CN116564690A - Manufacturing method of server power transformer - Google Patents
Manufacturing method of server power transformer Download PDFInfo
- Publication number
- CN116564690A CN116564690A CN202310464591.7A CN202310464591A CN116564690A CN 116564690 A CN116564690 A CN 116564690A CN 202310464591 A CN202310464591 A CN 202310464591A CN 116564690 A CN116564690 A CN 116564690A
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- magnetic core
- positioning
- copper sheet
- flat coil
- flat
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 20
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 92
- 229910052802 copper Inorganic materials 0.000 claims abstract description 92
- 239000010949 copper Substances 0.000 claims abstract description 92
- 239000003292 glue Substances 0.000 claims abstract description 21
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims abstract description 15
- 238000003466 welding Methods 0.000 claims abstract description 14
- 238000005476 soldering Methods 0.000 claims abstract description 9
- 238000004804 winding Methods 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 24
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 230000000670 limiting effect Effects 0.000 claims description 4
- 239000011265 semifinished product Substances 0.000 claims description 4
- 239000000853 adhesive Substances 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 238000005452 bending Methods 0.000 claims description 2
- 229910000679 solder Inorganic materials 0.000 claims description 2
- 238000004026 adhesive bonding Methods 0.000 claims 1
- 230000000712 assembly Effects 0.000 description 8
- 238000000429 assembly Methods 0.000 description 8
- 230000008021 deposition Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000007888 film coating Substances 0.000 description 1
- 238000009501 film coating Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
Classifications
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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
-
- 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
-
- 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
-
- 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
- H01F41/076—Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02D—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN INFORMATION AND COMMUNICATION TECHNOLOGIES [ICT], I.E. INFORMATION AND COMMUNICATION TECHNOLOGIES AIMING AT THE REDUCTION OF THEIR OWN ENERGY USE
- Y02D10/00—Energy efficient computing, e.g. low power processors, power management or thermal management
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Coils Or Transformers For Communication (AREA)
Abstract
The invention discloses a manufacturing method of a server power transformer, which relates to the technical field of transformers and comprises the following steps of 1, mounting a copper sheet frame module: the copper sheet frame module comprises more than one copper sheet with tin plated surface and a connecting positioning sheet, wherein the copper sheet is provided with a preset positioning pin and an external pin; inserting the preset positioning pins into the corresponding positioning welding holes and soldering and fixing the preset positioning pins; 2. and (3) installing a flat coil module: the flat coil module comprises more than two flat coils, wherein the coil bodies of the flat coils are coated with glue and solidified, and then the wire ends are gathered into corresponding common binding posts; 3. staggering the flat coil modules into the copper sheet frame modules: inserting the flat coil into the gap between adjacent copper sheets; 4. installing a magnetic core; 5. mounting a magnetic core; 6. and (5) fixing by dripping insulating glue. The transformer is simple in structure, simple in manufacturing method, easy to control in assembly quality, suitable for manual assembly, and cost-saving in a manual assembly mode for small-batch special transformers, and does not depend on an automatic machine table.
Description
Technical Field
The invention relates to the technical field of transformers, in particular to a manufacturing method of a server power transformer.
Background
At present, copper sheet type transformers are increasingly applied to server power supplies, and the copper sheet type transformers have small volumes and can meet the application requirements of low voltage and high current.
For example, in CN 216980295U, a transformer with multiple copper sheets in a grouping and clamping manner is provided, which comprises a magnetic core body and a diversion pin assembly, the magnetic core body comprises a magnetic core assembly, a primary winding assembly and a plurality of secondary winding assemblies, the diversion pin assembly is arranged below the magnetic core body, the primary winding assembly and the secondary winding assemblies are alternately arranged at intervals, a secondary outlet pin of the secondary winding assembly is inserted into the diversion pin assembly, the secondary winding assemblies are formed by a plurality of secondary winding copper sheet assemblies in parallel, and the number of the secondary winding copper sheet assemblies is increased or decreased so as to meet the requirements of different output currents. When the assembly is carried out, the primary winding group and the plurality of secondary winding assemblies are required to be overlapped and sleeved on the magnetic core, after the assembly is completed, the magnetic core body is installed on the guide pin assembly, and concretely, the guide pin assembly comprises a U-shaped groove guide pin copper piece and a PCB bottom plate, the PCB bottom plate is provided with a pin positioning hole, and a secondary wire outlet pin of the assembled magnetic core body is inserted into the pin positioning hole.
