DE1488795A1 - Transformer structure and process for its manufacture - Google Patents

Description

Transformer structure and process for its manufacture

The invention relates to electrical transformers and methods of making them.

For many decades, the great variety of different requirements in the field of transformer construction has Standardization and storage of transformers with variable exposure parameters prevented, as is the case with other types of electrical components, e.g. Resistors, capacitors and the like, yes long is possible. Every electrical appliance manufacturer has lost time and costs, such as those resulting from the winding of special transformers. These

Difficulty is based on the fact that not just different Wattage, but also one and the same wattage for a variety of different voltages in both primary and can also apply to the secondary winding. A task of the invention is to create new standardized transformer cores as well as several windings that are in different combinations can be assembled from elements kept in stock and thus the convenient construction of any transformer with any

9 O 9 8 1 5 / Q 5 5 1 BAD ORIGINAL

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Η88795

enable the desired primary or secondary voltage.

Another object of the invention is to provide a new To create transformer structure.

It is also an object of the invention to provide a new method for the manufacture of transformers to create the enables the user to select suitable sizes of standardized cores and windings and thus to meet every need and all Requirements essentially to be able to meet.

Further objects of the invention will become apparent from the description and are readily available in connection with the claims evident.

The invention is to be described in more detail below with reference to the drawing explained. Show it:

Figure 1 is an isometric view of an embodiment the invention and a side-by-side arrangement of the windings,

Figure 2 is a side view of a modified coaxial windings for mounting in the shown in Fig arrival 1, ₅ ~ -. Order. ,.

Figure 3 is a side view of a modified core and

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Figure 4 is also a side view of a modified one Kerns.

In Figure 1, a magnetic core 2 ^{1 is shown} in the usual design with plane-parallel silicon steel lamellae in the form of a three-legged, essentially E-shaped core 1'-1 '' - 1 '''which is located at the free ends of the legs 1' and 1 '''tapered to include two magnetic pole shoes 3' and 3. ' · Record. The pole shoes 3 'and 3 ^r ' are also correspondingly conical so that they fit into the space between the free end parts of the legs 1 ', 1' ^r and 1 '''and thus the ring of lines of magnetic flux around the core 2 ¹ close.

If the magnetic pole shoes 3 ¹ and 3 ^{11 are} removed or separated from the rest of the core 2 ', two separate annular windings W and ¥ _, which will be described later, can be placed next to one another on the middle leg 1 ^{11 of} the core 2'. The removable pole pieces 3 'and 3 ¹¹ can then be used for locking within the free space between the band parts of the legs 1' -1 '' or 1 '* -i''' and thus close the ring of the magnetic force flux lines. A resilient clamp or holding device 6, which is substantially L-shaped and has end and ^{central projections δ, δ ', β 11} , etc., can then be wrapped around the entire transformer assembly so that it is held in place, the projections in correspondingly arranged recesses 9 ^{, 9, 1} , 9 ″, etc. engage in the periphery of the core 2.

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In contrast to the usual transformers, the ring-shaped primary and secondary windings W ₁ and W _{2 of} the present invention are wound from copper wire on separate bobbins and separately embedded in plastic or another preferably elastic material, as is generally the case at 10 and 10 ' is shown. In the exemplary embodiment shown in FIG. 1, the internal configuration and the dimensions of the windings W ₁ and W ₂ essentially correspond to those of the internal one. Leg 1 '' on which the

up windings are mounted. A tight fit, which can be achieved by a somewhat conical limb, supported by the elastic character of the embedding material at 10 or 10 ·, causes the mounted windings W and W ₂ on the limb 1 · 'at an unchangeable distance are held from each other, wherein, if desired, an elastic spacer, a washer or a resilient insert or several such elements 11 can be used to prevent mutual displacement of the mounted windings in the event of a vibration of the transformer.

The separate core embedding construction of the windings W. and Wp fulfills other important things besides the holding described above Functions. This not only protects the environment, but also - a considerable reduction in the necessary tolerances the winding dimensions achieved with simultaneous maximum use of the winding space. A precise and compact mechanical Assembly is also achieved without any special

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Skill in assembling or a special expenditure of time would be required. Easy adjustment of the mutual connection between the windings, as well as others Adjustment operations, including convenient interchangeability of the windings, which are not possible with the usual fully embedded transformer designs, form features of the transformer according to the invention.

Although the foregoing is an easy to perform method of assembling transformers, and the fully assembled The subject of the transformer, whereby the mortage can even be carried out in the storage room by unskilled workers, has not yet been explained how the problem is solved using transformers of different energy consumption to create any primary and secondary voltage without the storage of an impractically large number of Windings is required.

