EP0395037B1 - Transformer for switching regulated power supply applications - Google Patents
Transformer for switching regulated power supply applications Download PDFInfo
- Publication number
- EP0395037B1 EP0395037B1 EP90107899A EP90107899A EP0395037B1 EP 0395037 B1 EP0395037 B1 EP 0395037B1 EP 90107899 A EP90107899 A EP 90107899A EP 90107899 A EP90107899 A EP 90107899A EP 0395037 B1 EP0395037 B1 EP 0395037B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- transformer according
- core
- transformer
- winding
- chambers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
Definitions
- the invention relates to a transformer according to the introductory part of patent claim 1.
- disk chamber transformers Transformers with disk windings in chamber form, so-called disk chamber transformers, are known in the field of switch mode power transformers, which are based on the standardized core shapes - in particular for ferritic E cores.
- the regulations for grid separation in accordance with VDE 0806 and 0860 must be taken into account, which either prescribe an air gap of 6 mm or a separation using appropriate insulation materials.
- the optimal design cannot be achieved with certainty.
- transformers that are to be operated at frequencies greater than or equal to 16 kHz are coupling, winding capacity, eddy current losses, copper losses, losses in the core material (here preferably ferrite), manufacturing difficulties, automation options, network separation in accordance with VDE 0806 or 0860 and maximum transferable power, based on the total volume of the transformer.
- the inventors have recognized that the winding windows of the standardized E / ETD etc. cores, which have been dimensioned for the optimal design of a layer winding, no longer meet modern requirements such as machine production and optimum power transmission and simultaneous network separation in accordance with VDE 0808 or 0860.
- transformers The disadvantage of such transformers is that at least 6 mm spacing is required for the winding wire guide with mains separation, which requires a voluminous construction of the coil body with excessively high flanges.
- the winding technology of such transformers is also complex, and because of winding inaccuracies (over-winding etc.), excessive safety clearances (greater than 6 mm) are required. A corona measurement is therefore mandatory to avoid all risks to exclude.
- transformer structure characterized in claim 1 which is a combination of a disk chamber transformer and a plug-in chamber transformer and results in a functionally optimal and particularly economically producible transformer for flyback converter and forward operation.
- a square winding window for E (and similar) core shapes was recognized as optimal, neglecting boundary conditions, and it was found that the influence of structural conditions still caused a certain deviation from this optimal square design of the winding window.
- the transformer structure according to the invention not only takes optimal account of network separation, coupling of the windings to one another, automatic production possibility, universality for almost all applications in the range up to 300 W (depending on the core size, small stray field, high efficiency, in contrast to the standardized core cuts), but it also has other advantages:
- FIG. 1 An exemplary embodiment for the coil form of the transformer according to the invention is illustrated in FIG. 1.
- the reference numeral 1 denotes a base coil body with a foot 2, which is provided with the necessary pins 3.
- This main coil former 1 is surrounded by a first auxiliary coil former 6, which has labyrinths 4, as is a second auxiliary coil former 7, which surrounds the auxiliary coil former 6 and is also provided with labyrinths 4 for the network separation.
- FIG. 2 an embodiment of the structure of the transformer according to the invention is shown schematically with the same indexing as in Fig.1 in connection with an E-core 9, the middle leg of the nested coil formers, the main coil form 1, the first auxiliary coil form 6 and the second Auxiliary bobbin 7 is surrounded.
