JP5680327B2 - Split winding transformer - Google Patents

Description

  The present invention relates to a split-winding transformer used in, for example, a converter that steps up and down a DC voltage.

In the split winding transformer, as shown in FIG. 8, the winding is wound around the winding portion 101 of the split winding bobbin 100, and the split winding 102 is provided to transfer the winding 110 to the adjacent winding portion 101. A predetermined number of turns are wound around all the winding portions 101 through the grooves 103.
In this case, the transition of the winding to the adjacent winding part 101 passes through the groove from the outer periphery of the winding coil and is transferred to the bottom of the saddle. Doing so may lead to smoke and fire accidents such as rare shorts (interlayer shorts).

In order to prevent the above-described rare short circuit, for example, in Patent Document 1, a wall 120 thinner than the flange 102 is provided in a portion of the groove 103 for transferring the winding to the adjacent winding portion 101.
According to such a configuration, as shown in FIG. 9, the transition lead wire 111 can be moved to the adjacent winding part while being hooked at the upper end of the wall 120, so that the start end of the winding coil in each winding part It can be started from the bottom of the wall, that is, the bottom of the wall, and it is said that it is possible to prevent smoke and fire accidents due to rare shorts.

Japanese Patent Laid-Open No. 5-267065

  However, even in the configuration as shown in FIG. 9, it is difficult to ensure a sufficient insulation distance between the transition lead wire and the winding coil. When the potential difference between the coil and the upper layer of the wound coil becomes large, rare shorts cannot be reliably prevented. Similarly, it is impossible to prevent a rare short-circuit between the winding start lead wire and the upper layer portion of the first wound coil.

  In order to reliably prevent such rare shorts, insulation tubes and insulation tape are also applied to the winding start lead wire and the transition lead wire, but this complicates the manufacturing process and hinders the automation of winding. At the same time, the winding coil is likely to be disturbed, causing variations in characteristics.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a highly reliable split winding transformer that enables reliable prevention of rare shorts and automation of windings.

The split-winding transformer of the present invention made to achieve the above object is
A bobbin in which a plurality of divided winding grooves are formed by a dividing rod having a transition groove;
Two or more layers are wound around each divided winding groove by alpha winding, the conductor wire straddling across the two divided winding grooves adjacent to the divided rod through the transition groove,
A magnetic core is incorporated in the bobbin ,
An insulating member corresponding to the shape of the transition groove is mounted on a conducting wire passing through the transition groove .

In a split winding transformer of the present invention, the transition groove, Tei Rukoto formed reaches the bottom of the discrete winding grooves, are preferred.

  According to the present invention, both ends of the winding are led out from the outermost layer (uppermost layer) by winding the conducting wire by alpha winding across two adjacent divided winding grooves. For this reason, it is not necessary to draw the winding start lead wire and transition lead wire from the top to the bottom of the winding groove as in the past, and it prevents rare shorts without applying insulating tape or insulation tube to the winding start lead wire or transition lead wire. In addition, the winding can be automated and a more reliable split winding transformer can be realized.

It is a disassembled perspective view of the division | segmentation winding transformer in the 1st Embodiment of this invention. FIG. 2 (a) is a completed perspective view of the split winding transformer of FIG. FIG. 2B is a cross-sectional view taken along the line AA in FIG. It is the schematic which shows an example of the winding apparatus used for manufacture of the division | segmentation winding transformer of FIG. It is a figure for demonstrating the winding process by the winding apparatus of FIG. Fig.5 (a) is explanatory drawing when a conducting wire is spanned through the narrow transition groove. FIG.5 (b) is explanatory drawing when a conducting wire is spanned through the wide transition groove. FIG. 6A shows a bottom view of the bobbin according to the second embodiment, and shows a case where the movable wall is not closed. FIG. 6B is a cross-sectional view taken along the line BB in FIG. FIG. 6C shows a bottom view of the bobbin when the movable wall of FIG. 6A is closed. FIG. 6D is a cross-sectional view taken along the section line CC in FIG. Fig.7 (a) shows the bottom view of the bobbin concerning 3rd Embodiment. FIG.7 (b) shows sectional drawing of the cutting line DD of Fig.7 (a). It is sectional drawing which wound the coil around the conventional split winding transformer. It is sectional drawing which wound the coil around another conventional split winding transformer.

  Hereinafter, embodiments of the present invention will be exemplarily described based on the drawings. However, the material, shape, relative arrangement, and the like of the component parts described in this embodiment are not intended to limit the scope of the present invention to that unless otherwise specified.

