Winding method of wire for valve reactor
By combining the winding device with the winding coil pattern, the problem of traditional winding machines having difficulty winding non-circular valve reactor coils is solved, achieving efficient and stable coil production, and suitable for valve reactor coils with complex shapes.
Patent Information
- Application Number
- CN202510923505.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-04
- Publication Date
- 2025-11-21
AI Technical Summary
Traditional winding machines struggle to efficiently wind non-circular valve reactor coils, resulting in high processing costs, unstable quality, and an inability to meet the demands of large-scale production.
The device employs a winding mechanism and coil winding pattern, including a winding base, winding tower blocks, winding wheel assembly, and shims. The bending and winding of the conductor is achieved through the height difference of the winding tower blocks and the rotation of the winding wheel, ensuring the independence of each corner position and the superposition of turns. It is suitable for non-circular coils of different shapes.
It improves the winding efficiency and quality stability of non-circular coils, reduces the labor intensity of workers, and is suitable for the production of valve reactor coils with complex shapes.
Smart Images
Figure CN120998672A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the technical field of valve reactor equipment, and in particular, a method for winding wires for valve reactors. Background Technology
[0002] Valve reactors are key components in the converter valve devices of high-voltage direct current (HVDC) transmission systems, used to protect thyristors. Their purpose is to limit the high rates of current rise (di / dt) and voltage rise (du / dt) generated in the electrical circuit during the switching process of semiconductor thyristors. Thus, valve reactors provide a reliable and efficient protection component for the thyristor's commutation operation. Valve reactors are indispensable basic components in power systems, especially the iron-core saturated valve reactor independently developed by our company, which is one of the main components of converter stations in HVDC transmission systems. The winding coil of the reactor is an important performance indicator; the continuity, integrity, and consistency of the coil winding are crucial technical guarantees for ensuring coil performance. Due to the special structure of reactors, their coils come in various shapes, commonly including circular, elongated, oblong, and triangular. The conductors are usually composed of pure metal or insulated metal conductors. Especially with insulated metal conductors, ensuring that the insulation layer is not damaged during production is critical in the winding coil.
[0003] Traditional reactor winding machines are typically suitable for winding circular coils. However, for non-circular coils, especially complex rectangular or elliptical valve reactor coils, it is difficult to guarantee dimensional accuracy and shape consistency during the winding process. The need for custom-made molds increases processing costs. Furthermore, for some special-shaped or large non-circular valve reactor coils, manual winding may be used. However, manual winding is not only inefficient and labor-intensive, but also struggles to guarantee coil quality stability. It is easily affected by factors such as the operator's skill level and experience, resulting in inconsistent product quality that cannot meet the demands of large-scale production. Summary of the Invention
[0004] In view of this, the present invention provides a method for efficiently winding wires for valve reactors to meet industrial needs.
[0005] A method for winding a conductor for a valve reactor includes the following steps:
[0006] Step S100: Provide a winding device and a winding coil pattern. The winding device includes a winding base, multiple winding tower blocks disposed on the winding base, a winding wheel assembly disposed on the winding base, and multiple shims. The winding base includes a winding base body, at least two winding stations, and at least two limiting holes respectively disposed in the winding stations. Each winding station is provided with a limiting hole. Each winding tower block includes a winding tower block body and an insertion hole disposed on the winding tower block body. The winding wheel assembly includes a winding frame, a winding shaft disposed at one end of the winding frame, and a winding wheel hinged to the winding frame. The multiple limiting holes are respectively disposed at various corner positions of the winding coil pattern;
[0007] Step S110: Place one of the winding tower blocks on a winding station in the winding base. This winding station is the initial winding station. Provide a wire, with one end of the wire fixed to the winding base of the initial winding station.
[0008] Step S120: Insert the winding shaft into the insertion hole of the winding tower block and the limiting hole of the winding base. The winding wheel rotates around the center of the winding shaft, forcing the wire to bend into shape according to the outer arc of the winding tower block. The winding wheel presses one end of the wire towards the center side of the winding tower block and tilts it. After the wire has been wound in one winding tower block, the winding wheel assembly is removed. When the winding wheel of the winding wheel assembly is released, the wire springs back.
