A three-dimensional wound iron core resin cast dry-type transformer and its manufacturing method

Abstract

The present invention discloses a three-dimensional wound core resin cast dry-type transformer and a manufacturing method thereof. The dry-type transformer comprises a three-dimensional wound core body mainly composed of three core columns arranged in a herringbone shape, each core column of the core body is provided with a low-voltage coil on the inside and a high-voltage coil on the outside, the low-voltage coil and the high-voltage coil on each core column are cast by epoxy resin into an inseparable integral structure, and a plurality of air passages capable of taking into account the main insulation function and the heat dissipation function are arranged in an annular direction between the low-voltage coil and the high-voltage coil in an inner and outer double-layer structure. The present invention is directed to a three-dimensional wound core, which has the characteristics of compact structure (small size, beautiful appearance), excellent electrical strength (high insulation strength, strong short-circuit resistance), excellent moisture-proof (corrosion-resistant) performance, excellent heat dissipation performance, high mechanical strength, etc., which is conducive to the promotion and application of three-dimensional wound core resin cast dry-type transformers in the market.

Description

Technical Field

[0001] The invention relates to a transformer, in particular to a three-dimensional wound iron core resin cast dry-type transformer and a manufacturing method of the transformer. Background Art

[0002] The transformer is mainly composed of a three-phase iron core column and low-voltage coils and high-voltage coils wound on the corresponding iron core columns. The iron core column serves as the magnetic circuit of the transformer, and the low-voltage coils and high-voltage coils serve as the windings of the transformer. The three-dimensional wound iron core is a three-phase iron core column arranged in a triangular shape and composed of three closed loops. The three-dimensional wound iron core dry-type transformer is favored by users for its high efficiency, energy saving, and low noise.

[0003] Generally speaking, if the winding of a resin-cast dry-type transformer is integrally cast with epoxy resin, it will have the characteristics of compact structure, good electrical strength, excellent moisture resistance, high mechanical strength, etc. This is most common in resin-cast dry-type transformers with planar laminated cores, such as the "High and Low Voltage Integral Coil Dry-Type Transformer" disclosed in the Chinese patent document (publication number CN 101083168, publication date December 5, 2007). However, due to the characteristics of the three-dimensional wound core formed by the closed-loop structure, if the winding is integrally cast with epoxy resin, the technical operation of the process links such as casting mold, demoulding and sealing is very difficult and difficult to achieve easily and economically. Therefore, the low-voltage coil of the common three-dimensional wound core resin-cast dry-type transformer is generally not resin-cast, and only the high-voltage coil is resin-cast, which greatly reduces its electrical strength, moisture resistance and mechanical strength.

[0004] In addition, the main insulation between the high and low voltage windings of the common three-dimensional wound core resin cast dry-type transformer is achieved by a half-combined structure insulation cylinder arranged between the high-voltage coil and the low-voltage coil. This is because the closed-loop structure characteristics of the three-dimensional wound core make it impossible to fit the insulation cylinder of the whole circular structure. The insulation cylinder can only be designed as a split structure that can be assembled in half for assembly. This process measure is very technically difficult and has high manufacturing costs. At the same time, there are technical problems such as low insulation strength and unsightly appearance.

[0005] In summary, these technical problems have largely restricted the promotion and application of three-dimensional wound core resin cast dry-type transformers in the market. Summary of the invention

[0006] The technical purpose of the present invention is to provide a three-dimensional wound iron core resin cast dry-type transformer with compact structure, good electrical strength, excellent moisture resistance and heat dissipation performance, and high mechanical strength, as well as a low-cost manufacturing method for the transformer in view of the particularity of the above-mentioned three-dimensional wound iron core and the shortcomings of the prior art.

[0007] The technical purpose of the present invention can be achieved through the following various technical solutions.

[0008] The first technical solution is a three-dimensional wound core resin-cast dry-type transformer, including a three-dimensional wound core body mainly composed of three core columns arranged in a herringbone shape, each core column of the core body is provided with a low-voltage coil on the inner side and a high-voltage coil on the outer side, the low-voltage coil is a wire-wound structure, the low-voltage coil and the high-voltage coil on each core column are cast by epoxy resin to form an inseparable integral structure, and a plurality of air ducts are arranged in an annular direction between the low-voltage coil and the high-voltage coil in an inner and outer double-layer structure, which can take into account both the main insulation function and the heat dissipation function.

[0009] A method for manufacturing the above-mentioned three-dimensional wound core resin cast dry-type transformer, the manufacturing method comprising the following process steps:

[0010] Step 1. Clamp the core body and assemble the winding mold on the corresponding core column;

[0011] The winding mold is mainly composed of an inner mold composed of multiple arc-shaped plates that can match the corresponding iron core column, a radial plate 1 connected to one end of the inner mold and extending radially outward, a radial plate 2 connected to the other end of the inner mold and extending radially outward, and an outer mold that matches the outer edge of the radial plate 1 and the outer edge of the radial plate 2 and is to be used during the winding process. The radial plate 2 is provided with a plurality of airway rod perforations in an inner and outer double-layer circumferential arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area;

[0012] Step 2. Winding the first insulation layer, the low-voltage electromagnetic wire and the interlayer insulation, and the fourth insulation layer on the inner mold in sequence;

[0013] The low-voltage inlet and outlet wires of the low-voltage coil are made of the electromagnetic wire of the original coil;

[0014] Step 3. Insert the inner airway sticks into the inner airway stick holes on the second spoke plate, with the insertion ends of the inner airway sticks pressed against the first spoke plate;

[0015] Step 4. Winding an insulating layer 5 on the inner airway rod;

[0016] Step 5. Insert the outer airway sticks into the outer airway stick perforations on the second spoke plate, with the insertion ends of the outer airway sticks pressed against the first spoke plate;

[0017] Step 6. Winding the sixth insulation layer, the high-voltage electromagnetic wire and the interlayer insulation, and the ninth insulation layer on the outer airway rod in sequence;

[0018] Step 7. Assembling an outer mold on the winding mold;

[0019] The inner mold, the first radial plate, the second radial plate and the outer mold of the winding mold form a pouring space capable of pouring epoxy resin;

[0020] Step 8. Perform true drying in a vacuum casting device;

[0021] Vacuum pouring epoxy resin into the mold cavity of the winding mold;

[0022] Step 9. Use a curing furnace to perform curing treatment;

[0023] Step 10. Remove the winding die;

[0024] The low-voltage coil and the high-voltage coil on the corresponding core column are cast with epoxy resin to form an inseparable integral structure;

[0025] Step 11. Repeat the above steps to make a low-voltage coil and a high-voltage coil of an integral structure on the next core column on the core body;

[0026] Until the low-voltage coils and high-voltage coils of the integral structures on the three-phase core columns of the core body are respectively manufactured and formed.

[0027] The second technical solution is a three-dimensional wound core resin cast dry-type transformer, comprising a three-dimensional wound core body mainly composed of three core columns arranged in a herringbone shape, each core column of the core body is provided with a low-voltage coil on the inner side and a high-voltage coil on the outer side, the low-voltage coil is a foil-wound structure, the low-voltage incoming line and the low-voltage outgoing line of the low-voltage coil are respectively composed of a plurality of arc-shaped thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm stacked and combined, the low-voltage incoming line and the low-voltage outgoing line are tightly welded on the copper foil / aluminum foil on the corresponding side of the low-voltage coil; the low-voltage coil and the high-voltage coil on each core column are cast by epoxy resin into an inseparable integral structure, and a plurality of air ducts capable of taking into account both the main insulation function and the heat dissipation function are arranged circumferentially between the low-voltage coil and the high-voltage coil in an inner and outer double-layer structure.

[0028] A method for manufacturing the above-mentioned three-dimensional wound core resin cast dry-type transformer, the manufacturing method comprising the following process steps:

[0029] Step 1. Clamp the core body and assemble the winding mold on the corresponding core column;

[0030] The winding mold is mainly composed of an inner mold composed of multiple arc-shaped plates that can match the corresponding iron core column, a radial plate 1 connected to one end of the inner mold and extending radially outward, a radial plate 2 connected to the other end of the inner mold and extending radially outward, and an outer mold that matches the outer edge of the radial plate 1 and the outer edge of the radial plate 2 and is to be used during the winding process. The radial plate 2 is provided with a plurality of airway rod perforations in an inner and outer double-layer circumferential arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area;

[0031] Step 2. Winding an insulating layer 1 on the inner mold;

[0032] Based on the outer circle formed by the inner mold, several thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form a low-voltage coil, forming a low-voltage inlet line on the low-voltage coil foil;

[0033] Winding low-voltage foil and interlayer insulation on the first insulation layer, the low-voltage incoming wire is located on the inner wall of the low-voltage coil in a tangential structure;

[0034] Taking the outer circle formed by the low-voltage coil as a reference, several thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form the low-voltage coil, and a low-voltage outlet line is formed on the low-voltage coil foil material;

[0035] Winding an insulating layer 4 on the low-voltage foil and interlayer insulation;

[0036] Step 3. Insert the inner airway sticks into the inner airway stick holes on the second spoke plate, with the insertion ends of the inner airway sticks pressed against the first spoke plate;

[0037] Step 4. Winding an insulating layer 5 on the inner airway rod;

[0038] Step 5. Insert the outer airway sticks into the outer airway stick perforations on the second spoke plate, with the insertion ends of the outer airway sticks pressed against the first spoke plate;

[0039] Step 6. Winding the sixth insulation layer, the high-voltage electromagnetic wire and the interlayer insulation, and the ninth insulation layer on the outer airway rod in sequence;

[0040] Step 7. Assembling an outer mold on the winding mold;

[0041] The inner mold, the first radial plate, the second radial plate and the outer mold of the winding mold form a pouring space capable of pouring epoxy resin;

[0042] Step 8. Perform true drying in a vacuum casting device;

[0043] Vacuum pouring epoxy resin into the mold cavity of the winding mold;

[0044] Step 9. Use a curing furnace to perform curing treatment;

[0045] Step 10. Remove the winding die;

[0046] The low-voltage coil and the high-voltage coil on the corresponding core column are cast with epoxy resin to form an inseparable integral structure;

[0047] Step 11. Repeat the above steps to make a low-voltage coil and a high-voltage coil of an integral structure on the next core column on the core body;

[0048] Until the low-voltage coils and high-voltage coils of the integral structures on the three-phase core columns of the core body are respectively manufactured and formed.

