阅读说明：本技术 一种变压器线生产方法及系统 (Transformer line production method and system ) 是由 肖俊杰 于 2019-12-02 设计创作，主要内容包括：本发明涉及到一种变压器线生产方法，其特征在于，包括，将骨架的PIN端送入绕线轴上顺时针准备绕线，分别完成引线E1、引线N1、引线E2、引线N2和引线N3的绕线工序；将产品上的线头缠绕于相对应的PIN脚上；将多余线头线头剪去；将次级引线分别浸入锡面；将已经镀锡的线包装上磁芯；将变压器进行含浸烘烧；再进行二次浸锡；将PIN脚校直；将变压器进行电性测试；再进行耐压测试。本申请提供的变压器线生产方法及系统，所制造的变压器外露的引线聚拢，接线容易，且在使用的过程中不容易脱落，不会对变压器的正常通电造成不利影响。(The invention relates to a production method of a transformer wire, which is characterized by comprising the steps of feeding a PIN end of a framework into a winding shaft to prepare for winding clockwise, and completing winding processes of a lead E1, a lead N1, a lead E2, a lead N2 and a lead N3 respectively; winding the thread ends on the product on the corresponding PIN PINs; cutting off the redundant thread ends; respectively immersing the secondary leads into the tin surfaces; mounting a tinned wire on a magnetic core; carrying out impregnation baking on the transformer; then carrying out secondary tin immersion; straightening the PIN PIN; carrying out electrical test on the transformer; and then carrying out a voltage withstanding test. According to the transformer wire production method and system, the exposed leads of the manufactured transformer are gathered, the wires are easy to connect, the manufactured transformer is not easy to fall off in the using process, and adverse effects on normal electrification of the transformer cannot be caused.)

1. A method for producing a transformer wire is characterized by comprising the following steps,

feeding the PIN end of the framework into a winding shaft to prepare for winding clockwise, and completing winding processes of a lead E1, a lead N1, a lead E2, a lead N2 and a lead N3 respectively;

winding the thread ends on the product on the corresponding PIN PINs;

cutting off the redundant thread ends;

respectively immersing the secondary leads into the tin surfaces;

mounting a tinned wire on a magnetic core;

carrying out impregnation baking on the transformer;

then carrying out secondary tin immersion;

straightening the PIN PIN;

carrying out electrical test on the transformer;

and then carrying out a voltage withstanding test.

2. The transformer line production method according to claim 1, wherein, after the withstand voltage test is performed,

a voltage peak test was performed.

3. The method for manufacturing a transformer according to claim 1, wherein the step of immersing the secondary leads into the tin surface comprises the steps of arranging the coils in a row, clamping the product, and immersing the PIN legs of the transformer in the flux, wherein the flux is just immersed in the soldering terminal.

4. Method for producing a transformer according to claim 1, characterized in that the coil which has been tinned is fitted to the core, in particular, a flat core is fitted on top of the coil and a PIN foot is fitted to the ground core.

5. The method of claim 1, wherein an outer tape is further wound between the step of mounting the tin-plated wire on the magnetic core and the step of baking the transformer.

6. The method for producing a transformer according to claim 1, wherein the transformer is impregnated and baked by a vacuum process in which the PIN is faced upward and then baked.

7. The method for producing the transformer according to claim 1, wherein the PIN alignment is specifically performed by aligning the PIN with a PIN alignment clamp, placing the transformer in a template of a PIN shearing machine, and shearing off redundant parts to make the PIN have a desired length.

8. A transformer production system, characterized in that the transformer production method according to any one of claims 1 to 7 is used, comprising,

the automatic winding machine is used for winding the framework;

the tin furnace is used for carrying out tin plating on a secondary lead of the transformer;

the vacuum impregnation machine is used for impregnating the transformer;

the oven is used for baking the impregnated transformer;

the transformer tester is used for carrying out electrical test on the transformer;

and the withstand voltage tester is used for carrying out high-voltage test on the transformer.

9. The transformer production system of claim 8, comprising a peak tester for peak testing the transformer after completion of the high voltage test.