The transformer structure and the assembly method have some disadvantages, such as: when the primary winding group and the secondary winding assemblies are stacked and sleeved on the magnetic core one by one, the circumferential positions of the primary winding group and the secondary winding assemblies are difficult to accurately position, after the components are stacked up and down, the secondary wire outlet pins are out of position accuracy controllability is not ideal, and then when the secondary wire outlet pins are inserted into the pin positioning holes, the pin positioning holes are required to be opened relatively widely, so that the problem of deviation of the position accuracy of the secondary wire outlet pins is solved, and in addition, special PCB bottom plates are required to be designed for different transformers, and for clients (such as server power supply factories, server production factories and the like), a plurality of working procedures are required for installing and applying the transformer, even if the PCB bottom plates are preset by a transformer manufacturer (the cost is increased), the space for placing the PCB bottom plates is reserved in the server power supply and how to form switching with the PCB bottom plates are required to be designed, so that more space is occupied in the server power supply, and the internal space layout of the server power supply is limited. And moreover, the assembly of the magnetic core body depends on the automatic assembly of a machine, and for a small-batch special transformer, the assembly process of the small-batch special transformer is suitable for a refitted machine, so that the cost is low, and if the assembly is carried out manually, the primary winding groups and the secondary winding groups are stacked and sleeved on the magnetic core one by one, so that the efficiency is low.
Therefore, a new technical solution is needed to solve the above problems.
Disclosure of Invention
In view of the above, the present invention aims at overcoming the drawbacks of the prior art, and its main objective is to provide a method for manufacturing a server power transformer, which has a simple structure, a simple manufacturing method, easy control of assembly quality, and is suitable for manual assembly, and for small-batch dedicated transformers, the manual assembly method saves cost and does not rely on an automaton table.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
a method for manufacturing a server power transformer comprises the following steps of
Step 1, a copper sheet frame module is installed: the copper sheet frame module comprises more than three copper sheets with tin plated surfaces and a connecting positioning sheet, wherein the copper sheets are provided with first through holes which are penetrated up and down, and are provided with preset positioning pins and external pins; the connecting positioning sheet is provided with more than three positioning welding holes which are arranged at right intervals up and down; inserting the pre-positioning pins of the copper sheet into corresponding positioning welding holes, and soldering the front side of the connecting positioning sheet so as to fix all the pre-positioning pins on the connecting positioning sheet in a welding way;
step 2, installing a flat coil module: the flat coil module comprises more than two flat coils, the flat coils are provided with second through holes which are penetrated up and down, the coil bodies of the flat coils are covered with glue to be solidified, then the end parts of the first wire heads of all the flat coils are gathered into a first common binding post, and the end parts of the second wire heads of all the flat coils are gathered into a second common binding post;
step 3, staggering the flat coil modules into the copper sheet frame modules: inserting the flat coil of the flat coil module into the gap between the adjacent copper sheets, wherein the second through hole is opposite to the first through hole;
step 4, mounting a magnetic core: the upper magnetic core comprises a top plate, an upper middle column and an upper side plate, wherein the upper middle column is formed by integrally extending downwards from the bottom of the top plate in a centering manner, and the upper side plate is formed by integrally extending downwards from the left side and the right side of the top plate respectively; the upper center column of the upper magnetic core extends downwards into the first through hole of the topmost copper sheet and continues to extend downwards, but does not reach the first through hole of the bottommost copper sheet;
step 5, mounting a magnetic core: the lower magnetic core comprises a bottom plate, a lower middle column and a lower side plate, wherein the lower middle column is formed by integrally extending upwards from the middle of the top of the bottom plate, and the lower side plate is formed by integrally extending upwards from the left side and the right side of the bottom plate respectively; turning upside down the semi-finished product assembled in the step 4 so that the top of the upper magnetic core is placed downwards, and then downwards extending a lower center pillar of the lower magnetic core into a first through hole of the copper sheet and continuing downwards extending until the lower center pillar and the upper center pillar are bonded and spliced into a center pillar, and bonding and splicing a lower side plate of the lower magnetic core and an upper side plate of the upper magnetic core into a side plate;
and 6, respectively dripping insulating glue at the front end and the rear end of the side plates, adhering and fixing the insulating glue on the upper side plate and the lower side plate, and adhering and fixing the copper sheet on the side plates by the insulating glue.