[0009] Step S130: Place the winding tower block on the next winding station on the winding base. Place a shim block under the winding tower block at the next winding station. The shim block creates a height difference between the winding tower block at this station and the winding tower block at the initial winding station. This ensures that when the wire reaches the position of the initial winding station during winding, the wire is above the winding tower block and does not interfere with it. Repeat step S120.
[0010] Step S140: Repeat step S130 at subsequent winding stations until the initial winding station is reached.
[0011] Step S150: Based on the requirements of the winding coil, it can be determined whether to continue placing a winding tower block at the initial winding station. When the winding coil is a multi-turn coil, another winding tower block is placed at the initial winding station. The sum of the heights of all the winding tower blocks at the initial winding station is higher than the sum of the heights of the winding towers and the shims on other winding tower blocks. Then, repeat steps S120 to S140 to wind the coil in a cyclical manner. When the winding coil is a single-turn coil, stop winding.
[0012] Furthermore, the distance between the winding shaft and the winding wheel is equal to the sum of the radius of the winding tower block and the thickness of the conductor, so that the conductor can be wound between the winding wheel and the winding tower block.
[0013] Furthermore, each of the winding tower blocks also includes a winding groove disposed on the side wall of the main body of the winding tower block.
[0014] Furthermore, the winding wheel includes a winding wheel body and a winding groove disposed on the side wall of the winding wheel.
[0015] Furthermore, when the winding shaft is inserted into the insertion hole of the winding tower block and the limiting hole of the winding base, the winding groove and the winding slot are on the same horizontal plane.
[0016] Furthermore, the shim block includes a shim block body, a shim block insertion hole disposed on the shim block body, and a shim block limiting flange disposed on the inner sidewall of one end of the shim block insertion hole. The shim block insertion hole and the shim block limiting flange are concentrically disposed, and the outer diameter of the shim block limiting flange is smaller than the diameter of the limiting hole. The diameter of the tower block limiting flange is smaller than the insertion hole and the shim block insertion hole.
[0017] Furthermore, the outer contour of the winding tower block is semi-circular.
[0018] Furthermore, an obstacle avoidance structure is provided on the raised block.
[0019] Furthermore, in step S130, the shim block on the next winding station forms a height difference between the winding tower block of the next station and the winding tower block of the initial winding station that is greater than the diameter of the conductor.
[0020] Compared with the prior art, the winding method for conductors of valve reactors provided by the present invention utilizes a winding device, a winding coil pattern, and conductors. The winding device includes a winding base, multiple winding tower blocks disposed on the winding base, a winding wheel assembly disposed on the winding base, and at least one shim block. The winding base includes a winding base body, at least two winding stations, and at least two limiting holes respectively disposed within the winding stations. Each winding station has one limiting hole. Each winding tower block includes a winding tower block body, an insertion hole disposed on the winding tower block body, and a winding groove disposed on the side wall of the winding tower block body. The winding wheel assembly includes a winding frame, a winding shaft disposed at one end of the winding frame, and a winding wheel hinged to the winding frame. The multiple limiting holes are respectively disposed at various corner positions of the winding coil pattern. During the winding process, a winding tower block is placed at a winding station in the winding base, which is the initial winding station. A wire is provided, one end of which is fixed to the winding base at the initial winding station. The winding shaft is inserted into the insertion hole of the winding tower block and the limiting hole of the winding base. The winding wheel rotates around the center of the winding shaft, forcing the wire to bend according to the outer arc of the winding tower block. The winding wheel presses one end of the wire towards the center of the winding tower block, tilting it inward. After the wire has been wound on one winding tower block, the winding wheel assembly is removed, and the wire springs back after the winding wheel assembly is released. In subsequent stations, a shim is placed below the winding tower block at the winding station, and the wire is wound until the cycle returns to the initial winding station. When the wound coil is a multi-turn coil, another winding tower block is placed at the initial winding station, and the winding cycle continues. It can be seen that the winding method for the conductor used in the valve reactor sets a winding tower block at each corner of the non-circular coil. Each winding tower block is independent, and its height is stacked according to the number of winding turns. During the winding process, each tower does not interfere with each other. It is suitable for winding non-circular coils of different shapes, and ensures the quality stability of the coil, reduces the labor intensity of workers, and improves processing efficiency. Attached Figure Description
[0021] Figure 1 A flowchart of a method for winding wires for a valve reactor provided by the present invention.