10. The transformer production system of claim 8, comprising an automated encapsulation machine for encapsulating the magnetic core-loaded transformer.

Technical Field

The invention relates to the technical field of transformers, in particular to a transformer production method and a transformer production system.

Background

A transformer is a device that changes an alternating voltage using the principle of electromagnetic induction, and main components are a primary coil, a secondary coil, and an iron core (magnetic core). The main functions are as follows: voltage transformation, current transformation, impedance transformation, isolation, voltage stabilization (magnetic saturation transformer), and the like. According to the application, the method can be divided into: power transformers and special transformers; the high frequency electronic transformer is defined accurately, that is, the electronic transformer with high working frequency, generally the working frequency is higher than 20kHz, the transformer is composed of an iron core (or a magnetic core) and a coil, the coil is provided with two or more than two windings, wherein the winding connected with a power supply is called a primary coil, and the other windings are called secondary coils. It can transform alternating voltage, current and impedance;

as a traditional industry, the production process of the transformer still uses manpower to complete specific work at present, exposed leads of the transformer are scattered randomly, wiring is difficult, the exposed leads are easy to fall off in the using process, and adverse effects are caused on normal electrification of the transformer.

Disclosure of Invention

The invention aims to solve the technical problems and provide a transformer production method, wherein exposed leads of a manufactured transformer are gathered, the leads are easy to connect, and are not easy to fall off in the using process, and the normal electrification of the transformer is not affected. Another object of the present invention is to provide a transformer production system, which applies the transformer production method and achieves the above effects.

The technical scheme of the invention is as follows:

a production method of a transformer wire comprises the steps of feeding a PIN end of a framework into a winding shaft to prepare for winding clockwise, and completing winding processes of a lead E1, a lead N1, a lead E2, a lead N2 and a lead N3 respectively; winding the thread ends on the product on the corresponding PIN PINs; cutting off the redundant thread ends; respectively immersing the secondary leads into the tin surfaces; mounting a tinned wire on a magnetic core; carrying out impregnation baking on the transformer; then carrying out secondary tin immersion; straightening the PIN PIN; carrying out electrical test on the transformer; and then carrying out a voltage withstanding test.

Preferably, after the withstand voltage test is performed, a voltage peak test is performed.

Preferably, the secondary leads are respectively immersed into the tin surface, specifically, the wire packages are orderly arranged in a row, the product is clamped, the PIN feet of the transformer are immersed into the soldering flux, and the liquid level of the soldering flux is just under the condition that the soldering end is just immersed.

Preferably, the coil which is already tinned is mounted on the magnetic core, specifically, the planar magnetic core is mounted at the top end of the coil, and the PIN foot end is mounted on the ground magnetic core.

Preferably, an outer adhesive tape is further wound between the step of mounting the tinned wire on the magnetic core and the step of baking the transformer.

Preferably, the transformer is impregnated in vacuum and baked, and the PIN is faced upward during impregnation, and then baked.

Preferably, the PIN is straightened by using a PIN straightening clamp, the transformer is placed in a template of a PIN shearing machine, and redundant parts are sheared, so that the length of the PIN meets the requirement.

The transformer production system comprises an automatic winding machine, a winding machine and a winding machine, wherein the automatic winding machine is used for winding a framework; the tin furnace is used for carrying out tin plating on a secondary lead of the transformer; the vacuum impregnation machine is used for impregnating the transformer; the oven is used for baking the impregnated transformer; the transformer tester is used for carrying out electrical test on the transformer; and the withstand voltage tester is used for carrying out high-voltage test on the transformer.

Preferably, the peak value tester is used for carrying out peak value test on the transformer after the high voltage test is finished.

Preferably, an automatic encapsulation machine is included for encapsulating the magnetic core-equipped transformer.

According to the transformer production method provided by the invention, after the secondary leads are respectively immersed into the tin surface, after the magnetic core is arranged, and the impregnation and baking are carried out, in order to effectively avoid that the transformer still occupies a small amount of varnish after the impregnation, secondary tinning is carried out, the exposed leads of the transformer are gathered together after the primary tinning, and the secondary tinning is carried out, so that the influence of the varnish on the tinning effect is reduced, the tinning effect is improved again, the exposed leads of the manufactured transformer are gathered together, the wiring is easy, the leads are not easy to fall off in the using process, and the adverse influence on the normal electrification of the transformer is avoided.