- FIG. 3 shows a structure of a transformer of prior art.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Coils Or Transformers For Communication (AREA)
- Coils Of Transformers For General Uses (AREA)
- Dc-Dc Converters (AREA)
- Details Of Television Scanning (AREA)
- Electron Sources, Ion Sources (AREA)
Abstract
Description
Die Erfindung bezieht sich auf einen Transformator gemäß dem einleitenden Teil des Patentanspruchs 1.The invention relates to a transformer according to the introductory part of
Es sind Transformatoren mit Scheibenwicklungen in Kammerform, sogenannte Scheibenkammertransformatoren, in dem Bereich der Switchmode-Leistungstrafos bekannt, die sich auf die genormten Kernformen - insbesondere für ferritische E-Kerne - stützen. Zu berücksichtigen bei der Auslegung derartiger Transformatoren sind in der BRD die Vorschriften für die Netztrennung nach VDE 0806 bzw. 0860, die entweder eine Luftstrecke von 6 mm vorschreiben oder eine Trennung durch entsprechende Isoliermaterialien. Außerdem ist bei den vorgegebenen genormten Kernabmessungen mit Sicherheit die optimale Auslegung nicht erreichbar.Transformers with disk windings in chamber form, so-called disk chamber transformers, are known in the field of switch mode power transformers, which are based on the standardized core shapes - in particular for ferritic E cores. When designing such transformers in Germany, the regulations for grid separation in accordance with VDE 0806 and 0860 must be taken into account, which either prescribe an air gap of 6 mm or a separation using appropriate insulation materials. In addition, with the given standardized core dimensions, the optimal design cannot be achieved with certainty.
Im Zuge der Weiterentwicklung des Standes der Technik, gestützt auf die anfallenden Stückzahlen, ist eine optimale Auslegung ohne Rücksicht auf Normen jedoch vorteilhaft, d.h. auch außerhalb der Normen liegende Kernformen haben in Bezug auf die Wirtschaftlichkeit durchaus eine Berechtigung zu erfinderischer Tätigkeit.In the course of the further development of the state of the art, based on the number of pieces, an optimal design without regard to standards is advantageous, i.e. Core forms that lie outside the standards also have a right to inventive step in terms of economy.
Die bekannten Scheibenkammer-Transformatoren im Frequenzbereich von größer gleich 16 kHz weisen neben unbestrittenen Vorteilen eine Reihe von Nachteilen auf, die in einer Tabelle nachfolgend aufgeführt werden. Darüber hinaus gibt es auch den sogenannten Steckkammer-Transformator, der verschiedene Nachteile des Scheibenkammer-Transformators nicht aufweist, dafür aber mit anderen Nachteilen behaftet ist. Auch hier wird auf die nachfolgende Tabelle verwiesen.The known disc chamber transformers in the frequency range greater than or equal to 16 kHz have undisputed ones Advantages have a number of disadvantages, which are listed in a table below. In addition, there is also the so-called plug-in chamber transformer, which does not have various disadvantages of the disc chamber transformer, but has other disadvantages. Here, too, reference is made to the table below.
Wichtige Gesichtspunkte bei der Auslegung von Transformatoren, die bei Frequenzen von größer gleich 16 kHz betrieben werden sollen, sind die Kopplung, Wicklungskapazität, Wirbelstromverluste, Kupferverluste, Verluste im Kernmaterial (hier vorzugsweise Ferrit), Fertigungsschwierigkeiten, Automatisierungsmöglichkeit, Netztrennung nach VDE 0806 bzw. 0860 und maximal übertragbare Leistung, bezogen auf das Gesamtvolumen des Transformators.Important aspects when designing transformers that are to be operated at frequencies greater than or equal to 16 kHz are coupling, winding capacity, eddy current losses, copper losses, losses in the core material (here preferably ferrite), manufacturing difficulties, automation options, network separation in accordance with VDE 0806 or 0860 and maximum transferable power, based on the total volume of the transformer.
Die Erfinder haben erkannt, daß die auf optimale Auslegung einer Lagenwicklung dimensionierten Wickelfenster der genormten E/ETD etc.-Kerne den modernen Erfordernissen wie Automatenfertigung sowie optimale Leistungsübertragung und gleichzeitige Netztrennung nach VDE 0808 bzw. 0860 nicht mehr entsprechen.The inventors have recognized that the winding windows of the standardized E / ETD etc. cores, which have been dimensioned for the optimal design of a layer winding, no longer meet modern requirements such as machine production and optimum power transmission and simultaneous network separation in accordance with VDE 0808 or 0860.
