EP2200052A2 - Electricity-compensated throttle and method for producing an electricity-compensated throttle - Google Patents

Abstract

The choke has a ring core including two coils provided with same number of windings, and a non-conductive body (14) i.e. disk, arranged in an interior of the ring core. The non-conductive body includes holes (15.1-15.6) formed in pairs in a mirror symmetrical manner to a symmetry axis of the ring core. The windings are guided through each hole of the pairs of symmetrical holes, and correspond to each other. The non-conductive body includes planar circular areas extending parallel to a direction in which an internal radius vector of the ring core extends. An independent claim is also included for a method for producing a current-compensated choke.

Description

The invention relates to a current-compensated choke according to the preamble of patent claim 1 and a method for producing such a current-compensated choke.

Chokes are inductive components in electrical engineering and electronics, which find use, inter alia, in the suppression of interference pulses. A widespread subspecies of interference suppression chokes, for example, for suppression of interference currents, which occur in the same direction in the forward and return lines are common mode chokes, which are also known under the name "common mode chokes". Current-compensated chokes are characterized by several, but at least two windings, which are flowed through in opposite directions from the working current from. As a consequence, ideal, i. E. mutually completely symmetrical windings with the same number of turns, the same sector and the same wire guide on the magnetic fields of the windings in the core of the throttle, so that the choke for the working current has a low inductance, while the inductance of the choke is high for the parasitic currents occurring in the same direction. Deviations from an ideal, completely symmetrical winding lead to losses that are to be kept as low as possible with increasing frequency of the working current.

The design of current-compensated chokes is subject to a variety of boundary conditions. In order to keep the ohmic losses low, one chooses the wires used for the winding as thick as possible. In order to achieve high inductances for the same direction interference currents, the winding is usually carried out on an annular magnetic core, but because of various installation conditions should be as small as possible. It should the single winding but at the same time include as many turns. Also important is the galvanic isolation between the windings. It must therefore be prevented that wires of the individual windings, the turns of which all must be guided through the inner hole of the annular magnetic core touch.

These constraints usually force the winding of common mode chokes by hand or by use of hand operated mechanical pullers and similar mechanical aids, e.g. of crochet hooks. With such a manual winding technique, however, it is practically impossible to achieve exactly symmetrical windings. In general, it comes in spite of the high production costs to crossovers between the wires of individual turns and inaccuracies in the leadership of the wires.

The object of the invention is to improve the symmetry of the windings in a current-compensated choke without increasing the effort.

This object is achieved by a current-compensated inductor having the features of claim 1 and a method for producing a current-compensated inductor having the features of claim 12. Advantageous embodiments and further developments of the invention are specified in the respective subclaims.

A current-compensated choke according to the invention has a toroidal core and an even number, but at least two windings each consisting of the same number of turns, wherein a non-conductive body with holes arranged mirror-symmetrically in pairs to an axis of symmetry of the toroidal core is furthermore arranged inside the toroidal core. In this case, each hole of at least some of the pairs is more symmetrical Holes each guided a turn, and through the two belonging to a pair of holes corresponding turns of mutually associated windings are performed.

The ring core serves as a support structure to which the windings are applied directly or indirectly.

Windings associated therewith are to be understood as meaning the windings whose magnetic fields, when the windings are traversed by the working current, are respectively to be compensated for, that is, in the ideal case, they are constructed completely symmetrically with respect to each other. This symmetry also determines which turns of the windings correspond to each other; As a rule, however, this compensation can also be determined by counting the turns of mutually corresponding windings in the same direction. In the case of symmetrical windings with N windings, the windings which are assigned the same ordinal number n with 1≤n≤N when counting will correspond to one another.

It is therefore provided according to the invention to specify the course of the individual turns exactly by defining their start and end points defined. By tightening the individual turns in the course of the manufacturing process, the shortest possible connection is made, taking into account the geometrical boundary conditions. With a pairwise symmetrical arrangement of the holes and specification of the same geometric boundary conditions for these pairs of holes, in particular by the geometry of the toroidal core and the geometric configuration of the non-conductive body, thereby the exact symmetry of the individual mutually associated turns of the compensating windings and thus the entire windings is guaranteed , In particular, an unwanted crossing of windings is excluded.

A particularly simple embodiment of the non-conductive body is in the interior of the ring core, so at smaller radii than the inner radius of the ring core, arranged disc, the circular surfaces parallel to the direction in which an inner radius vector of the toroidal extend.

