CN111029133B - Winding method of high-frequency high-power low-leakage-inductance transformer - Google Patents
Winding method of high-frequency high-power low-leakage-inductance transformer Download PDFInfo
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- CN111029133B CN111029133B CN201911392205.8A CN201911392205A CN111029133B CN 111029133 B CN111029133 B CN 111029133B CN 201911392205 A CN201911392205 A CN 201911392205A CN 111029133 B CN111029133 B CN 111029133B
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- winding
- enameled
- primary winding
- enameled wire
- enameled wires
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2895—Windings disposed upon ring cores
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
Abstract
The invention discloses a winding method of a high-frequency high-power low-leakage-inductance transformer, which comprises an annular iron core, a primary winding and a secondary winding, wherein the primary winding and the secondary winding are both composed of at least one enameled wire, and the purpose of reducing the leakage inductance of the transformer is realized by winding the primary winding and the secondary winding in a crossed manner.
Description
Technical Field
The invention relates to the technical field of winding methods of transformers, in particular to a winding method of a high-frequency high-power low-leakage-inductance transformer.
Background
A transformer is a device that changes an alternating voltage using the principle of electromagnetic induction, and main components are a primary coil, a secondary coil, and an iron core (magnetic core). The conventional transformer is formed by winding a plurality of turns of primary and secondary windings on one iron core (ferrite iron core), so that large leakage inductance can be generated, frequency and power cannot be considered, the transformer with high switching frequency has small power, and the transformer with high power has low switching frequency.
Disclosure of Invention
In order to reduce the leakage inductance of the transformer, the invention provides a winding method of a high-frequency high-power low-leakage-inductance transformer.
The technical scheme adopted by the invention for solving the problems is as follows:
a winding method of a high-frequency high-power low-leakage-inductance transformer comprises an annular iron core, a primary winding and a secondary winding, wherein the primary winding and the secondary winding are wound by at least one enameled wire, and the winding method comprises the following steps:
a1, selecting an enameled wire for a primary winding, selecting a starting point on an annular iron core, and uniformly and densely winding a layer around the annular outline of the iron core to enable the enameled wire for the primary winding to fill the inner diameter of the annular iron core, wherein the enameled wire for the primary winding on the outer diameter forms a plurality of gathering rings, each gathering ring is formed by at least two circles of enameled wires for the primary winding without gaps, and a gap exists between every two adjacent gathering rings;
a2, taking the enameled wire for the secondary winding, selecting a starting point from the gap generated in the step A1, and uniformly and densely winding a layer of enameled wire for the secondary winding at each gap around the annular outline of the iron core;
and A3, spraying an insulating layer outside the wound coil.
The primary coil and the secondary coil of the transformer are wound in a crossed manner to reduce the leakage inductance of the transformer; the enameled wire for the primary winding is fully wound in the inner diameter of the annular iron core, so that the magnetic flux in the iron core cannot penetrate through the inner wall to radiate outwards, and the leakage inductance is reduced; the outer diameter of the iron core adopts a gathering ring mode to reduce gaps among coils as much as possible, so that the outward radiation of magnetic flux is reduced, and the leakage inductance is reduced.
Further, as a preferred technical scheme, the annular iron core is replaced by annular iron-silicon-aluminum. The sendust has excellent magnetic performance, low power loss and high magnetic flux density, and can realize high frequency and high power of the transformer.
Further, as a preferred technical scheme, the enameled wire is a wire resistant to 180 ℃. Because the power of the transformer is high, the heat generation is increased, so that the enameled wire adopts a high-temperature-resistant enameled wire which can adopt a polyurethane enameled wire, a polyester-imide/polyamide composite enameled wire or a polyester-imide/polyamide-imide composite layer enameled wire.
Further, as a preferred technical scheme, the inner diameter of the annular sendust is 23mm, and the outer diameter is 46 mm.
Further, as a preferred technical scheme, the enameled wires for the primary winding are two enameled wires which are arranged side by side without a gap, and the enameled wires for the secondary winding are six enameled wires which are arranged side by side without a gap. The skin effect of the current can be reduced by adopting the stranded wires.
