阅读说明：本技术 焊接变压器 (Welding transformer ) 是由 内田光彦 百济真 冈珠实 于 2018-12-27 设计创作，主要内容包括：焊接变压器(10)具有铁芯(12)和在铁芯(12)上分别交替卷绕的一次绕线(18)及二次绕线(20)。一次绕线(18)具有宽度方向沿与穿过铁芯(12)的磁通的方向(Dy)平行地延伸的第一带状导体(40a)。二次绕线(20)具有宽度方向沿与穿过铁芯(12)的磁通的方向(Dy)平行地延伸的第二带状导体(40b),第一带状导体(40a)和第二带状导体(40b)分别交替地在与磁通的方向(Dy)正交的方向(Dx)上层叠。(A welding transformer (10) has an iron core (12), and a primary winding (18) and a secondary winding (20) that are alternately wound around the iron core (12). The primary winding (18) has a first strip conductor (40a) extending in the width direction parallel to the direction (Dy) of the magnetic flux passing through the core (12). The secondary winding (20) has a second strip conductor (40b) extending in the width direction parallel to the direction (Dy) of the magnetic flux passing through the core (12), and the first strip conductor (40a) and the second strip conductor (40b) are alternately laminated in the direction (Dx) orthogonal to the direction (Dy) of the magnetic flux.)

1. A welding transformer, comprising:

an iron core; and

a primary winding and a secondary winding alternately wound around the core,

the primary winding has a first strip conductor extending in a width direction in parallel to a direction of magnetic flux passing through the core,

the secondary winding has a second strip conductor extending in the width direction in parallel to the direction of the magnetic flux passing through the core,

the first strip conductors and the second strip conductors are alternately laminated in a direction orthogonal to the direction of the magnetic flux.

2. The welding transformer of claim 1,

the secondary winding includes a positive electrode side secondary winding and a negative electrode side secondary winding,

the core is wound with the primary winding, the positive-side secondary winding, and the negative-side secondary winding in this order, or with the primary winding, the negative-side secondary winding, and the positive-side secondary winding in this order.

3. The welding transformer of claim 2, having:

the iron core is annular;

a winding unit that is wound around the core and has the primary winding, the positive-side secondary winding, and the negative-side secondary winding connected between one input terminal and the other input terminal;

a negative electrode connected to a connection point of the positive-side secondary winding and the negative-side secondary winding; and

and a positive electrode connected to the positive-side secondary winding via a first rectifier element and connected to the negative-side secondary winding via a second rectifier element.

4. Welding transformer according to claim 3,

the primary winding includes a plurality of first strip conductors covering a part of the core,

the positive-side secondary winding includes a plurality of second strip conductors arranged between the first strip conductors,

the negative secondary winding has a plurality of third strip conductors respectively disposed between the first strip conductor and the second strip conductor,

each of the second strip conductors has a positive electrode connected to one end thereof and is wound at least 1 turn,

each of the third strip conductors has a negative electrode connected to one end thereof and is wound at least 1 turn,

the negative electrode electrically connecting the other end of the second strip conductor and the other end of the third strip conductor is disposed between the positive electrode and the negative electrode.

5. The welding transformer of claim 4,

the primary winding has a plurality of first connecting conductors for electrically connecting the first strip conductors to each other,

the positive electrode secondary winding has a plurality of second connection conductors electrically connecting the positive electrodes,

the negative electrode secondary winding has a plurality of third connection conductors for electrically connecting the negative electrodes,

the positive-side secondary winding and the negative-side secondary winding each have a plurality of fourth connection conductors electrically connecting the negative electrodes.

6. Welding transformer according to claim 5,

a plurality of the first connection conductors are formed on one end surface of the winding portion,

the one input terminal is connected to a first connection conductor located on an outer peripheral side of the winding portion among the plurality of first connection conductors,

the other input terminal is connected to the first connection conductor located on the inner peripheral side of the winding portion, among the plurality of first connection conductors.

7. Welding transformer according to claim 5 or 6,

the core has two elongated parallel portions,

the winding portion is wound around any one of the parallel portions,

at least one of a connection direction of the first connection conductor, a connection direction of the second connection conductor, a connection direction of the third connection conductor, and a connection direction of the fourth connection conductor is in a positional relationship in which the longitudinal direction of the parallel portion intersects with the connection direction of the first connection conductor.

8. The welding transformer of claim 7,

at least the connection direction of the second connection conductor is the same as the connection direction of the third connection conductor.

9. Welding transformer according to claim 8,

the winding portion has a first winding portion wound around one of the parallel portions and a second winding portion wound around the other of the parallel portions,

the winding device further includes a fifth connection conductor that electrically connects at least one of the first strip conductors of the first winding portion and at least one of the first strip conductors of the second winding portion.

