CN107546034B - Production method of iron core segmented high-voltage ring transformer - Google Patents
Production method of iron core segmented high-voltage ring transformer Download PDFInfo
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- CN107546034B CN107546034B CN201710784204.2A CN201710784204A CN107546034B CN 107546034 B CN107546034 B CN 107546034B CN 201710784204 A CN201710784204 A CN 201710784204A CN 107546034 B CN107546034 B CN 107546034B
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Abstract
The invention discloses a production method of a high-voltage ring transformer, which specifically comprises the following steps: step (1), respectively carrying out insulation treatment on annular iron core sections with the same inner diameter and outer diameter; step (2), winding a high-voltage coil on the insulated iron core section; step (3), insulating the high-voltage coil layer wound by each iron core section; step (4), overlapping each section of high-voltage coil layer in sequence and connecting outgoing lines of two adjacent layers of high-voltage coils; step (5) performing outer layer insulation treatment on the high-voltage coil section laminated by the high-voltage coil; step (6), winding a low-voltage coil on the high-voltage coil section subjected to the outer layer insulation treatment, and leading out lead-out wires at two ends of the high-voltage coil section and the low-voltage coil; and (7) performing outermost layer insulation treatment on the low-voltage coil. The high-voltage ring transformer produced by the method has high safety and reliability, is beneficial to the long-term stable work of the transformer, and has small production difficulty, low production cost and high production efficiency.
Description
Technical Field
The invention relates to a transformer, in particular to a production method of an iron core segmented high-voltage annular transformer.
Background
For ease of understanding, the simplest toroidal power transformer (1 primary winding and 1 secondary winding) is illustrated. Suppose the input winding of the ring power transformer has N turns1Corresponding to a voltage value of V1The number of turns of the output winding is N2Corresponding to a voltage value of V2(ii) a In the same annular iron core N1And V1,N2And V2In direct proportion.
The voltage can be divided into three cases according to the voltage of V1 and V2:
the first condition is that V1 is less than or equal to 400V, V2 is less than or equal to 400V, N1 and N2 coils are repeatedly wound along the annular iron core for 360 degrees when being wound, and because V1 and V2 are less than or equal to 400V, the insulation requirement between the coils can be met by completely depending on a lacquered wire paint layer, and the process can ensure the long-term reliable work of the transformer;
the second situation is that V1 is more than or equal to 400V, V2 and less than or equal to 1000V, when N1 and N2 coils are wound, insulation wrapping is carried out for a circle after the coils are wound for 360 degrees along an annular iron core, then a circle of coils are wound on an insulation layer, insulation is carried out again, and the coils are wound … again until the specified number of turns is reached, because interlayer insulation exists between the same coils, the turn-to-turn voltage can be controlled within a certain range, and the transformer can also work reliably for a long time as the insulation between a starting lead wire and each layer is processed;
the third situation is that V1 is more than or equal to 1000V, and V2 is more than or equal to 10000V, and the traditional toroidal transformer production process cannot well solve the insulation problem due to too high voltage, and is a forbidden zone for toroidal transformer production.
Disclosure of Invention
The invention provides a production method of an iron core segmented high-voltage ring transformer with the input and output voltage of more than 1000V.
As a method of producing an iron core segmented high voltage toroidal transformer, one embodiment of the present invention comprises:
step (1), respectively carrying out insulation treatment on annular iron core sections with the same inner diameter and outer diameter;
step (2), winding a high-voltage coil on the insulated iron core section;
step (3), insulating the high-voltage coil layer wound by each iron core section;
step (4), overlapping each section of high-voltage coil layer in sequence and connecting outgoing lines of two adjacent layers of high-voltage coils;
step (5), performing outer layer insulation treatment on the high-voltage coil section laminated by the high-voltage coil;
step (6), winding a low-voltage coil on the high-voltage coil section subjected to the outer layer insulation treatment, and leading out lead-out wires at two ends of the high-voltage coil section and the low-voltage coil;
and (7) performing outermost layer insulation treatment on the low-voltage coil.
Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
Drawings
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
fig. 1 is a flowchart of a method for producing an iron core segmented high-voltage toroidal transformer according to an embodiment of the present invention.
Detailed Description
All of the features disclosed in this specification, or all of the steps in any method or process so disclosed, may be combined in any combination, except combinations of features and/or steps that are mutually exclusive.
Any feature disclosed in this specification may be replaced by alternative features serving equivalent or similar purposes, unless expressly stated otherwise. That is, unless expressly stated otherwise, each feature is only an example of a generic series of equivalent or similar features.
The traditional production process of the toroidal transformer cannot solve the insulation problem of the high-voltage transformer with the input and output voltage of more than 1000V.
Aiming at the problems, the invention provides a production method of a high-voltage transformer, which has strong reliability, simple operation and low cost.
The basic implementation mode is as follows:
a production method of an iron core segmented high-voltage ring transformer specifically comprises the following steps:
step (1), respectively carrying out insulation treatment on annular iron core sections with the same inner diameter and outer diameter;
step (2), winding a high-voltage coil on the insulated iron core section;
step (3), insulating the high-voltage coil layer wound by each iron core section;
step (4), overlapping each section of high-voltage coil layer in sequence and connecting outgoing lines of two adjacent layers of high-voltage coils;
step (5), performing outer layer insulation treatment on the high-voltage coil section laminated by the high-voltage coil;
step (6), winding a low-voltage coil on the high-voltage coil section subjected to the outer layer insulation treatment, and leading out lead-out wires at two ends of the high-voltage coil section and the low-voltage coil;
and (7) performing outermost layer insulation treatment on the low-voltage coil.
The common transformer iron core is a cylinder iron core, a traditional integral annular iron core can be coiled into a plurality of annular iron core sections with the same inner diameter and outer diameter in the step (1), optimally, the sizes of the plurality of iron core sections are the same, and the traditional integral iron core can be coiled into a plurality of iron core sections with the same height and the same inner diameter and outer diameter. And respectively carrying out insulation treatment on each iron core segment, wherein the treatment mode comprises but is not limited to that insulation paper or an insulation seal layer is pasted on the outer surface of the iron core.
And (2) uniformly and flatly winding a high-voltage coil on each iron core section after insulation treatment, wherein the number of turns of the high-voltage coil wound by each iron core section is determined by the highest voltage, the number of the iron core sections and the sectional area of the iron core section. When the sizes of the iron core segments are the same, the number of turns of the high-voltage coil wound by each iron core segment is determined by the highest voltage and the number of the iron core segments.
And (3) after the high-voltage coil is wound by one iron core section, the high-voltage coil wound on the iron core section is a high-voltage coil layer, and the high-voltage coil layer of each iron core section is respectively subjected to insulation treatment in a treatment mode including but not limited to wrapping insulating paper outside the high-voltage coil layer. Optimally, before the insulation treatment is carried out on the high-voltage coil layer, the insulation treatment can be carried out on the wire head of the outgoing wire of the high-voltage coil layer, and the treatment mode includes but is not limited to that the wire head is coated with an insulation material.
And (4) sequentially superposing the high-voltage coil layers subjected to the insulation treatment, and sequentially connecting the outgoing lines of the two adjacent high-voltage coils. A plurality of high-voltage coils are laminated into a high-voltage coil section, and the input lines or the output lines of the adjacent high-voltage coil layers are in a connected state, so that the whole high-voltage coil section is in a connected state. The voltage difference between the first high-voltage coil layer and the last high-voltage coil layer is the largest, but the distance between the two high-voltage coil layers is the farthest, so that the reliability of the transformer is greatly improved, and the long-term stable work of the transformer is facilitated.
And (5) performing outer layer insulation treatment on the high-voltage coil section laminated by the high-voltage coil, wherein the treatment mode includes but is not limited to wrapping, isolating and insulating outside the high-voltage coil section.