[0022] Figure 2 This is an exploded structural diagram of the winding device in the method of winding wires for valve reactors.
[0023] Figure 3 This is a schematic cross-sectional view of the winding tower block in the winding device.
[0024] Figure 4This is a schematic cross-sectional view of the shim block in the winding device.
[0025] Figure 5 This is a schematic diagram of the winding device for winding the first coil in a method for winding wires used in valve reactors.
[0026] Figure 6 This is a schematic diagram of the winding device for winding the second coil in a method for winding wires used in valve reactors.
[0027] Figure 7 This is a schematic diagram of the winding device winding the second coil in a method for winding wires used in valve reactors.
[0028] Figure 8 This is a schematic diagram of the winding device for winding the third coil in a method for winding wires used in valve reactors.
[0029] Figure 9 for Figure 4 A side view of the winding device for winding coils in a method for winding conductors used in valve reactors.
[0030] Figure 10 This is a schematic diagram of the structure of an elongated oval coil wound using a method for winding wires for valve reactors.
[0031] Figure 11 This is a schematic diagram of a rectangular and triangular combination coil formed by winding the wires used in valve reactors.
[0032] Figure 12 This is a schematic diagram of a pentagonal coil formed by winding a conductor for use in a valve reactor. Detailed Implementation
[0033] The following provides a more detailed description of specific embodiments of the present invention. It should be understood that the description of the embodiments of the present invention herein is not intended to limit the scope of protection of the present invention.
[0034] like Figures 1 to 9 The diagram shown is a structural schematic of the winding method for a valve reactor provided by the present invention. The winding method for the valve reactor includes the following steps:
[0035] Step S100: Provide a winding device 10 and a winding coil pattern. The winding device 10 includes a winding base 11, a plurality of winding tower blocks 12 disposed on the winding base 11, a winding wheel assembly 13 disposed on the winding base 11, and a plurality of shims 14. The winding base 11 includes a winding base body 111, at least two winding stations 112, and at least two limiting holes 113 respectively disposed in the winding stations 112. Each winding station 112 is provided with a... Each winding tower block 12 includes a winding tower block body 121, a plug hole 122 disposed on the winding tower block body 121, and a winding groove 123 disposed on the side wall of the winding tower block body 121. The winding wheel assembly 13 includes a winding frame 131, a winding shaft 132 disposed at one end of the winding frame 131, and a winding wheel 133 hinged to the winding frame 131. The plurality of limiting holes 113 are respectively disposed at each corner position of the winding coil pattern.
[0036] Step S110: Place one of the winding tower blocks 12 on a winding station 112 of the winding base 11. This winding station 112 is the initial winding station. Place a shim block 14 on the other winding stations 112 and provide a wire 1. One end of the wire 1 is fixed on the winding base 11 of the initial winding station.
[0037] Step S120: Insert the winding shaft 132 into the insertion hole 122 of the winding tower block 12. The winding wheel 133 rotates around the center of the winding shaft 132, forcing the wire 1 to bend into shape according to the outer arc of the winding tower block 12. The winding wheel 133 presses one end of the wire 1 towards the center of the winding tower block 12 and tilts it. After the wire 1 has finished winding in one winding tower block 12, the winding wheel assembly 13 is removed. When the winding wheel 133 of the winding wheel assembly 13 is released, the wire 1 springs back.
[0038] Step S130: Place the winding tower block 12 on the next winding station 112 on the winding base 11. The shim block 14 of the next winding station 112 is below the winding tower block 12, and the shim block 14 on the next winding station forms a height difference between the winding tower block 12 of the station and the winding tower block 12 of the initial winding station, so that when the wire 1 reaches the position of the initial winding station during winding, the wire of the wire 1 is above the winding tower block 12 and does not interfere. Repeat step S120.
[0039] Step S140: Repeat step S130 at subsequent winding stations 112 until the initial winding station is reached.