As a preferred scheme, the copper sheet is including encircling the annular body that the extension of first through-hole set up, the front end deviation department disconnection of annular body has the broken groove in order to communicate first through-hole with the outer loop side of annular body, the pre-positioning foot is followed the front end of annular body is placed in the middle and is extended the setting forward, external pin in the front end of annular body corresponds the left side or the integrative forward extension setting in right side of broken groove, the pre-positioning foot with external pin is located respectively the both sides of broken groove.
In step 1, when assembling, the lower end of the connecting locating piece is inserted into the locating hole of the jig, so that the connecting locating piece is vertically located, then the pre-locating pins of the copper sheets are inserted into the corresponding locating welding holes, all the copper sheets are located at the rear side of the connecting locating piece, and the external pins of the two copper sheets adjacent up and down extend forwards at the left side and the right side of the connecting locating piece respectively.
In a preferred embodiment, in step 1, solder is applied to the front side of the connection positioning piece and the front side of the connection positioning piece is connected to one piece.
As a preferable scheme, an external force bendable arm is connected between the preset pin and the central part of the front end of the annular body, so that in the step 2, the copper sheet can swing up and down for a certain angle range around the external force bendable arm when the flat coil module is assembled subsequently.
As a preferable scheme, the first wire end and the second wire end of the flat coil are reserved with extension lengthening sections for sleeving the identification protection tube, and the first wire end and the second wire end extend from the rear side of the flat coil at left-right intervals; after winding, glue is coated on the upper side and/or the lower side of the coil body, so that the size of the coil body is fixed, then the end parts of the first wire heads of all the flat coils are peeled off and exposed to be collected into a first common binding post, the end parts of the second wire heads of all the flat coils are peeled off and exposed to be collected into a second common binding post, and the first common binding post and the second common binding post are formed by winding core wires into bundles and then coating soldering tin outside.
In a preferred embodiment, in step 3, the flat coil is pushed forward to the bottom, and the front end of the flat coil abuts against the rear side surface of the connecting positioning piece to indicate that the flat coil is in place.
As a preferable scheme, the rear end of the annular body of the copper sheet is integrally extended backwards to form a widened part, the widened part protrudes out of the rear end of the upper magnetic core, the left side and the right side of the widened part are utilized to be positioned or adhesively connected with the inner wall surface of the upper side plate of the upper magnetic core, a gap for extending and positioning an extension section is formed between the upper and lower adjacent widened parts, the extension section extends out of the gap, the subsequent extension section is limited by the limiting effect of the widened part when being bent, and the joint part of the extension section and the ring body is prevented from being pulled and loosened by stress.
As a preferred solution, the insulating glue adhesively fixes the widened portion to the side plate.
Compared with the prior art, the invention has obvious advantages and beneficial effects, in particular, the technical scheme is that the two windings are formed mainly through the arrangement of the copper sheet frame module and the flat coil module, the copper sheet frame module is skillfully utilized as a frame, then the flat coil module is inserted into the frame, and then the magnetic core and the lower magnetic core are arranged. In addition, the assembled transformer is convenient to wire when applied to a PCB, and is very convenient to install and apply to a client when applied to a server power supply, so that the assembly process of the client is simplified.
In order to more clearly illustrate the structural features and efficacy of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and examples.
