Toroid transformer wire process of toroid coil winding machie
Compared with toroid transformer, toroid transformer has the advantages of small magnetic leakage, high efficiency, low noise, light weight, small size, shape design has a certain flexibility and so on. The most outstanding is the light weight (about 50~70% of the annular transformer). But its disadvantages can not be ignored: the annular transformer basically does not have the impact current (harm to the power grid), installation is not as convenient as the annular transformer, the wire package is exposed, accidental fall is easy to damage, the cost is slightly higher.
Next, we will introduce the winding process and key points of toroid transformer wire
1. Winding system
The production line has two ways of winding: semi-automatic winding machine and automatic winding machine. Semi-automatic winding machine can generally be operated by two people, the enameled wire wound on the insulating ring core one by one. In order to make the winding neat and regular, in front of the winding, it is also necessary to clamp the iron core and pad the plastic diaphragm with "inline groove". The advantage of semi-automatic winding machine is that manual winding can actively adapt to different wire diameter enameled wire. Disadvantages are loose wire packaging, a little larger volume.
The working process of toroid winding machine is: in the winding machine there is a storage wheel with a split pin (also known as ring winding shuttle). Remove the cotter pin, cover the iron core from the opening, align the center of the inner ring of the iron core with the circumference of the wire storage wheel, close the cotter pin, store an appropriate amount of wires on the wire storage wheel, and then wrap the wires on the iron core with the stored wires. While the storage wheel is running and winding, the drive mechanism drives the core to rotate slowly so that the enameled wire is evenly wound around the core. In the process of wire storage and winding, the wire storage wheel always runs at high speed through the inner ring of the iron core. After the winding is completed, remove the remaining wires from the wire storage wheel, open the cotter pin and take out the iron core to complete the winding of the wire package.
Due to the different dimensions of the battery tank, the wire diameter of the enameled wire that can be wound by the winding machine is usually specified within a certain range.
2. Insulation bundling
Core wire insulation - the inside and outside sides are wrapped with ribbon insulating paper of the same height as the core wire, and the ends are filled with annular insulating paper of the same shape as the end face but slightly larger. Ensure that the tape is properly aligned with the paper tape, and then wrap the entire ring with narrow insulation tape from beginning to end. The above adhesive materials and material thickness may vary according to the insulation grade of different products.
Primary interstage insulation - The bonding method is the same as core insulation, except that the insulation requirements are higher and the number or thickness of the material is increased. For the isolation transformer of 220V power supply, the insulation winding of one level overlapping winding mode should not be less than 3 layers.
