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CN-122025403-A - Mo Zhaogao frequency network transformer coil manufacturing method, coil and network transformer

CN122025403ACN 122025403 ACN122025403 ACN 122025403ACN-122025403-A

Abstract

The invention discloses a manufacturing method of a coil of a ten-thousand-megabit high-frequency network transformer, a coil and a network transformer, wherein the manufacturing method sequentially comprises the steps of initial parallel winding and preparation of stranded wires, branching and positioning of clamped wires, grading of stranded wires, three-wire structure construction and integration to obtain the coil, two groups of three-color enameled stranded wires are firstly formed into twisted wires and are parallel and wound around a T1 magnetic ring, a bare ring is reserved, four extension wires at a magnetic ring port are separated by color, the same-side same-function wires are formed into a signal wire pair/tap wire group by two clamped wires, the signal wire pair/tap wire group is stranded and fixed by following a stranded bottom, finally a specific tap wire and an independent wire are stranded into a composite tap lead, and the specific signal wire and the independent wire are stranded into a three-wire structure wound T2 magnetic ring, so that subsequent fixed cutting is completed. The method standardizes and controls the process steps and parameters, ensures the symmetry and consistency of the coil structure, improves the high-frequency impedance balance performance, reduces the production skill dependence, improves the production efficiency and the product yield, and the prepared coil is suitable for the high-performance use requirement of the ten-thousand-megabyte high-frequency network transformer.

Inventors

  • YE XIAOLONG
  • SU XIANGHE
  • FU JINHUA

Assignees

  • 惠州攸特电子股份有限公司

Dates

Publication Date
20260512
Application Date
20260326

Claims (10)

  1. 1. The manufacturing method of the coil of the ten-thousand-megawatt high-frequency network transformer is characterized by comprising the following steps of: the initial parallel winding and preparation stranded wire, namely taking two groups of three-color enamelled stranded wires to form two groups of initial twisted wires, winding the two groups of initial twisted wires into a T1 magnetic ring in parallel, reserving a bare ring, and extending the two groups of initial twisted wires from the opening of the T1 magnetic ring to form four extension wires from the head to the tail after the winding is completed; Branching and positioning clamping wires, namely branching four extension wires from the head to the tail according to a preset branching sequence and a preset color at the naked ring of the T1 magnetic ring to obtain a signal wire and a tap wire, and positioning clamping wires are respectively carried out on the signal wire and the tap wire which are at the same side and have the same function to obtain a signal wire pair and a tap wire group; The step of grading stranded wires, which is to twist the signal wire pairs and the tap wire groups after wire clamping by wire division by preset pitch respectively, wherein the twisting meets the requirement of 'twisting bottom fixing'; and twisting the specific tap wire and the individual wire to form a composite tap lead, twisting the specific signal wire and the individual wire to form a three-wire structure, and winding the three-wire structure into a T2 magnetic ring to finish subsequent fixing and cutting treatment.
  2. 2. The manufacturing method of the multi-megasonic network transformer coil according to claim 1, wherein in the initial parallel winding and preliminary twisting steps, two groups of three-color enamelled twisted wires comprise Jin Jinhuang three-color wires and blue-red three-color wires, jin Jinhuang three-color wires and blue-red three-color wires are respectively twisted to form two groups of initial twisted wires, and the two groups of initial twisted wires are closely wound on the T1 magnetic ring in parallel in a clockwise direction, and bare rings are reserved.
  3. 3. The manufacturing method of the multi-megasonic network transformer coil according to claim 2, wherein in the initial parallel winding and preliminary wire twisting step, the twisted wire parts of four extension wires of two groups of initial twisted wires extending from the T1 magnetic ring opening from the head to the tail are controlled to be 2-2.5mm and are not loosened.
  4. 4. The manufacturing method of the multi-megawatt high-frequency network transformer coil according to claim 2, wherein in the step of branching and positioning and wire clamping, a red-head green-tail tap wire, a red-tail green-head signal wire, a gold-head blue-tail tap wire and a gold-tail blue-head signal wire are sequentially separated according to a preset branching sequence and a preset color; The positioning clamp wires are clamped and fixed by two wires with the same side and the same function, and specifically Jin Jinwei signal wires are clamped by the same-side red tail signal wires, blue-blue head signal wires are clamped by the same-side green head signal wires, blue-blue tail tap wires are clamped by the same-side green tail tap wires, and gold-head tap wires are clamped by the same-side red head tap wires to respectively obtain Jin Jinwei red tail signal wire pairs, blue-blue head green head signal wire pairs, blue-blue tail green tail tap wire groups and gold-head red head tap wire groups.
  5. 5. The method of manufacturing a multi-megasonic network transformer coil of claim 4 wherein the step of grading strands comprises: twisting the signal wire pairs, namely twisting Jin Jinwei signal wires in the red tail signal wire pair and blue head signal wires in the green head signal wire pair of Jin Jinwei split wire pairs at high density respectively, wherein the twisting meets the requirement of 'twisting bottom fixing'; And (3) pre-twisting the center tap wire, namely respectively pulling the blue tail tap wire in the blue tail clamp green tail tap wire group after wire-dividing and the gold head tap wire in the gold head clamp red head tap wire group to the central position of the T1 magnetic ring, and twisting the blue tail tap wire and the gold head tap wire together in medium density, wherein the twisting meets the requirement of 'twisting bottom fixation'.
  6. 6. The method of manufacturing a multi-megasonic network transformer coil of claim 5 wherein the number of twisted wire knots of the Jin Jinwei signal lines and the number of twisted wire knots of the blue-head signal lines are each 40-42 knots/inch and the number of twisted wire knots of the blue-tail tap line and the four gold-head tap line are each 25-27 knots/inch.
  7. 7. The method of manufacturing a multi-megasonic network transformer coil of claim 6 wherein the three-wire structure constructing and integrating step comprises: Taking a green tail tap wire and a red head tap wire as specific tap wires, adding a golden single wire, twisting three wires with twisted wire sections of 34-36 knots/inch, and twisting to the bottom to form a composite tap lead; Taking the red tail signal wire and the green head signal wire as specific signal wires, and twisting the specific signal wires with the golden single wire by using the twisted wire pitch number of 5-6 knots/inch to form a three-wire structure embryonic form which is ready to be connected with a T2 magnetic ring; uniformly winding the three-wire structure to a T2 magnetic ring according to preset turns, and controlling the preset distance between the T1 magnetic ring and the T2 magnetic ring to be 4-5mm; binding and fixing all the leads at the middle bare ring by utilizing the composite tap lead formed by the red-head green-tail golden tap wire; and cutting the extended part of the composite tap lead to a preset length and performing pre-soldering treatment.
  8. 8. The manufacturing method of a multi-megasonic network transformer coil according to claim 7, wherein in the three-wire structure constructing and integrating step, the portion of the composite tap lead extending out is cut to a predetermined length of 3.5-4.5mm, and soldering is performed by 2-2.5mm.
  9. 9. A coil manufactured by the manufacturing method of the tera-high frequency network transformer coil according to any one of claims 1-8.
  10. 10. A network transformer comprising the coil of claim 9.