[0049] The third technical solution is a three-dimensional wound core resin cast dry-type transformer, comprising an iron core body mainly composed of three iron core columns arranged in a herringbone shape, each iron core column of the iron core body is provided with a low-voltage coil on the inner side and a high-voltage coil on the outer side, the low-voltage coil is a foil-wound structure, the low-voltage incoming line and the low-voltage outgoing line of the low-voltage coil are respectively composed of a plurality of arc-shaped thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm stacked and combined, the low-voltage incoming line and the low-voltage outgoing line are tightly welded on the copper foil / aluminum foil on the corresponding side of the low-voltage coil; the low-voltage coil and the high-voltage coil on each iron core column are cast by epoxy resin into an inseparable integral structure, and a plurality of air ducts capable of taking into account the main insulation function and the heat dissipation function are arranged circumferentially between the low-voltage coil and the high-voltage coil in an inner and outer double-layer structure, and a plurality of low-voltage side air ducts are arranged circumferentially inside the low-voltage coil.

[0050] A method for manufacturing the above-mentioned three-dimensional wound core resin cast dry-type transformer, the manufacturing method comprising the following process steps:

[0051] Step 1. Clamp the core body and assemble the winding mold on the corresponding core column;

[0052] The winding mold is mainly composed of an inner mold composed of multiple arc-shaped plates that can match the corresponding iron core column, a radial plate 1 connected to one end of the inner mold and extending radially outward, a radial plate 2 connected to the other end of the inner mold and extending radially outward, and an outer mold that matches the outer edge of the radial plate 1 and the outer edge of the radial plate 2 and is to be used during the winding process, a plurality of airway rod through-holes are opened on the radial plate 2 in a circumferential arrangement structure corresponding to the center of the low-voltage coil winding area, and a plurality of airway rod through-holes are opened on the radial plate 2 in a circumferential arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area.

[0053] Step 2. Winding an insulating layer 1 on the inner mold;

[0054] Based on the outer circle formed by the inner mold, several thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form a low-voltage coil, forming a low-voltage inlet line on the low-voltage coil foil;

[0055] Winding low-voltage foil and interlayer insulation on the first insulation layer, the low-voltage incoming wire is located on the inner wall of the low-voltage coil in a tangential structure;

[0056] Winding a second insulating layer on the low-voltage foil and interlayer insulation;

[0057] Step 3. Insert low-pressure side airway sticks into the through holes of the low-pressure side airway sticks on the second spoke plate, with the insertion ends of the low-pressure side airway sticks pressed against the first spoke plate;

[0058] Step 4. Winding the third insulation layer, the low-voltage foil material and the interlayer insulation on the low-pressure side airway rod in sequence;

[0059] The low-pressure coil foil material inside the low-pressure side airway stick and the low-pressure coil foil material outside are continuous and uninterrupted;

[0060] Taking the outer circle formed by the low-voltage coil as a reference, several thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form the low-voltage coil, and a low-voltage outlet line is formed on the low-voltage coil foil material;

[0061] Winding an insulating layer 4 on the low-voltage foil and interlayer insulation;

[0062] Step 5. Insert the inner airway sticks into the inner airway stick holes on the second spoke plate, with the insertion ends of the inner airway sticks pressed against the first spoke plate;

[0063] Step 6. Winding an insulating layer 5 on the inner airway rod;

[0064] Step 7. Insert the outer airway sticks into the outer airway stick perforations on the second spoke plate, with the insertion ends of the outer airway sticks pressed against the first spoke plate;

[0065] Step 8. Winding the sixth insulation layer, the high voltage electromagnetic wire and the interlayer insulation, and the ninth insulation layer on the outer airway rod in sequence;

[0066] Step 9. Assembling an outer mold on the winding mold;

[0067] The inner mold, the first radial plate, the second radial plate and the outer mold of the winding mold form a pouring space capable of pouring epoxy resin;

[0068] Step 10. Perform true drying in a vacuum casting device;

[0069] Vacuum pouring epoxy resin into the mold cavity of the winding mold;

[0070] Step 11. Perform curing in a curing furnace;

[0071] Step 12. Remove the winding die;

[0072] The low-voltage coil and the high-voltage coil on the corresponding core column are cast with epoxy resin to form an inseparable integral structure;

[0073] Step 13. Repeat the above steps to make a low-voltage coil and a high-voltage coil of an integral structure on the next core column on the core body;

[0074] Until the low-voltage coils and high-voltage coils of the integral structures on the three-phase core columns of the core body are respectively manufactured and formed.

[0075] A fourth technical solution is a three-dimensional wound core resin cast dry-type transformer, comprising a three-dimensional wound core body mainly composed of three core columns arranged in a herringbone shape, each core column of the core body is provided with a low-voltage coil on the inner side and a high-voltage coil on the outer side, the low-voltage coil is a foil-wound structure, the low-voltage incoming line and the low-voltage outgoing line of the low-voltage coil are respectively composed of a plurality of arc-shaped thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm stacked and combined, the low-voltage incoming line and the low-voltage outgoing line are tightly welded on the copper foil / aluminum foil on the corresponding side of the low-voltage coil; the low-voltage coil and the high-voltage coil on each core column are cast by epoxy resin into an inseparable integral structure, and a plurality of air ducts capable of taking into account both the main insulation function and the heat dissipation function are arranged circumferentially between the low-voltage coil and the high-voltage coil in an inner and outer double-layer structure, and a plurality of high-voltage side air ducts are arranged circumferentially inside the high-voltage coil.

[0076] A method for manufacturing the above-mentioned three-dimensional wound core resin cast dry-type transformer, the manufacturing method comprising the following process steps:

[0077] Step 1. Clamp the core body and assemble the winding mold on the corresponding core column;

[0078] The winding mold is mainly composed of an inner mold composed of multiple arc-shaped plates that can match the corresponding iron core column, a radial plate 1 connected to one end of the inner mold and extending radially outward, a radial plate 2 connected to the other end of the inner mold and extending radially outward, and an outer mold that matches the outer edge of the radial plate 1 and the outer edge of the radial plate 2 and is to be used during the winding process, a plurality of airway rod through-holes are opened on the radial plate 2 in a ring-shaped arrangement structure corresponding to the center of the high-voltage coil winding area, and a plurality of airway rod through-holes are opened on the radial plate 2 in a ring-shaped arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area.

[0079] Step 2. Winding an insulating layer 1 on the inner mold;

[0080] Based on the outer circle formed by the inner mold, several thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form a low-voltage coil, forming a low-voltage inlet line on the low-voltage coil foil;

[0081] Winding low-voltage foil and interlayer insulation on the first insulation layer, the low-voltage incoming wire is located on the inner wall of the low-voltage coil in a tangential structure;

[0082] Taking the outer circle formed by the low-voltage coil as a reference, several thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form the low-voltage coil, and a low-voltage outlet line is formed on the low-voltage coil foil material;

[0083] Winding an insulating layer 4 on the low-voltage foil and interlayer insulation;

[0084] Step 3. Insert the inner airway sticks into the inner airway stick holes on the second spoke plate, with the insertion ends of the inner airway sticks pressed against the first spoke plate;

[0085] Step 4. Winding an insulating layer 5 on the inner airway rod;

[0086] Step 5. Insert the outer airway sticks into the outer airway stick perforations on the second spoke plate, with the insertion ends of the outer airway sticks pressed against the first spoke plate;

[0087] Step 6. Winding the sixth insulating layer, the high-voltage electromagnetic wire and the interlayer insulation, and the seventh insulating layer on the outer airway rod in sequence;

[0088] Step 7. Insert the high-pressure side airway rods into the through holes of the high-pressure side airway rods on the second spoke plate, with the insertion ends of the high-pressure side airway rods pressed against the first spoke plate;

[0089] Step 8. Winding the insulation layer eight, the high-voltage electromagnetic wire and the interlayer insulation, and the insulation layer nine on the high-voltage side airway rod in sequence; connecting the high-voltage electromagnetic wire inside the high-voltage side airway rod and the high-voltage electromagnetic wire outside;

[0090] Step 9. Assembling an outer mold on the winding mold;

[0091] The inner mold, the first radial plate, the second radial plate and the outer mold of the winding mold form a pouring space capable of pouring epoxy resin;

[0092] Step 10. Perform true drying in a vacuum casting device;

[0093] Vacuum pouring epoxy resin into the mold cavity of the winding mold;

[0094] Step 11. Perform curing in a curing furnace;

[0095] Step 12. Remove the winding die;

[0096] The low-voltage coil and the high-voltage coil on the corresponding core column are cast with epoxy resin to form an inseparable integral structure;

[0097] Step 13. Repeat the above steps to make a low-voltage coil and a high-voltage coil of an integral structure on the next core column on the core body;

[0098] Until the low-voltage coils and high-voltage coils of the integral structures on the three-phase core columns of the core body are respectively manufactured and formed.

[0099] The beneficial technical effects of the present invention are:

[0100] 1. The present invention is directed to a three-dimensional wound core, and the high and low voltage coils of the winding on the core column are cast with epoxy resin to form an inseparable integral structure. The main insulation area between the low voltage coil and the high voltage coil forms a plurality of air passages arranged in a double-layer ring. The air passage structure serves as the main insulation between the high and low voltage coils. Compared with the traditional insulation cylinder structure, it can obtain better electrical strength and mechanical strength at a low cost (including process and material aspects), so that the present invention has the characteristics of compact structure (small size, beautiful appearance), excellent electrical strength (high insulation strength, strong short circuit resistance), excellent moisture (corrosion) performance, excellent heat dissipation performance, high mechanical strength, etc., which is conducive to the promotion and application of three-dimensional wound core resin cast dry-type transformers in the market;

[0101] 2. The low-voltage coil of the present invention adopts the formation of a foil coil that helps to increase the capacity of the transformer; its inlet / outlet wires are easy to fold and hide, and there is no need to increase the core window height and the core column distance, and a higher current carrying capacity can be obtained through the skin effect of the current, that is, the compact structure of the core body can reliably realize the formation of a low-voltage foil coil with better performance and help to increase the capacity of the transformer, and the formed transformer is small in size and low in cost;

[0102] 3. The present invention forms a heat dissipation air channel inside the low-voltage coil or the high-voltage coil which helps to increase the transformer capacity structure, thereby effectively enhancing its heat dissipation performance, thereby ensuring that it can operate stably and reliably;

[0103] 4. The manufacturing method of the present invention can manufacture a transformer of a corresponding structure in a simple, efficient and economical manner, and has good economy, which is conducive to the promotion and application of the manufactured three-dimensional wound iron core resin cast dry-type transformer in the market. BRIEF DESCRIPTION OF THE DRAWINGS

[0104] Figure 1 It is a structural schematic diagram of the present invention (low-voltage coil wire-wound structure).

