A fully automatic high voltage coil winding machine and winding method

Abstract

The invention discloses a fully automatic high-voltage coil winding machine and a winding method. In this scheme, the coil winding method is improved, triangular areas are formed at the head and tail ends of the winding mold, and the coil is wound along the inclined surface between the triangular areas. The triangular areas are wrapped with an insulating layer to fix and improve the insulation performance. The winding method can quickly form the coil, which helps to reduce manual participation, and the formed coil has a small volume, high efficiency, and reduces the phenomenon of power outages.

Description

Technical Field

[0001] The invention relates to the technical field of winding devices, and in particular to a full-automatic high-voltage coil winding machine and a winding method. Background Art

[0002] Transformer coils are usually wound in two ways: cylindrical and continuous.

[0003] One is a cylindrical coil. The voltage between the conductor layers is high and interlayer insulation materials are required. When winding the previous layer of wire segments, an S-bend is required to raise the layer, and then place the interlayer insulation. This winding method requires interlayer insulation and end insulation for each layer, which is labor-intensive and bulky. The other is a continuous coil. The start of the wound coil is mostly drawn from the outer diameter of the wire segment, wound into a temporary wire segment, and then pushed down by hand, and the wire turns are manually folded, and finally become a formal wire segment starting from the outer diameter. Although this winding method does not require the placement of interlayer insulation and end insulation for each layer like a cylindrical coil, each segment needs manual assistance during winding, and manual turning is required when winding the reverse segment, which is time-consuming. Both of the above winding methods have problems such as too much personnel participation and low efficiency.

[0004] At the same time, in order to meet the requirements of insulation distance and electrical strength, it is necessary to increase the distance between segments or between cakes, which causes the overall height of the transformer coil to increase, the volume to increase, the material consumption to increase, and the product cost to increase. In this regard, the patent application number is 201910825680.3, a radially freely arranged continuous dry transformer winding and its processing method. A new structure is proposed in the patent, which can reduce materials and labor, but there is also the problem of excessive manual participation, which leads to the winding process of the freely arranged wires cannot accurately control the maximum voltage difference between the wires, which is easy to cause an increase in partial discharge, and the outer diameter of the coil is not mechanically controlled. It is difficult for manual braking in time, and it is necessary to constantly return and remedy, resulting in low efficiency. Summary of the invention

[0005] To solve at least one of the above technical defects, the present invention provides the following technical solutions:

[0006] This application document discloses a winding method of a fully automatic high voltage coil winding machine, comprising the following steps:

[0007] The first step is to wind the wire delivered by the feeding mechanism around the wire guide mechanism and fix it on the winding die on the rotating shaft;

[0008] The second step is to wind a right-angle triangle area 1 at the head end of the winding mold, and then to cover the wound right-angle triangle area 1 with an insulating layer;

[0009] The third step is to wind multiple inclined areas along the inclined surface of the right-angle triangle area one toward the tail end of the winding mold, and then wind the right-angle triangle area two at the terminal end of the winding mold in the opposite winding order to the right-angle triangle area one, and cover the right-angle triangle area with an insulating layer.

[0010] The present invention improves the coil winding method by forming triangular areas at the head and tail ends of the winding die and winding the coil along the inclined surface between the triangular areas. The triangular areas are wrapped with an insulating layer to fix and improve the insulation performance. The winding method can quickly form the coil, which helps to reduce manual participation. The formed coil is small in size, highly efficient, and reduces the phenomenon of power outages.

[0011] Furthermore, the method also includes the step of wrapping an insulating layer outside the wound coil, and wrapping the insulating layer again to improve the stability and insulation performance of the coil.

[0012] The present application discloses a fully automatic high-voltage coil winding machine, comprising a rotating shaft mechanism, a conductor mechanism, and a feeding mechanism. The conductor mechanism comprises a shifting mechanism 1 and a mounting frame, and the shifting mechanism 1 drives the mounting frame to move. The conductor mechanism also comprises a wire arranging mechanism, and the wire arranging mechanism comprises a frame body, a shifting mechanism 2 and a guide wheel 1. The frame body is connected to the mounting frame for synchronous movement. The shifting mechanism 2 is arranged on the frame body, and the shifting mechanism 2 drives the guide wheel 1 to move so that the guide wheel 1 changes its position in the axial direction of the rotating shaft in the rotating shaft mechanism, and the wire transported by the feeding mechanism is wound around the guide wheel 1. A limiting shaft and a wire arranging shaft for limiting the wire are arranged on the frame body, and a radial spacing of a predetermined distance exists between the limiting shaft and the winding die on the rotating shaft, and an angle between a length extension direction of the wire arranging shaft and the axial direction of the rotating shaft is a, 0<a<90°.