And (6) winding a low-voltage coil on the outer surface of the high-voltage coil section subjected to the outer layer insulation treatment, and leading out lead-out wires at two ends of the high-voltage coil section and the low-voltage coil after the low-voltage coil with the preset number of turns is wound, namely leading out the high-voltage coil section subjected to the outer layer insulation treatment and the lead-out wires at two ends of the low-voltage coil wound on the outer surface of the high-voltage coil section.
And (7) performing outermost layer insulation treatment on the low-voltage coil.
Optimally, epoxy resin encapsulation treatment can be carried out on the low-voltage coil in the step (7), and the input or output voltage of the iron core segmented high-voltage toroidal transformer subjected to epoxy resin encapsulation treatment is required to be between 1000V and 10000V. The iron core segmented high-voltage annular transformer can be integrally encapsulated by using an iron shell (or a plastic shell) and epoxy resin, so that the shock-proof, moisture-proof and explosion-proof capabilities of the transformer are improved, and the reliability of the transformer is improved.
The specific implementation mode is as follows:
power of the high-voltage ring transformer: 1500VA
Inputting: 3000V 50Hz Red
And (3) outputting: 220V 6.82A blue
The production process of the high-voltage annular transformer comprises the following steps:
step 1: determining the number of iron core segments and the specification size (unit: mm)
According to the power and the highest voltage of the toroidal transformer, 1 toroidal core is divided into 4 segments of 75 × 145 × 20 (inner diameter × outer diameter × height).
Step 2: the 4 segments of iron cores of 75X 140X 20 are respectively put on an insulating tape machine and insulated by polyester film.
And step 3: winding high-voltage winding and insulation treatment
and a, calculating the voltage, the wire diameter and the number of turns of the coil of the winding required on each section of the iron core.
The method comprises the following steps: the voltage over the segmented core was calculated to be 750V.
Secondly, the step of: calculating the wire diameter of the enameled wire input into the high-voltage winding as follows: 0.51 mm.
③: and calculating the number of turns of the high-voltage coil wound on each section of the iron core to be 3300T.
b, uniformly and flatly winding 3300T by using 0.51mm enameled wires on the insulated iron core sections by using an annular winding machine; after each winding, the insulation treatment of polyester film is needed until the 3300T coil is uniformly wound.
And c, respectively protecting and leading out the wire ends at the two ends of the high-voltage coil by using insulating sleeves.
d, using an insulating tape wrapping machine to respectively insulate the high-voltage coil layer wound by each iron core section by using a polyester film.
And 4, step 4: and (5) overlapping and connecting.
and a, randomly laminating four sections of high-voltage coils after insulation treatment, then sequentially connecting adjacent high-voltage coils from top to bottom, treating connection points by using an insulation sleeve, and finally connecting red leading-out wires according to requirements.
And 5: insulation treatment between high-voltage coil and low-voltage coil
and a, insulating the polyester film for the high-voltage coil which is connected in a superposed mode again.
Step 6: and winding the low-voltage coil.
The method comprises the following steps: and (3) calculating the no-load voltage, the wire diameter and the number of turns of the low-voltage winding as follows: 227.2V, 1.80mm and 250T.
Secondly, the step of: and uniformly and flatly winding the enameled wire with the diameter of 1.80mm on the high-voltage coil section subjected to the outer layer insulation treatment for 250T, and then connecting an output blue lead according to requirements.
And 7: outermost layer insulation treatment
and a, wrapping 4 layers of polyester films on the outer surface of the coil section to form the outermost layer of insulation, and finishing the production of the iron core sectional high-voltage ring transformer.
And 8: assembling and encapsulating
The advantages of the present invention are numerous. Different aspects, embodiments or implementations may yield one or more of the following advantages. One advantage of the present invention is: the high-voltage transformer with the input and output voltages of more than 1000V produced by the method has high safety and high reliability, and is beneficial to the long-term stable work of the transformer. Another advantage of the present invention is: the method for producing the high-voltage transformer with the input and output voltages of more than 1000V has the advantages of small production difficulty, low production cost and high production efficiency.
