TWM682191U - Transformer assembly mechanism - Google Patents

Abstract

This invention relates to a transformer assembly mechanism, comprising a winding frame with a first connecting mechanism; a coil assembly wound on the winding frame; a magnetic core passing through the winding frame and the coil assembly for induction; an insulating base assembled on the magnetic core and the winding frame, the insulating base having a second connecting mechanism; and a first wire connector with at least one mating mechanism. The first wire connector is temporarily fixed to the winding frame and connected to the coil assembly by engaging the mating mechanism with the first connecting mechanism. Then, the first wire connector is detached and rotated towards the insulating base to engage with the second connecting mechanism, thereby simplifying the transformer assembly process and reducing assembly difficulty.

Description

Transformer assembly mechanism

This invention relates to an assembly mechanism, particularly for assembling transformers, thereby simplifying the assembly process and reducing assembly difficulty.

A transformer's basic structure includes at least two independent coils, namely the "primary coil" and the "secondary coil." When energized, the voltage is converted based on the turns ratio of these two coils according to the principle of electromagnetic induction. The transformer is typically mounted on an independent insulating base. This base is pre-installed with multiple conductive elements or pins that connect to the coils, forming a transformer assembly. These conductive elements or pins are soldered to external circuits, allowing the transformer assembly to connect to external circuits for use. Simultaneously, the insulating base serves as signal isolation to prevent mutual interference.

The more loads a transformer connects to, the more complex and numerous the coil wiring becomes, making the wiring connections between the coil and the conductive components or contacts more difficult, especially when the coil's output is further away from these components or contacts.

The existing technology involves installing a protruding intermediate relay frame on the winding frame. The ends of the wire coils that are farther from the conductive components or contacts are pre-wound and positioned on this intermediate relay frame before being soldered to the conductive components or contacts.

While this relay rack design does aid welding, it also adds an extra step, hindering transformer assembly efficiency and making automated production difficult.

To address the shortcomings of prior art, this invention proposes a more novel transformer assembly mechanism, thereby simplifying the transformer assembly process and reducing assembly difficulty. This mechanism is also more suitable for integration into automated production operations, which is the primary objective of this invention.

To achieve the objective of this invention, the transformer assembly mechanism includes: a winding frame with a first connecting mechanism; a coil assembly wound on the winding frame; a magnetic core passing through the winding frame and the coil assembly; an insulating base assembled on the magnetic core and the winding frame, with a second connecting mechanism on the insulating base; and a first wire connector with at least one mating mechanism. The first wire connector is temporarily fixed to the winding frame and connected to the coil assembly by engaging the mating mechanism with the first connecting mechanism. Then, the first wire connector is removed and rotated towards the insulating base to engage with the second connecting mechanism. Thus, since the first wire connector is pre-positioned on the winding frame of the adjacent coil assembly, the distance between them is shortened, making the connection (welding) process more convenient, especially when the coil assembly has more and more complex lead ends, preventing interference. Furthermore, after the first wire connector is connected to the coil assembly, simply removing it from the winding frame and rotating it onto the insulating base completes the transformer assembly, making the assembly process easier to integrate with automated production lines and accelerate production efficiency.

Preferably, the present invention further includes an external circuit board. The first connector has at least one first wire groove for inserting and isolating the lead-out end of the coil assembly. After the lead-out end of the coil assembly is fixed in the first wire groove, it is connected to the circuit board. Once completed, the first connector is removed, and the coil assembly, along with the circuit board, is rotated toward the insulating base to engage with the second connecting mechanism.

Preferably, the present invention further includes an external circuit board. At least one first pin is provided on the first connector to provide connection between the lead-out end of the coil assembly and external signal communication. The first pin is connected to the lead-out end of the coil assembly and the circuit board. After connection, the first connector is removed, and the first connector, along with the circuit board, is rotated toward the insulating base to engage with the second connecting mechanism.

The embodiments of this invention will be described in detail below with reference to the accompanying drawings. It should be noted that, in accordance with industry standard practice, the features are not drawn to scale and are for illustrative purposes only. In fact, the dimensions of the components can be arbitrarily enlarged or reduced to clearly demonstrate the features of the embodiments of this invention.