[0105] Figure 2 for Figure 1 Schematic diagram of the winding mold structure used for transformer manufacturing (outer mold not shown).

[0106] Figure 3 for Figure 1 A schematic diagram of a transformer in a state during the manufacturing process is shown.

[0107] Figure 4 It is another structural schematic diagram of the present invention (low-voltage coil foil-wound structure).

[0108] Figure 5 for Figure 4 Schematic diagram of the winding mold structure used for transformer manufacturing (outer mold not shown).

[0109] Figure 6 for Figure 4 A schematic diagram of a transformer in a state during the manufacturing process is shown.

[0110] Meaning of the codes in the figure: 1—core body; 11—core column A; 12—core column B; 13—core column C; 2—low-voltage coil; 21—low-voltage incoming line; 22—low-voltage outgoing line; 23—insulation layer one; 24—low-voltage electromagnetic wire and interlayer insulation; 25—insulation layer two; 26—insulation layer three; 27—insulation layer four; 28—low-voltage side airway; 29—low-voltage foil and interlayer insulation; 3—airway; 31—inner airway; 32—outer airway; 33—insulation layer five; 4—high-voltage coil; 41—insulation Layer six; 42—high-voltage electromagnetic wire and interlayer insulation; 43—insulation layer seven; 44—insulation layer eight; 45—insulation layer nine; 5—winding mold; 51—inner mold; 52—spoke plate one; 53—gear ring one; 54—spoke plate two; 55—gear ring two; 56—inner airway rod perforation; 57—outer airway rod perforation; 58—inner airway rod; 59—outer airway rod; 510—low-pressure side airway rod perforation; 511—high-pressure side airway rod perforation; 512—low-pressure side airway rod; 513—high-pressure side airway rod. DETAILED DESCRIPTION

[0111] The present invention relates to a three-dimensional wound core resin cast dry-type transformer and a method for manufacturing the transformer. The main technical content of the present invention is described in detail with multiple embodiments below. Figure 1 , Figure 2 and Figure 3 The technical solution of the present invention is clearly and in detail explained; although the second embodiment does not have a separate drawing, its main structure can still refer to the drawing of the first embodiment; the third embodiment is combined with the drawings of the specification - that is, Figure 4 , Figure 5 and Figure 6 The technical solution of the present invention is clearly and in detail explained; Example 4 is combined with the accompanying drawings of the specification - that is, Figure 4 , Figure 5 and Figure 6 The technical solution of the present invention is explained clearly and in detail.

[0112] It should be particularly noted that the drawings of the present invention are schematic, and unnecessary details have been simplified to clarify the technical purpose of the present invention so as to avoid blurring the technical solution that the present invention contributes to the prior art.

[0113] Example 1

[0114] See also Figure 1 , Figure 2 and Figure 3As shown, the present invention includes a core body 1 of a three-dimensional wound core structure, that is, the core body 1 is mainly composed of three single-frame closed-loop cores connected together and arranged in a herringbone shape, namely, core columns A11, B12, and C13. A set of windings is arranged on each core column, and the windings are composed of a low-voltage coil 2 on the inside and a high-voltage coil 4 on the outside; the low-voltage coil 2 is a wire-wound structure, and its low-voltage incoming wire 21 and low-voltage outgoing wire 22 are directly made of the electromagnetic wire of the low-voltage coil 2.

[0115] The low-voltage coil 2 and the high-voltage coil 4 on each of the above-mentioned core columns are cast by epoxy resin to form an inseparable integral structure, that is, the low-voltage coil 2 and the high-voltage coil 4 constituting the winding on the core column are cured by the co-cast epoxy resin to form an inseparable integral structure. At the same time, in the main insulation area between the low-voltage coil 2 and the high-voltage coil 4, a number of air channels 3 are arranged in an annular direction with an inner and outer double-layer structure, and these air channels 3 are formed by integral casting of the high and low voltage coils; adjacent inner air channels 31 or adjacent outer air channels 32 are separated by epoxy resin respectively, and the inner air channel 31 and the outer air channel 32 are separated by an insulating layer 5 33 and the epoxy resin attached to the insulating layer 5 33, and the inner air channel 31 and the outer air channel 32 are in a one-to-one matching relationship; the cross-section of each of the aforementioned air channels 3 is a rectangular hole structure with rounded corners or a waist-shaped hole structure with semicircular ends, which can effectively prevent the outer diameter of the entire winding from being too large; the double-layer structure air channel 3 between the low-voltage coil 2 and the high-voltage coil 4 takes into account the main insulation function and the heat dissipation function, so that while forming the main insulation, it can also effectively increase the heat dissipation area between the high and low voltage coils, so as to reduce the problem of the coil burning due to insulation thermal aging due to insufficient heat dissipation during operation.

[0116] The reason why the double-layer structure air duct 3 is used between the low-voltage coil 2 and the high-voltage coil 4 is that the main insulation between the high and low voltage coils (i.e., the highest voltage) is mainly guaranteed by the air in the gap (distance) between the high and low voltage coils. The strength of air insulation is much lower than that of epoxy resin. Therefore, to achieve the same insulation strength, the gap (distance) must be increased. If an insulating cylinder is set between the high and low voltage coils, the gap (distance) can be reduced. In order to reduce the product volume and reduce costs, an insulating cylinder is generally set and supported and fixed on the outer surface of the low-voltage coil with several struts. However, compared with the double-layer structure air duct 3, the electrical strength and mechanical strength of this structure are obviously insufficient, and the process cost and material cost are higher than the double-layer structure air duct 3. If the double-layer structure air duct 3 is replaced by other layers, for a 10kV-class transformer, its cost will be much higher than the double-layer structure air duct 3.

[0117] The manufacturing method of the above-mentioned three-dimensional wound core resin cast dry-type transformer includes the following process steps (assuming that the manufacturing process is first the core column A11, then the core column B12, and finally the core column C13):

[0118] Step 1. Clamp the core body 1 and assemble the winding mold 5 on the core column A11;

[0119] The winding mold 5 is mainly composed of an inner mold 51 composed of multiple (usually three or four equally divided) arc-shaped plates that can match the core column A11, a radial plate 52 connected to one end of the inner mold 51 and extending radially outward, a radial plate 2 54 connected to the other end of the inner mold 51 and extending radially outward, and an outer mold that matches the outer edges of the radial plate 1 52 and the radial plate 2 54 and is on standby during the winding process; the radial plate 1 52 is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction, and the outer edge of the radial plate 1 52 is connected to a gear ring 1 53 in a detachable structure by fastening screws, etc. The gear ring 1 53 is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction. The outer mold is mainly composed of two separate parts that can be connected to form a full circle; the second spoke plate 54 is mainly composed of two separate parts that can be connected to form a full circle in the circumferential direction, and the outer edge of the second spoke plate 54 is connected to the second gear ring 55 in a detachable structure by fastening screws, etc., and the second gear ring 55 is mainly composed of two separate parts that can be connected to form a full circle in the circumferential direction; the outer mold is mainly composed of two separate parts that can be connected to form a full circle in the circumferential direction; the second spoke plate 54 is provided with a plurality of airway rod perforations in an inner and outer double-layer circumferential arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area, namely, the inner airway rod perforation 56 and the outer airway rod perforation 57;

[0120] Step 2. Winding the insulation layer 1 23, the low voltage electromagnetic wire and the interlayer insulation 24, and the insulation layer 4 27 on the inner mold 51 in sequence;

[0121] The insulating layer 1 23 is usually a 0.5 mm thick glass cloth plate or a 0.5-1 mm (e.g., 0.5 mm, 0.8 mm, or 1 mm, etc.) thick PET; when the insulating layer 1 23 is wound, the interface needs to be tightly bonded, and the gap between the insulating layer 1 23 and the spoke plate 1 52 and the spoke plate 2 54 needs to be sealed with a sealant;

[0122] In the process of winding the low-voltage electromagnetic wire and the interlayer insulation 24, the low-voltage incoming wire 21 and the low-voltage outgoing wire 22 are made from the original coil electromagnetic wire of the low-voltage coil 2, the low-voltage incoming wire 21 is located inside the low-voltage coil 2, and the low-voltage outgoing wire 22 is located outside the low-voltage coil 2;

[0123] The number of turns of the low voltage coil 2 is determined according to the design requirements;

[0124] The insulating layer 27 is an insulating mesh cloth structure;

[0125] Step 3. Insert the inner airway rods 58 into the inner airway rod through holes 56 on the second spoke plate 54, with the insertion ends of the inner airway rods 58 pressed against the first spoke plate 52 in a vertical fit manner, and the non-insertion ends of the inner airway rods 58 extending out of the second spoke plate 54;

[0126] The cross section of each inner airway rod 58 is a rectangular structure with rounded corners (or a "racetrack" structure with semicircular ends is used instead);

[0127] Step 4. Winding an insulating layer 53 on the inner airway rod 58;

[0128] The insulating layer five 33 is an insulating mesh cloth structure;

[0129] Step 5. Insert the outer airway rods 59 into the outer airway rod through holes 57 on the second spoke plate 54, with the insertion ends of the outer airway rods 59 pressed against the first spoke plate 52 in a vertical fit manner, and the non-insertion ends of the outer airway rods 59 extending out of the second spoke plate 54;

[0130] The cross section of each outer airway rod 59 is a rectangular structure with rounded corners (or a "runway" structure with semicircular ends is used instead);

[0131] Step 6. Wind the insulation layer 6 41, the high voltage electromagnetic wire and the interlayer insulation 42, and the insulation layer 9 45 on the outer airway rod 59 in sequence, and weld the terminal block;

