The resistance to voltage source manufacture method of high isolation
Technical field
The invention belongs to electric and electronic technical field, specifically, the present invention relates to a kind of system of the resistance to voltage source of high isolation
Make technology.
Background technology
At present, due to the power tube of high-tension high-power(IGBT, IGCT etc.)It is expensive, and supply cycle is long, therefore
Many companies save cost all in the mode for considering to connect using IGBT.But IGBT when being used in series busbar voltage it is very high,
This just brings problem for IGBT driving.Meanwhile, with the not only rise of power supply voltage level, many electrical equipments can not find
The resistance to voltage source of suitable high isolation, so as to have to improve cost, after being depressured with a bulky Industrial Frequency Transformer
Using.But the requirement more and more higher with people to power density, the cost control to product is more and more stricter, transformer
The need for the mode of decompression power supply can not meet people's use.The problem of these are sharp causes the resistance to voltage source of high isolation to have it
Necessity of presence.
And in design aspect, power supply typically adds the feedback system of optocoupler in output using TL431.With regard to opto-coupled feedback mode
Speech, the isolation strength of common optical coupler is up to 5000VAC, and 7500VAC can be reached on other occasions, and this is also just limited
The isolation strength of such power supply:Highest is no more than 7500VAC(And require isolating transformer can reach 7500VAC every
From intensity).Therefore, output cannot be used in isolation strength requirement using the TL431 power supplys for adding the feedback system of optocoupler to make and be more than
7500VAC place, otherwise will bring electrical equipment uses electrification.
In some special fields(Such as Aero-Space), opto-coupled feedback no longer be applicable, power supply can use magnetic to feed back.It is this
Mode mainly uses a small-sized feedback transformer to replace optocoupler, realizes output feedback.As long as the isolation of transformer is strong
Degree is enough, and this feedback system can also accomplish very high isolation voltage.But because there is isolating transformer and feedback change simultaneously
Depressor, so such product is to accomplish very high isolation voltage, it is desirable to two transformers of significant volume, thus can
Cause product that there is very big volume, to using bringing inconvenience.
Therefore, it is badly in need of designing a kind of isolation strength height, small volume at present, while the high isolation of enough power can also be provided
Resistance to voltage source is come the need for meeting electrical equipment.
The content of the invention
The purpose of the present invention is:To overcome the shortcomings of the pressure-resistant Power Management Design mode of high isolation in the prior art, from transformer
Innovated and improved in terms of manufacturing process there is provided a kind of high isolation Anti-voltage transformer and its manufacture method, and then using this
The resistance to voltage source of transformer manufacturing high isolation, so as to meet need of all kinds of electrical equipments to power supply in voltage levels occasion
Offer support is provided.
Specifically, the present invention is realized using following technical scheme:
The manufacture method of high isolation Anti-voltage transformer disclosed by the invention, comprises the following steps:
1)From horizontal-type skeleton E28 specifications magnetic core as the magnetic core of transformer, and the pin that goes out of horizontal-type skeleton is all pulled out
Remove;
2)3 windings of coiling successively on skeleton, constitute primary side self feed back structure, wherein the first winding N1 as input around
Group, the second winding N2 is as primary side feedback winding, and tertiary winding N3 is as output winding, and specific winding process is as follows:
At least 5 strata imide membrane adhesive tapes are first wound on skeleton, then carry out the first winding N1's using insulated wire
Coiling, single line is around multi-turn;
After the coiling for completing the first winding N1, continue to wind 1-2 strata imide membrane adhesive tapes on the first winding N1, connect
The coiling that the second winding N2 is carried out using insulated wire, Double-wire parallel wound multi-turn;
After the coiling for completing the second winding N2, continue to wind at least 10 strata imide membrane glue on the second winding N2
Band, then carries out tertiary winding N3 coiling, Double-wire parallel wound multi-turn using insulated wire;
After the coiling for completing tertiary winding N3, continue to wind at least 5 strata imide membrane adhesive tapes on tertiary winding N3;
The insulating capacity of the insulated wire of above-mentioned each winding of coiling is no more than 0.3mm in more than 5KV, diameter;Coiling it is each around
During group, the end of a thread is reserved to winding, for being connected with external circuit;The first winding N1 inductance value is controlled in 1200uH during coiling
In the range of ± 10%;
3)Dipping lacquer processing and embedding processing are carried out to transformer, the manufacture of transformer is completed.
The manufacture method of above-mentioned high isolation Anti-voltage transformer, it is further characterized by, and the insulated wire of each winding of coiling is
Three layer insulation wire.