Further, as a preferred technical scheme, two enameled wires of the enameled wire for the primary winding are 0.9mm enameled wires, and six enameled wires of the enameled wire for the secondary winding are 0.8mm enameled wires. 0.9mm is used for adapting to the inner diameter of the sendust and can be wound for just 36 circles, and 0.8mm is used for adapting to the outer diameter of the sendust and can be wound for 12 circles.
Further, as a preferred technical scheme, the gathering ring is formed by three circles of enameled wires for primary winding without gaps.
Compared with the prior art, the winding method has the advantages that the leakage inductance of the transformer can be effectively reduced by adopting the winding method, the leakage inductance of the general transformer in the market is about 2% of the inductance of the transformer, the transformer adopting the winding method is only 0.3%, the frequency and the power can be considered, and the 100K switching frequency and the 2KW power can be realized.
Drawings
FIG. 1 is a schematic diagram of a coil structure of an Fe-Si-Al outer surface;
FIG. 2 is a schematic structural view of the enameled wire wound with the primary winding according to the present invention;
reference numbers and corresponding part names in the drawings: 1. enameled wires for the primary winding, enameled wires for the secondary winding, and enameled wires for the secondary winding, wherein the enameled wires for the primary winding are 2, the gap and 3, and the gathering ring and the enameled wires for the secondary winding are 4.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited to these examples.
In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "longitudinal", "lateral", "horizontal", "inner", "outer", "front", "rear", "top", "bottom", and the like indicate orientations or positional relationships that are based on the orientations or positional relationships shown in the drawings, or that are conventionally placed when the product of the present invention is used, and are used only for convenience in describing and simplifying the description, but do not indicate or imply that the device or element referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and thus should not be construed as limiting the invention.
In the description of the present invention, it should also be noted that, unless otherwise explicitly specified or limited, the terms "disposed," "open," "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Examples
As shown in fig. 1, a winding method of a high-frequency high-power low-leakage inductance transformer according to a preferred embodiment of the present invention includes an annular iron core, a primary winding and a secondary winding, where the primary winding and the secondary winding are wound by at least one enameled wire, and the winding method includes the following steps:
a1, selecting an enameled wire 1 for a primary winding, selecting a starting point on an annular iron core, and uniformly and densely winding a layer around the annular outline of the iron core to enable the enameled wire 1 for the primary winding to fill the inner diameter of the annular iron core, wherein the enameled wire 1 for the primary winding on the outer diameter forms a plurality of gathering rings 3, each gathering ring 3 is formed by at least two circles of enameled wires 1 for the primary winding without gaps, and a gap 2 is formed between every two adjacent gathering rings 3;
a2, taking the enameled wire 4 for the secondary winding, selecting a starting point in the gap 2 generated in the step A1, and uniformly and densely winding a layer of enameled wire 4 for the secondary winding at each gap around the annular outline of the iron core;
and A3, spraying an insulating layer outside the wound coil.
The primary coil and the secondary coil of the transformer are wound in a crossed manner to reduce the leakage inductance of the transformer; the enameled wire for the primary winding is fully wound in the inner diameter of the annular iron core, so that the magnetic flux in the iron core cannot penetrate through the inner wall to radiate outwards, and the leakage inductance is reduced; the outer diameter of the iron core adopts a gathering ring mode to reduce gaps among coils as much as possible, so that the outward radiation of magnetic flux is reduced, and the leakage inductance is reduced.