[0132] The insulation layer six 41 and the insulation layer nine 45 are respectively an insulation mesh cloth structure;

[0133] The number of turns of the high voltage coil 4 is determined according to the design requirements;

[0134] Step 7. Assemble the outer mold on the winding mold 5 by tightening screws, etc.;

[0135] The inner mold 51, the first spoke plate 52, the second spoke plate 54 and the outer mold of the winding mold 5 form a pouring space capable of pouring epoxy resin;

[0136] Step 8. Perform true drying in a vacuum casting device;

[0137] Vacuum pouring epoxy resin into the mold cavity of the winding mold 5;

[0138] Step 9. Use a curing furnace to perform curing treatment;

[0139] Step 10. Dismantle the winding mold 5, including dismantling the outer mold, removing the inner and outer airway rods, dismantling the spoke plate 1 52, dismantling the spoke plate 2 55, dismantling the inner mold 51, etc.;

[0140] The low-voltage coil 2 and the high-voltage coil 4 on the core column A11 are cast with epoxy resin to form the above-mentioned inseparable integral structure;

[0141] Step 11. Repeat the above steps to make the low-voltage coil 2 and the high-voltage coil 4 of the integral structure on the core column B12 of the core body 1;

[0142] Step 12. Repeat the above steps 1 to 10 to manufacture the low-voltage coil 2 and the high-voltage coil 4 of the integral structure on the core column C12 of the core body 1;

[0143] At this point, the low-voltage coils 2 and high-voltage coils 4 of the integral structures on the three-phase core columns of the core body 1 are respectively manufactured and formed.

[0144] Through the above manufacturing method, it can be seen that the high and low voltage coils of each phase winding on the core body share the same set of molds for winding and casting, and the low voltage coil, main insulation and high voltage coil can finally be integrally formed with high strength, which is economical.

[0145] Example 2

[0146] The present invention includes a core body of a three-dimensional winding structure, that is, the core body is mainly composed of three single-frame closed-loop cores connected together and arranged in a herringbone shape, namely, core columns A, B, and C. A set of windings is arranged on each core column, and the windings are composed of a low-voltage coil on the inside and a high-voltage coil on the outside; the low-voltage coil is a foil-wound structure of copper foil (or aluminum foil), and its low-voltage incoming wire and low-voltage outgoing wire are respectively composed of a plurality of thin copper strips (thin aluminum strips) in an arc shape (having a certain width to form an arc shape) and a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) superimposed and combined, and the low-voltage incoming wire and the low-voltage outgoing wire are closely welded to the copper foil (aluminum foil) on the corresponding side of the low-voltage coil. Usually, the low-voltage incoming wire is on the inside of the low-voltage coil, and the low-voltage outgoing wire is on the outside of the low-voltage coil;

[0147] The low-voltage coil and the high-voltage coil on each of the above-mentioned core columns are cast with epoxy resin to form an inseparable integral structure, that is, the low-voltage coil and the high-voltage coil constituting the winding on the core column are solidified by the co-cast epoxy resin to form an inseparable integral structure. At the same time, in the main insulation area between the low-voltage coil and the high-voltage coil, a number of air ducts are arranged in an annular direction with an inner and outer double-layer structure, and these air ducts are formed by integral casting of the high and low voltage coils; adjacent inner air ducts or adjacent outer air ducts are separated by epoxy resin respectively, and the inner air duct and the outer air duct are separated by an insulating layer five and the epoxy resin attached to the insulating layer five, and the inner air duct and the outer air duct are in a one-to-one corresponding relationship; the cross-section of each of the aforementioned air ducts is a rectangular hole structure with rounded corners or a waist-shaped hole structure with semicircular ends, which can effectively prevent the outer diameter of the entire winding from being too large; the double-layer structure air duct between the low-voltage coil and the high-voltage coil takes into account the main insulation function and the heat dissipation function, so that while forming the main insulation, it can also effectively increase the heat dissipation area between the high and low voltage coils, thereby reducing the problem of the coil burning due to insulation thermal aging due to insufficient heat dissipation during operation.

[0148] The reason why a double-layer structure air duct is used between the low-voltage coil and the high-voltage coil is that the main insulation between the high-voltage and low-voltage coils (i.e. the place with the highest voltage) is mainly guaranteed by the air in the gap (distance) between the high-voltage and low-voltage coils. The strength of air insulation is much lower than that of epoxy resin. Therefore, to achieve the same insulation strength, the gap (distance) must be increased. If an insulating cylinder is set between the high-voltage and low-voltage coils, the gap (distance) can be reduced. In order to reduce the product volume and reduce costs, an insulating cylinder is generally set and supported and fixed on the outer surface of the low-voltage coil with several struts. However, compared with the double-layer structure air duct, the electrical strength and mechanical strength of this structure are obviously insufficient, and the process cost and material cost are higher than the double-layer structure air duct. If the double-layer structure air duct is replaced by other layers, for a 10kV transformer, its cost will be much higher than the double-layer structure air duct.

[0149] The manufacturing method of the above-mentioned three-dimensional wound core resin cast dry-type transformer includes the following process steps (assuming that the manufacturing process is first the core column A, then the core column B, and finally the core column C):

[0150] Step 1. Clamp the core body and assemble the winding die on the core column A;

[0151] The winding die mainly consists of an inner die composed of multiple (usually three or four equally divided) arc-shaped plates that can match the core column A, a radial plate 1 connected to one end of the inner die and extending radially outward, a radial plate 2 connected to the other end of the inner die and extending radially outward, and an outer die that matches the outer edges of the radial plate 1 and the radial plate 2 and is to be used during the winding process; the radial plate 1 is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction, and the outer edge of the radial plate 1 is connected to a gear ring 1 in a detachable structure through fastening screws, etc. The gear ring 1 is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction. The outer mold is mainly composed of two separate parts that can be butted together to form a full circle; the spoke plate 2 is mainly composed of two separate parts that can be butted together to form a full circle in the circumferential direction; the spoke plate 2 is mainly composed of two separate parts that can be butted together to form a full circle in the circumferential direction; the spoke plate 2 is mainly composed of two separate parts that can be butted together to form a full circle in the circumferential direction; the spoke plate 2 is provided with a plurality of airway rod perforations in an inner and outer double-layer circumferential arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area, namely, the inner airway rod perforations and the outer airway rod perforations;

[0152] Step 2. Wind the insulation layer 1 on the inner mold; the insulation layer 1 is usually a 0.5mm thick glass cloth plate or a 0.5-1mm (such as 0.5mm, 0.8mm or 1mm, etc.) thick PET; when winding the insulation layer 1, the interface needs to be tightly bonded, and the gap between the insulation layer 1 and the spoke plate 1 and the spoke plate 2 needs to be sealed with a sealant;

[0153] Based on the outer circle formed by the inner mold, several thin copper strips (or thin aluminum strips) with a certain width and a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) are pressed into an arc structure, and these thin copper strips (or thin aluminum strips) are superimposed and combined together, and welded and combined with the foil material - copper foil (or aluminum foil) that can form a low-voltage coil, to form a low-voltage inlet line on the low-voltage coil foil;

[0154] The low-voltage foil and interlayer insulation are wound on the first insulation layer, and the low-voltage incoming wire is placed on the inner wall of the low-voltage coil in a tangential structure;

[0155] Taking the outer circle formed by the low-voltage coil as a reference, several thin copper strips (or thin aluminum strips) with a certain width and a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) are pressed into an arc structure, and these thin copper strips (or thin aluminum strips) are superimposed and combined together, and closely welded and combined with the foil material - copper foil (or aluminum foil) that can form the low-voltage coil, so as to form a low-voltage outlet line on the low-voltage coil foil;

[0156] The number of turns of the low-voltage coil is determined according to the design requirements;

[0157] Winding an insulating layer 4 on the low-voltage foil material and the interlayer insulation; the insulating layer 4 is an insulating mesh cloth structure;

[0158] Step 3. Insert the inner airway sticks into the inner airway stick perforations on the second spoke plate, with the insertion ends of the inner airway sticks pressed against the first spoke plate in a vertical fit manner, and the non-insertion ends of the inner airway sticks extending out of the second spoke plate;

[0159] The cross section of each inner airway stick is a rectangular structure with rounded corners (or a "racetrack" structure with semicircular ends is used instead);

[0160] Step 4. Winding an insulating layer 5 on the inner airway rod; the insulating layer 5 is an insulating mesh cloth structure;

[0161] Step 5. Insert the outer airway sticks into the outer airway stick perforations on the second spoke plate, with the insertion ends of the outer airway sticks pressed against the first spoke plate in a vertical fit manner, and the non-insertion ends of the outer airway sticks extending out of the second spoke plate;

[0162] The cross section of each outer airway stick is a rectangular structure with rounded corners (or a "racetrack" structure with semicircular ends is used instead);

[0163] Step 6. Wind the insulation layer six, high voltage electromagnetic wire and interlayer insulation, insulation layer nine on the outer airway rod in sequence, and weld the terminal block;

[0164] The sixth insulation layer and the ninth insulation layer are respectively an insulation mesh cloth structure;

[0165] The number of turns of the high voltage coil is determined according to the design requirements;

[0166] Step 7. Assemble the outer mold on the winding mold by tightening screws, etc.;

[0167] The inner mold of the winding mold, the first radial plate, the second radial plate and the outer mold form a pouring space capable of pouring epoxy resin;

[0168] Step 8. Perform true drying in a vacuum casting device;

[0169] Vacuum pouring epoxy resin into the cavity of the winding die;

[0170] Step 9. Use a curing furnace to perform curing treatment;

[0171] Step 10. Dismantle the winding mold, including dismantling the outer mold, removing the inner and outer airway rods, dismantling the first spoke, dismantling the second spoke, dismantling the inner mold, etc.;

[0172] The low-voltage coil and the high-voltage coil on the core column A are cast with epoxy resin to form the above-mentioned inseparable integral structure;

[0173] Step 11. Repeat the above steps to make the low-voltage coil and the high-voltage coil of the integral structure on the core column B of the core body;

[0174] Step 12. Repeat the above steps 1 to 10 to make a low-voltage coil and a high-voltage coil of an integral structure on the core column C of the core body;

[0175] At this point, the low-voltage coils and high-voltage coils of the integral structures on the three-phase core columns of the core body are respectively manufactured and formed.