Dies gilt insbesondere auch für die bekannte Scheibenkammerkonstruktion derartiger Transformatoren.This applies in particular to the known disk chamber construction of such transformers.
Der Nachteil derartiger Transformatoren besteht darin, daß für die Wickeldrahtführung mit Netztrennung jeweils mindestens 6 mm Abstand erforderlich sind, was eine voluminöse Konstruktion des Spulenkörpers mit übermäßig hohen Flanschen erfordert. Auch die Wickeltechnik derartiger Transformatoren ist aufwendig, und wegen Wicklungsungenauigkeiten (Überwickeln etc.) sind übermäßige Sicherheitsabstände (größer 6 mm ) erforderlich. Eine Coronamessung ist dementsprechend obligatorisch, um sämtliche Risiken auszuschließen.The disadvantage of such transformers is that at least 6 mm spacing is required for the winding wire guide with mains separation, which requires a voluminous construction of the coil body with excessively high flanges. The winding technology of such transformers is also complex, and because of winding inaccuracies (over-winding etc.), excessive safety clearances (greater than 6 mm) are required. A corona measurement is therefore mandatory to avoid all risks to exclude.
Die oben angegebenen wichtigen Gesichtspunkte realisiert überraschend in optimaler Weise der im Patentanspruch 1 gekennzeichnete Transformatoraufbau, der eine Kombination aus einem Scheibenkammer-Transformator und einem Steckkammer-Transformator darstellt und einen funktionell optimalen sowie besonders wirtschaftlich fertigbaren Transformator für Sperrwandler- und Durchflußbetrieb ergibt. Dabei wurde als optimal unter Vernachlässigung von Randbedingungen ein quadratisches Wickelfenster für E(und ähnliche)- Kernformen erkannt, und es wurde gefunden, daß der Einfluß von konstruktiven Gegebenheiten noch eine gewisse Abweichung von dieser optimalen quadratischen Auslegung des Wickelfensters bedingt. Zu berücksichtigen ist bei jeglicher Auslegung eines Transformators, daß er vollautomatisch zu fertigen ist.The above-mentioned important aspects are surprisingly realized in an optimal manner by the transformer structure characterized in
Der erfindungsgemäße Transformatoraufbau berücksichtigt nicht nur in optimaler Weise Netztrennung, Kopplung der Wicklungen untereinander, automatische Fertigungsmöglichkeit, Universalität für fast alle Anwendungen im Bereich bis 300 W (in Abhängigkeit der Kerngröße, geringes Streufeld, hoher Wirkungsgrad, im Gegensatz zu den genormten Kernschnitten), sondern er führt darüber hinaus noch zu weiteren Vorteilen:The transformer structure according to the invention not only takes optimal account of network separation, coupling of the windings to one another, automatic production possibility, universality for almost all applications in the range up to 300 W (depending on the core size, small stray field, high efficiency, in contrast to the standardized core cuts), but it also has other advantages:
Aus der gemäß der Erfindung vorgesehenen Geometrie der Kernformen, die eine Voraussetzung für die erfindungsgemäße Ausgestaltung der Steck-Spulenkörper mit den Kammerwicklungen ist, ergibt sich zunächst einmal, daß die Grundfläche des Transformators größer und die Höhe geringer wird als bei den Scheibenkammer-Transformatoren und den Steckkammer-Transformatoren gemäß dem Stande der Technik. Dies ist insofern von Vorteil, als die Entflechtung der Schaltung und die Einhaltung von Sicherheitsabständen bei größerer Grundfläche leichter zu bewerkstelligen ist und sich mehr SMD-Bauteile auf dieser größeren Fläche unterbringen lassen. Die geringe Bauhöhe erweist sich bei der Steckkartentechnik jedenfalls als vorteilhaft.From the geometry of the core shapes provided according to the invention, which is a prerequisite for the inventive design of the plug-in bobbin with the chamber windings, it initially emerges that the base area of the transformer is larger and the height is smaller than in the disk-chamber transformers and Plug-in chamber transformers according to the state of the art. This is advantageous in that the unbundling of the circuit and the keeping of safety distances for larger ones Footprint is easier to accomplish and more SMD components can be accommodated on this larger area. The low height proves to be advantageous in any case with the plug-in card technology.