Assume that about forty different sizes of wire are required are in order to do justice to the large number of possible voltages and types of current in some types of transformers, then 1600 different ones would have to be required for a primary and a secondary winding Double coils are kept in stock in order to be able to carry out every possible combination. As this for any Order of magnitude of the power would have to be doubled,

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it would be necessary to keep a practically impossible number of combinations in stock. Because of the separate winding configuration of the present invention, only forty individual windings need to be kept in stock for each wattage in the side-by-side arrangement, and eighty individual windings for the coaxial arrangement, which is extremely convenient. These winding coils are sold as separate components that are connected to a magnetic core and a jig. The purchase requires a specific core size for the desired wattage, a primary coil suitable for a specific voltage and another corresponding coil for the secondary voltage. The correct winding coil can be selected from a table or graph, or the actual voltage can be printed on the coil, as will be explained later. To increase the usefulness of the coils, taps may be attached to the windings so that multiple voltages are available. If, for example, as explained below, two extra taps are provided on each coil, then each voltage - 3% can be achieved over a very wide voltage range. For forty wire gauges this range is almost 10,000: 1. Furthermore, the coil sizes can be kept so that sizes which are below the norm fit on larger units and thus form multiple secondary windings. Identical primary and secondary windings can be supplied or, if financial considerations make it necessary, secondary windings with center tap or those of a split design with non-identical

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built primary coils are coupled. However, identical windings ideally simplify the storage problem. According to the invention, open terminals 1, 2, 3 and 4 are provided in connection with the primary winding W in FIG. 1, with intermediate taps, for example between terminals 1 and 2, making up essentially six percent of the total number of all winding turns and essentially 12 percent between terminals 3 and 4. If χ represents the number of turns between terminals 2 and 3, W voltages are available from the individual winding that correspond to the following number of turns: χ (between terminals 2 and 3); χ + A (between 1 and 3); χ + 2A (between 2 and 4); and χ + 3A (between 1 and 4) where A is essentially said six percent. With the usual wire sizes, the cross-sectional area of which deviates by approximately 26% , the winding to be stored with the next smaller or finer wire size would have terminals according to a preferred embodiment of the invention, which ^{deliver χ +} 4A, χ + 5A and χ + 6A (ie not less than essentially six percent windings) .; and the winding with the next larger or more rigid wire would provide taps for χ - A, χ - 2A and χ - 3A. (In practice, each successive copper wire differs from the next larger by about 26 percent, where A may be closer to 5 or 7 percent, as can be seen in Table I below, but is described in this application as essentially 6 percent.) In this way, the possible selection of any combination of primary and secondary

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voltages for different wattages plus or minus
3 percent. Table 1 gives the technical data for the
Choice of several standard _{windings W 1} , W ₂ etc. of any primary and secondary voltage for a given wattage. With this table you only need those
Select the windings with the appropriate number of terminals
then connected with the suitable normal windings (listed one below the other in the leftmost column) for the desired purpose. In the narrower sense, the
desired output wattage (from 100 down to 10 watts in the vertical columns from left to right) selected and then under the watt column all required primary and
Secondary voltages selected. The corresponding number of
Terminals or taps is then read in the leftmost column for the selected primary and secondary voltages ^-::

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Terminal wire number d. 100 90 80 70 60 50 40 30 20 1 number strength turns watt watt watt watt watt watt watt watt watt wa

2-3
1-3 27
27 1 429
455 2-4
■ 1-4 27
27 1
1 482
511 6-7
5-7 28
28 1
T 542
575 6-8
5-8 28
28 610
647 10-11
9-11 29
29 686
727 10-1 2
9-12 29
29 771
817 14-15
13-15 30th
30th 866
918 14-16
13-16 30th
30th 973
031 1 8-1 9
17-19 31
31 093
159 1 8-20
17-20 31
31 229
303

134 124 113 103 98.0 92.7 87.5 82.4 77.7 73

142 132 120 109 104 98.3 92.8 87.4 82.4 77

151 140 127 116 110 104 98.3 92.7 87.4 82

160 148 134 123 117 110 104 98.2 92.7 87

170 157 143 130 124 117 111 104 98.2 92

180 167 151 138 131 124 117 111 104 98.

191 177 160 148 139 132 124 117 111 10 ^

203 188 170 155 148 140 132 124 117 111

215 199 180 165 156 148 140 132 124 117

22 8 211 191 174 166 157 148 140 132 12 ^

241 224 203 185 176 167 157 148 140 £ 13

256 237 215 196 186 177 167 157 148 14C

271 251 228 208 197 188 177 167 157 14t

287 266 241 220 209 199 188 177 167 157

305 282 256 234 222 211 199 188 177 167

323 299 271 247 235 224 211 199 188 177

342 317 287 262 249 237 224 211 199 18i

363 336 305 278 264 251 237 224 211 19 S.