It has also proven to be advantageous if the toroidal core is enclosed by a composite of at least two parts plastic body. By this measure can be achieved in a simple manner, an improved stability of the then formed by toroidal core and plastic body throttle body compared to the straight when using thick wires for the windings in the manufacture of the throttle high tensile forces. Furthermore, this reduces the influence of environmental influences on the toroidal core.

In this case, a particularly simple assembly of the current-compensated choke is possible when the non-conductive body is connected to one of the parts of the composite plastic body or is part of one of the parts of the composite plastic body. An embodiment of the plastic body which is easy to produce lies in one embodiment in particular as two annular half shells which receive or enclose the toroidal core.

The toroidal core becomes particularly effective against environmental influences which, upon local interaction with parts of the toroidal core at the affected locations, could change its magnetic properties and thus adversely affect the function of the current-compensated choke if the two half-shells of the plastic body overlap such that they are inside and outside are guided positively.

Depending on the application, it may be advantageous if the half shells of the plastic body with an ultrasonic weld together are connected, which leads to optimum sealing when the half shells of the plastic body by means of threaded on both sides are screwed together, which allows subsequent opening of the plastic body, or if the two half-shells of the plastic body are connected by a latching mechanism, which is a particularly simple and cost-effective Manufacturing brings with it.

In a particularly advantageous embodiment, guide elements for guiding and separating the turns are arranged on the surface of the plastic body and / or guiding elements are introduced into the surface of the plastic body. This makes it possible to influence the geometric boundary conditions and thus the course of the windings as desired, while without such guide elements always the shortest connection on the surface of the throttle body between the output side of the hole at which the turn in question and the input side of the hole, at which it ends, determines the course of the winding. The guide elements can be realized in particular as burrs, grooves or a combination of burrs and grooves.

Preferred material for the plastic body is a high temperature resistant plastic, in particular polyetheretherketone (PEEK) or polyphenylene sulphide (PPS).

Particularly simple is the production of the current-compensated choke when the holes in the non-conductive body in at least one direction have a tapered from the surface of the non-conductive body in the direction of extension of the hole insertion aid.

The preferred material for the toroidal core of the current-compensated choke is a soft magnetic ribbon and, because of the magnetic properties which are advantageous for most applications in particular a soft magnetic strip consisting of an amorphous or nanocrystalline alloy. The toroidal core may, for example, have an outer diameter of at least 20 mm.

As a material for the windings of such a current-compensated choke copper wire has proven particularly because of its good line properties, which is preferably painted and / or high-temperature resistant insulation, in particular polyester imide (PEI) or polyimide (PI) has. In order to conduct the currents occurring in typical applications loss, the copper wire may have a diameter of more than 2mm.

For the isolation of the current-compensated choke to the outside, in particular when using bare copper wire, the provision of an insulating coating of a thickness of between 5 and 200 μm (5 to 50 μm or 50 to 200 μm) may be advantageous, for example by spraying or dip coating during the production of the current-compensated choke can be obtained.

• a)Fixieren eines Ringkerns, der in seinem Inneren einen nicht leitenden Körper mit paarweise spiegelsymmetrisch zu einer Symmetrieachse des Ringkerns ausgeführte Löcher aufweist, wobei die auf der einen Seite der Symmetrieachse liegenden Löcher eine erste Gruppe und die auf der zweiten Seite der Symmetrieachse liegenden Löcher eine zweite Gruppe bilden,
• b)Führen eines Drahtabschnitts durch eines der Löcher einer der Gruppen,
• c)Führen mindestens eines der Enden des Drahtabschnittes in einer den Ringkern umschließenden Schlaufe durch ein weiteres Loch derselben Gruppe, wobei das erste Ende des Drahtabschnitts in entgegengesetzter Richtung durch Löcher geführt wird wie das zweite Ende und
• d)Wiederholen der Schritte b)und c)für die andere Gruppe mit einem weiteren Drahtabschnitt,

wobei ferner entweder nach der Durchführung der Schritte c) und d) an jedem der Drahtabschnitte ein Zug ausgeübt wird oder nach Ausführung des Schritts c) an dem entsprechenden Drahtabschnitt ein Zug ausgeübt wird.The method according to the invention for producing a current-compensated choke comprises at least the steps

• a) fixing a ring core having in its interior a non-conductive body with pairs mirror-symmetrical to an axis of symmetry of the ring core holes, wherein the lying on one side of the axis of symmetry holes a first group and lying on the second side of the axis of symmetry holes a form second group,
• b) passing a wire section through one of the holes of one of the groups,
• c) guiding at least one of the ends of the wire section in a loop enclosing the ring core through another hole of the same group, wherein the first end of the wire section is guided in the opposite direction through holes as the second end and
• d) repeating steps b) and c) for the other group with a further wire section,

Further, either after the implementation of steps c) and d) at each of the wire sections, a train is applied or after the execution of step c) on the corresponding wire section a train is exercised.

