CN1155155A - Mfg. method for wire-wound magnetic core whole-shielded transformer and product thereof - Google Patents

Abstract

The present invention relates to a method for making-fully-shielded transformer with wire-wound core and its structure. Said invented transformer is formed of magnetic core wound by wire material with high magnetic conductivity, coils wound by high magnetic conductivity wire material and skeleton supporting magnetic core and coils. Said transformer is high in conversion efficiency, small in size and light in weight.

Description

Manufacture method of wire-wound magnetic core full-shield transformer and products thereof

The invention belongs to the technical field of transformer in the essential electronic element.

Usually the iron core of transformer is repeatedly inserted with silicon steel sheet, and silicon strip is reeled or become type ferrite to make, and iron core and coil windings adopt different process to finish.So compatibility between high magnetic conduction, low eddy current magnetic core and the wound coil technology, and the electromagnetic leakage of transformer finished product is puzzlement transformer producer's two hang-ups always.

The present invention seeks to propose manufacture method of the complete compatible wire-wound magnetic core full-shield transformer of a kind of conversion efficiency height, full-shield, magnetic core and coil windings technology and products thereof.

The present invention seeks to realize like this:

A kind of manufacture method of wire-wound magnetic core full-shield transformer, it is characterized in that at room temperature, on skeleton according to the first floor height magnetic conduction wire rod, the second floor height electric wire, the magnetic core of outermost floor height magnetic conduction wire rod wraps up the parcel relation of coil entirely, order is twined high magnetic conduction wire rod and electric wire, the single wire winding of the full-shield transformer device structure of finishing;

Described high magnetic conduction wire rod is molybdenum manganese alloy or sloping film alloy enamelled wire;

Described high electric wire is copper or aluminium enamel-covered wire.

A kind of wire-wound magnetic core full-shield transformer is characterized in that by with high magnetic conduction wire rod enamelled wire wound core, with high electric wire coiling, forms the full-shield structure with the skeleton of anti-magnetic metal or paramagnetic metal or nonmetal support magnetic core of paramagnetic and coil;

Described coil is by the totally-enclosed parcel of the ectonexine of magnetic core, and draws primary and secondary lead-in wire;

Described skeleton is made up of hollow axle plintlet and the big clamp plate nested with the left and right sides;

In conjunction with the accompanying drawings, further specify content of the present invention.

Fig. 1 single-phase transformer manufacturing process flow diagram of the present invention

Fig. 2 single-phase transformer manufacturing process flow of the present invention final structure figure

Fig. 3 three-phase transformer manufacturing process flow diagram of the present invention

Fig. 4 three-phase transformer manufacturing process flow of the present invention final structure figure

Transformer has voltage transformation, three greatly effects of current transformation and impedance transformation; Three big performance indications of transformer are Efficient, capacity and loss (comprising whirlpool damage, copper loss, magnetic hysteresis, leakage field). Want to reduce loss, improve transformer conversion effect Rate must adopt magnetic (iron) core of high magnetic conduction, low eddy current; And, with magnetic (iron) core shielded coil, to cut off outside spoke The electromagnetic field of penetrating.

After the capacity of transformer is determined, its magnetic core sectional area: $\mathrm{\π}({\mathrm{\γ}}_2^2-{\mathrm{\γ}}_1^2),\mathrm{\π}{\mathrm{\γ}}_2(L_1-L_2),\mathrm{\π}({\mathrm{\γ}}_4^2-{\mathrm{\γ}}_3^2),$ Or $\mathrm{\π}({\mathrm{\γ}}_2^2-{\mathrm{\γ}}_1^2),\frac{\mathrm{\π}{\mathrm{\γ}}_2(L_4-3L_3)}{2},\mathrm{\π}({\mathrm{\γ}}_4^2-{\mathrm{\γ}}_3^2),$ Value also just determined, so transformer has also just had the size of determining.