Drawings
FIG. 1 is a top view of a server power transformer according to an embodiment of the present invention;
FIG. 2 is a partial top view of a server power transformer of an embodiment of the present invention after concealing the upper core and the terminal ends of the flat coil;
FIG. 3 is a top view of the upper and lower cores of a server power transformer according to an embodiment of the present invention;
FIG. 4 is a top view of a copper sheet frame module of a server power transformer according to an embodiment of the present invention;
FIG. 5 is an exploded view of a copper sheet frame module of a server power transformer according to an embodiment of the present invention;
FIG. 6 is a front view (i.e., front view) of a server power transformer according to an embodiment of the present invention;
FIG. 7 is an exploded view of a flat coil module according to an embodiment of the present invention;
FIG. 8 is a perspective view of a flat coil module (generally illustrating the integration of its terminal ends into corresponding common posts) according to an embodiment of the present invention;
fig. 9 is a schematic view of a flat coil module according to an embodiment of the present invention.
The attached drawings are used for identifying and describing: copper sheet frame module 10, copper sheet 11, connection spacer 12, first through hole 111, annular body 112, breaking groove 113, pre-positioning pin 114, external pin 115, widening 116, positioning welding hole 121, bendable arm 117 capable of external force, flat coil 21, second through hole 211, coil body 212, wire end 213, identification protection tube 214, first common terminal 215, second common terminal 216, upper magnetic core 30, upper center post 31, lower magnetic core 40, lower center post 41, and insulating glue 50.
Detailed Description
Referring to fig. 1 to 9, specific structures of embodiments of the present invention are shown.
In the description of the present invention, it should be noted that the azimuth or positional relationship indicated by the terms "upper", "lower", "left", "right", etc. are based on the azimuth or positional relationship shown in the drawings, and are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the apparatus or element referred to must have a specific azimuth, be constructed and operated in a specific azimuth, and thus should not be construed as limiting the present invention.
A method for manufacturing a server power transformer comprises the following steps of
Step 1, a copper sheet frame module 10 is installed: the copper sheet frame module comprises more than three copper sheets 11 with the surfaces being plated with tin and a connecting positioning sheet 12, wherein the connecting positioning sheet 12 is also plated with tin on the surfaces of copper base materials; the copper sheet with tin plated on the surface is adopted, namely, a layer of bright metal tin is deposited on the surface of the copper, so that the weldability and the decorativeness of the copper can be improved, the conductivity is not affected, meanwhile, the oxidation and the color change are prevented, the rust-proof period is prolonged, and the attractiveness of copper workpieces is improved. During manufacturing, the bare copper sheet is manufactured by punching, and then the procedures of degreasing, polishing, washing, chemical tinning (namely, putting the copper sheet into chemical tinning liquid for about 6 minutes), washing, drying by cold air and the like are sequentially carried out on the bare copper sheet, so that the copper sheet with the surface tinned is obtained. In consideration of the thickness requirement of tin, the tin deposition time can be adjusted and/or the tin deposition operation can be repeated more than twice. The copper sheet 11 has a first through hole 111 penetrating up and down, the copper sheet 11 includes an annular body 112 extending around the first through hole 111, a break groove 113 is broken at a front end of the annular body 112 away from a middle position so as to communicate the first through hole 111 with an outer ring side of the annular body 112 by using the break groove 113, a pre-positioning pin 114 extends forward from the middle of the front end of the annular body 112, an external pin 115 extends forward integrally from the front end of the annular body 112 corresponding to a left side or a right side of the break groove 113, the pre-positioning pin 114 and the external pin 115 are two pins of the copper sheet, and the pre-positioning pin 114 and the external pin 115 are respectively positioned at two sides of the break groove 113 in a left-right direction; the connecting and positioning sheet 12 is in a vertically extending sheet shape, and is provided with more