[0176] In the above manufacturing method, the portion of the low-voltage incoming wire that exceeds the low-voltage coil can be folded and hidden in the gap on one side of the low-voltage coil and the corresponding spoke plate of the winding mold.

[0177] Through the above manufacturing method, it can be seen that the high and low voltage coils of each phase winding on the core body share the same set of molds for winding and casting, and the low voltage coil, main insulation and high voltage coil can finally be integrally formed with high strength, which is economical.

[0178] Example 3

[0179] See also Figure 4 , Figure 5 and Figure 6 As shown, the present invention includes a core body 1 of a three-dimensional rolled structure, that is, the core body 1 is mainly composed of three single-frame closed-loop cores connected together and arranged in a herringbone shape, namely, core columns A11, B12, and C13. A set of windings is arranged on each core column, and the windings are composed of a low-voltage coil 2 on the inside and a high-voltage coil 4 on the outside; the low-voltage coil 2 is a foil-wound structure of copper foil (or aluminum foil), and its low-voltage incoming wire 21 and low-voltage outgoing wire 22 are respectively composed of a plurality of arc-shaped (having a certain width to form an arc shape) thin copper strips (thin aluminum strips) with a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) superimposed and combined, and the low-voltage incoming wire 21 and the low-voltage outgoing wire 22 are closely welded on the copper foil (aluminum foil) on the corresponding side of the low-voltage coil 2. Usually, the low-voltage incoming wire 21 is located on the inside of the low-voltage coil 2, and the low-voltage outgoing wire 22 is located on the outside of the low-voltage coil 2;

[0180] The low-voltage coil 2 and the high-voltage coil 4 on each of the above-mentioned core columns are cast by epoxy resin to form an inseparable integral structure, that is, the low-voltage coil 2 and the high-voltage coil 4 constituting the winding on the core column are cured by the co-cast epoxy resin to form an inseparable integral structure. At the same time, in the main insulation area between the low-voltage coil 2 and the high-voltage coil 4, a number of air channels 3 are arranged in an annular direction with an inner and outer double-layer structure, and these air channels 3 are formed by integral casting of the high and low voltage coils; adjacent inner air channels 31 or adjacent outer air channels 32 are separated by epoxy resin respectively, and the inner air channel 31 and the outer air channel 32 are separated by an insulating layer 5 33 and the epoxy resin attached to the insulating layer 5 33, and the inner air channel 31 and the outer air channel 32 are in a one-to-one corresponding matching relationship; the cross-section of each of the aforementioned air channels 3 is a rectangular hole structure with rounded corners or a waist-shaped hole structure with semicircular ends, which can effectively prevent the outer diameter of the entire winding from being too large; the double-layer structure air channel 3 between the low-voltage coil 2 and the high-voltage coil 4 takes into account the main insulation function and the heat dissipation function, so that while forming the main insulation, it can also effectively increase the heat dissipation area between the high and low voltage coils, thereby reducing the problem of coil burning due to insufficient heat dissipation during operation.

[0181] A plurality of low-pressure side air ducts 28 are arranged circumferentially in the radial middle region of the low-pressure coil 2. The low-pressure side air ducts 28 are formed by integrally pouring the high and low-pressure coils; the low-pressure side air ducts 28 can effectively increase the heat dissipation area of ​​the low-pressure coil 2. The cross section of each low-pressure side air duct 28 is a rectangular hole structure with rounded corners or a waist-shaped hole structure with semicircular ends, which can effectively prevent the outer diameter of the entire winding from being too large.

[0182] The reason why the double-layer structure air duct 3 is used between the low-voltage coil 2 and the high-voltage coil 4 is that the main insulation between the high and low voltage coils (i.e., the highest voltage) is mainly guaranteed by the air in the gap (distance) between the high and low voltage coils. The strength of air insulation is much lower than that of epoxy resin. Therefore, to achieve the same insulation strength, the gap (distance) must be increased. If an insulating cylinder is set between the high and low voltage coils, the gap (distance) can be reduced. In order to reduce the product volume and reduce costs, an insulating cylinder is generally set and supported and fixed on the outer surface of the low-voltage coil by several struts. However, compared with the double-layer structure air duct 3, the electrical strength and mechanical strength of this structure are obviously insufficient, and the process cost and material cost are higher than the double-layer structure air duct 3. If the double-layer structure air duct is replaced by other layers, for a 10kV transformer, its cost will be much higher than the double-layer structure air duct 3.

[0183] The manufacturing method of the above-mentioned three-dimensional wound core resin cast dry-type transformer includes the following process steps (assuming that the manufacturing process is first the core column A11, then the core column B12, and finally the core column C13):

[0184] Step 1. Clamp the core body 1 and assemble the winding mold 5 on the core column A11;

[0185] The winding mold 5 is mainly composed of an inner mold 51 composed of multiple (usually three or four equally divided) arc-shaped plates that can match the core column A11, a radial plate 52 connected to one end of the inner mold 51 and extending radially outward, a radial plate 2 54 connected to the other end of the inner mold 51 and extending radially outward, and an outer mold that matches the outer edges of the radial plate 1 52 and the radial plate 2 54 and is on standby during the winding process; the radial plate 1 52 is mainly composed of two separate parts that can be connected and combined into a whole circle in the circumferential direction, and the outer edge of the radial plate 1 52 is connected to a gear ring 1 53 in a detachable structure by fastening screws, etc., and the gear ring 1 53 is mainly composed of two separate parts that can be connected and combined into a whole circle in the circumferential direction; the radial plate 2 54 is mainly composed of two separate parts that can be connected and combined into a whole circle in the circumferential direction The outer edge of the spoke plate 54 is connected with a gear ring 55 in a detachable structure by fastening screws, etc. The gear ring 55 is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction; the outer mold is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction; the spoke plate 55 is provided with a plurality of airway rod through-holes in an inner and outer double-layer circumferential arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area, namely, the inner airway rod through-hole 56 and the outer airway rod through-hole 57; the spoke plate 54 is provided with a plurality of airway rod through-holes in an circumferential arrangement structure corresponding to the radial center of the low-voltage coil winding area, namely, the low-pressure side airway rod through-hole 510;

[0186] Step 2. Wind the insulating layer 1 23 on the inner mold 51; the insulating layer 1 is usually a 0.5 mm thick glass cloth plate or a 0.5-1 mm (e.g., 0.5 mm, 0.8 mm, or 1 mm, etc.) thick PET; when winding the insulating layer 1, the interface needs to be tightly bonded, and the gap between the insulating layer 1 and the spoke plate 1 and the spoke plate 2 needs to be sealed with a sealant;

[0187] Taking the outer circle formed by the inner mold 51 as a reference, a plurality of thin copper strips (or thin aluminum strips) with a certain width and a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) are pressed into an arc structure, and these thin copper strips (or thin aluminum strips) are stacked and combined together, and closely welded and combined with the foil material - copper foil (or aluminum foil) that can form a low-voltage coil, to form a low-voltage inlet line 21 on the low-voltage coil foil;

[0188] The low-voltage foil and interlayer insulation 29 are wound on the insulation layer 1 23, and the low-voltage incoming line 21 is located on the inner wall of the low-voltage coil in a tangential structure;

[0189] Winding the second insulating layer 25 on the low-voltage foil and the interlayer insulation 29; the second insulating layer 25 is an insulating mesh cloth structure;

[0190] Step 3. Insert the low-pressure side airway rods 512 into the low-pressure side airway rod through holes 510 on the second spoke plate 54, and the insertion ends of the low-pressure side airway rods 512 are pressed against the first spoke plate 52 in a vertically matched manner, and the non-insertion ends of the low-pressure side airway rods 512 extend out of the second spoke plate 54;

[0191] The cross section of each low-pressure side airway stick 512 is a rectangular structure with rounded corners (or a "runway" structure with semicircular ends is used instead);

[0192] Step 4. Wind the insulation layer 3 26, the low-voltage foil material and the interlayer insulation 29 on the low-pressure side airway rod 512 in sequence;

[0193] The insulating layer 3 26 is an insulating mesh cloth structure;

[0194] The low-pressure coil foil material inside the low-pressure side airway stick 512 and the low-pressure coil foil material outside are continuous and uninterrupted;

[0195] Taking the outer circle formed by the low-voltage coil 2 as a reference, several thin copper strips (or thin aluminum strips) with a certain width and a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) are pressed into an arc structure, and these thin copper strips (or thin aluminum strips) are superimposed and combined together, and closely welded and combined with the foil material - copper foil (or aluminum foil) that can form the low-voltage coil, to form a low-voltage outlet line 22 on the low-voltage coil foil;

[0196] The number of turns of the low-voltage coil is determined according to the design requirements;

[0197] An insulating layer 27 is wound on the low-voltage foil and the interlayer insulation 29; the insulating layer 27 is an insulating mesh cloth structure;

[0198] Step 5. Insert the inner airway rods 58 into the inner airway rod through holes 56 on the second spoke plate 54, with the insertion ends of the inner airway rods 58 pressed against the first spoke plate 52 in a vertical fit manner, and the non-insertion ends of the inner airway rods 58 extending out of the second spoke plate 54;

[0199] The cross section of each inner airway rod 58 is a rectangular structure with rounded corners (or a "racetrack" structure with semicircular ends is used instead);

[0200] Step 6. Winding an insulating layer 5 33 on the inner airway rod 58; the insulating layer 5 33 is an insulating mesh cloth structure;

[0201] Step 7. Insert the outer airway rods 59 into the outer airway rod through holes 57 on the second spoke plate 54, with the insertion ends of the outer airway rods 59 pressed against the first spoke plate 52 in a vertical fit manner, and the non-insertion ends of the outer airway rods 59 extending out of the second spoke plate 54;

[0202] The cross section of each outer airway rod 59 is a rectangular structure with rounded corners (or a "runway" structure with semicircular ends is used instead);

[0203] Step 8. Wind the insulation layer 6 41, the high voltage electromagnetic wire and the interlayer insulation 42, and the insulation layer 9 45 on the outer airway rod 59 in sequence, and weld the terminal block;

[0204] The insulation layer six 41 and the insulation layer nine 45 are respectively an insulation mesh cloth structure;

[0205] The number of turns of the high voltage coil is determined according to the design requirements;

[0206] Step 9. Assemble the outer mold on the winding mold 5 by tightening screws, etc.;

[0207] The inner mold 51, the first spoke plate 52, the second spoke plate 54 and the outer mold of the winding mold 5 form a pouring space capable of pouring epoxy resin;

[0208] Step 10. Perform true drying in a vacuum casting device;

[0209] Vacuum pouring epoxy resin into the mold cavity of the winding mold 5;

[0210] Step 11. Perform curing in a curing furnace;

[0211] Step 12. Dismantle the winding mold 5, including dismantling the outer mold, removing the inner and outer airway rods, removing the low-pressure side airway rod 512, removing the spoke plate 1 52, removing the spoke plate 2 54, and removing the inner mold 51;

[0212] The low-voltage coil 2 and the high-voltage coil 4 on the core column A11 are cast with epoxy resin to form the above-mentioned inseparable integral structure;

[0213] Step 13. Repeat the above steps to make the low-voltage coil 2 and the high-voltage coil 4 of the integral structure on the core column B12 of the core body 1;

[0214] Step 14. Repeat the above steps 1 to 12 to manufacture the low-voltage coil 2 and the high-voltage coil 4 of the integral structure on the core column C13 of the core body 1;

[0215] At this point, the low-voltage coils 2 and high-voltage coils 4 of the integral structures on the three-phase core columns of the core body 1 are respectively manufactured and formed.