Fig. 1 is the manufacturing process flow diagram of single-phase transformer of the present invention, and it is divided into six steps, and existing branch is chatted as follows:

Fig. 1 (a) is the axle skeleton with left and right sides plintlet, and it is with high temperature resistant anti-magnetic metal or the paramagnetics such as copper material that scribbles insulation The materials such as metal or paramagnetic are nonmetal are made.

With Alperm enamel-covered wire wound core internal layer, its thickness by the plintlet of skeleton radially at the axle skeleton for Fig. 1 (b) Highly decide; And insulation processing will be carried out in involutory gold thread two terminations, makes it be open-circuit condition; The Alperm that uses Enamel-covered wire is the wire rods such as molybdenum manganese alloy enamel-covered wire or sloping film alloy enamel-covered wire.

Fig. 1 (c) coil windings. Loop length is less than magnetic (iron) core length, and coil thickness is determined by turn ratio. Directly at magnetic core Coiling placed in the middle. Wire rod adopts copper or aluminium contour conductive paint envelope curve, cotton-covered wire or silk-covered wire.

Fig. 1 (d) gums down and is enclosed within the inside and outside coil windings of magnetic core, and draws primary and secondary coil lead. Used glue is ten thousand Energy glue, the glue such as epoxy resin.

Fig. 1 (e) is nested a pair of big clamp plate on the plintlet of axle. Big plintlet stick with glue connect fixing. Big clamp plate is provided with Fairlead. The big clamp plate external diameter determines the transformer external diameter.

Fig. 1 (f) forms half-finished space installing big clamp plate, around full Alperm enamel-covered wire, lacks about filling on the one hand Mouthful, encase on the other hand coil windings, take at last gluing fixedly lead riser. Its wire rod is identical with Fig. 1 (b), its end of a thread Make equally insulation processing, make it be open-circuit condition. Like this, a transformer has just been finished. Finished figure is seen Fig. 2. In addition, Can increase the shell that exposes lead-in wire.

Fig. 2 is single-phase transformer flow chart final structure figure of the present invention.Left figure is an elevational cross-sectional view, and right figure is a right side view.This transformer is by big clamp plate 1, the skeleton (no hatching) that plintlet 2 and axle 3 are formed, and wire-wound magnetic core 4 (the netted hatching of prismatic) and coil windings 5 (square grid shape hatching) are formed.The ectonexine of magnetic (iron) core 4 is wrapped in coil windings 5, and constitutes closed magnetic circuit.Therefore, magnetic core promptly is the shielding action that magnetic circuit plays winding again.Between the winding, insulant and electric screen layer reliably all to be arranged between winding and the magnetic core, and be open-circuit condition.

Add the short circuit and want ground connection voluntarily of screen (sheet copper or aluminium foil), screen between the primary and secondary in case of necessity coil.Skeleton plays the mechanical support effect, and axle is the hollow shape.This transformer size is determined by requirements such as capacity, is not subjected to process technology limit, and adopts unique wire winding once to finish.The transformer internal diameter equals the external diameter of skeleton axle, and the external diameter of transformer equals the external diameter of big clamp plate 1.

In whole manufacturing process, must meet following formula. $\mathrm{\π}({\mathrm{\γ}}_2^2-{\mathrm{\γ}}_1^2)=\mathrm{\π}{\mathrm{\γ}}_2(L1-L2)$ $=\mathrm{\π}({\mathrm{\γ}}_4^2-{\mathrm{\γ}}_3^2)$ Symbol is seen Fig. 2 in the=Sc formula, γ ₀The axle inside radius

γ ₁Skeleton axle outer radius γ ₃The coil outer radius

γ ₂Skeleton plintlet outer radius γ ₄Magnetic core outer radius (being the big clamp plate external diameter)

L ₁Loop length L ₂Core length Sc magnetic core sectional area

High permeability material wire-wound closed magnetic core both shielded, and transformer efficiency is improved greatly.