[0040] Step S150: According to the requirements of the winding coil, continue to place the winding tower block 12 at the initial winding station. When the winding coil is a multi-turn coil, continue to place a winding tower block 12 at the initial winding station. The sum of the heights of all the winding tower blocks 12 at the initial winding station is higher than the sum of the heights of the winding tower 2 and the shim block on the other winding tower blocks 12. Then repeat steps S120 to S140 to wind the coil in a cyclic manner. When the winding coil is a single-turn coil, stop the winding.
[0041] In step S120, the conductor 1 is bent into shape according to the outer arc of the winding tower block 12, and the winding wheel 133 presses one end of the conductor 1 towards the center of the winding tower block 12 at an inclination. The inclination angle of the one end of the conductor 1 towards the center of the winding tower block 12 is determined according to the material properties of the conductor 1, so that the conductor 1 can spring back to the position required by the design. Under the action of the rebound force, the bending angle of the conductor 1 springs back.
[0042] When the winding coil is an n-turn coil, in step S150, the initial winding station continues to place n-1 winding tower blocks 12, and the coil formed at the bottom and the coil formed subsequently form an n-turn coil.
[0043] Multiple limiting holes 113 are respectively set at each corner position of the winding coil pattern, that is, each corner of the winding coil pattern is provided with a winding station 112 to guide the coil to be bent at the corner position of the winding coil pattern to realize the coil forming.
[0044] In step S130, the shim block 14 creates a height difference between the winding tower block 12 of the current winding station and the winding tower block 12 of the initial winding station. This height difference is greater than the diameter of the wire in the conductor 1. Therefore, during the winding process, the conductor 1 is positioned above the winding tower block 12 of the initial winding station. This prevents interference between the conductors of the initial winding station and other stations, and avoids the inconvenience of forcing one end of the conductor 1 to tilt towards the center of the winding tower block 12 when winding the conductor at other stations, thus preventing insufficient conductor deformation. Furthermore, since the conductors in the reactor are composed of insulated metal conductors, both the insulation layer and the metal conductor have good resilience. If, during the winding process, one end of the conductor 1 cannot be forced to tilt towards the center of the winding tower block 12, proper conductor deformation cannot be achieved. The conductor, through its own resilience, cannot adhere to the winding tower block 12 for winding, affecting the coil winding process.
[0045] like Figure 10As shown, the wound coil has an elongated elliptical shape. The winding base has two winding stations 112. The winding tower block 12 is installed in the two winding stations 112 in sequence. The guide wire 1 is wound in the two winding stations 112 in sequence, so that the wound coil has an elongated elliptical outline.
[0046] like Figure 11 As shown, the winding coil diagram forms a combination coil of rectangle and triangle. The winding base 11 is respectively provided with three winding stations 112 to form a triangular winding area and four winding stations 112 to form a rectangular winding area. The center of the triangular winding area coincides with the center of the rectangular winding area. In this embodiment, during the first and second turns, the outer contour of the coil is wound into a rectangle. When the outer contour of the coil is wound into a rectangle, the four winding stations 112 in the rectangular winding area are sequentially installed on the winding tower block 12 and wound. The winding wheel assembly 13 guides the wire 1 to be wound sequentially in the four winding stations 112 respectively. The winding coil has a rectangular outline. The outer contours of the 3rd, 4th, and 5th turns of the coil form a triangle. In the three winding stations 112 in the triangular winding area, the winding tower block 12 is installed on the three winding stations 112 in sequence and the winding is performed. The winding wheel assembly 13 guides the wire 1 to be wound in the three winding stations 112 in sequence, so that the outline of the wound coil is triangular, thus forming a combination coil of rectangle and triangle.
[0047] like Figure 12 As shown, the winding coil is formed into a five-pointed star shape. When the outer contour of the coil is in the shape of a five-pointed star, there are nine winding stations 112 on the winding base. The winding tower block 12 is installed in the nine winding stations 112 in sequence. The guide wire 1 is wound in the nine winding stations 11 in sequence to form a five-pointed star-shaped coil.