Specifically, as shown in fig. 2, taking the transformer input 320V and output 105V as an example, the voltage ratio is about 3, so the turn ratio of the primary winding to the secondary winding in the following winding is also 3, the toroidal core is replaced by toroidal sendust, the inner diameter of the toroidal sendust is 23mm, and the outer diameter is 46 mm; the enameled wire is resistant to 180 ℃; the enameled wires 1 for the primary winding are two enameled wires of 0.9mm which are arranged side by side without gaps, and the enameled wires 4 for the secondary winding are six enameled wires of 0.8mm which are arranged side by side without gaps. Winding is carried out according to the following steps:
a1, selecting an initial point on the annular iron-silicon-aluminum, uniformly and densely winding a layer around the annular outline of the iron-silicon-aluminum, so that the inner diameter of the annular iron core is filled with the primary winding enameled wire 1, the primary winding on the outer diameter forms a plurality of gathering rings 3 with the enameled wire 1, each gathering ring 3 is composed of three circles of the primary winding enameled wire 1 without gaps, and a gap 2 exists between every two adjacent gathering rings 3; in this embodiment, the inner diameter of the ring-shaped sendust is 23mm, the corresponding circumference is 23 × 3.14 — 72mm, the actual 0.9mm enameled wire is about 0.98mm, and the primary winding enameled wire 1 can be wound by just 36 turns according to the calculation, that is, 72 lines are shared on the inner diameter of the sendust, that is, 72 × 0.98 — 70.5mm, plus the winding gap is just 72 mm; each focus ring contains 6 turns of 0.9mm enameled wire.
A2, taking the enameled wire for secondary winding 4, selecting a starting point in the gap generated in the step a1, and uniformly and densely winding a layer of the enameled wire for secondary winding 4 around the annular contour of the iron core at each gap. In the present embodiment, 12 turns of the enameled wire 4 for the secondary winding are wound, that is, 72 sections of the enameled wire with 0.8mm are actually about 0.88mm, the total width of the enameled wire with 0.98mm plus 72 turns of the enameled wire with 72 turns is 72 × 0.98+72 × 0.88 ═ 134mm, the outer circumference of the sendust is 46 × 3.14 ═ 144mm, and the winding gap is just suitable plus, and the number ratio of the turns of the primary winding to the turns of the secondary winding is equal to 3 per 36 turns/12 turns.
And A3, spraying an insulating layer outside the wound coil.
In the embodiment, the sendust has excellent magnetic property, small power loss and high magnetic flux density, and can realize high frequency and high power of the transformer by matching with the coil, and can realize 100K switching frequency and 2KW power; because the power of the transformer is high, the heat generation is increased, so that the enameled wire needs to adopt a high-temperature-resistant enameled wire, the high-temperature-resistant enameled wire can adopt a polyurethane enameled wire, a polyester-imide/polyamide composite enameled wire or a polyester-imide/polyamide-imide composite layer enameled wire, and the enameled wire adopts a polyester-imide/polyamide-imide composite layer enameled wire in the embodiment; in addition, two 0.9mm and six 0.8mm enamel wires are used in the present embodiment in order to reduce the skin effect of the current.
As described above, the present invention can be preferably realized.
The foregoing is only a preferred embodiment of the present invention, and the present invention is not limited thereto in any way, and any simple modification, equivalent replacement and improvement made to the above embodiment within the spirit and principle of the present invention still fall within the protection scope of the present invention.
Claims (4)
1. A winding method of a high-frequency high-power low-leakage-inductance transformer comprises an annular iron core, a primary winding and a secondary winding, and is characterized in that the primary winding and the secondary winding are wound by at least one enameled wire, and the winding method comprises the following steps:
a1, taking an enameled wire (1) for a primary winding, wherein an annular iron-silicon-aluminum core is adopted, the inner diameter of the annular iron-silicon-aluminum core is 23mm, the outer diameter of the annular iron-silicon-aluminum core is 46mm, two enameled wires of the enameled wire (1) for the primary winding are both 0.9mm, a starting point is selected on the annular iron core, a layer is uniformly and densely wound around the annular outline of the iron core, so that the inner diameter of the annular iron core is filled with the enameled wire (1) for the primary winding, a plurality of gathering rings (3) are formed by the enameled wire (1) for the primary winding on the outer diameter, each gathering ring (3) is formed by at least two circles of enameled wires (1) for the primary winding without gaps, and a gap (2) is formed between every two adjacent gathering rings;
a2, taking enameled wires (4) for secondary windings, wherein six enameled wires of the enameled wires (4) for secondary windings are 0.8mm, selecting a starting point in the gap (2) generated in the step A1, and uniformly and densely winding a layer of enameled wires (4) for secondary windings around the annular outline of the iron core at each gap (2);
a3, spraying an insulating layer outside the wound coil.