10. Welding transformer according to claim 9,

one of the first connection conductors, which is 1 or more, is formed on one end surface of the first winding portion,

of the plurality of first connection conductors, the other 1 or more first connection conductors are formed on one end surface of the second winding portion,

the fifth connecting conductor is connected from a position corresponding to the first connecting conductor located on the outer peripheral side or inner peripheral side of the first winding portion among the one 1 or more first connecting conductors to a position corresponding to the first connecting conductor located on the outer peripheral side or inner peripheral side of the second winding portion among the other 1 or more first connecting conductors,

one input terminal is connected to the first connection conductor located on the inner or outer peripheral side of the first wound portion among the 1 or more first connection conductors,

the other input terminal is connected to the first connection conductor located on the inner or outer peripheral side of the second winding portion, among the other 1 or more first connection conductors.

11. Welding transformer according to claim 9 or 10,

the core has two elongated parallel portions,

the first winding portion is wound around one of the parallel portions,

the second winding portion is wound around any other one of the parallel portions,

at least one of the connection direction of the first connection conductor, the connection direction of the second connection conductor, the connection direction of the third connection conductor, and the connection direction of the fourth connection conductor and the fifth connection conductor is in a positional relationship in which the connection direction intersects with the longitudinal direction of the parallel portion.

12. The welding transformer of claim 11,

at least the connection direction of the second connection conductor, the connection direction of the third connection conductor, and the connection direction of the fifth connection conductor are the same.

13. The welding transformer according to any one of claims 5 to 12,

a positive electrode conductor connected to the second connection conductor and a negative electrode conductor connected to the third connection conductor,

the positive electrode is connected between the positive conductor and the negative conductor,

the first rectifying element is connected between the positive electrode conductor and the positive electrode,

the second rectifying element is connected between the negative electrode conductor and the positive electrode.

14. The welding transformer according to any one of claims 5 to 13,

the plurality of fourth connection conductors electrically connected between the negative electrodes and the positive electrode are disposed on one end surface side of the wound portion,

the one input terminal and the other input terminal are disposed on the other end surface side of the winding portion.

Technical Field

The present invention relates to a welding transformer used for resistance welding or the like.

Background

The welding transformer disclosed in japanese patent No. 5220931 has a problem in that it can perform high-speed and precise welding control with a large current and reduce power consumption.

In order to solve this problem, a welding transformer described in japanese patent No. 5220931 includes an annular core, a primary coil that is wound in divided fashion, and a plurality of positive-side coils and a plurality of negative-side coils that are alternately interposed in gaps of the primary coil. The coil is fixed to one surface of the connection substrate. On the other surface of the connection substrate, the positive side coil is electrically connected to the positive side conductor via the first connection plate. The negative side coil is electrically connected to the negative side conductor via the second connection plate. The connection portion of the positive side coil and the negative side coil is electrically connected to the third connection plate. A positive conductor, a rectifying element and a first electrode plate are arranged on one side, a negative conductor, a rectifying element and a second electrode plate are arranged on the other side, and the first electrode plate and the second electrode plate are electrically connected through a third electrode plate.

Disclosure of Invention

However, the welding transformer described in japanese patent No. 5220931 is configured such that a first unit in which only the positive side coil is wound, a second unit in which only the primary coil is wound, and a third unit in which only the negative side coil is wound are stacked in this order to form a single structure. Then, a plurality of structures are arranged in the lateral direction. Therefore, a plurality of connection electrode plates (first connection electrode plate, second connection electrode plate, and third connection electrode plate) for supporting a plurality of structures are required, which leads to a problem of complicated structure.

The present invention has been made in view of such problems, and an object of the present invention is to provide a welding transformer that can be made smaller and lighter, and that can perform high-frequency, large-current, and efficient power conversion.

One embodiment of the present invention includes: an iron core; and a primary winding and a secondary winding alternately wound around the core, the primary winding including a first strip-shaped conductor extending in a width direction in parallel to a direction of a magnetic flux passing through the core, the secondary winding including a second strip-shaped conductor extending in a width direction in parallel to a direction of a magnetic flux passing through the core, the first strip-shaped conductor and the second strip-shaped conductor being alternately laminated in a direction orthogonal to the direction of the magnetic flux.

The performance of the welding transformer can be improved by improving the coupling of the primary winding and the secondary winding and reducing the high frequency loss, which is completely dependent on the structure of the windings. In order to improve the coupling, how to reduce the leakage magnetic flux is concerned, but the welding transformer of the present invention has the following configuration.

That is, in one aspect of the present invention, the primary winding and the secondary winding, which are wound in a direction perpendicular to the direction of the magnetic flux passing through the core, are divided into the number of turns or the cross-sectional area, and the primary winding and the secondary winding are formed at alternate positions and are connected in series or in parallel. This can improve the coupling between the primary circuit and the secondary circuit.

In order to improve the coupling, the inductance value viewed from the primary side is reduced by short-circuiting the secondary side, and the inductance value is reduced in accordance with the number of division as compared with the case where the inductance when not divided is L. The decrease in the inductance value is a value substantially inversely proportional to the number of divisions.

As a measure for reducing high-frequency loss, a strip conductor is used for a wire winding. Since the strip conductor has extremely low skin loss associated with high-frequency current and also has low eddy current loss due to current, the strip conductor is an ideal material for high-frequency applications. In addition, generally, litz wires are used as the high-frequency conductors in many cases, but the ribbon conductors do not form spaces (gaps) as compared with, for example, round litz wires, and therefore, the occupancy can be designed to be large, and the reduction in size and weight can be achieved.