Drawings

In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments described in the present application, and other drawings can be obtained by those skilled in the art without creative efforts.

FIG. 1 is a schematic diagram of a method for producing a transformer according to the present embodiment;

fig. 2 is a schematic diagram of a transformer production system in the present embodiment.

Detailed Description

In order to make those skilled in the art better understand the technical solutions in the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

In the description of the present invention, it is to be understood that the terms "upper", "lower", and the like, indicate an orientation or positional relationship only for convenience of description and simplicity of description, but do not indicate or imply that the referenced components or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention.

As shown in fig. 1 to fig. 2, the method for manufacturing a transformer wire according to the present invention includes feeding the PIN end of the bobbin into the bobbin to prepare for winding clockwise, and completing the winding process of the lead E1, the lead N1, the lead E2, the lead N2, and the lead N3; winding the thread ends on the product on the corresponding PIN PINs; cutting off the redundant thread ends; respectively immersing the secondary leads into the tin surfaces; mounting a tinned wire on a magnetic core; carrying out impregnation baking on the transformer; then carrying out secondary tin immersion; straightening the PIN PIN; carrying out electrical test on the transformer; and then carrying out high-pressure test. The application provides a transformer production method, through after immersing the tin face respectively with secondary lead, after the dress magnetic core, after soaking the baking again, still possess a small amount of varnish in order to effectively having avoided the transformer to soak after, carry out the secondary tinning again, make the exposed lead wire of transformer gather together at first tinning, the secondary tinning, the influence of varnish to the tinning effect has been reduced, the tinning effect has been promoted once more, make the exposed lead wire of transformer of making gather together, the wiring is easy, and be difficult to drop at the in-process that uses, can not cause adverse effect to the normal circular telegram of transformer.

The transformer is subjected to voltage withstanding test, wherein the voltage withstanding test comprises insulation voltage and insulation resistance, 3750VAC is adopted between a primary lead and a secondary lead, and the test condition is 2mA and 3 s; 1500VAC is adopted between the primary lead and the magnetic core, and the test condition is 2mA and 3 s; 1500VAC is adopted between the secondary lead and the magnetic core, the test condition is 2mA and 3s, and the insulation voltage test is carried out. Insulation resistance test was performed using 100M Ω between the primary lead and the magnetic core or between the secondary lead and the magnetic core under test conditions AT DC 500V.

In the embodiment provided by the invention, after the high-voltage test is carried out, the voltage peak value test is carried out. When carrying out the voltage peak value test, put the transformer on the test jig earlier, push down the product with the fixed bolster, test, the test condition is 220Vac,50HZ, requires the test value peak result: and V is not more than 3.5, which is qualified. During testing, the probe of the oscilloscope is adjusted to 10 times, and the oscilloscope is also set to perform attenuation testing of 10 times. The oscilloscope is set to be Vp-p (peak-to-peak), the grounding probe of the oscilloscope is connected with the shielding wire, and the signal probe of the oscilloscope is connected with the central line. It should be noted that the power line of the oscilloscope cannot have a PIN connected to ground, and the oscilloscope cannot be connected to any place and close to metal objects during testing. The transformer is just produced, long-time examination in severe environment is not carried out, and dangerous high-energy transient can be caused when thunder hits an outdoor line, so that voltage peak value test is carried out on the produced transformer, accurate transformer peak voltage can be provided for a user, the user can conveniently and reasonably arrange a peak voltage absorption circuit, and the motor, the capacitor and power conversion equipment are protected.