(First embodiment)
FIG. 1 is an exploded perspective view of a split winding transformer 1 according to the first embodiment of the present invention. 2A is a completed perspective view of the split winding transformer 1 of FIG. FIG. 2B is a cross-sectional view taken along the line AA in FIG.
As shown in FIGS. 1 and 2, the split-winding transformer 1 in this embodiment is formed of an insulating resin and has a bobbin 10 having a plurality of substantially square-shaped split rods in the winding axis direction, and is wound around the bobbin 10. This is a horizontal type that includes a coil 40 and two E-type cores 50 in which a magnetic core is incorporated in the bobbin 10 and is placed with a low height so that the core is laid down.

The bobbin 10 has an outer casing 12 on both sides of a rectangular tubular winding part 11, and a terminal block 13 below the outer casing 12. The terminal block 13 has a plurality of connection terminals 14 that are planted so as to extend upward in the drawing, and the terminals of the coil 40 are connected to the connection terminals 14.
The bobbin 10 has a central dividing rod 15 provided between the outer rods 12 and a both-end divided rod 16 provided between the central dividing rod 15 and the outer rod 12, and a plurality of divided windings are formed by these dividing rods. A groove 17 is formed.

The central split rod 15 is formed with a transition groove 18 for passing a conductor (a primary winding 41 described later in this example) between the split winding grooves 17 on both sides. In this example, the transition groove 18 is formed by cutting out a part of the center dividing rod 15 on the terminal block 13 side (the upper side in the drawing of FIG. 1) to the bottom of the divided winding groove 17 in a rectangular shape.
Further, the central dividing rod 15 is formed with outer peripheral grooves 19 at both outer peripheral portions of the transition groove 18.

Reference numeral 60 denotes an insulating member made of a resin molded body. The insulating member 60 includes a rectangular insertion portion 61 corresponding to the shape of the transition groove 18, a support portion 62 extending on both sides of the insertion portion 61, and a locking portion 63 positioned at the tip of the support portion 62. It is formed to have the same thickness as the central dividing rod 15.
The insulating member 60 is attached to the bobbin 10 by locking the locking portion 63 to the outer peripheral groove 19. Thereby, the insertion part 61 of the insulating member 60 is mounted on the conducting wire passing through the transition groove 18 (see FIG. 2).

  The coil 40 includes one primary winding 41 and two secondary windings 42. In the present embodiment, the primary winding 41 is made of, for example, a litz wire in which a large number of conductive wires having an insulating film are provided, and suppresses an increase in heat generation of the winding due to a high frequency. The primary winding 41 may be a single wire having an insulating film. The secondary winding 42 is made of a single wire having an insulating film.

  The two secondary windings 42 are respectively wound around the two divided winding grooves 17 between the both-end split rod 16 and the outer rod 12, and the terminal 42A is connected to the connection terminal 14 of each terminal block 13 on both sides. . In this example, two secondary windings 42 are provided. However, the number of secondary windings 42 may be one, and the number of secondary windings 42 is appropriately selected depending on the drive circuit of the converter in which the split-winding transformer 1 is incorporated.

  One primary winding 41 is spanned across the two split winding grooves 17 adjacent to the central split rod 15 through the transition groove 18, and is wound around the split winding grooves 17 in multiple layers by alpha winding (α winding). The terminal 41A is connected to the connection terminals 14 of the terminal blocks 13 on both sides.

Next, a winding method for winding a conducting wire around the bobbin 10 by alpha winding will be described.
FIG. 3 is a schematic diagram showing an example of a winding device 30 used for manufacturing the split-winding transformer 1 of the present example. FIG. 4 is a diagram for explaining a winding process by the winding apparatus 30 of FIG.

The winding device 30 includes a winding jig 31, a supply bobbin 32, and an auxiliary bobbin 33.
First, the primary winding 41 having a number equal to or greater than the number of turns wound in one of the divided winding grooves 17 adjacent to the central dividing rod 15 is wound from the supply bobbin 32 to the auxiliary bobbin 33.
Then, the bobbin 10 is mounted on a winding jig 31 fixed to the winding device 30, and the primary winding 41 is stretched across the two divided winding grooves 17 adjacent to the central dividing rod 15 through the transition groove 18. (See FIG. 4A).