In one aspect of the present invention, the secondary winding includes a positive-side secondary winding and a negative-side secondary winding, and is wound around the core in the order of the primary winding, the positive-side secondary winding, and the negative-side secondary winding, or in the order of the primary winding, the negative-side secondary winding, and the positive-side secondary winding. Therefore, coupling between the primary winding and the secondary winding can be improved, and high-frequency loss can be reduced.

Further, the rise of the primary current can be made steep, and accordingly, the frequency of the primary current can be increased, and the rise of the secondary current can be increased. As a result, fine control can be performed. Further, since a high current can be supplied to a workpiece (raw material) in a short time, welding to a workpiece having high conductivity such as aluminum or copper is also facilitated.

In one aspect of the present invention, there is provided: an annular iron core; a winding portion wound around the annular core and having a primary winding, a positive-side secondary winding, and a negative-side secondary winding connected between one input terminal and the other input terminal; a negative electrode connected to a connection point of the positive-side secondary winding and the negative-side secondary winding; and a positive electrode connected to the positive-side secondary winding via a first rectifier element and connected to the negative-side secondary winding via a second rectifier element.

In one aspect of the present invention, the primary winding includes a plurality of first strip conductors covering a part of the core, the positive-side secondary winding includes a plurality of second strip conductors arranged between the first strip conductors, respectively, the negative-side secondary winding includes a plurality of third strip conductors arranged between the first strip conductors and the second strip conductors, respectively, each of the second strip conductors has a positive electrode connected to one end thereof and is wound at least 1 turn, each of the third strip conductors has a negative electrode connected to one end thereof and is wound at least 1 turn, and the negative electrode electrically connecting the other end of the second strip conductor and the other end of the third strip conductor is arranged between each of the positive electrodes and the negative electrodes.

The primary winding includes a plurality of first strip conductors covering a portion of the core, the positive-side secondary winding includes a plurality of second strip conductors respectively disposed between the first strip conductors, and the negative-side secondary winding includes a plurality of third strip conductors respectively disposed between the first strip conductors and the second strip conductors. Each second strip conductor is connected to the positive electrode at one end and wound at least 1 turn, and each third strip conductor is connected to the negative electrode at one end and wound at least 1 turn. This makes it possible to reduce the size of the winding portion and to reduce the size of the welding transformer.

In addition, since the negative electrodes are respectively disposed between the positive electrode and the negative electrode and the other end portion of the second strip conductor and the other end portion of the third strip conductor are electrically connected, the negative electrode can be easily connected to the winding portion. In particular, the negative electrode can be connected to the secondary winding by a tap, and the positive electrode secondary winding and the negative electrode secondary winding can be formed in the winding portion.

In addition, in one embodiment of the present invention, the following effects are obtained because of the above-described configuration. That is, in general, when the frequency is increased, the core can be reduced in size, and therefore, the welding transformer can be downsized. However, increasing the frequency lowers the efficiency of the transformer, and thus there is a limit to miniaturization.

In contrast, in one embodiment of the present invention, since the rise of the primary current is rapid, the period for effectively outputting the secondary voltage can be extended, and the efficiency of the transformer can be improved and the size can be reduced even if the frequency is increased.

In one aspect of the present invention, the primary winding includes a plurality of first connection conductors that electrically connect the first strip conductors to each other, the positive-side secondary winding includes a plurality of second connection conductors that electrically connect the positive electrodes to each other, the negative-side secondary winding includes a plurality of third connection conductors that electrically connect the negative electrodes to each other, and the positive-side secondary winding and the negative-side secondary winding include a plurality of fourth connection conductors that electrically connect the negative electrodes to each other.

By electrically connecting the first strip conductors to each other through the first linking conductor, the primary winding can be configured, and the primary winding can be easily drawn out to the outside of the winding portion. Further, the positive electrodes are electrically connected to each other by the second connection conductor, whereby the positive electrode secondary winding can be configured, and the positive electrode secondary winding can be easily drawn out to the outside of the winding unit. Similarly, the negative electrodes are electrically connected to each other by the third connection conductor, whereby the negative electrode secondary winding can be formed, and the negative electrode secondary winding can be easily drawn out of the winding portion.

In one aspect of the present invention, the plurality of first connection conductors are formed on one end surface of the winding portion, the one input terminal is connected to a first connection conductor located on an outer peripheral side of the winding portion among the plurality of first connection conductors, and the other input terminal is connected to a first connection conductor located on an inner peripheral side of the winding portion among the plurality of first connection conductors.

Since the first connecting conductors are formed on one end surface of the winding portion, the first strip conductors can be electrically connected to each other easily via the first connecting conductors, and the primary winding can be easily configured. Further, the primary winding can be easily drawn out of the winding portion. As a result, one of the input terminals can be connected to the first connection conductor located on the outer peripheral side of the winding portion among the plurality of first connection conductors, and the other input terminal can be connected to the first connection conductor located on the inner peripheral side of the winding portion among the plurality of first connection conductors.