[0013] In this scheme, the winding machine is improved, and the shifting mechanism 2 cooperates with the guide wheel 1 to realize the change of the winding direction of the wire, which is convenient for winding the inclined area of ​​the above-mentioned coil, and a limiting axis is added to limit the radial height of the coil. When the shifting mechanism 2 drives the guide wheel 1 to move and change the winding direction of the wire, the wire arrangement axis is used to limit the position of the wire to improve stability. Under this structure, it is convenient to quickly wind the forming coil, with less manual participation and high efficiency.

[0014] The predetermined distance between the limiting axis and the winding die refers to the radial height of the coil, and the limiting axis is preferably parallel to the axial direction of the rotating shaft, and of course it can also be deformed corresponding to the shape of the wound coil. The limiting axis can be installed on the frame by bolts, nuts, etc., so as to facilitate the adjustment of the position according to the different heights of the coil.

[0015] Similarly, the end of the cable shaft can also be fixed to the frame by bolts, nuts, etc., so as to facilitate the adjustment of the tilt direction according to the change of the coil.

[0016] Furthermore, a roller is arranged on the frame, so that the roller abuts against the peripheral surface of the winding mold arranged on the rotating shaft, and the roller moves along the winding mold to improve stability.

[0017] For the shift mechanism 2 and the shift mechanism 1, you can choose the ball screw nut mechanism, gear rack mechanism, cylinder or hydraulic cylinder telescopic mechanism on the market according to your needs. Of course, the displacement error of the cylinder or hydraulic cylinder telescopic mechanism is relatively large.

[0018] Furthermore, the frame and the mounting frame are pivotally connected, the frame is displaced up and down relative to the rotating shaft, and a spring is arranged on the mounting frame below the pivotal connection, and the other end of the spring is connected to the frame. The addition of the spring facilitates pressing the frame toward the winding die at all times, and better maintains the relative position of the frame and the winding die.

[0019] Furthermore, the shifting mechanism 1 is a ball screw nut mechanism, and the shifting mechanism 1 is located on one side of the rotating shaft and moves the mounting frame along the axial direction of the rotating shaft.

[0020] Furthermore, the second shifting mechanism is a ball screw nut mechanism, and the second shifting mechanism moves the guide wheel one along the axial direction of the rotating shaft.

[0021] Preferably, a second guide wheel is provided on the mounting frame, and the wire conveyed by the feeding mechanism is sequentially wound around the second guide wheel and the first guide wheel, thereby improving the stability of the winding.

[0022] Further, the feeding mechanism includes a bracket, on which are arranged guide wheels 3, 4, 5, a tension adjustment mechanism, a conductor sensor, and a guide umbrella, and the wire on the wire drum passes through the guide umbrella, the conductor sensor, the 5th guide wheel, the 4th guide wheel, the tension adjustment mechanism, the 3rd guide wheel, and the 1st guide wheel in sequence;

[0023] The rotating shaft mechanism includes a main box, a power mechanism, a rotating shaft and a tailstock. The power mechanism is arranged in the main box, the output end of the power mechanism is connected to the rotating shaft, the other end of the rotating shaft is arranged on the tailstock, the rotating shaft is arranged on a winding mold, and baffles are arranged at opposite ends of the winding mold.

[0024] For the guide wheel, a single wheel, an upper and lower wheel, or an anti-jump line type guide wheel can be used. Of course, the guide wheel can also be replaced by a guide shaft or a guide roller.

[0025] Furthermore, it also includes a control system connected to the rotating shaft mechanism, the wire mechanism, and the feeding mechanism. The control system includes a control cabinet and an operation panel. The operation panel is arranged on the main box to facilitate automatic control operation.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. The present invention improves the coil winding method, which helps to reduce the volume of the coil after forming and increase the winding speed.