By means of the method according to the invention, a current-compensated choke is produced in a safe and reproducible manner, ensuring that it has almost identical, to a very good approximation symmetrical windings, so that the losses in the current-compensated choke also and especially when using high-frequency operating current significantly be reduced. This is achieved by the fact that given default of the holes in the non-conductive body through which a given turn is guided, by geometric constraints, the course of the winding, which it occupies in train on the wire, is uniquely predetermined. A symmetrical arrangement of the holes through which the windings of one or the other winding are guided, leads to identical windings identical conditions for the individual windings, which are ensured by the toroidal core and the shape of the non-conductive body, thus automatically to identical windings, as long the given winding in both cases are guided by corresponding pairs of holes. In particular, a crossover of turns only consciously by choosing appropriate hole combinations for the course of the intersecting Windings are brought about and is otherwise excluded.

Very advantageous is the use of a double-sided train, as this ensures that all turns that are exposed to the train, are stretched approximately equally strong. This is particularly relevant because a sufficient train must be exercised to impart to the winding material of all windings the course given by the geometric constraints. In the case of very inhomogeneous stress on the individual windings, this means that a significantly higher load than the sufficient tension occurs at some points of the annular body, which can lead to its breakage at the points in question.

A very few steps procedure is obtained when the pull is applied after passing the wire section through all the holes belonging to one group or through all the holes belonging to both groups. However, high tensile forces are necessary for this.

If you want to minimize the required tensile forces, which is the case especially when using very thick wires as the material for the windings, it is advantageous if the train is exercised each time when the wire section was passed through another hole.

Figur 1

einen Drosselkörper einer erfindungsgemäßen stromkompensierten Drossel in Frontalansicht,

Figur 2

einen Schnitt durch den Drosselkörper aus Figur 1 entlang der Schnittlinie A-A,

Figur 3

einen Schnitt durch den Drosselkörper aus Figur 1 entlang der Schnittlinie B-B und

Figur 4

den mit Wicklungen versehenen Drosselkörper aus Figur 1 in Frontalansicht.

The invention will be explained in more detail with reference to the embodiments illustrated in the figures of the drawing, identical components, unless otherwise stated, are designated in all figures with the same reference numerals. It shows:

FIG. 1

a throttle body of a current-compensated throttle according to the invention in a front view,

FIG. 2

a section through the throttle body FIG. 1 along the section line AA,

FIG. 3

a section through the throttle body FIG. 1 along the section line BB and

FIG. 4

the provided with windings throttle body FIG. 1 in frontal view.

FIG. 1 shows a throttle body 10 according to the invention, so the unwound throttle, in a front view. It is shown a first half-shell 11 of a plastic body, the ridges 12 and recesses 13 has. With the half-shell 11 is designed as a disk non-conductive body 14 integrally connected, the visible upper circular surface parallel to an inner radius vector, not shown in a FIG. 1 obscured by the first half shell 11, but in FIGS. 2 and 3 recognizable ring core 23 extends. The non-conductive body 14 is penetrated by holes 15.1, 15.2, 15.3, 15, 15, 15 and 15.6 in the viewing direction. The holes 15.1 to 15.3 form a first group of holes, the holes 15.4 to 15.6 a second group of holes which are arranged symmetrically to the first groups of holes 15.1 to 15.3 with respect to the axis of symmetry AA. The holes 15.1 and 15.4, 15.2 and 15.5 and 15.3 and 15.6 are each pairwise symmetrical to each other or form pairs of symmetrical holes. In addition to the axis of symmetry AA is still a sectional axis BB shown in the FIG. 3 illustrated section illustrates.