In one aspect of the present invention, the core includes two elongated parallel portions, the winding portion is wound around any one of the parallel portions, and at least one of a connection direction of the first connection conductor, a connection direction of the second connection conductor, a connection direction of the third connection conductor, and a connection direction of the fourth connection conductor is in a positional relationship in which a longitudinal direction of the parallel portion intersects with a connection direction of the first connection conductor. Here, the intersecting relationship means a relationship in which an angle formed by at least one connecting direction and the longitudinal direction of the parallel portion is 60 ° to 120 °. Preferably 90 deg. (orthogonal relationship).

In this way, the first connection conductor can be disposed on the upper portion or the lower portion of the winding portion, and any one of the second connection conductor, the third connection conductor, and the fourth connection conductor can be disposed on the lower portion or the upper portion of the winding portion, which contributes to the compactness of the welding transformer. In particular, by setting the connection direction of all of the second, third, and fourth connection conductors to a positional relationship intersecting the longitudinal direction of the parallel portion, all of the second, third, and fourth connection conductors can be disposed at the lower portion or the upper portion of the wound portion, and the welding transformer can be further made compact.

In one aspect of the present invention, at least a connection direction of the second connection conductor and a connection direction of the third connection conductor are the same.

Thus, the second connection conductor and the third connection conductor can be arranged in parallel to form one base, and two rectifying elements, a positive electrode, and the like can be arranged on the base. As a result, the welding transformer can be made compact.

In one aspect of the present invention, the winding portion includes a first winding portion wound around one of the parallel portions and a second winding portion wound around the other of the parallel portions, and further includes a fifth connection conductor electrically connecting at least one of the first strip-shaped conductors of the first winding portion and at least one of the first strip-shaped conductors of the second winding portion.

Even when the winding portion is composed of the first winding portion and the second winding portion, 1 primary winding can be configured by electrically connecting the first strip conductor of the first winding portion and the first strip conductor of the second winding portion by the fifth linking conductor. Therefore, as the welding transformer, a type having one winding portion and a type having two winding portions can be provided, and various selections can be made according to the use.

In one aspect of the present invention, among the plurality of first connection conductors, one of 1 or more first connection conductors is formed on one end surface of the first winding portion, among the plurality of first connection conductors, the other of 1 or more first connection conductors is formed on one end surface of the second winding portion, the fifth connection conductor is connected from a position corresponding to the first connection conductor located on the outer peripheral side or the inner peripheral side of the first winding portion among the one of 1 or more first connection conductors to a position corresponding to the first connection conductor located on the outer peripheral side or the inner peripheral side of the second winding portion among the other of 1 or more first connection conductors, among the one of 1 or more first connection conductors, the one input terminal is connected to the first connection conductor located on the inner peripheral side or the outer peripheral side of the first winding portion, the other input terminal is connected to the first connection conductor located on the inner or outer peripheral side of the second winding portion, among the other 1 or more first connection conductors.

In the plurality of first connection conductors, one of the first connection conductors may be formed on one end surface of the first winding portion, and the other of the first connection conductors may be formed on one end surface of the second winding portion. Further, the fifth connection conductor may be connected to the first connection conductor located on the outer peripheral side or the inner peripheral side of the first winding portion among the one first connection conductors and the first connection conductor located on the outer peripheral side or the inner peripheral side of the second winding portion among the other first connection conductors.

This makes it possible to electrically connect the first strip conductors of the first winding portion to each other easily via one of the first connecting conductors. Similarly, the first strip conductors of the second winding portion can be electrically connected to each other easily by the other first connecting conductor. That is, one primary winding can be easily formed in the first winding portion and the second winding portion. Further, the primary winding can be easily drawn out of the first winding portion and the second winding portion.

As a result, the first connection conductor positioned on the inner or outer peripheral side of the first winding portion among the first connection conductors can be connected to the input terminal on the one hand, and the first connection conductor positioned on the inner or outer peripheral side of the second winding portion among the first connection conductors on the other hand can be connected to the input terminal on the other hand.

In one aspect of the present invention, the core includes two elongated parallel portions, the first wound portion is wound around one of the parallel portions, the second wound portion is wound around the other of the parallel portions, and at least one of a connection direction of the first connection conductor, a connection direction of the second connection conductor, a connection direction of the third connection conductor, and a connection direction of the fourth connection conductor and the fifth connection conductor and a longitudinal direction of the parallel portion are in a positional relationship of intersecting with each other.

Here, the intersecting relationship means a relationship in which an angle formed by at least one connecting direction and the longitudinal direction of the parallel portion is 60 ° to 120 °. Preferably 90 deg. (orthogonal relationship).

In this way, the first connection conductor can be disposed above or below the first wound portion and the second wound portion, and any one of the second connection conductor, the third connection conductor, and the fourth connection conductor can be disposed below or above the first wound portion and the second wound portion, which contributes to the compactness of the welding transformer. In particular, by setting the connection direction of all of the second connection conductor, the third connection conductor, and the fourth connection conductor to a positional relationship intersecting the longitudinal direction of the parallel portion, all of the second connection conductor, the third connection conductor, and the fourth connection conductor can be disposed at the lower portion or the upper portion of the first winding portion and the second winding portion, and the welding transformer can be further made compact.

