Design considerations for high and low frequency transformer skeleton

When designing the framework structure of the high and low frequency transformer skeleton, it is necessary to design a three-dimensional model based on the drawings or samples provided by the customer, combined with one's own design experience, to avoid defects and modifications in the two-dimensional drawings. If the customer's design is unreasonable, they should proactively reconfirm the skeleton structure with the customer's technical personnel. When designing the skeleton, attention should be paid to the following aspects.

1. The raw materials should meet the customer's process and requirements, and the framework should be designed according to the characteristics of the materials. In general, the thickness of the skeleton wall is determined by referring to the yellow card

2. Metal wire traces can smoothly or smoothly pass through the customer's PCB, usually using iron (steel) wire traces. For customers with special requirements for better conductivity, copper and other conductive materials should be considered.

Currently, environmental requirements such as RoHS, halogen-free, and SVHC are becoming increasingly urgent, and these requirements need to be met when selecting materials.

4. It should meet the model requirements of high-frequency transformers, and the external dimensions should be smaller than the size of the finished transformer.

5. The size of the core hole should match the size of the core column, generally greater than the upper limit tolerance of the core column; The inner diameter tolerance of fixed magnetic core blades is usually smaller than the inner diameter tolerance of the magnetic core. The purpose of this design is to facilitate subsequent wear and tear repair. The fitting tolerance of the core hole and the winding fixture should be controlled within 0.05 to meet the corresponding needs of the tight customer's automatic winding operation (loose fitting will cause the skeleton to fall off in the winding, and it will be difficult for the operator to insert or remove if tight).

6. The groove is the turning trajectory of copper wire. In order to avoid damage, pin splitting, sand clamping, and other abnormal situations in production, the width of the groove should be considered as follows: copper wire diameter, pinholes with wall thickness, and rough edges with sand particle size.

7. The pinhole should not be too deep, and the bottom wall thickness of the pinhole should be greater than 0.5mm to avoid adverse effects such as pinhole cracking or perforation.

8. It is necessary to perform R-angle transition, which can not only improve strength, prevent damage, but also improve some production problems. Especially at the edges of the trunking, it can prevent scratches on the insulation coating of the copper wire; The edge of the core hole allows for easy insertion of the core; Wrapping around the pipeline can increase the strength of the blades, etc.