FIG. 2 shows a section through the throttle body 10 from FIG. 1 along the axis of symmetry AA. In turn, the first half-shell 11 is shown, the sectional area of which is recognizable here by hatching from top left to bottom right, as well as the ridges 12 of the first half-shell and the one-piece with the first half-shell 11 and as a disc and Therefore also shown non-conductive body 14. Further shown is a second half-shell 21, the sectional surface is shown here by hatching from top right to bottom left, and ridges 22 has. First and second half-shell 21,22 enclose the ring core 23, in such a way that they are guided on the inner circumference 24 and the outer circumference 25 in each case form-fitting manner.

FIG. 3 shows a section through the throttle body 10 from FIG. 1 along the symmetry axis BB. It can be recognized as in FIG. 2 the first half-shell 11, whose sectional area is also shown here by hatching from top left to bottom right, and the non-conductive body 14 and the second half-shell 21, which are embodied in one piece with the first half-shell 11 as a disk and therefore also hatched, whose sectional area is here hatched by top right to bottom left is shown. First and second half-shell 21,22 enclose the ring core 23 such that they are guided on the inner circumference 24 and the outer circumference 25 in each case in a form-fitting manner. Additionally are in FIG. 3 also to recognize the holes 15.2 and 15.5, enforce the designed as a disk non-conductive body 14. At the entrance and exit of the holes, these each have from the surface of the non-conductive body 14 in the extension direction of the hole conically tapered insertion aids 31,32,33,34.

Based on FIGS. 1 to 3 the process of the invention is exemplified. First, a throttle body 10, as in the FIGS. 1 to 3 is shown, and thus the ring core 23 contained in this fixed. Then, a wire section opposite to the viewing direction of FIG. 1 passed through the hole 15.2. The insertion process is facilitated by the insertion aid 31. That from the hole 15.2 in the representation of FIG. 1 opposite end of the wire section is then in a ring surrounding the core Loop, thus of the in FIG. 1 invisible side of the non-conductive body 14 forth passed through the hole 15.1. That from the hole 15.2 in the representation of FIG. 1 emerging in the direction of the end of the wire section is in a loop surrounding the ring core, thus of the in FIG. 1 visible side of the non-conductive body 14, passed through the hole 15.3. Now, if a double-sided train exercised on the wire section, put the loops, guided by the ridges 12 and recesses 13, as turns of a winding around the bobbin.

Subsequently, a second wire section opposite to the viewing direction of FIG. 1 passed through the hole 15.5. The insertion process is facilitated by the insertion 33. That from the hole 15.5 in the representation of FIG. 1 opposite to the line of sight emerging end of the wire section is then in a loop surrounding the ring core, thus of the in FIG. 1 invisible side of the non-conductive body 14 forth passed through the hole 15.4. That from the hole 15.5 in the representation of FIG. 1 emerging in the direction of the end of the wire section is in a loop surrounding the ring core, thus of the in FIG. 1 visible side of the non-conductive body 14 ago, passed through the hole 15.6. Now, if a double-sided train exercised on the wire section, put the loops, guided by the ridges 12 and recesses 13, as turns of a winding around the bobbin. The windings with three windings can thus be produced in each case by a single pulling operation.

Of course, a one-sided train could be exercised, the train could be exercised already after laying a single loop, or it could be exercised after laying the loops for both wire sections of the train simultaneously or successively on these wire sections.

FIG. 4 shows the wrapped throttle body 10 from FIG. 1 , So the completed current-compensated choke 1 in different perspective. Visible are the first half-shell 11 and the non-conductive body 14 formed integrally therewith. The holes 15.1 to 15.6 of the non-conductive body 14 are in FIG. 4 no longer recognizable because they are filled by wire. The first winding 41 with turns 42.1 and 42.2 and the second winding 43 with turns 44.1 and 44.2 can be seen further. First winding 41 and second winding 43 are constructed exactly symmetrical to each other, the same applies accordingly to each corresponding turns 42.1 and 44.1 or 42.2 and 44.2.