In one aspect of the present invention, at least a connection direction of the second connection conductor, a connection direction of the third connection conductor, and a connection direction of the fifth connection conductor are the same.

Thus, the second connection conductor and the third connection conductor can be arranged in parallel to form one base, and two rectifying elements, a positive electrode, and the like can be arranged on the base. As a result, the welding transformer can be made compact. Further, since the connection direction of the fifth connection conductor is also the same, the lead-out direction of the one input terminal and the other input terminal can be easily grasped, and the mounting work of the welding transformer is also facilitated.

In one aspect of the present invention, the rectifier device includes a positive electrode conductor connected to the second connection conductor and a negative electrode conductor connected to the third connection conductor, the positive electrode is connected between the positive electrode conductor and the negative electrode conductor, the first rectifier element is connected between the positive electrode conductor and the positive electrode, and the second rectifier element is connected between the negative electrode conductor and the positive electrode.

In this way, a combined structure of the positive electrode conductor, the first rectifying element, the positive electrode, the second rectifying element, and the negative electrode conductor can be arranged on one end surface side of the winding portion, which contributes to the compactness of the welding transformer.

In one aspect of the present invention, the plurality of fourth connection conductors electrically connecting the negative electrodes and the positive electrode are disposed on one end surface side of the wound portion, and the one input terminal and the other input terminal are disposed on the other end surface side of the wound portion.

In this way, the welding machine connected to the welding transformer can be disposed on the positive electrode and the negative electrode disposed on one end surface side of the winding portion, and the circuit connected to the preceding stage of the welding transformer can be disposed on the one input terminal and the other input terminal disposed on the other end surface side of the winding portion. That is, in the welding transformer, a portion to which the welding machine is connected and a portion to which a circuit of a preceding stage is connected can be clearly separated, so that a connection error can be prevented in advance, and work efficiency can be improved.

According to the welding transformer of the present invention, it is possible to realize miniaturization and weight reduction, and to perform high-frequency, large-current, and efficient power conversion.

Drawings

Fig. 1 is a cross-sectional view of a welding transformer according to the present embodiment, with a part of the transformer omitted.

Fig. 2 is a circuit diagram showing a schematic configuration of a welding transformer (first welding transformer) according to the first embodiment together with a welding machine.

Fig. 3A is a perspective view of the first welding transformer as viewed from one direction, and fig. 3B is a perspective view of the first welding transformer as viewed from another direction.

Fig. 4 is an exploded perspective view showing the structure of the first welding transformer.

In fig. 5, fig. 5A is a perspective view showing a configuration of a main winding portion of the first welding transformer as viewed from one direction, and fig. 5B is a plan view showing a winding structure of the winding portion as viewed from the other direction.

Fig. 6 is a sectional view taken along line VI-VI of fig. 5B.

Fig. 7 is a sectional view taken on the line VII-VII of fig. 5B.

Fig. 8A and 8B in fig. 8 are perspective views showing winding states of the positive-side secondary winding (second strip conductor) and the negative-side secondary winding (third strip conductor) and arrangement relations of the positive electrode, the negative electrode, and the negative electrode.

In fig. 9, fig. 9A is a diagram showing a primary current waveform of the example, and fig. 9B is a diagram showing a primary current waveform of the comparative example.

Fig. 10A is a perspective view of the welding transformer (second welding transformer) according to the second embodiment as viewed from one direction, and fig. 10B is a perspective view of the second welding transformer as viewed from another direction.

Fig. 11A is a perspective view showing a configuration of a winding portion of the second welding transformer as viewed from one direction, and fig. 11B is a plan view showing a winding structure of the winding portion as viewed from the other direction.

Fig. 12 is a sectional view taken on the line XII-XII of fig. 11B.

FIG. 13 is a cross-sectional view taken along line XIII-XIII in FIG. 11B.

In fig. 14, fig. 14A is a perspective view showing a structure of the first primary winding and the second primary winding of the second welding transformer as viewed from one direction, and fig. 14B is an enlarged view showing a structure of the first connection conductor and the fifth connection conductor.

Fig. 15 is an exploded perspective view showing the structure of the second welding transformer.

Detailed Description

Hereinafter, embodiments of a welding transformer according to the present invention will be described with reference to fig. 1 to 15.

First, a basic structure of welding transformer 10 according to the present embodiment will be described with reference to fig. 1.

As shown in fig. 1, the basic structure of welding transformer 10 includes a core 12, and primary windings 18 and secondary windings 20 alternately wound around core 12. The primary winding 18 has a first strip conductor 40a (see fig. 5A) extending in the width direction in parallel to the direction Dy of the magnetic flux passing through the core 12. The secondary winding 20 has a second strip conductor 40b extending in the width direction in parallel with the direction Dy of the magnetic flux passing through the core 12. The first strip conductors 40a and the second strip conductors 40b (see fig. 5A) are alternately stacked in a direction Dx orthogonal to the direction Dy of the magnetic flux.

