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US3452431A - Pulse transformer fabrication - Google Patents

Pulse transformer fabrication Download PDF

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Publication number
US3452431A
US3452431A US571106A US3452431DA US3452431A US 3452431 A US3452431 A US 3452431A US 571106 A US571106 A US 571106A US 3452431D A US3452431D A US 3452431DA US 3452431 A US3452431 A US 3452431A
Authority
US
United States
Prior art keywords
core
wires
wire
windings
interior
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US571106A
Other languages
English (en)
Inventor
Herbert K Hazel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
International Business Machines Corp
Original Assignee
International Business Machines Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by International Business Machines Corp filed Critical International Business Machines Corp
Application granted granted Critical
Publication of US3452431A publication Critical patent/US3452431A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core

Definitions

  • This invention relates to a method of fabricating a winding on a core wherein a number of wires are bent around the core to form single turns of wire, then the wires are skewed relative to one another, and then the wires are welded together such that a multiturn winding is formed.
  • the present invention relates to the fabrication of windings on cores and more particularly to joining wire segments together on cores to form windings.
  • the multi-turn windings of pulse transformers are wound on the cores of the transformers by wrapping continuous lengths of wire around the cores.
  • One problem with this method is that the electrical characteristics of the pulse transformers so produced differ materially from one transformer to another. These material differences are due to a large degree on the inability to hold the interwire spacings and the core to wire spacings within desired tolerances with known wire wrapping techniques and to repeat the same spacings for transformer after transformer.
  • Another object of this invention is to provide a method for fabricating cores which enables accurate spacing of the wires with respect to one another and with respect to the core body.
  • Another objects of this invention include providing an efiicient method of forming windings on cores and providing a rapid method of forming windings on cores.
  • a new method of winding cores involves the forming of separate segments of wires around the cores and then joining the ends of the various segments together to complete a winding of the core.
  • This method involves the forming of separate segments of wires around the cores and then joining the ends of the various segments together to complete a winding of the core.
  • FIGURE 1 illustrates the threading of wires through a core
  • FIGURE 2 illustrates the fixing of the position of the wires relative to the core by splined mandrels
  • FIGURE 3 illustrates the shaping of the wires around the core
  • FIGURE 4 shows the wires positioned around the core in U-shaped segments
  • FIGURE 5 illustrates skewing the exterior portion of the wires relative to the core and the interior portions of the wire
  • FIGURE 6 shows the wires on the core after they have been skewed in accordance with the operation illustrated in FIG. 5;
  • FIGURE 7 illustrates the cutting of the exterior legs of the wires after skewing
  • FIGURE 8 illustrates the final forming of the interior legs of the wires
  • FIGURE 9 illustrates the cutting of the interior legs of the wires
  • FIGURES 10 and 11 illustrate the welding of the ends of the wires together to make complete windings
  • FIGURE 12 shows a top View of the core after its completion.
  • FIG. 1 is a schematic in which a number of spools 14 and wires 16 have been left out for purposes of clarity, However, if there were to be two windings of 20 turns each, there would be 40 spools 14 to thread 40 wires 16 through the plate in the described manner.
  • the core 10 is made of insulating material to prevent the shorting out of the windings of the uninsulated wires 16.
  • a conductive core can be employed if it is given an insulating coating prior to the threading of the wires 16 through the core as described above.
  • the wires 16 After the wires 16 have been threaded through the core, the wires are oriented against the interior of the core 10 as illustrated in FIG. 2.
  • a splined mandrel 18 with protruding tip 20 is passed upward through the aperture in the core 10. This fixes the wires against the interior of the core 10 in the grooves 22 of the mandrel 18 so that they are equally spaced around the interior of the core 10.
  • a second splined mandrel 24 with a socket 26 is mated with the first splined mandrel 18.
  • the core is transferred from the first splined mandrel 18 to the second splined mandrel 24 and there positioned against a shoulder 28. Then, the wires 16 are out from the spools 14, and the second splined mandrel 24 with the core 10 positioned on the shoulder 28 is moved to a new fixture for further fabrication.
  • the wires are skewed as shown in FIG. 5.
  • the sliding members 30 hold the exterior portions of the wires 16 stationary against the exterior wall of the core 10 while the mandrel 24 with the core 10 on it is rotated with respect to the inwardly moving members 30.
  • This causes the core 10 and the interior portions of the wires 16 to move relative to the exterior portions of the wire 16 causing a skewing of the wires 16 as illustrated in FIG. 6.
  • each of the interior portions of the wire have been skewed two wire positions by the rotation of the mandrel 24. This is because two windings are to be fabricated on the core 10.
  • a different number of windings can also be fabricated by this method by merely changing the amount of the skew; for instance, if a single winding is wanted, the wires 16 are skewed only one wire position, and if three windings are wanted, the wires are skewed three wire positions and so on.
  • the exterior portions of the wires 16 are cut off flush with the top of the core as illustrated in FIG. 7. Then the interior portions of wires 16 are bent down and folded over the top of the core 50 that the interior segment of wire extends radially out from its position against the interior of the core 10. So bent, the interior portion of each wire passes over the cut exterior portion of a wire displaced by two positions from it as shown in FIG. 8.
  • each interior portion is then clipped slightly beyond the edge 38 of the interiorly moving members 30 by a downwardly moving blade 40.
  • all the wires extend approximately the same distance beyond the outer edge of the core 10.
  • the wires are then ready for connection together. This is done by welding.
  • a welding tip 42 is positioned close to each extending end of wire 16 and an arc is drawn by making the welding tip 42 negative with respect to the wire 16. This causes the wire to melt joining the two overlapping ends together and positioning them closely to the edge of the core 10 as illustrated in FIG. 11. When the ends melt together the arcing stops because the space between the different potentials is too large to be bridged by the arc.
  • the windings are fin: ished and the core 10 with the windings on it is coated with an insulating substance.
  • leads 44 for windings one set of opposing ends of wires 16 for each winding are not cut and welded together as shown in FIGS. 7 through 11. Instead they are left long and wardiy as shown in FIG. 12.
  • a method of fabricating a winding on a core comprising the steps of dressed outan electrode and certain of the ends of the turns of wire so that each of those certain ends melts and flows together with the end of the wire with which it is aligned by the skewing of the ends.
  • a method of fabricating windings on a toroidal core comprising the steps of:

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Coil Winding Methods And Apparatuses (AREA)
US571106A 1966-08-08 1966-08-08 Pulse transformer fabrication Expired - Lifetime US3452431A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US57110666A 1966-08-08 1966-08-08

Publications (1)

Publication Number Publication Date
US3452431A true US3452431A (en) 1969-07-01

Family

ID=24282359

Family Applications (1)

Application Number Title Priority Date Filing Date
US571106A Expired - Lifetime US3452431A (en) 1966-08-08 1966-08-08 Pulse transformer fabrication

Country Status (10)

Country Link
US (1) US3452431A (xx)
AT (1) AT271657B (xx)
BE (1) BE699745A (xx)
CH (1) CH470740A (xx)
DE (1) DE1589960B2 (xx)
ES (1) ES343894A1 (xx)
FR (1) FR1530101A (xx)
GB (1) GB1173667A (xx)
NL (1) NL6710361A (xx)
SE (1) SE336836B (xx)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4634045A (en) * 1982-01-19 1987-01-06 Baldwin Alan D Dewatering screen manufacture and method thereof

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3741391C1 (en) * 1987-12-07 1989-04-27 Schaffner Elektronik Ag Winding element for a winding on an enclosed core

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1801214A (en) * 1928-04-28 1931-04-14 American Electric Fusion Corp Edgewise coil and method of making the same
US1852805A (en) * 1931-10-02 1932-04-05 Gen Electric Transformer winding
US2479987A (en) * 1947-10-11 1949-08-23 Brush Dev Co Multiplate electrotransducer
US3181803A (en) * 1962-02-14 1965-05-04 Gen Dynamics Corp Toroidal core winding machine
US3243750A (en) * 1961-03-02 1966-03-29 Collins Corp G L Method of winding toroids and toroids produced thereby
US3286327A (en) * 1962-07-27 1966-11-22 Ward Leonard Electric Co Method of manufacturing electrical resistors

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1801214A (en) * 1928-04-28 1931-04-14 American Electric Fusion Corp Edgewise coil and method of making the same
US1852805A (en) * 1931-10-02 1932-04-05 Gen Electric Transformer winding
US2479987A (en) * 1947-10-11 1949-08-23 Brush Dev Co Multiplate electrotransducer
US3243750A (en) * 1961-03-02 1966-03-29 Collins Corp G L Method of winding toroids and toroids produced thereby
US3181803A (en) * 1962-02-14 1965-05-04 Gen Dynamics Corp Toroidal core winding machine
US3286327A (en) * 1962-07-27 1966-11-22 Ward Leonard Electric Co Method of manufacturing electrical resistors

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4634045A (en) * 1982-01-19 1987-01-06 Baldwin Alan D Dewatering screen manufacture and method thereof

Also Published As

Publication number Publication date
DE1589960B2 (de) 1972-05-18
AT271657B (de) 1969-06-10
ES343894A1 (es) 1968-10-01
GB1173667A (en) 1969-12-10
FR1530101A (fr) 1968-06-21
CH470740A (de) 1969-03-31
SE336836B (xx) 1971-07-19
NL6710361A (xx) 1968-02-09
BE699745A (xx) 1967-11-16
DE1589960A1 (de) 1970-12-23

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