In the embodiment provided by the invention, the secondary leads are respectively immersed into the tin surface, namely, the coils are orderly arranged in a row, the product is clamped, the PIN feet of the transformer are immersed into the soldering flux, and the liquid level of the soldering flux is just under the condition that the welding ends are just immersed. The tin furnace is provided with a tin hanging knife to scrape off oxide or a magazine layer on the surface of the tin liquid and keep the tin liquid bright and clean. And (3) arranging qualified coils in a row, clamping the product by using a long clamp, and then soaking the PIN of the semi-finished transformer in soldering flux, wherein the liquid level of the soldering flux is just the level of the immersed soldering end. The position where the solder is required to be bright and free from accumulated impurities. The welding surface needs to be smooth and flat without pinhole defects. The adhesive tape and the framework cannot be scalded in the welding process, and phenomena of insufficient soldering, missing soldering, broken wire, dirty and non-bright welding spots, adhesion of the welding spots, deflection of tin ends and the like cannot occur, so that exposed leads of the transformer are easy to fall off easily under the conditions, and further, the normal electrification of the transformer is adversely affected. Preferably, the tin plating temperature is controlled within the range of 420 ℃ +/-10 ℃, and the tin soldering time cannot be overlong.

In the embodiment provided by the invention, the tinned coil is assembled on the magnetic core, specifically, the planar magnetic core is assembled at the top end of the coil, and the PIN end is assembled on the ground magnetic core. When the magnetic core is assembled, proper force is required, the magnetic core cannot be assembled forcibly when the wire package is too large so as to avoid damage to the magnetic core, the abutting surface of the magnetic core needs to be kept clean and free of dregs during assembly, and attention needs to be paid to the fact that the adhesive tape of the wire package cannot be clamped at the abutting position of the magnetic core during assembly so as to avoid poor inductance.

In the embodiment provided by the invention, an outer wrapping adhesive tape is wound between the step of mounting the tinned wire on the magnetic core and the step of carrying out impregnation and baking on the transformer. Specifically, 0.025-8.5 adhesive tape is used for starting the package from the thread end, and the adhesive tape is cut off at the middle position of the magnetic core surface after one circle of the package, and the adhesive tape is required to be pressed against the thread end during the package starting. The package of the adhesive tape can not be wound when the package is loose, the coil frame can not be fixed, the number of turns is not right or the direction is different. When the adhesive tape is wrapped, the adhesive tape is placed in a middle bag, and the adhesive tape is flat and cannot be folded, warped or wrinkled, deflected once, stuck and the like. This condition can effectively guarantee the performance of transformer.

In the embodiment provided by the invention, the transformer is impregnated and baked, specifically, the transformer is impregnated in vacuum, the PIN is upward during impregnation, and then baking is carried out. Preferably, the impregnation is carried out in vacuum for 10 minutes with the PIN facing upward, and the baking is preferably carried out at 850 ℃ for 2 hours. I when soaking, the solenoid inlayer need be soaked to the standing water, toast until standing water is dry, for the line that makes the transformer gathers together, be difficult to drop during the use, carry out first tinning, still toast after soaking to and tin-plating for the second time, make the exposed lead wire of transformer gather together, but the practicality of maximum promotion wiring position, the at utmost has avoided the problem that transformer lead wire position drops easily, the circular telegram of transformer lead wire position to the transformer caused adverse effect has been reduced.

In the embodiment provided by the invention, the PIN is straightened specifically, the PIN is straightened by using a PIN straightening clamp, the transformer is placed into a template of a PIN shearing machine, and redundant parts are sheared, so that the length of the PIN meets the requirement.

The invention provides a transformer production system, and the transformer production method comprises an automatic winding machine, a winding machine and a winding machine, wherein the automatic winding machine is used for winding a framework; the tin furnace is used for carrying out tin plating on a secondary lead of the transformer; the vacuum impregnation machine is used for impregnating the transformer; the oven is used for baking the impregnated transformer; the transformer tester is used for carrying out electrical test on the transformer; and the withstand voltage tester is used for carrying out high-voltage test on the transformer.

The transformer peak value testing device comprises a peak value tester and is used for carrying out peak value testing on the transformer after high voltage testing is finished.

Further, the transformer comprises an automatic rubber coating machine which is used for coating the transformer provided with the magnetic core.

The embodiments in the present specification are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same or similar parts in the embodiments are referred to each other.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.