CN116844851A - A new winding method for PFC inductors - Google Patents

Abstract

The invention provides a winding method of a PFC inductor by a novel winding method, which comprises the following steps: acquiring an enameled wire and a PFC inductor to be wound; dividing the enameled wire into two sections, determining the length of one end of the enameled wire, and winding the enameled wire in the core in the above dividing mode; one end of the enameled wire and the other end of the enameled wire are respectively wound in two directions, and after reaching a winding preset value, the enameled wire is reversely wound, and the end point is the initial branching point to finish a first-section winding and a second-section winding; and the wire length of the residual enameled wire is subjected to back and forth wire arrangement operation in the residual space of the magnetic core to finish the residual section of winding, and the number of turns of the winding of the first section of winding, the second section of winding and the residual section of winding are equal. The invention solves the problems of low winding efficiency, poor impedance performance, higher turn-to-turn capacitance of the finished product inductance, increased heating value of PFC inductance and reduced working efficiency.

Description

A new winding method for PFC inductors

Technical field

The present invention relates to the technical field of new energy magnetic devices, and in particular to a new winding method for winding PFC inductors.

Background technique

The PFC inductor is the core component of the PFC circuit. Among them, the iron-silicon-aluminum PFC inductor core is made of iron-silicon-aluminum material, which not only has good current superposition performance but also has a negative temperature coefficient. It also has good constant inductance characteristics and resistance to DC bias. With the continuous improvement of system efficiency, the requirements for the inter-winding capacitance, inter-layer capacitance, winding capacitance and spectrum curve of PFC inductors are also increasing.

Traditional PFC inductors are wound in a forward winding manner. The winding efficiency is low, the impedance performance is poor, and the inter-turn capacitance of the finished inductor is high. This results in an increase in the heat generated by the PFC inductor and a reduction in working efficiency. It is difficult to meet the requirements of the existing circuit system. need.

Contents of the invention

In order to overcome the shortcomings of the existing technology, the purpose of the present invention is to provide a new winding method for PFC inductors. The present invention solves the problem of low winding efficiency, poor impedance performance and high inter-turn capacitance of the finished inductor. The problem of increased heat generation and reduced working efficiency of PFC inductors.

In order to achieve the above objects, the present invention provides the following solutions:

A new winding method for PFC inductors, including:

Obtain the enameled wire and the PFC inductor to be wound;

Divide the enameled wire into two sections, determine the length of one end of the enameled wire and wind the enameled wire inside the magnetic core in the above dividing method;

One end of the enameled wire and the other end of the enameled wire are wound in two directions respectively. After reaching the preset value of the winding, they are wound in the opposite direction. The end point is the starting branch line, and the first winding and the second winding are completed;

The remaining length of the enameled wire is arranged back and forth in the remaining space of the magnetic core to complete the remaining section winding. The number of turns of the first section winding, the second section winding and the remaining section winding is equal.

Preferably, the material of the PFC inductor is iron-silicon, iron-silicon-aluminum, or iron-nickel.

Preferably, dividing the enameled wire into two sections includes:

One section of the enameled wire is 1/3 of the total length, and the other section is 2/3 of the total length of the enameled wire.

Preferably, the production process of the enameled wire is:

Obtain embryo material;

The blank is subjected to multiple large stretches to obtain a primary wire;

Clean the primary wire to obtain the secondary wire;

Perform annealing treatment on the secondary wire rod to obtain an annealed secondary wire rod;

Perform cooling treatment on the annealed secondary wire rod to obtain a cooled wire rod;

Paint and bake the cooled wire to obtain a primary enameled wire;

Perform secondary cooling treatment on the primary enameled wire to obtain a secondary enameled wire;

The secondary enameled wire is lubricated and taken up to obtain the enameled wire.

According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects:

The present invention provides a new winding method for PFC inductor. By using multi-section winding of enameled wire, the impedance characteristics of the PFC inductor can be improved, the inter-turn capacitance and inter-layer capacitance of the winding can be reduced, and the temperature rise of the product can be reduced. , improve the overall performance of the PFC inductor.

Description of the drawings

In order to explain the embodiments of the present invention or the technical solutions in the prior art more clearly, the drawings needed to be used in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some of the drawings of the present invention. Embodiments, for those of ordinary skill in the art, other drawings can also be obtained based on these drawings without exerting creative efforts.

Figure 1 is a flow chart of a winding method for a new type of PFC inductor in an embodiment of the present invention;

Figure 2 is a schematic diagram of multi-section winding in an embodiment of the present invention;

Figure 3 is a comparison chart of the impedance characteristics of the traditional conventional winding method and the multi-stage PFC inductor winding method under the same conditions in the embodiment of the present invention.

Detailed ways

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.

The purpose of the present invention is to provide a new winding method for PFC inductors. The present invention solves the problem of low winding efficiency, poor impedance performance and high inter-turn capacitance of the finished inductor, which results in increased heat generation of the PFC inductor and poor work efficiency. reduce the problem.

In order to make the above objects, features and advantages of the present invention more obvious and understandable, the present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments.

As shown in Figure 1, the present invention provides a new winding method for PFC inductors, including:

Step 100: Obtain the enameled wire and the PFC inductor to be wound;

Step 200: Divide the enameled wire into two sections, determine the length of one end of the enameled wire, and wind the enameled wire inside the magnetic core in the above dividing method;

Step 300: One end of the enameled wire and the other end of the enameled wire are wound in two directions respectively. After reaching the winding preset value, the winding is performed in the opposite direction. The end point is the starting branch line, and the first winding and the second winding are completed. winding;

Step 400: The remaining length of the enameled wire is arranged back and forth in the remaining space of the magnetic core to complete the remaining section winding. The number of turns of the first section winding, the second section winding and the remaining section winding is equal.