[0048] The distance between the winding shaft 132 and the winding wheel 133 is equal to the radius of the winding tower block 12 and the thickness of the wire 1, so that the wire 1 can be wound between the winding wheel 133 and the winding tower block 12, thereby improving the winding effect of the wire 1.
[0049] The winding wheel 133 includes a winding wheel body 1331 and a winding groove 1332 disposed on the side wall of the winding wheel 1331.
[0050] Furthermore, the outer contour of the winding tower block 12 is semi-circular, and each winding tower block 12 also includes a winding groove 123 disposed on the side wall of the winding tower block body 121, and a tower block limiting flange 124 disposed at one end of the insertion hole 122. The winding groove 1332 and the winding groove 123 are both used to guide the rotation of the conductor 1 around the side wall of the winding tower block 12. When the winding shaft 132 is inserted into the insertion hole 122 of the winding tower block 12, the winding groove 1332 and the winding groove 123 of the winding groove 1332 are on the same horizontal plane, thereby stabilizing the coil winding process.
[0051] The shim block 14 includes a shim block body 141, a shim block insertion hole 142 disposed on the shim block body 141, and a shim block limiting flange 143 disposed on the inner sidewall of one end of the shim block insertion hole 142. The shim block insertion hole 142 and the shim block limiting flange 143 are concentrically arranged, and the outer diameter of the shim block limiting flange 143 is smaller than the diameter of the limiting hole 113. The diameter of the tower block limiting flange 124 is smaller than the insertion hole 122 and the shim block insertion hole 142. The tower block limiting flange 124 can be inserted into the insertion hole 122 or the shim block insertion hole 142, thereby realizing the mutual overlap of the winding tower block 12 and the shim block 14. When the winding tower block 12 overlaps with the winding tower block 12 and the winding tower block 12 overlaps with the shim block 14, the position is stable, so as to facilitate winding on the winding tower block 12.
[0052] Compared with the prior art, the winding method for the conductor of the valve reactor provided by the present invention includes a winding device 10, a winding coil pattern, and a winding conductor 1. The winding device 10 includes a winding base 11, a plurality of winding tower blocks 12 disposed on the winding base 11, a winding wheel assembly 13 disposed on the winding base 11, and at least one shim block 14. The winding base 11 includes a winding base body 111, at least two winding stations 112, and at least two limiting holes 113 respectively disposed in the winding stations 112. Each winding station 112 is provided with a limiting hole 113. Each winding tower block 12 includes a winding tower block body 121, an insertion hole 122 disposed on the winding tower block body 121, and a winding groove 123 disposed on the side wall of the winding tower block body 121. The winding wheel assembly 13 includes a winding frame 131, a winding shaft 132 disposed at one end of the winding frame 131, and a winding wheel 133 hinged to the winding frame 131. The plurality of limiting holes 113 are respectively disposed at various corner positions of the winding coil pattern. During the winding process, a winding tower block 12 is placed on a winding station 112 of the winding base 11. This winding station 112 is the initial winding station. A wire 1 is provided, and one end of the wire 1 is fixed on the winding base 11 of the initial winding station. The winding shaft 132 is inserted into the insertion hole 122 of the winding tower block 12. The winding wheel 133 rotates around the center of the winding shaft 132, forcing the wire 1 to bend according to the outer arc of the winding tower block 12. The winding wheel 133 presses one end of the wire 1 towards the center of the winding tower block 12 and tilts it. After the wire 1 has been wound on a winding tower block 12, the winding wheel assembly 13 is removed. When the winding wheel 133 of the winding wheel assembly 13 is released, the wire 1 springs back. In subsequent workstations, at winding station 112, a shim 14 is placed below the winding tower block 12, and the wire 1 is wound until the cycle returns to the initial winding station. When the wound coil is a multi-turn coil, another winding tower block 12 is placed at the initial winding station, and the winding cycle continues. It can be seen that this winding method for the wires used in valve reactors sets a winding tower block at each corner of the non-circular coil. Each winding tower block is independent, and its height is stacked according to the number of winding turns. During the winding process, each tower does not interfere with the others. This method is suitable for winding non-circular coils of different shapes, ensures the stability of coil quality, reduces the labor intensity of workers, and improves processing efficiency.