In der nachstehenden Tabelle werden Vor- und Nachteile der vorgenannten Konstruktionen miteinander verglichen, wobei die Überlegenheit des erfindungsgemäßen Transformators ersichtlich wird.
Ein Ausführungsbeispiel für die Spulenkörper des erfindungsgemäßen Transformators veranschaulicht die Fig. 1.An exemplary embodiment for the coil form of the transformer according to the invention is illustrated in FIG. 1.
In Fig. 1 bezeichnet die Bezugszahl 1 einen Grundspulenkörper mit einem Fuß 2, der mit den notwendigen Anschlußstiften 3 versehen ist. Dieser Grundspulenkörper 1 wird von einem ersten Hilfsspulenkörper 6 umgeben, der Labyrinthe 4 aufweist, ebenso wie ein zweiter Hilfsspulenkörper 7, der den Hilfsspulenkörper 6 umgibt und für die Netztrennung ebenfalls mit Labyrinthen 4 versehen ist.In Fig. 1, the
In Fig. 2 ist ein Ausführungsbeispiel für den Aufbau des erfindungsgemäßen Transformators schematisch unter gleicher Indexierung wie in Fig.1 in Verbindung mit einem E-Kern 9 dargestellt, dessen Mittelschenkel von den ineinandergesteckten Spulenkörpern, dem Grundspulenkörper 1, dem ersten Hilfsspulenkörper 6 und dem zweiten Hilfsspulenkörper 7, umgeben ist.In Fig. 2, an embodiment of the structure of the transformer according to the invention is shown schematically with the same indexing as in Fig.1 in connection with an
Die Fig. 3 zeigt einen Aufbau eines Transformators bisheriger Technik.3 shows a structure of a transformer of prior art.
Anhand der zeichnerischen Darstellung werden die Vorteile des erfindungsgemäßen Transformartors nachstehend noch einmal zusammengestellt (sh. auch die Tabelle).
- 1) Die
1,6,7 sind vollautomatisch zu bewickeln, wobei bei allen Spulenkörpern das Drahtanlegen ebenfalls vollautomatisch erfolgen kann.einzelnen Steckeinheiten - 2) Die Auslegung des Transformators ist universell möglich, wobei allen vorkommenden Kopplungsverhältnissen Rechnung getragen wird.
- 3) Der Wirkungsgrad ist größer durch optimale Kernkonfiguration, Wickelraumausnutzung und Verbesserung der Verkopplung.
- 4) Die übertragbare Leistung kann durch die vorgenannten Maßnahmen bis zu 40% über denen vergleichbarer Normkerne liegen.
- 5) Die Netztrennung ist so zuverlässig, daß sie keiner Nachprüfung bedarf (Prüfaufwand = Null).
- 6) Das Streufeld (wichtig bei TV- und Monitoranwendung) wird reduziert.
- 7) Etwa drei bis vier Trafogrößen im Frequenzbereich größer gleich 16 kHz und in einem Leistungsbereich bis zu 300 Watt sind bei gleicher Grundkonzeption möglich.
- 8) Anwendung bei Sperr-, Fluß- und Sinuswandler ist möglich.
- 9) Weitgehende Freiheit in der Anpassung an gegebene Forderungen ohne konstruktive Änderungen in allen Betriebsarten wie freischwingender, festfrequentierter Betrieb, sowie Dreiecks- oder Trapezbetrieb.
- 10) Vorteile in Bezug auf die Automatisierung der Wickeltechnik.