[0028] 2. The present invention improves the structure of the winding machine with respect to the winding method, adds a second shifting mechanism to cooperate with the guide shaft to adjust the winding direction of the wire so as to wind the coil along the inclined surface. This mechanism helps to improve the degree of automation, reduce manual participation, and improve forming efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0030] Figure 1 1 is a front view structural schematic diagram of the fully automatic high voltage coil winding machine in Example 1;

[0031] Figure 2 1 is a schematic diagram of the side view of the fully automatic high-voltage coil winding machine in Example 1;

[0032] Figure 3 It is a schematic diagram of the winding sequence;

[0033] Wherein, the accompanying drawings are marked as follows:

[0034] 1. Main chassis; 2. Wire mechanism; 3. Feeding mechanism; 4. Base; 5. Tail stock; 6. Control system; 7. Rotating shaft; 8. Winding mold; 20. Frame; 21. Shifting mechanism 1; 22. Mounting frame; 23. Spring; 24. Guide wheel 2; 25. Wire arrangement mechanism; 31. Guide wheel 3; 32. Tension adjustment mechanism; 33. Guide wheel 4; 34. Guide wheel 5; 35. Wire sensor; 36. Guide umbrella; 37. Bracket; 61. Operation panel; 211. Guide column; 251. Guide wheel 1; 252. Shifting mechanism 2; 253. Limiting shaft; 254. Roller; 255. Wire arrangement shaft; 256. Plate; 257. Connecting shaft. DETAILED DESCRIPTION

[0035] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0036] Example 1

[0037] like Figure 1 , Figure 2As shown, in this embodiment, a common form of a fully automatic high-voltage coil winding machine is used for display, including a rotating shaft mechanism, a wire mechanism, and a feeding mechanism. The rotating shaft mechanism adopts a common component mechanism, including a main box 1, a power mechanism, a rotating shaft 7 and a tailstock 5. The power mechanism is installed in the main box 1, which is composed of a servo motor, a reduction mechanism, etc. A box body is installed between the main box 1 and the tailstock 5, and the box body and the tailstock are both located on a base 4. A rotating shaft 7 and a wire mechanism 2 are installed in the box body, and a feeding mechanism 3 is arranged at a position parallel to the box body where the rotating shaft 7 is located. Figure 2 The output end of the power mechanism is fixed to the rotating shaft 7, the other end of the rotating shaft 7 is located on the tailstock 5, a winding die 8 is installed on the rotating shaft, and baffles, such as movable baffles, are installed at opposite ends of the winding die 8 to facilitate the adjustment of the spacing.

[0038] like Figure 2 As shown, the feeding mechanism 3 includes a bracket 37, on which are mounted guide wheels 31, 4th guide wheels 33, 5th guide wheels 34, a tension adjustment mechanism 32, a wire sensor 35, and a guide umbrella 36. The wire on the wire drum below the guide umbrella 36 passes through the guide umbrella 36 and the wire sensor 35 (to monitor whether there is a wire), and then passes through the guide wheel 5 34 to turn to a horizontal state, and then passes through the guide wheel 4 33, the tension adjustment mechanism 32, and the wire wheel 3 31 to connect with the wire mechanism 2. Any one of the guide wheels 5, 4, and 3 can be changed to an upper and lower double wheel structure as needed, such as Figure 2 As shown in the middle guide wheel four, the anti-jump line and tension adjustment mechanism can be selected from the market according to needs. For example, in this embodiment, a guide wheel or a guide shaft is selected, and a sensor is installed on the guide wheel or the guide shaft to sense the pressure. Then, the position can be adjusted up and down on the bracket according to needs.

[0039] like Figure 1 , Figure 2As shown, the focus of our company's improvement is the wire mechanism. The wire mechanism 2 includes a shift mechanism 21 and a mounting frame 22. The shift mechanism 21 uses a ball screw nut mechanism. The mounting frame 22 is fixed on the nut seat and moved along the axis of the rotating shaft. On this basis, a wire arrangement mechanism 25 is added, including a frame, a shift mechanism 252, and a guide wheel 251. In this embodiment, the frame is composed of a vertical plate 256 and a horizontal connecting shaft 257. The vertical plate 256 is located above the winding mold 8 on the rotating shaft 7. The end of the connecting shaft 7 and the mounting frame 22 are pivotally connected to move synchronously and can rotate up and down. A spring 23 is installed on the mounting frame 22 below the pivot connection. The other end of the spring 23 is fixed to the middle position of the connecting shaft 257. The spring 23 is pressed down to better maintain the relative position of the frame and the winding mold. In addition, the wire arrangement mechanism can be flipped up and down by pivoting, and its purpose is to facilitate manual assistance in winding on the winding mold. A second shifting mechanism 252 is installed on the connecting shaft 257, and a ball screw nut mechanism is also selected. A guide wheel 251 is installed on the nut seat of the second shifting mechanism, so that the second shifting mechanism drives the guide wheel 251 to change the position of the axial direction of the rotating shaft. If the moving direction of the second shifting mechanism is parallel to the axial direction of the rotating shaft, as in this embodiment Figure 1 As shown; or with an inclined angle. The wire delivered by the feeding mechanism 3 is fixed on the winding die of the rotating shaft after winding around the guide wheel 1 251. In order to improve the stability of this embodiment, the guide wheel 24 is installed on the mounting frame, and an upper and lower double wheel structure is adopted to prevent wire jumping.