than three positioning welding holes 121 which are vertically opposite to each other and are arranged at intervals, the lower end of the connecting and positioning sheet 12 is extended with PCB connecting pins, the left and right widths of the PCB connecting pins are slightly smaller than the body part of the connecting and positioning sheet 12, and the connecting and positioning sheet is in a T shape, so that the positioning is convenient when the subsequent transformer is downwards inserted into the first connecting hole on the PCB. During assembly, the lower end of the connection positioning sheet 12 is inserted into the positioning hole of the jig to enable the connection positioning sheet 12 to be vertically positioned, then the pre-positioning pins 114 of the copper sheets are inserted into the corresponding positioning welding holes 121 (before assembly, the surfaces of the copper sheets are covered with insulating films, only the pre-positioning pins 114 and the external pins 115 are exposed, and the insulating films are automatically pasted after the copper sheets are automatically punched out), all the copper sheets are positioned at the rear side of the connection positioning sheet 12, the external pins 115 of two copper sheets adjacent to each other up and down extend forwards at the left side and the right side of the connection positioning sheet 12 respectively, and the external pins 115 and the connection positioning sheet 12 keep a distance to avoid short circuit; finally, soldering is performed on the front side of the connection location sheet 12 to weld and fix all the pre-location pins 114 on the connection location sheet 12, so as to form the copper sheet frame module 10; the front side of the connection location piece 12 can be covered with soldering tin to form a piece, which plays a role in increasing the front and back thickness of the connection location piece 12 and strengthens the structural strength of the connection location piece 12. The preset pins 114 and the central portion of the front end of the annular body 112 are connected with an externally bendable arm, the left-right width of the externally bendable arm is smaller than the left-right width of the preset pins 114, and generally, two externally bendable arms 117 with left-right spacing are formed by punching, so that the copper sheet is easy to process, and meanwhile, when the copper sheet is subsequently assembled into a flat coil module, the copper sheet can swing up and down by a certain angle range around the externally bendable arms 117, so that the flat coil module can be successfully and quickly assembled, and as the externally bendable arm 117 can swing only in a small angle range (for example, 5-15 degrees in an up-down swinging manner) which is possibly required for assembling the flat coil module, the bending loss of the externally bendable arm 117 is avoided.
Step 2, installing a flat coil module 20: the flat coil module 20 includes more than two flat coils 21, the flat coils 21 have a second through hole penetrating up and down, the flat coils 21 are formed by winding thin wires with insulated outer surfaces around the second through hole 211, the wound coil body 212 may be wound with one layer or two layers stacked up and down, the two wire ends 213 (i.e. the first wire end and the second wire end) of the flat coils 21 are reserved with an extension section for sleeving the identification protection tube 214, the first wire end and the second wire end extend from the left and right sides of the rear side of the flat coils 21 at a left and right distance, the coil body 212 of the flat coils 21 is impregnated with glue and cured (i.e. the wound coil body 212 is put into a liquid glue and is taken out, dried or air-dried and cured), or glue-cured, etc. for example, when the coil body 212 is wound, the position of the second through hole 211 is penetrated by a jig boss, so that after the winding is finished, the coil body 212 is covered with glue on the upper side and/or lower side of the coil body 212, so that the coil body 212 is fixed in a better consistency. And then peeling and exposing the ends of the first wire ends of all the flat coils 21 to collect into a first common binding post 215, peeling and exposing the ends of the second wire ends of all the flat coils 21 to collect into a second common binding post 216, wherein the first common binding post 215 and the second common binding post 216 are formed by winding each core wire into a bundle and then coating soldering tin, are cylindrical or approximately cylindrical, and are convenient to be directly inserted into corresponding second connecting holes and third connecting holes of a PCB (printed circuit board) and then welded and fixed.