- 11) Die sich durch die Vergrößerung der Grundfläche eines erfindungsgemäßen Transformators anscheinend ergebenden Nachteile werden dadurch mehr als kompensiert, daß nun mehr SMD-Bauteile besser auf der Unterseite montiert werden können und die Entflechtung der Schaltung vereinfacht wird; eine Erhöhung der Zahl der benötigten, auch netzgetrennten Anschlüsse ist leicht zu bewerkstelligen.
- 12) Die Bauhöhe des optimierten Trafos wird geringer, so daß mechanische Festigkeitsprobleme weniger gravierend in Erscheinung treten (Hebel-Kipp-Bewegung bei Fallbeanspruchung).
- 13) Eine eventuell notwendige Abschirmung kann auf das gleiche Potential geschaltet werden, wie der
Kern 9, d.h. entweder auf die Netz- oder die netzgetrennte Seite, so daß Isolationsprobleme nicht entstehen. - 14) Für den Fall der Wirbelstrombeeinflußung der Wicklung im
Grundkörper 1 durch Wirbelströme, verursacht durch den Luftspalt, können die Kammern 8 in diesem Bereich einen größeren Abstand vomKern 9 aufweisen. - 15) Man kann jeden Spulenkörper ohne Mehrkosten mit dem elektrisch optimierten Draht wickeln, z.B. wegen möglicher Wirbelstromverluste Litzendraht nur auf dem
Grundspulenkörper 1.
- 1) The individual plug-in
1, 6, 7 are to be wound fully automatically, whereby the wire application can also be carried out fully automatically for all coil formers.units - 2) The transformer can be designed universally, taking into account all coupling conditions.
- 3) The efficiency is greater through optimal core configuration, use of the changing space and improvement of the Coupling.
- 4) The transferable performance can be up to 40% higher than that of comparable standard cores due to the aforementioned measures.
- 5) The grid separation is so reliable that it does not need to be checked (test effort = zero).
- 6) The stray field (important for TV and monitor applications) is reduced.
- 7) About three to four transformer sizes in the frequency range greater than or equal to 16 kHz and in a power range up to 300 watts are possible with the same basic concept.
- 8) Use with flyback, forward and sine converters is possible.
- 9) Extensive freedom in adapting to given requirements without design changes in all operating modes such as free-swinging, fixed-frequency operation, as well as triangular or trapezoidal operation.
- 10) Advantages in terms of automation of the winding technology.
- 11) The disadvantages which apparently result from the enlargement of the base area of a transformer according to the invention are more than compensated for by the fact that more SMD components can now be better mounted on the underside and the unbundling of the circuit is simplified; an increase in the number of required, even network-separated, connections is easy to achieve.
- 12) The overall height of the optimized transformer is reduced, so that mechanical strength problems appear less seriously (lever-tilt movement when falling).
- 13) Any necessary shielding can be switched to the same potential as the
core 9, ie either on the network or the network-separated side, so that insulation problems do not arise. - 14) In the event of eddy current influencing the winding in the
base body 1 by eddy currents caused by the air gap, the chambers 8 can have a greater distance from thecore 9 in this area. - 15) You can wind each bobbin with the electrically optimized wire at no additional cost, e.g. because of possible eddy current losses, stranded wire only on the
basic bobbin 1.
Claims (9)
- Transformer for switching power supply applications with a switching frequency greater than or equal to 16 kolohertz, with a magentically conductive core, preferably of ferrite, and a winding carrier surrounding the core, characterised thereby that the core (9) has an almost square winding window (9) and the winding carrier consists of two or more coil bodies (1; 6; 7), which can be plugged into one another and each of which is divided into winding chambers (8).
- Transformer according to claim 1, characterised thereby that the winding chambers (8) of the coil bodies (1; 6; 7) plugged into one another respectively correspond to one another, i.e. that the chambers (8) in each case lie at the same height as those of the other coil bodies plugged into one another in order to ensure the required close magnetic coupling.