2. The winding method of the high-frequency high-power low-leakage-inductance transformer according to claim 1, wherein the enameled wire is a wire which can resist 180 ℃.
3. The winding method of the high-frequency high-power low-leakage-inductance transformer according to claim 1, wherein the enameled wires (1) for the primary winding are two enameled wires without gaps side by side, and the enameled wires (4) for the secondary winding are six enameled wires without gaps side by side.
4. The winding method of a high-frequency high-power low-leakage-inductance transformer according to claim 1, wherein the gathering ring (3) is composed of three-turn enameled wires (1) for primary winding without gap.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911392205.8A CN111029133B (en) | 2019-12-30 | 2019-12-30 | Winding method of high-frequency high-power low-leakage-inductance transformer |
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| Application Number | Priority Date | Filing Date | Title |
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| CN201911392205.8A CN111029133B (en) | 2019-12-30 | 2019-12-30 | Winding method of high-frequency high-power low-leakage-inductance transformer |
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| CN111029133A CN111029133A (en) | 2020-04-17 |
| CN111029133B true CN111029133B (en) | 2021-12-14 |
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Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4811477A (en) * | 1985-03-01 | 1989-03-14 | Gfs Manufacturing Company, Inc. | Method of winding toroid transformers |
| RU2054722C1 (en) * | 1991-03-25 | 1996-02-20 | Научно-производственное объединение автоматики и приборостроения | Transformer |
| CN1564277A (en) * | 2004-04-21 | 2005-01-12 | 深圳市瑞凌实业有限公司 | High efficiency low leakage intermediate-frequency power transformer and its mfg. method |
| CN102969135A (en) * | 2012-11-21 | 2013-03-13 | 王奉瑾 | Ring-shaped transformer |
| WO2015171560A1 (en) * | 2014-05-05 | 2015-11-12 | Hubbell Incorporated | Adjustable inductor |
| CN105353180A (en) * | 2015-12-28 | 2016-02-24 | 武汉磐电科技有限公司 | Strong current generator with multiple uniformly distributed conductors |
| CN107025987A (en) * | 2017-05-26 | 2017-08-08 | 云南电网有限责任公司电力科学研究院 | A kind of distribution transformer and core manufacturing method with iron based nano crystal iron core |
| CN110233044A (en) * | 2019-07-12 | 2019-09-13 | 蚌埠市双环电感股份有限公司 | A kind of ring-shaped inductors method for winding and its inductance |
-
2019
- 2019-12-30 CN CN201911392205.8A patent/CN111029133B/en active Active
Patent Citations (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4811477A (en) * | 1985-03-01 | 1989-03-14 | Gfs Manufacturing Company, Inc. | Method of winding toroid transformers |
| RU2054722C1 (en) * | 1991-03-25 | 1996-02-20 | Научно-производственное объединение автоматики и приборостроения | Transformer |
| CN1564277A (en) * | 2004-04-21 | 2005-01-12 | 深圳市瑞凌实业有限公司 | High efficiency low leakage intermediate-frequency power transformer and its mfg. method |
| CN102969135A (en) * | 2012-11-21 | 2013-03-13 | 王奉瑾 | Ring-shaped transformer |
| WO2015171560A1 (en) * | 2014-05-05 | 2015-11-12 | Hubbell Incorporated | Adjustable inductor |
| CN105353180A (en) * | 2015-12-28 | 2016-02-24 | 武汉磐电科技有限公司 | Strong current generator with multiple uniformly distributed conductors |
| CN107025987A (en) * | 2017-05-26 | 2017-08-08 | 云南电网有限责任公司电力科学研究院 | A kind of distribution transformer and core manufacturing method with iron based nano crystal iron core |
| CN110233044A (en) * | 2019-07-12 | 2019-09-13 | 蚌埠市双环电感股份有限公司 | A kind of ring-shaped inductors method for winding and its inductance |
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| CN111029133A (en) | 2020-04-17 |
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