A: Transformer

B: Circuit board

1: Winding Frame

2: Coil Set

20: Beginner Side Lineup

21: Secondary Side Lineup

210: Outgoing cable end

3: Magnetic core

4: Insulation base

5: First Line Seat

50: First cable tray

51: First contact

6: Second line seat

60: Second cable tray

61: Second footwork

70: First Linkage Mechanism

71: The first contact organization

80: Second Linkage Mechanism

81: Second docking organization

Figure 1 is an exploded view of the transformer of this invention;

Figure 2 shows the assembled diagram of the transformer of this novel invention;

Figure 3 shows another view of the assembled transformer of this novel invention;

Figure 4 is a schematic diagram of the assembly of the new transformer, showing the first connector corresponding to the first connecting mechanism of the winding frame;

Figure 5 is a schematic assembly diagram of the transformer of this invention, showing in a side cross-section the state in which the first connector is fixed to the first connecting mechanism;

Figure 6 is a schematic assembly diagram of the transformer of this invention, showing in a top cross-sectional view the state in which the first connector is fixed to the first connecting mechanism;

Figure 7 is a schematic assembly diagram of the transformer of this invention, showing in a side cross-section the state in which the first connector is fixed to the second connecting mechanism;

Figure 8 is a schematic assembly diagram of the transformer of this invention, showing in a top cross-sectional view the state in which the first connector is fixed to the second connecting mechanism;

Figure 9 is another assembly schematic diagram of the transformer of this invention, showing the connection status of the first connector to the circuit board;

Figure 10 shows the circuit board of Figure 9 after it has been connected to the first connector and rotated towards the insulating base, where it is then fixed to the second connecting mechanism.

Figure 11 is another assembly schematic diagram of the transformer of this invention, showing another connection state between the first connector and the circuit board;

Figure 12 shows the circuit board of Figure 11 after it has been connected to the first connector and rotated towards the insulating base, where it is then fixed to the second connecting mechanism.

The quantity of the described objects may be described using "at least one" in the following text, but unless otherwise expressly stated, it should not be limited to the case where the quantity is "only one". Terms such as "forming", "joining", "connecting", "setting", and "configuring" may also be used to describe the relative positional relationships between multiple layers, structures, or components, but unless otherwise expressly stated, they may cover situations where the said layers, structures, or components are in direct contact with each other, or where one or more intermediate media or other layers, structures, or components may exist between the said layers, structures, or components. Terms such as "first" and "second" may also be used in the following text, but this is primarily to distinguish elements or operations described with the same term, rather than to define the order or sequence of elements or operations.

As shown in Figures 1 to 8, this invention relates to a transformer assembly mechanism. The transformer A includes a winding frame 1, a coil assembly 2, a magnetic core 3, an insulating base 4, a first wire connector 5, and a second wire connector 6. The coil assembly 2 is mainly wound on the winding frame 1. The magnetic core 3 passes through the winding frame 1 and interacts with the coil assembly 2. The insulating base 4 is included in and assembled on the magnetic core 3 and the winding frame 1 to increase the insulation isolation of the transformer A. After the coil assembly 2 is energized, it generates magnetic interaction with the magnetic core 3.

In the embodiments disclosed in the various figures of this novel invention, the coil assembly 2 includes a primary coil 20 and a secondary coil 21, but is not limited thereto; after the primary coil 20 is energized, the secondary coil 21 is energized, and the voltage value is converted according to the turns ratio of the two coils 20 and 21.

The two coils 20 and 21 are wound in series on the winding frame 1, but this is not a limitation. The primary coil 20 is adjacent to the insulating base 4, while the secondary coil 21 is relatively far from the insulating base 4. The first connector 5 and the second connector 6 are arranged on opposite sides of the insulating base 4. That is, the distance that the secondary coil 21 needs to travel to connect with the first connector 5 or the second connector 6 is much greater than the distance that the primary coil 20 needs to travel to connect with the first connector 5 or the second connector 6.