Description

Mo Zhaogao frequency network transformer coil manufacturing method, coil and network transformer Technical Field The invention relates to the technical field of electronic components, in particular to a manufacturing method of a coil of a multi-megabyte high-frequency network transformer, the coil and the network transformer. Background With the large-scale application of the technology of the tera ethernet (10G BASE-T), a network transformer coil is taken as a key component for signal transmission, and the impedance balance performance (namely, in differential signal transmission, the impedance characteristics (including resistance, inductance and capacitance distribution) of a pair of signal wires (differential wire pair) to the reference ground are kept highly consistent. The existing tera-mega network transformer coil, especially the coil adopting a 'three-wire structure' or similar complex structure, faces the following general technical problems and defects when pursuing high-frequency performance: Firstly, the traditional technology relies on the proficiency of operators to carry out branching and stranding, and it is difficult to ensure that the lead length, the stranding compactness and the space trend of each pair of differential signal wires (such as TX+ and TX-) corresponding to the same channel are completely consistent. The small difference in physical structure is converted into significant parasitic inductance and distributed capacitance difference at the frequency of hundreds of MHz, impedance balance is seriously damaged, return Loss (Return Loss) is deteriorated, the center tap in the existing three-wire structure needs additional splicing and twisting procedures, if the splicing point is unstable or twisting joint number and length control are inaccurate, random parasitic parameters and potential failure points are introduced, stability and reliability of integral performance are affected, the existing wire package process for realizing better performance is complex in steps, a plurality of control points (such as a plurality of twisted wire joints and lengths), requirements on staff skills are high, production beats are slow, yield fluctuation is large, manufacturing cost is high, and fourth, unreasonable wire separation and twisted wire sequence may cause uneven stress of wires in the wire package, tiny deformation is generated due to stress release in the subsequent assembly or use process, high-frequency electrical parameters are further changed, and long-term reliability is affected. In view of the above, a high-performance tera-mega-high-frequency transformer coil manufacturing method is proposed which can ensure structural symmetry and consistency from a manufacturing process source and simplify the flow. Disclosure of Invention The invention aims to overcome at least one defect in the prior art and provides a manufacturing method of a high-performance tera-mega-high-frequency transformer coil, which can ensure structural symmetry and consistency from a manufacturing process source and simplify the flow. The aim of the invention is realized by the following technical scheme: A manufacturing method of a multi-megabyte high-frequency network transformer coil comprises the following steps: the initial parallel winding and preparation stranded wire, namely taking two groups of three-color enamelled stranded wires to form two groups of initial twisted wires, winding the two groups of initial twisted wires into a T1 magnetic ring in parallel, reserving a bare ring, and extending the two groups of initial twisted wires from the opening of the T1 magnetic ring to form four extension wires from the head to the tail after the winding is completed; Branching and positioning clamping wires, namely branching four extension wires from the head to the tail according to a preset branching sequence and a preset color at the naked ring of the T1 magnetic ring to obtain a signal wire and a tap wire, and positioning clamping wires are respectively carried out on the signal wire and the tap wire which are at the same side and have the same function to obtain a signal wire pair and a tap wire group; The step of grading stranded wires, which is to twist the signal wire pairs and the tap wire groups after wire clamping by wire division by preset pitch respectively, wherein the twisting meets the requirement of 'twisting bottom fixing'; and twisting the specific tap wire and the individual wire to form a composite tap lead, twisting the specific signal wire and the individual wire to form a three-wire structure, and winding the three-wire structure into a T2 magnetic ring to finish subsequent fixing and cutting treatment. In one embodiment, in the initial parallel winding and preliminary stranding step, two groups of three-color enamelled stranded wires comprise Jin Jinhuang three-color wires and blue-red three-color wires, jin Jinhuang three-color wires and blue-red three-color wires are respectively str