Because the relative permeability μ γ of silicon sheet core ₁=7.5 * 10 ³

And the maximum relative permeability scope 6 * 10 of molybdenum manganese alloy ⁵～1.2 * 10 ⁶, thereby get the iron core relative permeability μ γ of molybdenum manganese alloy ₂=7.5 * 10 ⁵, the just real relative permeability μ γ that gets ₂=100 μ γ ₁This derivation of equation is as follows:

The title in the derivation and the symbol table of comparisons are as follows:

Magnetic permeability mu silicon steel sheet relative permeability μ γ ₁

Umber of turn N molybdenum manganese alloy relative permeability μ γ ₂

The shared volume V cu of the heavy Gcu winding of winding copper

Copper loss Pcu magnetic circuit average length L

Elementary winding hollow is disconnected and is flowed I _oPower loss P _Decrease

Sky is disconnected and is flowed I _oMain flux Φ transformer capacity P

The heavy G of the long-pending S iron core iron of core section _Fe

The shared volume V of iron core _FeIron loss P _Fe

More than (descending) respective symbol bottom right footmark 1 be the corresponding techniques mark of reference of making transformer with prior art.Respective symbol bottom right footmark 2 for make transformer corresponding techniques mark of reference with wire-wound magnetic core full-shield transformer technology: $\mathrm{\&Phi;}=\frac{\mathrm{\&mu;NS}{I}_o}{L}$ (when P determines, Φ is constant, I _oΦ is not influenced).μ → big  N → little, S → little.If it is identical that N.S reduces ratio, we are as can be known so: $\mathrm{\&mu;}{\mathrm{\&gamma;}}_2=100\mathrm{\&mu;}{\mathrm{\&gamma;}}_1\&DoubleRightArrow;N_2{S}_2=\frac{N_1{S}_1}{100}\&DoubleRightArrow;N_2=\frac{N_1}{10},$ $S_2=\frac{S_1}{10}\&DoubleRightArrow;G_{\mathrm{cu}2}<\frac{G_{\mathrm{cu}1}}{10},G_{\mathrm{Fe}2}<\frac{G_{\mathrm{Fe}1}}{10}\&DoubleRightArrow;P_{\mathrm{cu}2}<\frac{P_{\mathrm{cu}1}}{10},$ $G_{\mathrm{cu}2}<\frac{G_{\mathrm{cu}1}}{10},G_{\mathrm{Fe}2}<\frac{G_{\mathrm{Fe}1}}{10}\&DoubleRightArrow;V_{\mathrm{cu}2}<\frac{V_{\mathrm{cu}1}}{10},V_{\mathrm{Fe}2}<\frac{V_{\mathrm{Fe}1}}{10}$ $\&DoubleRightArrow;V_2<\frac{V_1}{10}\&DoubleRightArrow;L_1>L_2\&DoubleRightArrow;N_2\&le;N_1,S_2\&le;S_1\&DoubleRightArrow;G_{\mathrm{cu}2}<G_{\mathrm{cu}1},G_{\mathrm{Fe}2}<G_{\mathrm{Fe}1}$  P _Cu2＜P _Cu1, P _Fe2＜P _Fe1 P _{Decrease 2}＜P _{Decrease 1}

Fig. 3 Fig. 4 is three-phase transformer manufacturing process flow diagram of the present invention and structure chart

Three-phase transformer is the single-phase transformer expanded application, and its structure and manufacture method and Fig. 1, structure shown in Figure 2 and technology are basic identical.The technique for coiling flow process is seen Fig. 3, and structure is seen Fig. 4, unique different be exactly that winding is divided into three sections, (seeing among the figure the netted hatching of lattice), and evenly arrange.