[0216] In the above manufacturing method, the portion of the low-voltage incoming wire that exceeds the low-voltage coil can be folded and hidden in the gap on one side of the low-voltage coil and the corresponding spoke plate of the winding mold.

[0217] Through the above manufacturing method, it can be seen that the high and low voltage coils of each phase winding on the core body share the same set of molds for winding and casting, and the low voltage coil, main insulation and high voltage coil can finally be integrally formed with high strength, which is economical.

[0218] Example 4

[0219] See also Figure 4 , Figure 5 and Figure 6 As shown, the present invention includes a core body 1 of a three-dimensional rolled structure, that is, the core body 1 is mainly composed of three single-frame closed-loop cores connected together and arranged in a herringbone shape, namely, core columns A11, B12, and C13. A set of windings is arranged on each core column, and the windings are composed of a low-voltage coil 2 on the inside and a high-voltage coil 4 on the outside; the low-voltage coil 2 is a foil-wound structure of copper foil (or aluminum foil), and its low-voltage incoming wire 21 and low-voltage outgoing wire 22 are respectively composed of a plurality of arc-shaped (having a certain width to form an arc shape) thin copper strips (thin aluminum strips) with a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) superimposed and combined, and the low-voltage incoming wire 21 and the low-voltage outgoing wire 22 are closely welded on the copper foil (aluminum foil) on the corresponding side of the low-voltage coil 2. Usually, the low-voltage incoming wire 21 is located on the inside of the low-voltage coil 2, and the low-voltage outgoing wire 22 is located on the outside of the low-voltage coil 2;

[0220] The low-voltage coil 2 and the high-voltage coil 4 on each of the above-mentioned core columns are cast by epoxy resin to form an inseparable integral structure, that is, the low-voltage coil 2 and the high-voltage coil 4 constituting the winding on the core column are cured by the co-cast epoxy resin to form an inseparable integral structure. At the same time, in the main insulation area between the low-voltage coil 2 and the high-voltage coil 4, a number of air channels 3 are arranged in an annular direction with an inner and outer double-layer structure, and these air channels 3 are formed by integral casting of the high and low voltage coils; adjacent inner air channels 31 or adjacent outer air channels 32 are separated by epoxy resin respectively, and the inner air channel 31 and the outer air channel 32 are separated by an insulating layer 5 33 and the epoxy resin attached to the insulating layer 5 33, and the inner air channel 31 and the outer air channel 32 are in a one-to-one matching relationship; the cross-section of each of the aforementioned air channels 3 is a rectangular hole structure with rounded corners or a waist-shaped hole structure with semicircular ends, which can effectively prevent the outer diameter of the entire winding from being too large; the double-layer structure air channel 3 between the low-voltage coil 2 and the high-voltage coil 4 takes into account the main insulation function and the heat dissipation function, so that while forming the main insulation, it can also effectively increase the heat dissipation area between the high and low voltage coils, so as to reduce the problem of the coil burning due to insulation thermal aging due to insufficient heat dissipation during operation.

[0221] A plurality of high-voltage side air passages 46 are arranged in an annular manner in the radial middle region of the high-voltage coil 4. The high-voltage side air passages 46 are formed by integrally pouring the high-voltage and low-voltage coils; the high-voltage side air passages 46 can effectively increase the heat dissipation area of ​​the high-voltage coil 4. The cross section of each high-voltage side air passage 46 is a rectangular hole structure with rounded corners or a waist-shaped hole structure with semicircular ends, which can effectively prevent the outer diameter of the entire winding from being too large.

[0222] The reason why the double-layer structure air duct 3 is used between the low-voltage coil 2 and the high-voltage coil 4 is that the main insulation between the high and low voltage coils (i.e., the highest voltage) is mainly guaranteed by the air in the gap (distance) between the high and low voltage coils. The strength of air insulation is much lower than that of epoxy resin. Therefore, to achieve the same insulation strength, the gap (distance) must be increased. If an insulating cylinder is set between the high and low voltage coils, the gap (distance) can be reduced. In order to reduce the product volume and reduce costs, an insulating cylinder is generally set and supported and fixed on the outer surface of the low-voltage coil by several struts. However, compared with the double-layer structure air duct 3, the electrical strength and mechanical strength of this structure are obviously insufficient, and the process cost and material cost are higher than the double-layer structure air duct 3. If the double-layer structure air duct is replaced by other layers, for a 10kV transformer, its cost will be much higher than the double-layer structure air duct 3.

[0223] The manufacturing method of the above-mentioned three-dimensional wound core resin cast dry-type transformer includes the following process steps (assuming that the manufacturing process is first the core column A11, then the core column B12, and finally the core column C13):

[0224] Step 1. Clamp the core body 1 and assemble the winding mold 5 on the core column A11;

[0225] The winding mold 5 is mainly composed of an inner mold 51 composed of multiple (usually three or four equally divided) arc-shaped plates that can match the core column A11, a radial plate 52 connected to one end of the inner mold 51 and extending radially outward, a radial plate 2 54 connected to the other end of the inner mold 51 and extending radially outward, and an outer mold that matches the outer edges of the radial plate 1 52 and the radial plate 2 54 and is on standby during the winding process; the radial plate 1 52 is mainly composed of two separate parts that can be connected and combined into a whole circle in the circumferential direction, and the outer edge of the radial plate 1 52 is connected to a gear ring 1 53 in a detachable structure by fastening screws, etc., and the gear ring 1 53 is mainly composed of two separate parts that can be connected and combined into a whole circle in the circumferential direction; the radial plate 2 54 is mainly composed of two separate parts that can be connected and combined into a whole circle in the circumferential direction The outer edge of the spoke plate 54 is connected with a gear ring 55 in a detachable structure by fastening screws, etc. The gear ring 55 is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction; the outer mold is mainly composed of two separate parts that can be connected and combined into a full circle in the circumferential direction; the spoke plate 54 is provided with a plurality of airway rod perforations in an inner and outer double-layer circumferential arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area, namely, the inner airway rod perforation 56 and the outer airway rod perforation 57; the spoke plate 54 is provided with a plurality of airway rod perforations in an circumferential arrangement structure corresponding to the radial center of the high-voltage coil winding area, namely, the high-pressure side airway rod perforation 511;

[0226] Step 2. Wind the insulating layer 1 23 on the inner mold 51; the insulating layer 1 is usually a 0.5 mm thick glass cloth plate or a 0.5-1 mm (e.g., 0.5 mm, 0.8 mm, or 1 mm, etc.) thick PET; when winding the insulating layer 1, the interface needs to be tightly bonded, and the gap between the insulating layer 1 and the spoke plate 1 and the spoke plate 2 needs to be sealed with a sealant;

[0227] Taking the outer circle formed by the inner mold 51 as a reference, a plurality of thin copper strips (or thin aluminum strips) with a certain width and a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) are pressed into an arc structure, and these thin copper strips (or thin aluminum strips) are stacked and combined together, and closely welded and combined with the foil material - copper foil (or aluminum foil) that can form a low-voltage coil, to form a low-voltage inlet line 21 on the low-voltage coil foil;

[0228] The low-voltage foil and interlayer insulation 29 are wound on the insulation layer 1 23, and the low-voltage incoming line 21 is located on the inner wall of the low-voltage coil in a tangential structure;

[0229] Taking the outer circle formed by the low-voltage coil 2 as a reference, several thin copper strips (or thin aluminum strips) with a certain width and a thickness of 0.1 to 1 mm (for example, 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm or 1 mm, etc.) are pressed into an arc structure, and these thin copper strips (or thin aluminum strips) are superimposed and combined together, and closely welded and combined with the foil material - copper foil (or aluminum foil) that can form the low-voltage coil, to form a low-voltage outlet line 22 on the low-voltage coil foil;

[0230] The number of turns of the low voltage coil 2 is determined according to the design requirements;

[0231] An insulating layer 27 is wound on the low-voltage foil and the interlayer insulation 29; the insulating layer 27 is an insulating mesh cloth structure;

[0232] Step 3. Insert the inner airway rods 58 into the inner airway rod through holes 56 on the second spoke plate 54, with the insertion ends of the inner airway rods 58 pressed against the first spoke plate 52 in a vertical fit manner, and the non-insertion ends of the inner airway rods 58 extending out of the second spoke plate 54;

[0233] The cross section of each inner airway rod 58 is a rectangular structure with rounded corners (or a "racetrack" structure with semicircular ends is used instead);

[0234] Step 4. Winding an insulating layer 5 33 on the inner airway rod 58; the insulating layer 5 33 is an insulating mesh cloth structure;

[0235] Step 5. Insert the outer airway rods 59 into the outer airway rod through holes 57 on the second spoke plate 54, with the insertion ends of the outer airway rods 59 pressed against the first spoke plate 52 in a vertical fit manner, and the non-insertion ends of the outer airway rods 59 extending out of the second spoke plate 54;