As shown in Figure 2-3, PFC inductors usually use alloy cores, such as iron-silicon, iron-silicon-aluminum, iron-nickel and other materials.

Further, taking the three-section type as an example: dividing the enameled wire into two sections includes:

One section of the enameled wire is 1/3 of the total length, and the other section is 2/3 of the total length of the enameled wire. The enameled wire is divided into two sections: one section is 1/3 of the total length, and the other end is 2/3 of the total length; the enameled wire is inside the magnetic core. Winding is carried out in the above splitting method; the enameled wires at both ends are wound in two directions, with the winding range being 2/3 of the outer circumference of the magnetic core, and then wound in the opposite direction, with the end point being the starting splitting point. Winding back and forth; the remaining 1/3 of the 2/3 wire head part is used in the remaining space of the magnetic core to arrange the wire; the number of turns of the three partial windings is equal to achieve three-stage winding. By analogy, you can start with multi-stage winding. Winding.

Table 1 is the impedance test data table under different winding methods. Table 1 is as follows:

Further, the production process of the enameled wire is:

Step 1: Obtain the blank and prepare the copper material as the blank. The copper material is industrial pure copper with a purity of more than 99.95% and a conductivity of not less than 98%. When preparing the copper material, check whether its size is within the tolerance range and Ensure that the appearance of the copper material is free of oxidation, burrs, and cracks;

Step 2: Perform multiple large drawings on the blank to obtain a primary wire. The copper material is stretched multiple times at a speed of 780-980m/min until the diameter is 6-8 times the diameter of the final wire. Stretch the greatly stretched wire multiple times to the final diameter of the wire at a speed of 1000-1100m/min;

Step 3: Clean the primary wire to obtain a secondary wire, and clean the wire processed in step 2) through a cleaning device to remove oil stains and particles on the surface of the wire after drawing;

Step 4: Perform annealing treatment on the secondary wire rod to obtain an annealed secondary wire rod, and anneal the cleaned wire rod in a 460-700°C annealing furnace;

Step 5: Perform cooling treatment on the annealed secondary wire rod to obtain a cooled wire rod, which is used to cool the annealed wire rod;

Step 6: Paint and bake the cooled wire to obtain a primary enameled wire, paint the surface of the wire processed in step 5), and bake and solidify after painting;

Step 7: Perform a secondary cooling process on the primary enameled wire to obtain a secondary enameled wire, and cool it again to make the performance of the enameled wire better;

Step 8: Lubricate and take up the secondary enameled wire to obtain the enameled wire, apply lubricant to the surface of the baked wire through a lubrication device, take up the wire by the take-up device, and transport the rolled wire Store in storage warehouse.

The beneficial effects of the present invention are as follows:

It can improve the impedance characteristics of PFC inductors, reduce the inter-winding capacitance and inter-layer capacitance, reduce the temperature rise of the product, and improve the overall performance of PFC inductors.

Each embodiment in this specification is described in a progressive manner. Each embodiment focuses on its differences from other embodiments. The same and similar parts between the various embodiments can be referred to each other.

This article uses specific examples to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only used to help understand the method and the core idea of the present invention; at the same time, for those of ordinary skill in the art, according to the present invention There will be changes in the specific implementation methods and application scope of the ideas. In summary, the contents of this description should not be construed as limitations of the present invention.

Claims (4)

1. The winding method of the PFC inductor by the novel winding method is characterized by comprising the following steps of:

acquiring an enameled wire and a PFC inductor to be wound;

dividing the enameled wire into two sections, determining the length of one end of the enameled wire, and winding the enameled wire in the core in the above dividing mode;

one end of the enameled wire and the other end of the enameled wire are respectively wound in two directions, and after reaching a winding preset value, the enameled wire is reversely wound, and the end point is the initial branching point to finish a first-section winding and a second-section winding;

and the wire length of the residual enameled wire is subjected to back and forth wire arrangement operation in the residual space of the magnetic core to finish the residual section of winding, and the number of turns of the winding of the first section of winding, the second section of winding and the residual section of winding are equal.

2. The method for winding the PFC inductor according to claim 1, wherein the PFC inductor is made of iron-silicon, iron-silicon-aluminum and iron-nickel.

3. The method for winding the PFC inductor according to claim 1, wherein the step of dividing the enamel wire into two sections comprises:

one section of the enameled wire is 1/3 of the total length, and the other section is 2/3 of the total length of the enameled wire.

4. The winding method of the novel winding PFC inductor according to claim 1, wherein the production process of the enameled wire is as follows:

obtaining a blank;

carrying out large stretching on the blank for multiple times to obtain a primary wire rod;

cleaning the primary wire rod to obtain a secondary wire rod;

annealing the secondary wire rod to obtain an annealed secondary wire rod;

cooling the annealed secondary wire rod to obtain a cooled wire rod;

painting and baking the cooled wire rod to obtain a primary enamelled wire;

performing secondary cooling treatment on the primary enameled wire to obtain a secondary enameled wire;

and carrying out lubrication and wire winding treatment on the secondary enameled wire to obtain the enameled wire.