In manufacture process, also must meet following formula: $\mathrm{\&pi;}({\mathrm{\&gamma;}}_2^2-{\mathrm{\&gamma;}}_1^2)=\mathrm{\&pi;}{\mathrm{\&gamma;}}_2\frac{(L_4-{3L}_3)}{2}$ $=\mathrm{\&pi;}({\mathrm{\&gamma;}}_4^2-{\mathrm{\&gamma;}}_3^2)$ ＝Sc

Advantage of the present invention:

1,, thereby reduced iron-loss per unit weight and with iron amount G because this transformer magnetic (iron) core material has adopted the more excellent permeability alloys of magnetic property _Fe, so plant the iron loss P of magnetic (iron) core _FeAlso can correspondingly reduce.

2, since magnetic (iron) so the circuit in the core is the open-circuit condition eddy current can't circulate in magnetic (iron) core.So planting the whirlpool of magnetic (iron) core decreases minimum.

3, because magnetic (iron) core material of this transformer has adopted the better permeability alloys of magnetic property, thus the magnetic flux density Bm of magnetic (iron) core is increased, again because of $\mathrm{No}=\frac{{10}^4}{4.44\mathrm{fBmSc}}$ So Bm → big  No → little, the voltage turns ratio No event coil windings will reduce.Therefore so coil windings number of turn N also can correspondingly reduce copper loss Pcu and also can correspondingly reduce.

4, magnetic (iron) core is closed magnetic circuit, and is shielding coil windings, has therefore eliminated the electromagnetic leakage problem basically.In addition, also improved the heat conductivility of transformer effectively.

5, magnetic (iron) core and coil windings are coiling, have solved the processing compatibility problem of magnetic core and line chart winding.

Embodiment 1 single-phase transformer,

Get transformer internal diameter γ ₁=0.3cm, skeleton hollow shaft thickness=0.1cm

Transformer external diameter γ ₄=2.8cm, coil windings internal diameter γ ₂=1.3cm,

The transformer length L ₁=7.6cm, coil windings external diameter γ ₃=2.5cm,

The coil windings length L ₂=6.37cm.

Big clamp plate thickness=0.2cm; With molybdenum manganese alloy enamelled wire wound core, with copper enamelled wire coiling winding.Manufacture according to Fig. 1 Fig. 2 process chart, adopt the product structure of Fig. 2.

The efficient of small capacity transformer can improve 30～13%.

Embodiment 2 three-phase transformers

Get the single-phase length L of transformer ₃=1.72cm, three-phase coil winding total length 3L ₃=5.16cm,

The transformer length L ₄=7.6cm, big clamp plate thickness=0.2cm,

Other sizes are with embodiment 1

With molybdenum manganese alloy enamelled wire wound core, with copper enamelled wire coiling winding.

Make according to Fig. 3 Fig. 4 process chart, finished product adopts Fig. 4 structure, and the efficient of small capacity transformer can improve 30～13%.

Claims (4)

1, a kind of manufacture method of wire-wound magnetic core full-shield transformer, it is characterized in that at room temperature, on skeleton according to the first floor height magnetic conduction wire rod, the second floor height electric wire, the magnetic core of outermost floor height magnetic conduction wire rod wraps up the parcel relation of coil entirely, order is twined high magnetic conduction wire rod and electric wire, the single wire winding of the full-shield transformer device structure of finishing;

2, transformer according to claim 1 is characterized in that described high magnetic conduction wire rod is molybdenum manganese alloy or sloping film alloy enamelled wire;

3, transformer according to claim 1 is characterized in that described high electric wire is copper or aluminium enamel-covered wire.

4, a kind of wire-wound magnetic core full-shield transformer is characterized in that by with high magnetic conduction wire rod enamelled wire wound core, with high electric wire coiling, with the skeleton of anti-magnetic metal or paramagnetic metal or nonmetal support magnetic core of paramagnetic and coil, forms the full-shield structure;

Described coil is by the totally-enclosed parcel of the ectonexine of magnetic core, and draws the primary and secondary lead-in wire;

Described skeleton is made up of hollow axle plintlet and the big clamp plate nested with the left and right sides;

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