Author Topic: Transformer Winding Machine  (Read 1680 times)

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Offline xzswq21Topic starter

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Transformer Winding Machine
« on: August 12, 2021, 06:34:47 pm »
Hello
I want to wind up several Flyback transformers as following:




The core is small, it's a cylinder with a Diameter of 1" and a Length of 1.5"

so I need a winding machine but it should be accurate. (not for funny, I want to produce some hundred Flyback transformers)

Thanks
« Last Edit: August 12, 2021, 07:13:43 pm by xzswq21 »
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Offline Benta

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Re: Transformer Winding Machine
« Reply #1 on: August 12, 2021, 08:56:38 pm »
Your winding schematic is very odd, but I guess you have reasons for it.
Normally you'd wind back-and-forth to get a smooth winding and maximum bobbin fill.

Second, this is something I'd shop out to a company doing it all day and having the necessary machines.

 

Offline bob91343

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Re: Transformer Winding Machine
« Reply #2 on: August 12, 2021, 09:44:46 pm »
The odd winding scheme has to do with high frequency performance of the transformer.  It reduces the interwinding capacitance by separating the parts of the winding that have high potential between them.  It's basically a pi-wound coil which, electrically, is several smaller coils in series.  Magnetically, they are all linked equally.
 

Offline xzswq21Topic starter

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Re: Transformer Winding Machine
« Reply #3 on: August 12, 2021, 09:56:34 pm »
The odd winding scheme has to do with high frequency performance of the transformer.  It reduces the interwinding capacitance by separating the parts of the winding that have high potential between them.  It's basically a pi-wound coil which, electrically, is several smaller coils in series.  Magnetically, they are all linked equally.

Yes, exactly :)








« Last Edit: August 12, 2021, 10:00:10 pm by xzswq21 »
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Offline Red Squirrel

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Re: Transformer Winding Machine
« Reply #4 on: August 12, 2021, 10:05:33 pm »
That pattern also prevents arcing between the wires as the voltage difference between any wires that are near is minimized.  This at least applies to high voltage transformers anyway.

I learned this the hard way.  :-DD   Kapton tape between the layers helps a lot too.

 

Offline Benta

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Re: Transformer Winding Machine
« Reply #5 on: August 12, 2021, 10:12:56 pm »
I have a few problems accepting this explanation.
The interwinding capacitance is from my analysis the same with both winding methods.
The isolation stress is higher with a back-and-forth winding. Yes. We can agree on that.

But the big difference is the winding segmentation, and I'm totally with you that it'll give another result.

 

Offline jonpaul

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Re: Transformer Winding Machine
« Reply #6 on: August 13, 2021, 01:12:40 am »
Hello: We made 1000s of similar transformers 1W to 100s of  watts and up to 20kV.

The segmented bobbin is a very old method and reduces the wire insulation stress, as well as self capacitance.

Either layer wound perfect lay as show or random wind is used but the best is a universal winding where the wires cross at an angle.

Old Stevens and MicaFil machines appear on occasion but the best are Adams Maxwell, 1201-01 or 1201-02 costly but excellent. We have about 5 of these in continous use for decades.

http://adamsmaxwell.com/


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Jon
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