The performance of the welding transformer 10 can be improved by improving the coupling of the primary winding 18 and the secondary winding 20 and reducing high frequency losses, depending entirely on the configuration of the windings.

In order to improve the coupling, how to reduce the leakage magnetic flux is related, but the welding transformer 10 of the present embodiment has the above-described configuration. That is, the primary winding 18 and the secondary winding 20, which are wound in a direction Dx perpendicular to the direction Dy of the magnetic flux passing through the core 12, are divided into the number of turns or the cross-sectional area, and the primary winding 18 and the secondary winding 20 are formed at alternate positions and connected in series or in parallel, respectively, whereby the coupling between the primary circuit and the secondary circuit can be improved.

In order to improve the coupling, the inductance value viewed from the primary side is reduced by short-circuiting the secondary side, and the inductance value is reduced in accordance with the number of division as compared with the case where the inductance when not divided is L. The decrease in the inductance value is a value substantially inversely proportional to the number of divisions.

Further, in the present embodiment, as a measure for reducing the high-frequency loss, a strip conductor is used for the wire rod. The high-frequency current has a property of flowing only on the surface of the conductor due to the skin effect, but since the strip conductor is thin, the current can flow through the entire conductor, and as a result, the skin loss is extremely small. In addition, since the eddy current loss due to the current is small, it is an ideal material for high frequency. In addition, generally, litz wires are used as the high-frequency conductors in many cases, but the ribbon conductors do not form spaces (gaps) as compared with, for example, round litz wires, and therefore, the occupancy can be designed to be large, and the reduction in size and weight can be achieved.

Next, a preferred application example of welding transformer 10 according to the present embodiment will be described with reference to fig. 2 to 15.

As shown in the circuit diagram of fig. 2, welding transformer 10 includes iron core 12 and winding portion 14 wound around iron core 12. The winding portion 14 includes a primary winding 18, a positive-side secondary winding 20p, and a negative-side secondary winding 20n connected between one input terminal 16a and the other input terminal 16 b. In addition, the welding transformer 10 has a negative electrode 22N and a positive electrode 22P. The negative electrode 22N is connected to a connection point 24 (tap) between the positive electrode side secondary winding 20p and the negative electrode side secondary winding 20N. The positive electrode 22P is connected to the positive secondary winding 20P via a first rectifier device 26a, and is connected to the negative secondary winding 20n via a second rectifier device 26 b.

Welding transformer 10 is connected to a preceding stage circuit (for example, an inverter), not shown, via one input terminal 16a and the other input terminal 16b, and to welder 28 via negative electrode 22N and positive electrode 22P.

As shown in fig. 3A to 4, in the welding transformer (hereinafter, referred to as a first welding transformer 10A) of the first embodiment, a winding portion 14 is wound around one of two elongated parallel portions (for example, a first parallel portion 30A) of an annular core 12 having the two parallel portions (the first parallel portion 30A and a second parallel portion 30 b).

As shown in fig. 5A and 5B, the primary winding 18 constituting the winding portion 14 includes, for example, five first strip conductors 40a covering a part of the annular core 12. The positive-side secondary winding 20p has, for example, four second strip conductors 40b arranged between the first strip conductors 40 a. The negative secondary winding 20n has, for example, four third strip conductors 40c each disposed between the first strip conductor 40a and the second strip conductor 40 b.

As shown in fig. 6 and 7, the first strip conductor 40a is configured such that the insulating film 42 and the conductive film 44 are alternately laminated so as to include the inner insulating film 42a, the conductive film 44, the interlayer insulating film 42b, and the conductive film …, respectively, as the conductive film 44.

Of the five first strip conductors 40a, the outermost first strip conductor 40a and the innermost first strip conductor 40a are wound with the conductor film 44 for 1 turn or more, for example, 5 turns, respectively, and the central three first strip conductors 40a and the conductor film 44 are wound with the conductor film 44 for 1 turn or more, for example, 8 turns, respectively. That is, the conductor film 44 is wound a total of 5 or more turns, for example, 34 turns. Here, the arrangement structure of the first strip conductor 40a is (a).

When viewed in a cross section taken along line VI-VI of fig. 5B, the second strip conductor 40B is formed of a conductive film 44, and a positive electrode 50p formed of, for example, a metal plate 45 is connected to an inner end surface thereof and wound at least 1 turn, as shown in fig. 6. Further, an inter-winding insulating film 42c is interposed between the conductor film 44 outside the first strip conductor 40a and the positive electrode 50 p.

The third strip conductor 40c is formed of a conductor film 44, and the negative electrode 22N formed of, for example, a metal plate 45 is connected to an outer end surface thereof and wound at least 1 turn. An interlayer insulating film 42b is interposed between the conductor film 44 of the second strip conductor 40b and the conductor film 44 of the third strip conductor 40 c. A negative electrode 50N formed of a metal plate 45 is disposed on an outer end surface of the negative electrode 22N via an inter-electrode insulating film 42 d. An inter-winding insulating film 42c is disposed on an outer end surface of the negative electrode 50 n. Here, the arrangement structure from the inter-winding insulating film 42c disposed on the outer end surface of the first strip conductor 40a to the inter-winding insulating film 42c disposed on the outer end surface of the negative electrode 50n is (B).