385 356 323 295 280 266 251 237 224 2V

408 378 343 313 297 281 266 251 235 22 ^

As stated above, identical primary and secondary windings can be supplied, both of which have the S -% - resp.
12% taps, or if financial considerations make it necessary, secondary windings with center taps can be used
or those of a split design coupled to the primary windings
that have the 6% and 12% taps. Here too
However, identical windings ideally simplify this

Storage problem. GOPY ^

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For example, for a 150 V primary voltage in a 100 W transformer, the number "151 ^{fl" is found} in the vertical 100 W column and it is established that the normal winding with terminals 2 and 4 (482 turns) is suitable. In Similarly, the secondary winding can be chosen for any voltage plus or minus 3%.

From this it follows: The creation of several separate encapsulated standard or normal windings for each one of a series of different wire sizes, each of which has a cross-sectional area that differs by about 26% from that of the next larger wire size, with terminals or taps being provided that are essentially six or corresponds to twelve percent of the respective winding length, and the whole thing is laid out in a convenient construction consisting of core and clamping device, enables the storage of standard parts and the easy assembly of transformers of any determinant sizes a result that has been achieved in the field of standardization and storage of transformers so far hadn't thought possible.

As mentioned earlier, multiple secondary windings can be used, and the width of the core legs 1 ', 1 ·', 1 '' ' can be altered to accommodate this, although the width of the core is a function of wattage, i. H. that the width is doubled if the wattage is to double, see the dimension arrow 12 in FIG.

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The encapsulated windings W ₁ and W ₂ can also be constructed in groups so that they partially or completely overlap coaxially, as shown by the windings W '''and W ₂ ¹ in Pig. 2 is shown. These windings can be, for example

in this way coaxially on the leg 1 '· of the core 2' in

the

Fig. 1 set. In the present package, the internal design and the dimensions of one group of windings W ₂ ¹ correspond to the external design and the dimensions of the winding group W '. so that the larger winding can slide over the smaller winding and this in turn fits over the core leg 1 ″. If a double secondary winding is used, only two bond taps are required for each winding. The windings can both be connected in series, both parallel springs and both in series with a center tap, whereby all settings can be made on the terminals of the primary winding. The coaxial construction has only a fraction (about a ninth, more or less) of the scatter that occurs with the side-by-side construction (Fig. 1) and shows a smaller phase shift, but it is not quite as universal as the winding shape, which only Has coils of one size. The core 2 * can also be modified as required. The snap-in, removable pole pieces 3 ', 3''can be replaced by a locking design between the core 2' and a flat, separable element - 3111 i _n pig, 3, or by a double Ε construction, as shown in Fig. 4 is shown, flat surfaces lying close to one another having a negligible one

9 0 9 81B / OB 5 1

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Loss of air gap results in »Clearly different designs than symmetrical E-shaped learning can also be used including unsymmetrical Ε-kernels, E-, I-, P-, U-, L-shaped and spiral cores *

The invention includes everything that is contained in the description and / or shown in the drawing, including of what deviates from the specific exemplary embodiments obvious to the expert "

Claims: JB / Sp - 17 026

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BATH ORIGINAL

Claims (1)