Next, the supply bobbin 32 and the auxiliary bobbin 33 are planetarily rotated in opposite directions with respect to the bobbin 10 (see FIG. 3). Both ends of this winding are wound from the bottom of the split winding groove 17 near the central split rod 15 toward the double split rod 16 (see FIG. 4 (b)). After that, two layers are wound toward the central dividing rod 15 and are sequentially laminated, and can be derived from the outermost layer (uppermost layer) of the wound coil. In this example, the primary winding 41 wound around the divided winding grooves 17 is wound around each divided winding groove 17 in 8 rows in the winding axis direction and 10 layers in the direction perpendicular to the winding axis.
Thereafter, the terminal 41A of the primary winding 41 derived from the outermost layer is connected to the connection terminal 14 of the terminal block 13 on both sides (see FIG. 4C).

Thus, in the split winding transformer of this example, the winding is wound by alpha winding across two adjacent split winding grooves, so that both ends of the winding are derived from the outermost layer (uppermost layer) of the winding coil. The For this reason, it is not necessary to draw the winding start lead wire and the transition lead wire from the upper layer portion to the bottom of the winding groove as in the prior art, and a rare short can be achieved without applying insulating tape or insulating tube to the winding start lead wire or the transition lead wire. In addition to being able to prevent this, the winding can be automated, and a more reliable split winding transformer can be realized.
Further, since it is not necessary to draw the lead wire or the transition lead wire at the bottom of the divided winding groove into the lowermost layer, the winding coil is hardly disturbed, and variations in characteristics can be reduced.
In addition, since the conductive wire is wound around each divided winding groove across two adjacent divided winding grooves, if the supply bobbin and the auxiliary bobbin are rotated on the planet at the same time, the winding can be wound in half the time compared to the conventional case. Process time can be greatly reduced.

Moreover, in the split winding transformer 1 of this example, since the insulating member 60 (insertion portion 61) corresponding to the shape of the transition groove 18 is mounted on the conducting wire passing through the transition groove 18, the following effects are obtained. is there.
Since the central split rod 15 is formed higher than the outermost layer of the wound coil, when the thickness in the winding axis direction is sufficiently thick, the central split rod 15 was wound around the two divided winding grooves 17 adjacent to the central split rod 15. There is no need for insulation between winding coils.
However, if the thickness of the central split rod 15 is reduced in order to reduce the size of the split-winding transformer 1, the distance between the winding coils is reduced. In particular, in the case of winding by alpha winding as in the present invention, Since the potential difference between the outermost layers of two adjacent wound coils is higher than that of the conventional winding method, it is difficult to secure a sufficient insulation distance in the transition groove 18 portion.
For this reason, a rare short-circuit can be prevented more reliably by attaching the insulating member to the transition groove portion where the withstand voltage is lowered particularly as in this example.

When the insulating member 60 as in this example is used, the shape of the insertion portion 61 is preferably a tapered shape that narrows toward the distal end side with respect to the insertion direction into the transition groove. With such a shape, even if the wound coil slightly enters the transition groove, it can be easily inserted into the transition groove. In addition, since the thickness of the insulating member 60 becomes thicker in the outermost layer portion where the potential difference occurs, the insulation measure can be strengthened.
In this example, when the insulating member 60 is mounted on the bobbin 10, a space H1 corresponding to one layer of the conductive wire is formed below the insertion portion 61 from the bottom of the transition groove 18 (see FIG. 2B). However, there is almost no potential difference generated between the lowest layers, and rare shorts do not occur.
Further, the insulating member 60 can be easily attached to the bobbin because the engaging portion 63 is engaged with the outer peripheral groove 19 of the central split rod.

  In the present invention, the shape of the transition groove 18 is not particularly limited. However, as in the transition groove 18 of the present example, a part of the central dividing rod 15 is cut out to the bottom of the divided winding groove 17. good. As a result, the conductor can be bridged over the adjacent two divided winding grooves through the transition groove without bending the conductor, and the surface of the conductor can be prevented from being damaged. Since the lead-in to the lowermost layer is eliminated and the distance of the conductor wire between the divided winding grooves is shortened, the amount of the conductor wire used can be reduced.

  Further, the width W0 of the transition groove 18 may be at least a width through which the conductor can pass. However, when the width W0 of the transition groove 18 is too narrow, the surface of the conductor is strongly against the corner of the side wall 20 of the transition groove 18. There is a possibility of contact and damage (see FIG. 5A). On the other hand, when the width W0 of the transition groove 18 is too wide, the strength of the center split rod 15 itself tends to be weak (see FIG. 5B). For this reason, the width W0 of the transition groove is preferably 2/3 or less of the width W of the winding part 11 of the bobbin 10 and twice or more the conductor diameter, and is 1 of the width W of the winding part 11 of the bobbin 10 It is particularly preferable that it is not more than / 2 and is not less than 3 times the conductor diameter.