In the embodiments disclosed in the various figures of this novel invention, the primary coil 20 is connected to the second connector 6, and the secondary coil 21 is connected to the first connector 5, but is not limited thereto; the second connector 6 is connected to an external power supply terminal, and the first connector 5 is connected to an external load to supply power.

The first and second connectors 5 and 6 are respectively provided with at least one first cable groove 50 and at least one second cable groove 60; or at least one first pin 51 and at least one second pin 61; or simultaneously provided with the first cable groove 50 and the first pin 51, and the second cable groove 60 and the second pin 61. The first and second cable grooves 50 and 60 respectively provide for the insertion of the wire ends of the secondary-side coil 21 and the primary-side coil 20 for cable management and isolation, while the first and second pins 51 and 61 are respectively used to connect to the secondary-side coil 21 and the primary-side coil 20 as a medium for communication with external signals.

In the above-described winding frame 1, a first connecting mechanism 70 is also provided, and a first mating mechanism 71 is provided on the first wire seat 5. The first mating mechanism 71 and the first connecting mechanism 70 can be correspondingly engaged, so that the first wire seat 5 can be fixed on the winding frame 1. The first connecting mechanism 70 is located adjacent to the secondary side coil 21 on the winding frame 1.

Furthermore, a second mating mechanism 81 is provided on the first wire connector 5, and a second connecting mechanism 80 is provided on the insulating base 4. The second mating mechanism 81 and the second connecting mechanism 80 can also be correspondingly engaged, allowing the first wire connector 5 to be fixed to the insulating base 4. Preferably, the first mating mechanism 71 can also be compatiblely engaged with the second connecting mechanism 80 on the insulating base 4, thus reducing the number of components on the first wire connector 5 and lowering production costs.

The assembly sequence of the aforementioned transformer A of this new type is as follows:

(1) The second wire connector 6 is arranged on one side of the winding frame 1, and the primary side coil 20 and the secondary side coil 21 are wound in series on the winding frame 1. In the embodiments disclosed in the various figures of this novel invention, the winding position of the primary side coil 20 is adjacent to the second wire connector 6, and the second pin 61 on the second wire connector 6 is connected to the primary side coil 20 for electrical communication.

(2) The first mating mechanism 71 is engaged with the first connecting mechanism 70, temporarily fixing the first wire connector 5 to the winding frame 1, and connecting the lead-out end 210 of the secondary side coil 21 adjacent to the first wire connector 5 to the first pin 51 on the first wire connector 5.

(3) The magnetic core 3 and the insulating base 4 are fitted onto the winding frame 1, with the second wire connector 6 exposed on one side of the insulating base 4.

(4) Disconnect the first mating mechanism 71 from the first connecting mechanism 70, remove the first wire connector 5 from the winding frame 1 and rotate it towards the insulating base 4. Then, connect the first mating mechanism 71 or the second mating mechanism 81 to the second connecting mechanism 80 on the insulating base 4, so that the first wire connector 5 and the second wire connector 6 are positioned on opposite sides of the insulating base 4.

The assembled transformer A has its first connector 5 and second connector 6 connected to a circuit board B. The second connector 6 is connected to the power supply terminal of circuit board B, and the first connector 5 is connected to the load terminal of circuit board B. When the primary winding 20 is energized, the secondary winding 21 is sensed, and voltage is converted according to the turns ratio of the two windings 20 and 21 before being supplied to the load terminal.

According to the above-described transformer assembly mechanism, the first connector 5 is pre-positioned on the winding frame 1 adjacent to the secondary coil 21, which shortens the distance between the first connector 5 and the secondary coil 21, making the connection (welding) process between the two more convenient. In particular, it will not cause interference when the output terminals 210 of the secondary coil 21 are more numerous and complex. In addition, after the first connector 5 and the secondary coil 21 are connected, the transformer A can be assembled simply by removing the first connector 5 from the winding frame 1 and rotating it to the insulating base 4. This makes the assembly operation easier to coordinate with the automated production process and accelerates production efficiency. It is indeed a novel and progressive design.