Step 3, staggering the flat coil 21 and the flat coil 21 module 20 into the copper sheet frame module 10: inserting the flat coil 21 of the flat coil 21 module 20 into the gap between the adjacent copper sheets, and pushing the flat coil 21 forward to the bottom, namely, the front end of the flat coil 21 abuts against the rear side surface of the connecting positioning sheet 12 to indicate that the flat coil 21 is in place, wherein the second through hole 211 is opposite to the first through hole 111;
step 4, installing a magnetic core 30: the upper magnetic core 30 comprises a top plate, an upper middle column 31 and an upper side plate, wherein the upper middle column 31 is formed by integrally extending downwards from the bottom of the top plate in a centering manner, and the upper side plate is formed by integrally extending downwards from the left side and the right side of the top plate respectively; the upper middle column 31 of the upper magnetic core 30 extends downwards into the first through hole 111 of the topmost copper sheet and continues to extend downwards into the first through hole 111 of the bottommost copper sheet, but does not reach the inside; because the rear end of the annular body 112 of the copper sheet integrally extends backwards to form a widened portion 116, the widened portion 116 protrudes beyond the rear end of the upper magnetic core 30, the left side and the right side of the widened portion can be used for positioning or adhesively connecting and positioning with the inner wall surface of the upper side plate of the upper magnetic core 30, meanwhile, the rear end of the widened portion plays a role in protecting the upper magnetic core 30, for the whole transformer, the limit size of the rear end is limited by the rear end of the widened portion 116, a gap for extending and positioning an extension section can be formed between two upper and lower adjacent widened portions 116, and when the subsequent extension section is bent, the subsequent extension section is limited by the limiting function of the widened portion, so that the joint part of the extension section and the ring body 212 is prevented from being pulled and loosened by stress.
Step 5, mounting the magnetic core 40: the lower magnetic core 40 comprises a bottom plate, a lower middle column 41 and a lower side plate, the lower middle column 41 is formed by integrally extending upwards from the middle of the top of the bottom plate, and the lower side plate is formed by integrally extending upwards from the left side and the right side of the bottom plate respectively; the semi-finished product assembled in the step 4 is firstly lifted up from the jig and turned upside down, so that the top of the upper magnetic core 30 is placed downwards, then the lower middle column 41 of the lower magnetic core 40 is downwards extended into the first through hole 111 of the copper sheet and is continuously downwards extended until the lower middle column 41 and the upper middle column 31 are bonded and spliced into a middle column, and the lower side plate of the lower magnetic core 40 and the upper side plate of the upper magnetic core 30 are bonded and spliced into side plates (namely a left side plate and a right side plate).
Step 6, respectively dripping insulating glue 50 at the front end and the rear end of the side plates, adhering and fixing the insulating glue 50 on the upper side plate and the lower side plate, and adhering and fixing the widened part 116 on the side plates by the insulating glue 50; thus, the transformer quality assembly is completed.
It should be noted that, in this embodiment, the stamping and insulating film coating of the copper sheet are performed on the automaton, the connection positioning sheet 12 is also formed by stamping the automaton, the copper sheet can be manually inserted on the connection positioning sheet 12, the welding can be performed manually or by a welding machine, the flat coil 21 of the flat coil 21 module 20 is wound by the automaton, the insulating adhesive is coated and solidified, the sleeve identification protection tube can be manually or automatically sleeved into the thermal shrinkage identification protection tube, the end of the wire end of the flat coil 21 is peeled and the core is exposed to be assembled into a common binding post, preferably performed manually, or the core wire is manually combined with the semi-automaton to complete peeling, the winding of the core wire into a bundle and the coating of the soldering tin are performed manually, the steps 3, 4 and 5 are performed manually, and the step 6 can be manually or automatically drip the insulating adhesive on the automaton. In a word, the whole process is not dependent on an automatic machine table, and the process which can be automatically completed by the automatic machine table can be performed by a universal machine table without changing the machine table. The first step is to assemble the copper sheets around to form a frame, so that the accurate control of the positions of the pre-positioning pins 114 (also referred to as one pin of the copper sheets) is ensured, the gaps between the adjacent copper sheets are accurately controlled, the relative positions of the pre-positioning pins 114 and the external pins 115 are easily controlled by stamping metal pieces for the copper sheets, and the positions of the pre-positioning pins 114 are determined during assembly, so that the position accuracy of the external pins 115 is ensured, and therefore, the position accuracy of the pre-positioning pins 114 and the external pins 115 is reliably ensured for a plurality of copper sheets; on the basis of forming the frame, the flat coil 21 module 20 of the flat coil 21 can be simply and quickly inserted into place, the dimension consistency of the flat coil 21 is good in controllability, the first through hole 111 and the second through hole 211 can be easily and completely opposite to each other, and the assembly of the magnetic core 30 and the lower magnetic core 40 is smooth. In the whole assembly process, the PCB connecting pins connected with the lower ends of the positioning sheets 12 are used for process positioning in the step 1, so that no additional positioning tool is needed in the frame assembly process of the step 1, after the frame is obtained, the flat coil 21 module 20 of the flat coil 21 module of the step 3 is inserted into the frame, and no additional positioning tool is needed in the step of installing the magnetic core 30 of the step 4, after the magnetic core 30 is installed, the semi-finished product is turned upside down, the top of the upper magnetic core 30 is placed downwards, the bottom datum positioning can be realized, no additional positioning tool is needed in the subsequent step 5, the additional positioning tool is also not needed in the step of installing the lower magnetic core 40, and likewise, the glue dispensing step of the step 6 is also not needed in the additional positioning tool after the assembly of the lower magnetic core 40 is completed.