The manufacture method of above-mentioned high isolation Anti-voltage transformer, it is further characterized by, the first winding of coiling N1 insulation
A diameter of 0.28mm of line, the coiling number of turns is 49 circles;A diameter of 0.25mm of the second winding of coiling N2 insulated wire, the coiling number of turns
For 6 circles;A diameter of 0.25mm of coiling tertiary winding N3 insulated wire, the coiling number of turns is 10 circles.
The manufacture method of above-mentioned high isolation Anti-voltage transformer, it is further characterized by, and the length of the end of a thread of each winding is
2-3cm。
The manufacture method of above-mentioned high isolation Anti-voltage transformer, it is further characterized by, and is at least using breakdown voltage
25KV/mm casting glue carries out embedding processing to transformer.
High isolation Anti-voltage transformer disclosed by the invention, is manufactured using the manufacture method of above-mentioned high isolation Anti-voltage transformer.
The resistance to voltage source of high isolation disclosed by the invention, including with lower component:Input rectifying filter circuit, output rectification filter
Circuit, switching device, feedback circuit, primary and primary side PWM controllers and transformer, wherein transformer are public for the present invention
The high isolation Anti-voltage transformer opened, input voltage is primary and primary side through input rectifying filter circuit rectifying and wave-filtering rear portion
PWM controllers are powered, another part passes to transformer secondary by the first winding N1 of the switching device through transformer primary side
Tertiary winding N3 is exported after output rectifier and filter rectifying and wave-filtering again, the second winding N2 of transformer primary side output voltage
Be supplied to as feedback signal through feedback circuit it is primary with primary side PWM controllers, it is primary with primary side PWM controllers according to
Feedback signal is controlled by switching device to electric power output voltage.
The above-mentioned resistance to voltage source of high isolation, it is further characterized by, the primary model with primary side PWM controllers
For LNK6667E, the topological structure of power supply uses reverse exciting topological.
The manufacture method of the above-mentioned resistance to voltage source of high isolation is as follows:The manufacturer of above-mentioned high isolation Anti-voltage transformer is used first
Legal system makes transformer, then each part of power supply is arranged on pcb board according to circuit construction of electric power, wherein transformer each winding
The end of a thread is directly welded on pcb board to be connected with associated components, finally obtains power supply finished product.
Beneficial effects of the present invention are as follows:
1st, compared with existing product, the high isolation Anti-voltage transformer manufactured by the inventive method can keep less
Volume is issued to very high compressive resistance.In general, transformer requires high isolation and small size, this is a pair of relative contradictions
Requirement.But, in the present invention, by the redesign and innovation to transformer manufacturing technique, employ N1, N2, N3 around
The coiling order of coiling successively is organized, and targetedly for Sexual behavior mode magnetic core of transformer, coiling line, insulating tape and casting glue etc.
Material, by carrying out dipping lacquer processing and embedding processing to transformer, can finally be obtained under less volume while having good
The transformer of good isolation voltage endurance capability.Shown according to experimental data, under conditions of 50Hz, manufactured by the inventive method
The average compressive resistance of high isolation Anti-voltage transformer can continuously rise to 35KV intensity in more than 20KV, so as to for
The mini-plant worked in 10KV busbar voltage provides 35KV insulating power supply.
2nd, compared with existing product, the resistance to voltage source of high isolation manufactured by the inventive method can ensure that high isolation is strong
Accomplish higher power output, precision and efficiency in the case of degree, small volume.The resistance to voltage source of high isolation of the inventive method manufacture
Belong to primary side saturation type mode on circuit structure.Generally, it is strong in isolation using the power supply of primary side self feed back mode
Degree is high and when not using output feedback, uses opened loop control more, while primary side switch pipe can be controlled, makes it keep fixing
Dutycycle is switched.This sample loading mode can cause power output not high general in 3-5W or so, to by force improve power, then export
Voltage can be pulled low, and influence normal work.Precision is not also high simultaneously, and reason is to input duty with fixed by transformer voltage ratio
, can because the discrete factor of transformer than adjusting output voltage(Leakage inductance, parasitic capacitance etc.)Cause the defeated of each power supply individual
Go out to have very big difference, generally output meeting deviation exceedes ± 20%.And due to the high isolation manufactured by the inventive method
Anti-voltage transformer has the good pressure-resistant performance of isolation in itself so that using the resistance to voltage source of high isolation of the invention of the transformer
Can more existing primary side saturation type power supply ensureing high isolation intensity, accomplishing higher output work in the case of small volume
Rate.The LNK6667E primary and primary side PWM controllers and the electric source topology knot of reverse exciting topological such as used with reference to the present invention
Structure, its power output is up between 20W-40W, and output voltage control is in 24V or so.DC/DC is such as carried out again to the 24V of output
Conversion(Back topologys), just can obtain the+16V and -9V required for IGBT drivings.Meanwhile, output accuracy can control left ± 5%
The right side, even up to ± 3% or higher, delivery efficiency can be 75% or so.