U88T95 PATENTANWALT BlPL ^ (Ν® .. HANS - HEtNFtte.H ^ tBSHMAVERST'BASSe ** »5 Oh Dr. I. J » • Mm t of 741 Mi3 * ii <i © a * R © a €, s ρ r tL c-h 1 % middle on: m ^ _p.etiseta: Sefeeafeeil f% _stk: ^ lt © _n: -Jf- 11 stand ». 4, transformer according to claim 2 »characterized in that that oils holding means have a tapered training of the Enclose thighs. 5. Transformer according to claim 1, characterized in that that the separable element of snap-in pole shoes consists. 6 »Transformer according to claim 1» characterized in that that the separable element (3) has a conical pole piece © are. 7 * Transformer according to claim 1, characterized in that » <5 the magnetic core and the magnetic element are provided with interlocking connecting means. 8 * Transformer according to claim 1 "characterized" that the magnetic core is essentially E-shaped, where the stool is the middle leg of the Ε-core % Transformer according to claim 8 »characterized in that - the linear element ei® essentially & eB. flat element. is "connecting the Sehenkel -of S ^e s. * Tra® $ f © r »atOT 'maclt claim 8, thereby gefeeaaaseidtaet ,, that -4g - IS is so that it is congruent closely against the core can lay. 11. Transformer according to one of claims 1 to 10, characterized in that the coil formers are substantially identical Have internal dimensions and correspond essentially to the dimensions of the Kerrischenkels on which they are next to each other to be ordered. 12. Transformer according to one of claims 1 to 10, characterized in that the inner dimensions of the one coil body (W * _{) correspond essentially to the outer dimensions of the other encapsulated winding (W 1} '), the inner dimensions of which in turn essentially correspond to the The dimensions of the magnetic core arm correspond to which the windings are mounted in an overlapping coaxial arrangement. 13. Transformer according to one of claims 1 to 12, characterized in that that the ends of at least one winding have taps at locations that are essentially six and twelve, respectively Percent of the winding turns. 14. Transformer according to one of claims 1 to 12, in which the ends of both windings have taps at points which essentially correspond to six or twelve percent of the respective winding _{turns, βAD} ο, .- ν 909815/0551 H88795 15. Transformer according to one of claims 1 to 14, wherein the Clamping device (β) is designed to be resilient and elastic and in connection with the core cooperating projections or recesses (8 ', 8 "or 9', 9") to the clamping device to clamp the magnetic core. 16. Transformer according to one of claims 1 to 15, characterized by several separately encapsulated ring-shaped windings with different numbers of turns and different wire thicknesses, each of which has a cross-sectional area that differs by essentially 26% from the next thicker wire thickness _f - with at least some of the windings exposed ends have taps, including taps, which correspond essentially to six or twelve percent of the respective winding length and with 82 % of the number of turns of the next smallest wire size not less than essentially six . Percentage have only fewer turns than the total number of turns the winding with the next larger wire thickness and a magnetic core, each with several windings of different sizes Record wire size. 17. Transformer according to claim 16, characterized in that the pre-selection of the windings is essentially done according to the following information: COPY 9098 15/0551 Terminal wire number d. 100 90 80 70 60 50 40 30 20 1C number strength turns watt watt watt watt watt watt watt watt watt wafer 134 124 113 103 98.0 92.7 87.5 82.4 77-7 73 142 132 120 109 104 98.3 92.8 87.4 82.4 77 151 140 127 116 "110 104 98.3. 92.7 87.4 82 160 148 134 123 117 110 104 98.2 92.7 87 170 157 143 130 124 117 111 104 98.2 92 180 167 151 138 131 124 117 1.11 104 98 191 177 160 148 139 132 124 117 111 10- 203 188 170 155 148 140 132 124 117 11 215 199 180 165 156 148 140 132 124 11 228 211 191 174 166 157 148 140 132 12 241 224 203 185 176 167 157 148 140 13 256 237 215 196 18.6 177 167 157 148 14 271 251 228 208 197 188 177 167 157 14 287 266 241 220 209 199 188 177 167 15 305 282 256 234 222 211 199 188 177 16 323 299 271 247 235 224 211 199 188 17 342 317 287 262 249 237 224 211 199 18 363 336 305 278 2fc4 251 237 224 211 19 385 356 323 295 280 266 251 237 224 21 408 378 343 313 297 281 266 251 235 22 2-3
1-3 27
27 429
455 2-4
T-4 27
27 482
511 6-7
5-7 28
28 542
575 6-8
5-8 28
28 610
647 10-11
9-11 29
29 686
727 10-12
9-12 29
29 771
817 14-1 5
13-15 30th
30th 866
918 14-1 6
1 3-16 30th
30th 973
1031 1 8-1 9
17-19 31
31 1093
1159 18-20
17-20 31
31 1229
1303 18. Transformer according to claim 16, wherein groups of windings in the have essentially identical internal dimensions, which correspond essentially to the dimensions of certain magnetic core legs on which they are in Can be mounted side by side. 19. The transformer of claim 16, wherein the internal dimensions some of the encapsulated windings are essentially the outer ones J _ 9098 15/055 1 ^J - 6 - ORIGINAL INSPECTED H88795 "Sr" Dimensions of other encapsulated windings correspond, their internal dimensions in turn essentially correspond to the dimensions of some of the magnet legs on which the preselected windings are stacked can be mounted in a coaxial arrangement. 20. A method for assembling transformers, characterized by the winding of several separate ring-shaped windings with different numbers of turns and several different wire thicknesses, each of which has a cross-sectional area which essentially differs by 26% from the next thicker wire thickness and where 82% of the turns of the next smaller wire thickness are not less than have essentially six percent more turns than the total number of turns of the winding with the next thicker wire thickness, by creating electrical taps at points on the windings which correspond essentially to six or twelve percent of the respective number of turns; by mounting preselected windings on the leg of a magnetic core either in side-by-side arrangement or in overlapping coaxial arrangement, by closing the magnetic ring of force lines of the core by means of the preselected windings installed in the manner described above, and by clamping the installed windings and the core, 21. The method according to claim 20, wherein the further method step the winding preselection takes place according to the information in claim 17. 90 9815/0551. - 7 - 13 e 22. The method according to claim 20, wherein the width of the magnetic core leg is changed depending on the desired wattage of the transformer. - 17 026 9 0 98 15/0 551