structure that improves EMI performance without significantly complicating the manufacturing process
2Productivity
If traditional sandwich winding method is used, then the manufacturing time is shorter, but the EMI curves exceed regulatory limits
Solution Approach 1:
The third and fourth winding wires are prepared and positioned in advance, and the insulation materials are pre-applied to specific sections before the final winding assembly. This preliminary preparation allows for faster assembly while achieving the required EMI performance through the specific parallel winding configuration of the third and fourth wires
3Object-affected harmful factors
If multiple winding wires are wound in parallel and connected in series, then the EMI performance improves below regulatory limits, but the winding process becomes more complex
Solution Approach 1:
The winding structure employs asymmetric configuration where the third and fourth winding wires are wound in parallel but with different connection points and different numbers of turns. The first winding wire is wound separately with a different pattern. This asymmetric design achieves superior EMI cancellation while the modular connection approach keeps the manufacturing process manageable
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed method significantly improves EMI performance by ensuring that the EMI quasi-peak and average strength curves are below regulatory limits, while also simplifying the winding process and reducing manufacturing time.
Implementation Method 1
A transformer at least includes a primary coil and a secondary coil, and a ratio of the number of turns of the primary coil to the secondary coil determines a voltage ratio of the transformer
Data Source
AI summary
A manufacturing method of a transformer includes: winding a first winding wire around a bobbin, wherein two ends of the first winding wire are connected to a first and a second pin of the bobbin respectively; winding a second winding wire around the bobbin, wherein two ends of the second winding wire are connected to a third and a fourth pin of the bobbin respectively; and winding a third and a fourth winding wire in parallel around the bobbin, wherein two ends of the third winding wire are connected to the second and a fifth pin of the bobbin respectively, and two ends of the fourth winding wire are connected to the fifth and a sixth pin respectively. The first, the third and the fourth winding wires form a primary coil, and the second winding wire is a secondary coil.