The first strip conductor 40a is disposed on the outer end surface of the negative electrode 50N with the inter-winding insulating film 42c interposed therebetween, and the inter-winding insulating film 42c, the negative electrode 50N, the interlayer insulating film 42b, the third strip conductor 40c, the negative electrode 22N, the inter-electrode insulating film 42d, the positive electrode 50p, the second strip conductor 40b, and the inter-winding insulating film 42c are disposed on the outer end surface of the first strip conductor 40 a. Here, the arrangement structure from the inter-winding insulating film 42C disposed on the outer end surface of the first strip conductor 40a to the inter-winding insulating film 42C disposed on the outer end surface of the second strip conductor 40b is (C).

The arrangement structures (a), (C), (a), (B), and (a) are arranged on the outer end surface of the arrangement structure (C), and the outer insulating film 42e is arranged outside the outermost first strip conductor 40 a.

Similarly, when viewed in a cross section taken along line VII-VII in fig. 5B, as shown in fig. 7, the second strip conductor 40B has the positive electrode 50p disposed on the inner end surface thereof with the interlayer insulating film 42B interposed therebetween, has the negative electrode 22N connected to the outer end surface thereof, and is wound at least 1 turn. Further, an inter-winding insulating film 42c is interposed between the conductor film 44 outside the first strip conductor 40a and the positive electrode 50 p.

The third strip conductor 40c has a negative electrode 50n connected to an inner end surface thereof, and is wound at least 1 turn. An inter-electrode insulating film 42d is interposed between the negative electrode 50N and the negative electrode 22N. That is, the negative electrode 50N, the inter-electrode insulating film 42d, and the negative electrode 22N are interposed between the second strip conductor 40b and the third strip conductor 40 c. Here, the arrangement structure from the inter-winding insulating film 42c disposed on the outer end surface of the first strip conductor 40a to the inter-winding insulating film 42c disposed on the outer end surface of the third strip conductor 40c is (D).

A first strip conductor 40a is disposed on an outer end surface of the negative electrode 50N with an inter-winding insulating film 42c interposed therebetween, and an inter-winding insulating film 42c, a negative electrode 50N, a third strip conductor 40c, an interlayer insulating film 42b, a second strip conductor 40b, a negative electrode 22N, an inter-electrode insulating film 42d, a positive electrode 50p, and an inter-winding insulating film 42c are disposed on an outer end surface of the first strip conductor 40 a. Here, the arrangement structure from the inter-winding insulating film 42c disposed on the outer end surface of the first strip conductor 40a to the inter-winding insulating film 42c disposed on the outer end surface of the positive electrode 50p is (E).

The arrangement structures (a), (E), (a), (D), and (a) are arranged on the outer end surface of the arrangement structure (E), and the outer insulating film 42E is arranged outside the outermost first strip conductor 40 a.

The above arrangement structure is merely an example, and various winding structures can be realized by interposing the arrangement structure (a) and appropriately arranging the arrangement structures (B) to (E).

The first strip conductor 40a, the second strip conductor 40b, and the third strip conductor 40c have widths of 60 to 400 mm. The inner insulating film 42a, the interlayer insulating film 42b, the inter-winding insulating film 42c, the inter-electrode insulating film 42d, and the outer insulating film 42e are made of insulating paper, resin, enamel, or the like, and have a thickness of 0.05 to 0.25 mm. The conductor film 44 is made of aluminum, aluminum alloy, copper alloy, or the like, and has a thickness of 0.1 to 3.0 mm.

As shown in fig. 8A and 8B, the positive electrode 50p is formed of a metal plate such as aluminum, an aluminum alloy, copper, or a copper alloy, and is configured by integrally forming a positive electrode main body 50pa extending in the axial direction of the wound portion 14 and a positive electrode mounting portion 50pb extending in the lateral direction from, for example, an upper portion of the positive electrode main body 50 pa. The thickness of the positive electrode 50p is 0.1 to 3.0 mm.

The negative electrode 50n is made of a metal plate such as aluminum, an aluminum alloy, copper, or a copper alloy, and is configured by integrally forming a negative electrode main body 50na extending in the axial direction of the wound portion 14 and a negative electrode mounting portion 50nb extending in the lateral direction from, for example, an upper portion of the negative electrode main body 50 na. The thickness of the negative electrode 50n is 0.1 to 3.0 mm.

The negative electrode 22N is made of a metal plate such as aluminum, an aluminum alloy, copper, or a copper alloy, and is configured by integrally forming a negative electrode main body 22Na (see fig. 8A) extending in the axial direction of the wound portion 14 and a negative electrode mounting portion 22Nb (see fig. 8B) extending in the lateral direction from, for example, an upper portion of the negative electrode main body 22 Na. The thickness of the negative electrode main body 22Na is 0.1 to 3.0mm, and the thickness of the negative electrode mounting part 22Nb is 0.1 to 3.0 mm.