[0053] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions or improvements within the spirit of the present invention are covered within the scope of the claims of the present invention.
Claims
1. A method for winding a conductor for a valve reactor, characterized in that: Includes the following steps: Step S100: Provide a winding device and a winding coil pattern. The winding device includes a winding base, a plurality of winding tower blocks disposed on the winding base, a winding wheel assembly disposed on the winding base, and a plurality of shims. The winding base includes a winding base body, at least two winding stations, and at least two limiting holes respectively disposed in the winding stations. Each winding station is provided with one limiting hole. Each winding tower block includes a winding tower block body and an insertion hole disposed on the winding tower block body. The winding wheel assembly includes a winding frame, a winding shaft disposed at one end of the winding frame, and a winding wheel hinged to the winding frame. The plurality of limiting holes are respectively disposed at various corner positions of the winding coil pattern. Step S110: Place one of the winding tower blocks on a winding station of the winding base. This winding station is the initial winding station. Place a shim block on the other winding stations and provide a wire. One end of the wire is fixed on the winding base of the initial winding station. Step S120: Insert the winding shaft into the insertion hole of the winding tower block. The winding wheel rotates around the center of the winding shaft, forcing the wire to bend into shape according to the outer arc of the winding tower block. The winding wheel presses one end of the wire towards the center side of the winding tower block and tilts it. After the wire has been wound in one winding tower block, the winding wheel assembly is removed. When the winding wheel of the winding wheel assembly is released, the wire springs back. Step S130: Place the winding tower block on the next winding station on the winding base. The shim block 14 of the next winding station 112 is below the winding tower block 12, and the shim block on the next winding station forms a height difference between the winding tower block of the station and the winding tower block of the initial winding station, so that when the wire reaches the position of the initial winding station during winding, the wire is above the winding tower block and does not interfere. Repeat step S120. Step S140: Repeat step S130 at subsequent winding stations until the initial winding station is reached. Step S150: Based on the requirements of the winding coil, it can be determined whether to continue placing a winding tower block at the initial winding station. When the winding coil is a multi-turn coil, another winding tower block is placed at the initial winding station. The sum of the heights of all the winding tower blocks at the initial winding station is higher than the sum of the heights of the winding towers and the shims on other winding tower blocks. Then, steps S120 to S140 are repeated for cyclic winding. When the winding coil is a single-turn coil, winding is stopped.
2. The method for winding the conductor for a valve reactor as described in claim 1, characterized in that: The distance between the winding shaft and the winding wheel is equal to the sum of the radius of the winding tower block and the thickness of the conductor, so that the conductor can be wound between the winding wheel and the winding tower block.
3. The method for winding the conductor for a valve reactor as described in claim 1, characterized in that: Each of the winding tower blocks also includes a winding groove disposed on the side wall of the main body of the winding tower block, and a tower block limiting flange disposed at one end of the insertion hole.
4. The method for winding the conductor for a valve reactor as described in claim 3, characterized in that: The winding wheel includes a winding wheel body and a winding groove disposed on the side wall of the winding wheel.
5. The method for winding the conductor for a valve reactor as described in claim 4, characterized in that: When the winding shaft is inserted into the insertion hole of the winding tower block and the limiting hole of the winding base, the winding groove and the winding slot of the winding tower block are on the same horizontal plane.
6. The method for winding the conductor for a valve reactor as described in claim 5, characterized in that: The shim block includes a shim block body, a shim block insertion hole disposed on the shim block body, and a shim block limiting flange disposed on the inner sidewall of one end of the shim block insertion hole. The shim block insertion hole and the shim block limiting flange are concentrically disposed, and the outer diameter of the shim block limiting flange is smaller than the diameter of the limiting hole. The diameter of the tower block limiting flange is smaller than the insertion hole and the shim block insertion hole.
7. The method for winding the conductor for a valve reactor as described in claim 1, characterized in that: The outer contour of the winding tower block is semi-circular.
8. The method for winding the conductor for a valve reactor as described in claim 1, characterized in that: In step S130, the shim block on the next winding station will make the height difference between the winding tower block of the next station and the winding tower block of the initial winding station greater than the diameter of the conductor.