LIST OF REFERENCE NUMBERS

1

current-compensated choke

10

throttle body

11

first half shell

12

ridge

13

deepening

14

non-conductive body

15.1-15.6

holes

21

second half shell

22

ridge

23

toroidal

24

inner circumference

25

outer circumference

31,32,33,34

insertion

41

first winding

42.1, 42.2

convolution

43

second winding

44.1, 44.2

convolution

A-A

Symmetry axis (and also cutting axis)

B-B

section axis

Claims (15)

Current-compensated choke (1) having a toroidal core (23) and at least two windings (41, 43) each consisting of the same number of turns (42.1, 42.2, 44.1, 44.2),
characterized in that in the interior of the toroidal core (23) a non-conductive body (14) with pairs mirror-symmetrical to an axis of symmetry (AA) of the toroidal core holes (15.1, 15.2, 15.3, 15.4, 15.5, 15.6) is arranged, wherein by each Hole of at least some of the pairs of symmetrical holes (15.1, 15.4, 15.2, 15.5, 15.3, 15.6) is guided in each case one turn (42.1, 42.2, 44.1, 44.2), and by the two belonging to a pair of holes (15.1, 15.4, 15.2 , 15.5, 15.3, 15.6) corresponding turns (42.1, 44.1, 42.2, 44.2) of different windings (41, 43) are guided. A current-compensated choke (1) according to claim 1,
characterized in that the non-conductive body (14) is a disc arranged in the interior of the ring core, the circular surfaces of which extend parallel to a direction in which an inner radius vector of the toroidal core (23) extends. A current-compensated choke (1) according to claim 1 or 2,
characterized in that the toroidal core (23) is enclosed by a composite of at least two parts plastic body. A current-compensated choke (1) according to claim 3,
characterized in that the or non-conductive body (14) is connected to one of the parts of the composite plastic body part one of the parts of the composite plastic body. Current-compensated choke (1) according to claim 3 or 4,
characterized in that the plastic body consists of two half-shells (11, 21). Current-compensated choke according to claim 5,
characterized in that the two half shells (11, 21) of the plastic body overlap such that they are positively guided in the inner and outer periphery (24, 25). A current-compensated choke (1) according to claim 5 or 6,
characterized in that the two half-shells (11, 21) of the plastic body are connected to each other by an ultrasonic welding seam or by means of threads applied on both sides by a latching mechanism. A current-compensated choke (1) according to any one of claims 5 to 7,
characterized in that arranged on the surface of the plastic body guide elements for guiding and separating the turns and / or guide elements are introduced into the surface of the plastic body. Current-compensated choke (1) according to one of the preceding claims,
characterized in that the holes (15.1, 15.2, 15.3, 15.4, 15.5, 15.6) in the non-conductive body (14) in at least one direction extending from the surface of the non-conductive body (14) in the extension direction of the hole (15.1 , 15.2, 15.3, 15.4, 15.5, 15.6) have a conically tapered insertion aid (31, 32, 33, 34). Current-compensated choke (1) according to one of the preceding claims,
characterized in that the annular core (23) comprises a soft magnetic ribbon (23) made of an amorphous or nanocrystalline alloy. Current-compensated choke (1) according to one of the preceding claims,
characterized in that the windings (41, 43) comprise wire with a diameter of more than 2mm. A method of making a current compensated choke (1) comprising the steps a) fixing a ring core (23) having in its interior a non-conductive body (14) with pairwise mirror-symmetrical to an axis of symmetry (AA) of the toroidal core (23) executed holes (15.1, 15.2, 15.3, 15.4, 15.5, 15.6) in which the holes (15.1, 15.2, 15.3) lying on one side of the axis of symmetry (AA) form a first group and the holes (15.4, 15.5, 15.6) lying on the second side of the symmetry axis form a second group, b) passing a wire section through one of the holes (15.1, 15.2, 15.3 or 15.4, 15.5, 15.6) of one of the groups c) passing at least one of the ends of the wire section in a loop enclosing the ring core (23) through another hole (15.1, 15.2, 15.3, 15.4, 15.5, 15.6) of the same group, the first end of the wire section being passed in opposite directions through holes (15). 15.1, 15.2, 15.3, 15.4, 15.5, 15.6) is performed as the second end d) repeating steps b) and c) for the other group with a further wire section, wherein either after the implementation of steps c) and d) at each of the wire sections a train is exercised or after the execution of step c) on the corresponding wire section a train is exercised. Method according to claim 12,
characterized in that a double-sided train is exercised. Method according to claim 12 or 13,
characterized in that the train is applied after the wire section passes through all the holes belonging to one group (15.1, 15.2, 15.3 or 15.4, 15.5, 15.6) or through all the holes belonging to both groups (15.1, 15.2, 15.3, 15.4, 15.5 , 15.6). A method according to claim 21 or 22,
characterized in that the train is exerted each time the wire section has passed through another hole (15.1, 15.2, 15.3, 15.4, 15.5, 15.6).

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