The invention is not limited to the foregoing embodiments. The invention extends to any novel feature or any novel combination of features disclosed in this specification and any novel method or process steps or any novel combination of features disclosed.
Claims (5)
1. A production method of an iron core segmented high-voltage ring transformer is characterized by comprising the following steps:
step (1), respectively carrying out insulation treatment on annular iron core sections with the same inner diameter and outer diameter;
step (2), winding a high-voltage coil on the insulated iron core section;
step (3), insulating the high-voltage coil layer wound by each iron core section;
step (4), overlapping each section of high-voltage coil layer in sequence and connecting outgoing lines of two adjacent layers of high-voltage coils; step (5), performing outer layer insulation treatment on the high-voltage coil section laminated by the high-voltage coil;
step (6), winding a low-voltage coil on the high-voltage coil section subjected to the outer layer insulation treatment, and leading out lead-out wires at two ends of the high-voltage coil section and the low-voltage coil;
step (7), performing outermost layer insulation treatment on the low-voltage coil;
in the step (1), a whole annular iron core is split-rolled into a plurality of annular iron core sections with the same inner diameter and outer diameter.
2. The method for producing an iron core segmented high-voltage toroidal transformer according to claim 1, wherein in the step (3), insulation protection treatment is performed on the lead wire ends of the high-voltage coil before insulation treatment is performed on the high-voltage coil layer.
3. The method for producing an iron core segmented high-voltage toroidal transformer according to claim 1, wherein the outermost insulation treatment of the low-voltage coil in the step (7) is epoxy resin potting treatment of the low-voltage coil.
4. The method for manufacturing a core segment high voltage toroidal transformer as claimed in claim 3, wherein the input or output voltage of the core segment high voltage transformer subjected to epoxy potting is required to be between 1000V and 10000V.
5. The method of claim 1, wherein the number of turns of the high voltage coil wound in each core segment is determined by the maximum voltage of the high voltage winding, the number of core segments and the sectional area of the core segments.
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| CN112599342B (en) * | 2020-12-16 | 2022-08-19 | 河南合瑞电气有限公司 | Annular transformer and preparation method thereof |
| CN113593891A (en) * | 2021-07-13 | 2021-11-02 | 中车株洲电机有限公司 | Auxiliary transformer coil winding method |
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| CN101884075A (en) * | 2007-10-24 | 2010-11-10 | 亚尔科·萨洛迈基 | Procedure for manufacturing of a magnetic core and a magnetic core |
| CN102568772A (en) * | 2010-12-27 | 2012-07-11 | 新华都特种电气股份有限公司 | Co-wound high-voltage and low-voltage coil of transformer and winding method of co-wound high-voltage and low-voltage coil |
| CN206134441U (en) * | 2016-09-28 | 2017-04-26 | 东莞市嘉龙海杰电子科技有限公司 | Sectional type transformer of reducible voltage difference |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US4901773A (en) * | 1988-10-24 | 1990-02-20 | Kuhlman Corporation | High voltage coil winding machine |
| CN102651277A (en) * | 2012-06-05 | 2012-08-29 | 江苏中容科技有限公司 | Preloading method of high-voltage and low-voltage insulation tube of three-dimensional rolling iron core dry type transformer |
| CN103426627B (en) * | 2013-08-29 | 2015-09-02 | 宁夏银利电器制造有限公司 | The manufacture method of oil-immersed and high-voltage isolation, pulse transformer and technique |
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Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101884075A (en) * | 2007-10-24 | 2010-11-10 | 亚尔科·萨洛迈基 | Procedure for manufacturing of a magnetic core and a magnetic core |
| CN102568772A (en) * | 2010-12-27 | 2012-07-11 | 新华都特种电气股份有限公司 | Co-wound high-voltage and low-voltage coil of transformer and winding method of co-wound high-voltage and low-voltage coil |
| CN206134441U (en) * | 2016-09-28 | 2017-04-26 | 东莞市嘉龙海杰电子科技有限公司 | Sectional type transformer of reducible voltage difference |
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