(Second Embodiment)
Fig.6 (a) shows the bottom view of the bobbin 10 concerning 2nd Embodiment, and shows the time when the movable wall 21 is not closed. FIG. 6B is a cross-sectional view taken along the line BB in FIG. FIG. 6C shows a bottom view of the bobbin 10 when the movable wall 21 of FIG. 6A is closed. FIG. 6D is a cross-sectional view taken along the section line CC in FIG.
In FIG. 6, the same components as those in the first embodiment are denoted by the same reference numerals, and redundant description is omitted.

The present embodiment is different from the first embodiment in that a movable wall 21 is integrally formed on the side wall 20 of the transition groove 18 of the central dividing rod 15.
This movable wall 21 has a thin portion 22 between the side wall 20 of the transition groove 18, and the conductive wire passes over the two divided winding grooves 17 passing through the transition groove 18 of the central split rod 15. Then, the opening of the transition groove 18 is closed via the thin portion 22.

  Also in this example, since the insulating member 60 (movable wall 21) is attached to the transition groove 18 where the withstand voltage decreases, it is possible to reliably prevent a rare short. In addition, since the bobbin and the insulating member 60 are integrally formed, the number of parts is small and the manufacturing process can be simplified and the cost can be reduced.

(Third embodiment)
Fig.7 (a) shows the bottom view of the bobbin 10 concerning 3rd Embodiment. FIG.7 (b) shows sectional drawing of the cutting line DD of Fig.7 (a).
In FIG. 7, the same components as those of the first embodiment are denoted by the same reference numerals, and redundant description is omitted.

  In the present embodiment, the difference from the first embodiment is that the transition groove 23 is formed so that a conducting wire stretched in a straight line across two adjacent divided winding grooves 17 can pass. The side walls 24 are formed so as to overlap each other in the winding axis direction in a non-contact manner.

In this example, the transition groove 23 having a reduced withstand voltage has a shape in which the side walls 24 of the transition groove 23 are stacked in a non-contact manner in the winding axis direction, so that an insulation distance can be secured and a rare short circuit can be prevented. In addition, since the above-mentioned side wall 20 is formed on the bobbin, the number of parts is reduced without adding an insulating member, and the manufacturing process can be simplified and the cost can be reduced.
Moreover, since the span of the conducting wire between the adjacent divided winding grooves 17 is the shortest, the amount of conducting wire used can be reduced.
Further, the width of the transition groove 23 only needs to be a width that allows the conducting wire to pass therethrough, and the width of the transition groove can be formed narrow, so that the strength of the central split rod itself is hardly impaired.

DESCRIPTION OF SYMBOLS 1 Divided winding transformer 10 Bobbin 11 Winding part 12 Outer cage 13 Terminal block 14 Connection terminal 15 Central division cage 16 Both ends division cage 17 Divided winding groove 18 Transition groove 19 Peripheral groove 20 Side wall 21 Movable wall 22 Thin part 23 Transition groove 24 Side wall 30 Winding Device 31 Winding Jig 32 Supply Bobbin 33 Auxiliary Bobbin 40 Coil 41 Primary Winding 41A End of Primary Winding 42 Secondary Winding 42A End of Secondary Winding 50 E Type Core 60 Insulating Member 61 Insertion Portion 62 Supporting part 63 Locking part H1 Space W Bobbin winding width W0 Transition groove width

Claims (5)

A bobbin in which a plurality of divided winding grooves are formed by a dividing rod having a transition groove;
Two or more layers are wound around each divided winding groove by alpha winding, the conductor wire straddling across the two divided winding grooves adjacent to the divided rod through the transition groove,
A magnetic core is incorporated in the bobbin ,
An insulating member corresponding to the shape of the transition groove is mounted on a conducting wire passing through the transition groove . The transition groove is constructed from a discrete winding transformer according to claim 1, wherein the bottom Tei Rukoto formed reached the discrete winding groove. The insulating member has an insertion part corresponding to the shape of the transition groove, a support part extending on both sides of the insertion part, and a locking part located at the tip of the support part,
An outer peripheral groove is formed in the outer peripheral portion of the transition groove in the split rod,
The split winding transformer according to claim 1, wherein the insulating member is attached to the bobbin by locking the locking portion to the outer peripheral groove. The split winding transformer according to claim 3, wherein a shape of the insertion portion is a taper shape narrower toward a distal end side with respect to an insertion direction into the transition groove. 3. The split winding transformer according to claim 1, wherein the insulating member includes a movable wall integrally formed on a side wall of the transition groove of the split rod.

Images