- Transformer according to claims 1 and 2, characterised thereby that the number of chambers (8) is the same for all coil bodies (1; 6; 7).
- Transformer according to one of the preceding claims, characterised thereby that the middle limb of the core (9) has a round or approximately round cross-section.
- Transformer according to one of the preceding claims, characterised thereby that the mains separation is effected by labyrinths (4) at the ends of the coil bodies (6, 7).
- Transformer according to one of the preceding claims, characterised thereby that the core (4) is associated with screening either at the mains-connected side or the mains-separated side.
- Transformer according to one of the preceding claims, characterised thereby that the base coil body (1) has in the region of the air gap in the middle limb of the core (9) a larger diameter for the avoidance of eddy current losses.
- Transformer according to one of the preceding claims, characterised thereby that the base coil body (1) is would with stranded wire.
- Modification of the transformer according to one of the preceding claims for use with low power, characterised thereby that the base body (1) has no chambers (8).
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AT90107899T ATE93646T1 (en) | 1989-04-27 | 1990-04-26 | TRANSFORMER FOR SWITCHING POWER SUPPLY APPLICATIONS. |
DE9007765U DE9007765U1 (en) | 1989-04-27 | 1990-04-26 | Transformer for switching power supply applications |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE3913852 | 1989-04-27 | ||
DE3913852A DE3913852A1 (en) | 1989-04-27 | 1989-04-27 | INNOVATIVE PLUG-IN DISC TRANSFORMER |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0395037A2 EP0395037A2 (en) | 1990-10-31 |
EP0395037A3 EP0395037A3 (en) | 1991-03-06 |
EP0395037B1 true EP0395037B1 (en) | 1993-08-25 |
Family
ID=6379550
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP90107899A Expired - Lifetime EP0395037B1 (en) | 1989-04-27 | 1990-04-26 | Transformer for switching regulated power supply applications |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP0395037B1 (en) |
AT (1) | ATE93646T1 (en) |
DE (2) | DE3913852A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE4139217A1 (en) * | 1991-11-29 | 1993-06-03 | Tamura Hinchley Ltd | Transformer coil body for switched mode power supplies - has inbuilt-in stray-flux barriers forming end-walls |
US9985488B2 (en) * | 2011-07-22 | 2018-05-29 | RWXT Nuclear Operations Group, Inc. | Environmentally robust electromagnets and electric motors employing same for use in nuclear reactors |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1439441A1 (en) * | 1963-09-18 | 1968-12-05 | Sits Soc It Telecom Siemens | Low-loss coil winding for an inductance |
NL7204034A (en) * | 1972-03-25 | 1973-09-27 | ||
DE3147984A1 (en) * | 1981-12-04 | 1983-06-16 | Licentia Patent-Verwaltungs-Gmbh, 6000 Frankfurt | TRANSFORMER, ESPECIALLY FOR A SWITCHING POWER SUPPLY IN A TELEVISION RECEIVER |
DE8328331U1 (en) * | 1983-10-01 | 1989-02-09 | Grundig E.M.V. Elektro-Mechanische Versuchsanstalt Max Grundig holländ. Stiftung & Co KG, 8510 Fürth | Chamber coil body |
-
1989
- 1989-04-27 DE DE3913852A patent/DE3913852A1/en not_active Withdrawn
-
1990
- 1990-04-26 EP EP90107899A patent/EP0395037B1/en not_active Expired - Lifetime
- 1990-04-26 DE DE90107899T patent/DE59002422D1/en not_active Revoked
- 1990-04-26 AT AT90107899T patent/ATE93646T1/en not_active IP Right Cessation
Also Published As
Publication number | Publication date |
---|---|
DE59002422D1 (en) | 1993-09-30 |
EP0395037A2 (en) | 1990-10-31 |
ATE93646T1 (en) | 1993-09-15 |
EP0395037A3 (en) | 1991-03-06 |
DE3913852A1 (en) | 1990-10-31 |
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