The invention mainly uses copper sheet frame module 10 and flat coil 21 module 20 to form two windings, skillfully uses copper sheet windings as a frame, firstly installs copper sheet frame module 10, then inserts flat coil 21 module 20 of flat coil 21 into the frame, and subsequently installs magnetic core 30 and lower magnetic core 40. In addition, the assembled transformer is convenient to wire when applied to a PCB, and is very convenient to install and apply to a client when applied to a server power supply, so that the assembly process of the client is simplified.
The foregoing description is only a preferred embodiment of the present invention, and is not intended to limit the technical scope of the present invention, so any minor modifications, equivalent changes and modifications made to the above embodiments according to the technical principles of the present invention are still within the scope of the technical solutions of the present invention.
Claims (9)
1. A manufacturing method of a server power transformer is characterized by comprising the following steps: comprises the following steps of
Step 1, a copper sheet frame module is installed: the copper sheet frame module comprises more than three copper sheets with tin plated surfaces and a connecting positioning sheet, wherein the copper sheets are provided with first through holes which are penetrated up and down, and are provided with preset positioning pins and external pins; the connecting positioning sheet is provided with more than three positioning welding holes which are arranged at right intervals up and down; inserting the pre-positioning pins of the copper sheet into corresponding positioning welding holes, and soldering the front side of the connecting positioning sheet so as to fix all the pre-positioning pins on the connecting positioning sheet in a welding way;
step 2, installing a flat coil module: the flat coil module comprises more than two flat coils, the flat coils are provided with second through holes which are penetrated up and down, the coil bodies of the flat coils are covered with glue to be solidified, then the end parts of the first wire heads of all the flat coils are gathered into a first common binding post, and the end parts of the second wire heads of all the flat coils are gathered into a second common binding post;
step 3, staggering the flat coil modules into the copper sheet frame modules: inserting the flat coil of the flat coil module into the gap between the adjacent copper sheets, wherein the second through hole is opposite to the first through hole;
step 4, mounting a magnetic core: the upper magnetic core comprises a top plate, an upper middle column and an upper side plate, wherein the upper middle column is formed by integrally extending downwards from the bottom of the top plate in a centering manner, and the upper side plate is formed by integrally extending downwards from the left side and the right side of the top plate respectively; the upper center column of the upper magnetic core extends downwards into the first through hole of the topmost copper sheet and continues to extend downwards, but does not reach the first through hole of the bottommost copper sheet;
step 5, mounting a magnetic core: the lower magnetic core comprises a bottom plate, a lower middle column and a lower side plate, wherein the lower middle column is formed by integrally extending upwards from the middle of the top of the bottom plate, and the lower side plate is formed by integrally extending upwards from the left side and the right side of the bottom plate respectively; turning upside down the semi-finished product assembled in the step 4 so that the top of the upper magnetic core is placed downwards, and then downwards extending a lower center pillar of the lower magnetic core into a first through hole of the copper sheet and continuing downwards extending until the lower center pillar and the upper center pillar are bonded and spliced into a center pillar, and bonding and splicing a lower side plate of the lower magnetic core and an upper side plate of the upper magnetic core into a side plate;
and 6, respectively dripping insulating glue at the front end and the rear end of the side plates, adhering and fixing the insulating glue on the upper side plate and the lower side plate, and adhering and fixing the copper sheet on the side plates by the insulating glue.