As shown in fig. 5A, the primary winding 18 includes a plurality of first connecting conductors 52a, for example, four first connecting conductors 52a, each of which electrically connects the first strip conductors 40 a. The first connection conductor 52a is formed of, for example, a U-shaped metal thin plate. The plurality of first connection conductors 52a are formed on the other end surface 14b of the winding portion 14. Of the plurality of first connecting conductors 52a, for example, one input terminal 16a is connected to the first connecting conductor 52a located on the inner peripheral side of the wound portion 14, and of the plurality of first connecting conductors 52a, for example, the other input terminal 16b is connected to the first connecting conductor 52a located on the outer peripheral side of the wound portion 14.

As shown in fig. 3A and 3B, the positive-side secondary winding 20p has a plurality of second connection conductors 52B that electrically connect the positive electrodes 50p in the lateral direction, respectively. The second connection conductor 52b is formed of, for example, a block-shaped metal plate connected between the positive electrode mounting portions 50 pb.

On the other hand, as shown in fig. 4, the negative-side secondary winding 20n has a plurality of third connection conductors 52c that electrically connect the negative electrodes 50n to each other in the lateral direction. The third connecting conductor 52c is formed of, for example, a block-shaped metal plate connected between the negative electrode mounting portions 50nb (see fig. 3A). As shown in fig. 4, the positive-side secondary winding 20p and the negative-side secondary winding 20N each have a plurality of fourth connection conductors 52d for electrically connecting the negative electrodes 22N to each other. The fourth connection conductor 52d is formed of, for example, a block-shaped metal plate connected between the negative electrode mounting portions 22Nb (see fig. 3A).

At least one of the connection direction of the first connection conductor 52a, the connection direction of the second connection conductor 52b, the connection direction of the third connection conductor 52c, and the connection direction of the fourth connection conductor 52d is in a positional relationship such that it intersects with the longitudinal direction of the core 12 (the first parallel portion 30a and the second parallel portion 30 b). The intersecting relationship is a relationship in which an angle formed by at least the one connecting direction and the longitudinal direction of the core 12 is 60 ° to 120 °. Preferably 90 ° (orthogonal relationship). In the first welding transformer 10A, all of the connection direction of the first connection conductor 52a, the connection direction of the second connection conductor 52b, the connection direction of the third connection conductor 52c, and the connection direction of the fourth connection conductor 52d are in a positional relationship intersecting the longitudinal direction of the core 12.

As shown in fig. 4, first welding transformer 10A includes: a positive electrode conductor 54p connected to the second connection conductor 52b and standing in the longitudinal direction; and a negative electrode conductor 54n connected to the third connection conductor 52c and vertically rising opposite to the second connection conductor 52 b.

The positive electrode 22P is connected between the positive conductor 54P and the negative conductor 54n, the first rectifier device 26a is connected between the positive conductor 54P and the positive electrode 22P, and the second rectifier device 26b is connected between the negative conductor 54n and the positive electrode 22P.

Further, the plurality of fourth connecting conductors 52d electrically connecting the negative electrodes 22N and the positive electrode 22P are disposed on the side of one end face 14a of the wound portion 14, and the one input terminal 16a and the other input terminal 16b are disposed on the side of the other end face 14b of the wound portion 14.

In this way, in first welding transformer 10A, primary winding 18 has a plurality of first strip conductors 40A covering a portion of core 12, positive-side secondary winding 20p has a plurality of second strip conductors 40b disposed between first strip conductors 40A, respectively, and negative-side secondary winding 20n has a plurality of third strip conductors 40c disposed between first strip conductors 40A and second strip conductors 40b, respectively. The positive electrode 50p is connected to one end portion 40ba (see fig. 5B) of each second strip conductor 40B, and is wound at least 1 turn. The negative electrode 50n is connected to one end 40ca (see fig. 5B) of each third strip conductor 40c, and is wound at least 1 turn. This enables winding portion 14 to be formed compactly, and enables first welding transformer 10A to be downsized.

In addition, since the negative electrodes 22N are respectively disposed between the positive electrode 50p and the negative electrode 50N and the other end portion 40bb (see fig. 5B) of the second strip conductor 40B and the other end portion 40cb (see fig. 5B) of the third strip conductor 40c are electrically connected, the negative electrodes 22N can be easily connected to the winding portion 14. In particular, the negative electrode 22N can be connected to the secondary winding 20 by a tap, and the positive electrode secondary winding 20p and the negative electrode secondary winding 20N can be formed in the winding portion 14.

Further, first welding transformer 10A has the above-described configuration, and therefore, the following effects are exhibited. That is, in general, when the frequency is increased, the core can be reduced in size, and therefore, the welding transformer can be downsized. However, increasing the frequency lowers the efficiency of the transformer, and thus there is a limit to miniaturization.

In contrast, since the first welding transformer 10A has a steep rise in the primary current, the period for effectively outputting the secondary voltage can be extended, and the efficiency of the transformer can be improved even if the frequency is increased, and the size can be reduced.

Here, an experimental example will be explained. The experimental example confirms the primary current waveforms of the examples and comparative examples.