Brief description of the drawings
Fig. 1 is the winding construction schematic diagram of high isolation Anti-voltage transformer.
Fig. 2 is the schematic block circuit diagram of the resistance to voltage source of high isolation.
Embodiment
The present invention is described in further detail with reference to the accompanying drawings and with reference to example.But the invention is not restricted to given
Example.
One embodiment of the present of invention, the purpose is to provide a kind of high isolation resistance to voltage source, it is desirable to can ensure high isolation
Accomplish higher power output, precision and efficiency in the case of intensity, small volume.
For up to this target, the embodiment looks for another way on power circuit first, abandons TL431 common in the art
Plus the feedback system of feedback system and the magnetic feedback of optocoupler, and use primary side self feed back mode, that is, remove in opto-coupled feedback or magnetic
By the path of secondary side feedback to primary side in feedback system(Remove TL431 and optocoupler in the feedback system of TL431 plus optocoupler;Magnetic
Remove feedback transformer in feedback), output is changed into two groups from one group, and the coil of two groups of output is all wound on same transformation
On device, one of which coil provides feedback signal as primary side feedback winding, and another group of coil provides voltage output.It is specific to become
Depressor winding construction is as shown in figure 1, the N1 in Fig. 1 is input winding, and N2 is primary side feedback winding, N3 be output around
Group.
Specifically, the circuit theory of the resistance to voltage source of the high isolation of the embodiment is as shown in Fig. 2 including input rectifying filtering
Circuit, output rectifier and filter, switching device, feedback circuit, primary and primary side PWM controllers and transformer.Input
Voltage is powered through input rectifying filter circuit rectifying and wave-filtering rear portion for primary and primary side PWM controllers, another part leads to
Cross input winding of the switching device through transformer primary side and pass to the output winding of transformer secondary again through output rectification filter electricity
Exported after the rectifying and wave-filtering of road, the output voltage of transformer primary side feedback winding is supplied to primary as feedback signal through feedback circuit
With primary side PWM controllers, primary and primary side PWM controllers export electricity by switching device according to feedback signal to power supply
Pressure is controlled.In this embodiment, it is primary to use Power Integrations with primary side PWM control implement bodies
The chip LNK6667E that company produces, the topological structure of power supply uses reverse exciting topological.
The design objective of the embodiment is:The isolation strength of transformer primary side feedback winding is 2kV or so, output winding
Isolation strength requirement reaches more than 20kV.In order to reach this index, the embodiment employs a kind of high isolation Anti-voltage transformer.
This transformer is obtained by using a kind of special innovative technology processing and manufacturing, mainly including the following aspects:
First, the coiling copper cash of winding is screened.In view of the high pressure-resistant Kelvin effect with high frequency electric source of insulation
Problem, the copper cash insulating capacity of selection is preferably in more than 5KV, and diameter is preferably not more than 0.3mm(100KHz input frequency
Rate).Summary condition, have selected three layer insulation wire as coiling copper cash.
Secondly, transformer framework is handled.Transformer uses E28 specification magnetic cores.For EC28 magnetic cores, horizontal bone
The spacing of frame secondary more former than vertical-type skeleton is big, so using horizontal-type skeleton.Simultaneously for reinforced insulation intensity, it is necessary to by horizontal bone
The pin that goes out of frame is all pulled out, transformer(Winding)Outlet is directly welded on pcb board, and the not pin offer that goes out by skeleton electrically connects
Connect.
Again, it is selection insulating tape.By comparing, selection Kapton adhesive tape is used as insulating tape.This adhesive tape
Thickness is only 0.06mm, but can provide every layer of more than 1000V voltage endurance capability.
Finally, dipping lacquer processing to be carried out and embedding processing need to be considered.The present embodiment uses 40*35*30mm3 shell
Potted transformer, the shell loads magnetic core of transformer enough.The breakdown voltage of casting glue used in embedding should be not less than 25KV/
Mm, in the present embodiment, specifically uses 906 type insulation encapsulated glue, and by Nanjing Heineken, special adhesive Co., Ltd produces.