[0236] The cross section of each outer airway rod 59 is a rectangular structure with rounded corners (or a "runway" structure with semicircular ends is used instead);

[0237] Step 6. Wind the insulation layer 6 41, the high voltage electromagnetic wire and the interlayer insulation 42, and the insulation layer 7 43 on the outer airway rod 59 in sequence;

[0238] The insulating layer six 41 and the insulating layer seven 43 are respectively insulating mesh cloth structures;

[0239] Step 7. Insert the high-pressure side airway rods 513 into the high-pressure side airway rod through holes 511 on the second spoke plate 54, with the insertion ends of the high-pressure side airway rods 513 pressed against the first spoke plate 52 in a vertically matched manner, and the non-insertion ends of the high-pressure side airway rods 513 extending out of the second spoke plate 54;

[0240] The cross section of each high-pressure side airway rod 513 is a rectangular structure with rounded corners (or a "runway" structure with semicircular ends is used instead);

[0241] Step 8. Wind the insulation layer eight 44, the high-voltage electromagnetic wire and the interlayer insulation 42, and the insulation layer nine 45 on the high-pressure side airway rod 513 in sequence, and weld the terminal block;

[0242] The insulating layer eight 44 and the insulating layer nine 45 are respectively insulating mesh cloth structures;

[0243] The number of turns of the high voltage coil is determined according to the design requirements;

[0244] The high-voltage electromagnetic wire inside the high-pressure side airway rod 513 is connected to the high-voltage electromagnetic wire outside;

[0245] Step 9. Assemble the outer mold on the winding mold 5 by tightening screws, etc.;

[0246] The inner mold 51, the first spoke plate 52, the second spoke plate 54 and the outer mold of the winding mold 5 form a pouring space capable of pouring epoxy resin;

[0247] Step 10. Perform true drying in a vacuum casting device;

[0248] Vacuum pouring epoxy resin into the mold cavity of the winding mold 5;

[0249] Step 11. Perform curing in a curing furnace;

[0250] Step 12. Dismantle the winding mold 5, including dismantling the outer mold, removing the inner and outer airway rods, removing the high-pressure side airway rod 513, removing the spoke plate 1 52, removing the spoke plate 2 54, and removing the inner mold 51;

[0251] The low-voltage coil 2 and the high-voltage coil 4 on the core column A11 are cast with epoxy resin to form the above-mentioned inseparable integral structure;

[0252] Step 13. Repeat the above steps to make the low-voltage coil 2 and the high-voltage coil 4 of the integral structure on the core column B12 of the core body 1;

[0253] Step 14. Repeat the above steps 1 to 12 to manufacture the low-voltage coil 2 and the high-voltage coil 4 of the integral structure on the core column C13 of the core body 1;

[0254] At this point, the low-voltage coils 2 and high-voltage coils 4 of the integral structures on the three-phase core columns of the core body 1 are respectively manufactured and formed.

[0255] In the above manufacturing method, the portion of the low-voltage incoming wire that exceeds the low-voltage coil can be folded and hidden in the gap on one side of the low-voltage coil and the corresponding spoke plate of the winding mold.

[0256] Through the above manufacturing method, it can be seen that the high and low voltage coils of each phase winding on the core body share the same set of molds for winding and casting, and the low voltage coil, main insulation and high voltage coil can finally be integrally formed with high strength, which is economical.

[0257] The above embodiments are only used to illustrate the present invention, not to limit it. Although the present invention is described in detail with reference to the above embodiments, a person skilled in the art should understand that the above embodiments can still be modified, or some of the technical features thereof can be replaced by equivalents, for example, annularly arranged air ducts are respectively provided inside the low-voltage coil and inside the high-voltage coil, etc., and these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the present invention.

Claims

1. A three-dimensional wound core resin cast dry-type transformer, comprising a three-dimensional wound core body (1) mainly composed of three core columns arranged in a herringbone shape, each core column of the core body (1) being provided with a low-voltage coil (2) located inside and a high-voltage coil (4) located outside, the low-voltage coil (2) being a wire-wound structure; Features: The low-voltage coil (2) and the high-voltage coil (4) on each core column are cast with epoxy resin to form an inseparable integral structure, and a plurality of air passages (3) capable of taking into account both main insulation function and heat dissipation function are arranged in an annular direction between the low-voltage coil (2) and the high-voltage coil (4) in an inner and outer double-layer structure; The three-dimensional wound iron core resin cast dry-type transformer is manufactured by a manufacturing method with the following process steps: Step 1. Clamp the core body (1) and assemble the winding mold (5) on the corresponding core column; The winding mold (5) is mainly composed of an inner mold (51) composed of a plurality of arc-shaped plates capable of matching the corresponding iron core column, a radial plate 1 (52) connected to one end of the inner mold (51) and extending radially outward, a radial plate 2 (54) connected to the other end of the inner mold (51) and extending radially outward, and an outer mold matched to the outer edge of the radial plate 1 (52) and the outer edge of the radial plate 2 (54) and to be used during the winding process, wherein the radial plate 2 (54) is provided with a plurality of airway rod perforations in an inner and outer double-layer annular arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area; Step 2. Winding the insulation layer 1 (23), the low-voltage electromagnetic wire and the interlayer insulation (24), and the insulation layer 4 (27) on the inner mold (51) in sequence; The low-voltage inlet wire (21) and the low-voltage outlet wire (22) of the low-voltage coil (2) are made of the electromagnetic wire of the original coil; Step 3. Insert the inner airway rods (58) into the inner airway rod perforations (56) on the second spoke plate (54), and the insertion ends of the inner airway rods (58) are pressed against the first spoke plate (52); Step 4. Winding an insulating layer five (33) on the inner airway rod (58); Step 5. Insert the outer airway rods (59) into the outer airway rod perforations (57) on the second spoke (54), with the insertion ends of the outer airway rods (59) pressed against the first spoke (52); Step 6. Winding the insulation layer six (41), the high voltage electromagnetic wire and the interlayer insulation (42), and the insulation layer nine (45) on the outer airway rod (59) in sequence; Step 7. Assembling an outer mold on the winding mold (5); The inner mold (51), the first radial plate (52), the second radial plate (54) and the outer mold of the winding mold (5) form a pouring space capable of pouring epoxy resin; Step 8. Perform vacuum drying in a vacuum casting device; Vacuum pouring epoxy resin into the mold cavity of the winding mold (5); Step 9. Use a curing furnace to perform curing treatment; Step 10. Remove the winding die (5); The low-voltage coil (2) and the high-voltage coil (4) on the corresponding iron core column are cast with epoxy resin to form an inseparable integral structure; Step 11. Repeat the above steps to manufacture the low-voltage coil (2) and the high-voltage coil (4) of the integral structure on the next core column on the core body (1); Until each integrally structured low-voltage coil (2) and high-voltage coil (4) on the three-phase iron core column of the iron core body (1) are respectively manufactured and formed.

2. A three-dimensional wound core resin cast dry-type transformer, comprising a three-dimensional wound core body (1) mainly composed of three core columns arranged in a herringbone shape, each core column of the core body (1) being provided with a low-voltage coil (2) located inside and a high-voltage coil (4) located outside, the low-voltage coil (2) being a foil-wound structure; Features: The low-voltage inlet wire (21) and the low-voltage outlet wire (22) of the low-voltage coil (2) are respectively formed by stacking and combining a plurality of arc-shaped thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm, and the low-voltage inlet wire (21) and the low-voltage outlet wire (22) are tightly welded on the copper foil / aluminum foil on the corresponding side of the low-voltage coil (2); The low-voltage coil (2) and the high-voltage coil (4) on each core column are cast with epoxy resin to form an inseparable integral structure, and a plurality of air passages (3) capable of taking into account both main insulation function and heat dissipation function are arranged in an annular direction between the low-voltage coil (2) and the high-voltage coil (4) in an inner and outer double-layer structure; The three-dimensional wound iron core resin cast dry-type transformer is manufactured by a manufacturing method with the following process steps: Step 1. Clamp the core body (1) and assemble the winding mold (5) on the corresponding core column; The winding mold (5) is mainly composed of an inner mold (51) composed of a plurality of arc-shaped plates capable of matching the corresponding iron core column, a radial plate 1 (52) connected to one end of the inner mold (51) and extending radially outward, a radial plate 2 (54) connected to the other end of the inner mold (51) and extending radially outward, and an outer mold matched to the outer edge of the radial plate 1 (52) and the outer edge of the radial plate 2 (54) and to be used during the winding process, wherein the radial plate 2 (54) is provided with a plurality of airway rod perforations in an inner and outer double-layer annular arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area; Step 2. Winding an insulating layer 1 (23) on the inner mold (51); Taking the outer circle formed by the inner mold (51) as a reference, a plurality of thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc-shaped structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form a low-voltage coil, so as to form a low-voltage inlet line (21) on the low-voltage coil foil material; The low-voltage foil and interlayer insulation (29) are wound on the insulating layer 1 (23), and the low-voltage incoming line (21) is located on the inner wall of the low-voltage coil in a tangential structure; Taking the outer circle formed by the low-voltage coil (2) as a reference, a plurality of thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc-shaped structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form the low-voltage coil, so as to form a low-voltage outlet wire (22) on the low-voltage coil foil material; Winding an insulating layer 4 (27) on the low-voltage foil and interlayer insulation (29); Step 3. Insert the inner airway rods (58) into the inner airway rod perforations (56) on the second spoke plate (54), and the insertion ends of the inner airway rods (58) are pressed against the first spoke plate (52); Step 4. Winding an insulating layer five (33) on the inner airway rod (58); Step 5. Insert the outer airway rods (59) into the outer airway rod perforations (57) on the second spoke (54), with the insertion ends of the outer airway rods (59) pressed against the first spoke (52); Step 6. Winding the insulation layer six (41), the high voltage electromagnetic wire and the interlayer insulation (42), and the insulation layer nine (45) on the outer airway rod (59) in sequence; Step 7. Assembling an outer mold on the winding mold (5); The inner mold (51), the first radial plate (52), the second radial plate (54) and the outer mold of the winding mold (5) form a pouring space capable of pouring epoxy resin; Step 8. Perform vacuum drying in a vacuum casting device; Vacuum pouring epoxy resin into the mold cavity of the winding mold (5); Step 9. Use a curing furnace to perform curing treatment; Step 10. Remove the winding die (5); The low-voltage coil (2) and the high-voltage coil (4) on the corresponding iron core column are cast with epoxy resin to form an inseparable integral structure; Step 11. Repeat the above steps to manufacture the low-voltage coil (2) and the high-voltage coil (4) of the integral structure on the next core column on the core body (1); Until each integrally structured low-voltage coil (2) and high-voltage coil (4) on the three-phase iron core column of the iron core body (1) are respectively manufactured and formed.