It is worth mentioning that the above-mentioned novel transformer assembly mechanism design can also help with the wiring process between the transformer and the external circuit board B. As shown in Figure 9, when the first connector 5 is temporarily fixed to the winding frame 1 and is preparing or completing the connection with the secondary side coil 21, it can be simultaneously connected to the circuit board B by soldering the first pin 51. After completion, the first connector 5 and the circuit board B are rotated together toward the insulating base 4 and fixed to the insulating base 4 by engaging the first mating mechanism 71 or the second mating mechanism 81 with the second connecting mechanism 80, as shown in Figure 10. In this way, the connection between the first wire connector 5, the secondary side wire coil 21, and the circuit board B can be completed in the same process, thereby simplifying the assembly process and increasing production efficiency. Furthermore, based on the above, and referring to Figure 11, when the secondary coil 21 has a thicker wire diameter, it can be directly inserted into the first slot 50 of the first connector 5 for fixation. The output terminal 210 of the secondary coil 21 can then be directly electrically connected to the circuit board B. This eliminates the need for a first pin 51 on the first connector 5, reducing component requirements and manufacturing costs. After completion, the first connector 5 and the circuit board B are rotated together towards the insulating base 4 and fixed to the insulating base 4 by engaging the first mating mechanism 71 or the second mating mechanism 81 with the second connecting mechanism 80, as shown in Figure 12.

The above embodiments detail the features and advantages of this invention, and their content is sufficient for anyone skilled in the art to understand the technical content of this invention and implement it accordingly. Furthermore, based on the content disclosed in this specification, the scope of the patent application, and the drawings, anyone skilled in the art should be able to easily understand this invention. Therefore, this is stated in advance.

A: Transformer

1: Winding Frame

2: Coil Set

20: Beginner Side Lineup

21: Secondary Side Lineup

210: Outgoing cable end

3: Magnetic core

4: Insulation base

5: First Line Seat

50: First cable tray

51: First contact

6: Second line seat

60: Second cable tray

61: Second footwork

70: First Linkage Mechanism

71: The first contact organization

80: Second Linkage Mechanism

81: Second docking organization

Claims (8)

A transformer assembly mechanism, comprising: A winding frame having a first connecting mechanism; A single coil is wound onto the winding frame; A magnetic core is inserted between the winding frame and the coil assembly for induction; An insulating base having a second connecting mechanism; and, A first wire holder, having at least one first mating mechanism, engages with a first connecting mechanism to temporarily fix it to the winding frame and connect it to the coil assembly. After connection is complete, the first wire holder is detached and rotated toward the insulating base to engage with a second connecting mechanism. The transformer assembly mechanism as described in claim 1, wherein the coil assembly includes a primary-side coil and a secondary-side coil wound in series on the winding frame, and the first connecting mechanism is located adjacent to the secondary-side coil. The transformer assembly mechanism as described in claim 1 or 2, wherein the first connector further includes a second mating mechanism for engaging with the second connecting mechanism. The transformer assembly mechanism as described in claim 1 or 2, wherein the first connector has at least one first groove for inserting and isolating the outlet of the coil assembly. The transformer assembly mechanism as described in claim 1 or 2, wherein the first connector has at least one first pin providing a lead-out connection for the coil assembly to communicate with external signals. The transformer assembly mechanism as described in claim 4 further includes an external circuit board, wherein the lead-out end of the coil assembly is engaged and fixed in the first wire slot and connected to the circuit board. After completion, the first wire connector is removed, and the coil assembly, along with the circuit board, is rotated toward the insulating base to engage with the second connecting mechanism. The transformer assembly mechanism as described in claim 5 further includes an external circuit board, wherein the first pin is connected to the lead-out terminal of the coil assembly and the circuit board. After completion, the first connector is removed, and the circuit board, together with the connector, is rotated toward the insulating base to engage with the second connecting mechanism. The transformer assembly mechanism as described in claim 1 or 2, wherein the insulating base is included and assembled on the magnetic core and the winding frame to increase the insulation isolation of the transformer.