2. The method for manufacturing the server power transformer according to claim 1, wherein: the copper sheet is including encircling the annular body that first through-hole extends the setting, the front end deviation department of annular body breaks off in the middle has the broken channel in order to communicate first through-hole with the outer loop side of annular body, the pre-positioning foot is followed the front end of annular body is placed in the middle and is extended the setting forward, external pin in the front end of annular body corresponds the left side or the integrative forward extension setting in right side of broken channel, the pre-positioning foot with external pin is located respectively the both sides of broken channel.
3. The method for manufacturing the server power transformer according to claim 1, wherein: in step 1, during assembly, the lower end of the connecting locating piece is inserted into the locating hole of the jig first, so that the connecting locating piece is vertically located, then the pre-locating pins of the copper sheets are inserted into the corresponding locating welding holes, all the copper sheets are located at the rear side of the connecting locating piece, and the external pins of the two copper sheets, which are adjacent up and down, extend forwards at the left side and the right side of the connecting locating piece respectively.
4. The method for manufacturing the server power transformer according to claim 1, wherein: in step 1, solder is coated on the front side of the connecting and positioning sheet to be connected into a whole.
5. The method for manufacturing the server power transformer according to claim 1, wherein: in the step 2, the copper sheet can swing up and down for a certain angle range around the external force bending arm when the flat coil module is assembled subsequently.
6. The method for manufacturing the server power transformer according to claim 1, wherein: the first wire end and the second wire end of the flat coil are reserved with extension lengthening sections for sleeving the identification protection tubes, and the first wire end and the second wire end extend from the rear side of the flat coil at left-right intervals; after winding, glue is coated on the upper side and/or the lower side of the coil body, so that the size of the coil body is fixed, then the end parts of the first wire heads of all the flat coils are peeled off and exposed to be collected into a first common binding post, the end parts of the second wire heads of all the flat coils are peeled off and exposed to be collected into a second common binding post, and the first common binding post and the second common binding post are formed by winding core wires into bundles and then coating soldering tin outside.
7. The method for manufacturing the server power transformer according to claim 1, wherein: in step 3, the flat coil is pushed forward to the bottom, and the front end of the flat coil abuts against the rear side surface of the connecting positioning piece to indicate that the flat coil is put in place.
8. The method for manufacturing the server power transformer according to claim 1, wherein: the rear end of the annular body of the copper sheet integrally extends backwards to form a widened part, the widened part protrudes out of the rear end of the upper magnetic core, the left side and the right side of the widened part are utilized to be positioned or are connected and positioned by gluing with the inner wall surface of the upper side plate of the upper magnetic core, a gap for extending and positioning an extension section is formed between the upper and lower adjacent widened parts, the extension section extends out of the gap, the subsequent extension section is limited by the limiting effect of the widened part when being bent, and the joint part of the extension section and the ring body is prevented from being pulled and loosened by stress.
9. The method for manufacturing the server power transformer according to claim 8, wherein: the widened portion is adhered and fixed on the side plate through the insulating adhesive.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310464591.7A CN116564690A (en) | 2023-04-26 | 2023-04-26 | Manufacturing method of server power transformer |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310464591.7A CN116564690A (en) | 2023-04-26 | 2023-04-26 | Manufacturing method of server power transformer |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN116564690A true CN116564690A (en) | 2023-08-08 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310464591.7A Pending CN116564690A (en) | 2023-04-26 | 2023-04-26 | Manufacturing method of server power transformer |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN116564690A (en) |
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2023
- 2023-04-26 CN CN202310464591.7A patent/CN116564690A/en active Pending
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