In the present embodiment, transformation implement body manufacturing process is as follows:
1)The pin that goes out on the E28 specification magnetic core frameworks of horizontal-type skeleton is all pulled out;
2)3 windings of coiling successively on skeleton, constitute primary side self feed back structure, wherein the first winding N1 as input around
Group, the second winding N2 is used as output winding as primary side feedback winding, tertiary winding N3;
3)Dipping lacquer processing is carried out to transformer, and embedding processing is carried out to transformer with 906 type insulation encapsulated glue being filled
It is enclosed in shell, completes the manufacture of transformer.
Wherein, the specific winding process of winding is as follows:
At least 5 strata imide membrane adhesive tapes are first wound on skeleton, then using the three-layer insulated of a diameter of 0.28mm
Line carries out the first winding N1 coiling, and single line controls the first winding N1 inductance value in 1200uH ± 10% during coiling around multi-turn
In the range of.In order to reach the design objective of the present embodiment, N1 windings are total to the circle of coiling 49 in the present embodiment.
After the coiling for completing the first winding N1, continue to wind 1-2 strata imide membrane adhesive tapes on the first winding N1, connect
The coiling that the second winding N2 is carried out using a diameter of 0.25mm three layer insulation wire, Double-wire parallel wound multi-turn.In order to reach this reality
The design objective of example is applied, N2 windings are total to the circle of coiling 6 in the present embodiment.
After the coiling for completing the second winding N2, continue to wind at least 10 strata imide membrane glue on the second winding N2
Band, then carries out tertiary winding N3 coiling, Double-wire parallel wound multi-turn using a diameter of 0.25mm three layer insulation wire.In order to reach
The design objective of the present embodiment, in the present embodiment the N3 windings circle of coiling 10 altogether.
After the coiling for completing tertiary winding N3, continue to wind at least 5 strata imide membrane adhesive tapes on tertiary winding N3.
In each winding of coiling, the end of a thread is reserved to winding, for being connected with external circuit, length in 2-3cm or so more
Properly.
If reaching higher design objective, such as require to reach more than 35KV isolation strength, can be in the present embodiment
On the basis of increase transformer primary side and secondary insulating tape the number of plies come continue improve transformer voltage endurance capability.It is such to become
The mini-plant that depressor is sufficient for working in the busbar voltage for 10KV provides the demand of 35KV insulating power supply.
Process using the resistance to voltage source of high isolation of above-mentioned transformer manufacturing the present embodiment is as follows:First using it is above-mentioned it is high every
Manufacture method from Anti-voltage transformer manufactures transformer, and each part of power supply then is arranged on into pcb board according to circuit construction of electric power
On, the end of a thread of wherein each winding of transformer is directly welded on pcb board to be connected with associated components, finally obtains power supply finished product.
Show through experimental data, the present embodiment has obvious technical advantage compared with existing product:
1st, the high isolation Anti-voltage transformer in the present embodiment can reach very high compressive resistance.
To the voltage-withstand test of the transformer progress 1 minute in the present embodiment under conditions of 50Hz, 20KV, leakage current is less than
1mA.Destructive testing is carried out to it afterwards, punctured under conditions of 50Hz, 25KVAC.
To the voltage-withstand test of the transformer progress 1 minute in the present embodiment under the conditions of 30KVDC, leakage current is less than 1mA.
Because Hi-pot Tester range problem, it is impossible to which high voltage carries out destructive testing to it again.
Then to doing Consistency test with a batch of 52 transformers, under conditions of 50Hz, they average pressure-resistant
Intensity has reached the design objective of the present embodiment in more than 20KV.
2nd, the resistance to voltage source of high isolation in the present embodiment can accomplish in the case where ensureing high isolation intensity, small volume compared with
High power output, precision and efficiency.
As a result of above-mentioned high isolation Anti-voltage transformer, the resistance to voltage source of high isolation in the present embodiment has been likewise supplied with height
The advantage of isolation strength and small volume, it is primary with primary side PWM controllers and reverse exciting topological in combination with LNK6667E
Power supply topologies, the power supply of the more typical primary side self feed back mode of its power output is greatly improved, and can reach that 20W ~ 40W is left
It is right.Output voltage can be exported between 5V ~ 35V, and precision is 5% or so, and even up to ± 3% or higher, delivery efficiency can be 75%
Left and right.Input range then can be between 100VDC ~ 300VDC, and nominal voltage can meet general industry input in 150VDC or so
Requirement.
Although the present invention is disclosed as above with preferred embodiment, embodiment is not for limiting the present invention's.Not
In the spirit and scope for departing from the present invention, any equivalence changes done or retouching also belong to the protection domain of the present invention.Cause
The content that this protection scope of the present invention should be defined using claims hereof is standard.