3. A three-dimensional wound core resin cast dry-type transformer, comprising a three-dimensional wound core body (1) mainly composed of three core columns arranged in a herringbone shape, each core column of the core body (1) being provided with a low-voltage coil (2) located inside and a high-voltage coil (4) located outside, the low-voltage coil (2) being a foil-wound structure; Features: The low-voltage inlet wire (21) and the low-voltage outlet wire (22) of the low-voltage coil (2) are respectively formed by stacking and combining a plurality of arc-shaped thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm, and the low-voltage inlet wire (21) and the low-voltage outlet wire (22) are tightly welded on the copper foil / aluminum foil on the corresponding side of the low-voltage coil (2); The low-voltage coil (2) and the high-voltage coil (4) on each core column are cast with epoxy resin to form an inseparable integral structure, and a plurality of air passages (3) capable of taking into account both main insulation function and heat dissipation function are arranged in an annular direction between the low-voltage coil (2) and the high-voltage coil (4) in an inner and outer double-layer structure, and a plurality of low-pressure side air passages (28) are arranged in an annular direction inside the low-voltage coil (2); The three-dimensional wound iron core resin cast dry-type transformer is manufactured by a manufacturing method with the following process steps: Step 1. Clamp the core body (1) and assemble the winding mold (5) on the corresponding core column; The winding mold (5) is mainly composed of an inner mold (51) composed of multiple arc-shaped plates that can match the corresponding iron core column, a radial plate (52) connected to one end of the inner mold (51) and extending radially outward, a radial plate (54) connected to the other end of the inner mold (51) and extending radially outward, and an outer mold that matches the outer edge of the radial plate (52) and the outer edge of the radial plate (54) and is ready for use during the winding process, and a plurality of airway rod through holes are opened on the radial plate (54) in a ring-shaped arrangement structure corresponding to the center of the low-voltage coil winding area, and a plurality of airway rod through holes are opened on the radial plate (54) in a ring-shaped arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area. Step 2. Winding an insulating layer 1 (23) on the inner mold (51); Taking the outer circle formed by the inner mold (51) as a reference, a plurality of thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc-shaped structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form a low-voltage coil, so as to form a low-voltage inlet line (21) on the low-voltage coil foil material; The low-voltage foil and interlayer insulation (29) are wound on the insulating layer 1 (23), and the low-voltage incoming line (21) is located on the inner wall of the low-voltage coil in a tangential structure; Winding a second insulating layer (25) on the low-voltage foil and the interlayer insulation (29); Step 3. Insert the low-pressure side airway rods (512) into the low-pressure side airway rod perforations (510) on the second spoke plate (54), and the insertion ends of the low-pressure side airway rods (512) are pressed against the first spoke plate (52); Step 4. Winding the insulation layer 3 (26), the low-voltage foil material and the interlayer insulation (29) on the low-pressure side airway rod (512) in sequence; The low-pressure coil foil material on the inner side and the low-pressure coil foil material on the outer side of the low-pressure side airway stick (512) are continuous and uninterrupted; Taking the outer circle formed by the low-voltage coil (2) as a reference, a plurality of thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc-shaped structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form the low-voltage coil, so as to form a low-voltage outlet wire (22) on the low-voltage coil foil material; Winding an insulating layer 4 (27) on the low-voltage foil and interlayer insulation (29); Step 5. Insert the inner airway rods (58) into the inner airway rod perforations (56) on the second spoke plate (54), and the insertion ends of the inner airway rods (58) are pressed against the first spoke plate (52); Step 6. Winding an insulating layer five (33) on the inner airway rod (58); Step 7. Insert the outer airway rods (59) into the outer airway rod perforations (57) on the second spoke plate (54), and the insertion ends of the outer airway rods (59) are pressed against the first spoke plate (52); Step 8. Winding the insulation layer six (41), the high voltage electromagnetic wire and the interlayer insulation (42), and the insulation layer nine (45) on the outer airway rod (59) in sequence; Step 9. Assembling an outer mold on the winding mold (5); The inner mold (51), the first radial plate (52), the second radial plate (54) and the outer mold of the winding mold (5) form a pouring space capable of pouring epoxy resin; Step 10. performing vacuum drying in a vacuum casting device; Vacuum pouring epoxy resin into the mold cavity of the winding mold (5); Step 11: Use a curing furnace to perform curing treatment; Step 12. Remove the winding die (5); The low-voltage coil (2) and the high-voltage coil (4) on the corresponding iron core column are cast with epoxy resin to form an inseparable integral structure; Step 13. Repeat the above steps to manufacture the low-voltage coil (2) and the high-voltage coil (4) of the integral structure on the next core column on the core body (1); Until each integrally structured low-voltage coil (2) and high-voltage coil (4) on the three-phase iron core column of the iron core body (1) are respectively manufactured and formed.

4. A three-dimensional wound core resin cast dry-type transformer, comprising a three-dimensional wound core body (1) mainly composed of three core columns arranged in a herringbone shape, each core column of the core body (1) being provided with a low-voltage coil (2) located inside and a high-voltage coil (4) located outside, the low-voltage coil (2) being a foil-wound structure; Features: The low-voltage inlet wire (21) and the low-voltage outlet wire (22) of the low-voltage coil (2) are respectively formed by stacking and combining a plurality of arc-shaped thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm, and the low-voltage inlet wire (21) and the low-voltage outlet wire (22) are tightly welded on the copper foil / aluminum foil on the corresponding side of the low-voltage coil (2); The low-voltage coil (2) and the high-voltage coil (4) on each core column are cast with epoxy resin to form an inseparable integral structure, and a plurality of air passages (3) capable of taking into account both main insulation function and heat dissipation function are arranged in an annular direction between the low-voltage coil (2) and the high-voltage coil (4) in an inner and outer double-layer structure, and a plurality of high-voltage side air passages (46) are arranged in an annular direction inside the high-voltage coil (4); The three-dimensional wound iron core resin cast dry-type transformer is manufactured by a manufacturing method with the following process steps: Step 1. Clamp the core body (1) and assemble the winding mold (5) on the corresponding core column; The winding mold (5) is mainly composed of an inner mold (51) composed of multiple arc-shaped plates that can match the corresponding iron core column, a radial plate (52) connected to one end of the inner mold (51) and extending radially outward, a radial plate (54) connected to the other end of the inner mold (51) and extending radially outward, and an outer mold that matches the outer edge of the radial plate (52) and the outer edge of the radial plate (54) and is ready for use during the winding process, and a plurality of airway rod through holes are opened on the radial plate (54) in a ring-shaped arrangement structure corresponding to the center of the high-voltage coil winding area, and a plurality of airway rod through holes are opened on the radial plate (54) in a ring-shaped arrangement structure corresponding to the main insulation area between the low-voltage coil winding area and the high-voltage coil winding area. Step 2. Winding an insulating layer 1 (23) on the inner mold (51); Taking the outer circle formed by the inner mold (51) as a reference, a plurality of thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc-shaped structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form a low-voltage coil, so as to form a low-voltage inlet line (21) on the low-voltage coil foil material; The low-voltage foil and interlayer insulation (29) are wound on the insulating layer 1 (23), and the low-voltage incoming line (21) is located on the inner wall of the low-voltage coil in a tangential structure; Taking the outer circle formed by the low-voltage coil (2) as a reference, a plurality of thin copper strips / thin aluminum strips with a thickness of 0.1 to 1 mm are pressed into an arc-shaped structure, and these thin copper strips / thin aluminum strips are stacked and combined together, and welded and combined with foil materials that can form the low-voltage coil, so as to form a low-voltage outlet wire (22) on the low-voltage coil foil material; Winding an insulating layer 4 (27) on the low-voltage foil and interlayer insulation (29); Step 3. Insert the inner airway rods (58) into the inner airway rod perforations (56) on the second spoke plate (54), and the insertion ends of the inner airway rods (58) are pressed against the first spoke plate (52); Step 4. Winding an insulating layer five (33) on the inner airway rod (58); Step 5. Insert the outer airway rods (59) into the outer airway rod perforations (57) on the second spoke (54), with the insertion ends of the outer airway rods (59) pressed against the first spoke (52); Step 6. Winding the insulation layer six (41), the high voltage electromagnetic wire and the interlayer insulation (42), and the insulation layer seven (43) on the outer airway rod (59) in sequence; Step 7. Insert the high-pressure side airway rods (513) into the high-pressure side airway rod perforations (511) on the second spoke plate (54), and the insertion ends of the high-pressure side airway rods (513) are pressed against the first spoke plate (52); Step 8. Winding the insulation layer eight (44), the high-voltage electromagnetic wire and the interlayer insulation (42), and the insulation layer nine (45) on the high-voltage side airway rod (513) in sequence; the high-voltage electromagnetic wire inside the high-voltage side airway rod (513) is connected to the high-voltage electromagnetic wire outside; Step 9. Assembling an outer mold on the winding mold (5); The inner mold (51), the first radial plate (52), the second radial plate (54) and the outer mold of the winding mold (5) form a pouring space capable of pouring epoxy resin; Step 10. performing vacuum drying in a vacuum casting device; Vacuum pouring epoxy resin into the mold cavity of the winding mold (5); Step 11: Use a curing furnace to perform curing treatment; Step 12. Remove the winding die (5); The low-voltage coil (2) and the high-voltage coil (4) on the corresponding iron core column are cast with epoxy resin to form an inseparable integral structure; Step 13. Repeat the above steps to manufacture the low-voltage coil (2) and the high-voltage coil (4) of the integral structure on the next core column on the core body (1); Until each integrally structured low-voltage coil (2) and high-voltage coil (4) on the three-phase iron core column of the iron core body (1) are respectively manufactured and formed.

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