[0040] In view of the special method of inclined winding, in this embodiment, a limiting shaft 253 and a wire arrangement shaft 255 for limiting the wire are fixed on the vertical plate 256, such as Figure 1 , Figure 2 As shown, the limit shaft 253 is parallel to the axial direction of the rotating shaft 7 and is located above the rotating shaft. The end of the limit shaft 253 can be fixed to the vertical plate 256 by bolts, nuts, etc., so as to facilitate the adjustment of the position to meet the winding requirements of different radial heights. The radial spacing between the limit shaft and the winding mold can be calculated in advance to meet the radial height of the coil. The wire arrangement shaft 255 is located on one side of the vertical plate 256. The tail end of the wire arrangement shaft 255 is connected to the vertical plate 256, preferably pivotally connected, to adjust the angle a between the wire arrangement shaft 255 and the axial direction of the rotating shaft 7. In this embodiment, the angle a can be 60°, 45°, etc., so as to limit the position of the wire material by the wire arrangement shaft. In this embodiment, a roller 254 is installed at the bottom of the vertical plate, so that the roller 254 abuts against the circumference of the winding mold 8 on the rotating shaft to ensure that the shape of the winding is consistent with the winding mold.

[0041] Of course, guide posts 211 may also be added to the installation location of the displacement mechanism 1 21 on the frame, and guide posts may be installed above and below the lead screw to guide the nut seat.

[0042] In this embodiment, a control system 6 is installed on the main box 1 to control the shaft mechanism, the wire mechanism, and the feeding mechanism. The control cabinet and the operation panel 61 are composed. The control cabinet can be built inside or outside the main box 1, and the operation panel 61 is located on the main box 1 to facilitate operation.

[0043] The specific winding method is as follows:

[0044] The first step is to wind the wire delivered by the feeding mechanism around the guide wheel 2 and the guide wheel 1 in the conductor mechanism and then fix the wire on the winding die on the rotating shaft;

[0045] The second step is to manually turn over the wire arrangement mechanism to free up operating space, and manually wind a right-angle triangle area at the head end of the winding die. Figure 3 As shown in the middle figure, the dotted triangle area is triangle area 1 (left side) and triangle area 2 (right side). The small circle in the figure represents a single wire, and the direction of the line is the winding order. There are various winding methods for triangle area 1. Figure 3 Take the middle figure as an example, first wind two circles horizontally as the bottom layer; then turn back and wind two layers radially, namely the next first layer and the second layer; then turn back from the second layer to the next first layer and the bottom layer, and repeat the cycle to form a right triangle area 1, that is, the order shown by the lines in the figure; after winding, wrap the outer insulation layer and fix it. Of course, it can also be based on Figure 3 Wind as shown above or below.

[0046] The third step is to use shift mechanism 1 to move the wire arrangement mechanism toward the tail end of the winding mold for coarse adjustment, and use shift mechanism 2 to move guide wheel 1 for fine adjustment, and wind multiple inclined surface areas along the inclined surface of right-angled triangle area 1, and reciprocate along the inclined surface of right-angled triangle area 1. Then, in the opposite winding order of right-angled triangle area 1, manually assist in winding right-angled triangle area 2 at the terminal end of the winding mold, and cover the right-angled triangle area with an insulating layer.

[0047] The fourth step is to wrap the wound coil with an insulating layer.

[0048] Of course, under the structure of this machine, multiple wires can be wound together, and flat wires can also be wound, which will not be described in detail here.

[0049] The above are only preferred embodiments of the present invention. The protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

Claims

1. A fully automatic high-voltage coil winding machine, comprising a rotating shaft mechanism, a conductor mechanism (2), and a feeding mechanism (3), wherein the conductor mechanism (2) comprises a shift mechanism (21) and a mounting frame (22), wherein the shift mechanism drives the mounting frame to move, and wherein: The wire guide mechanism (2) further comprises a wire arrangement mechanism (25), the wire arrangement mechanism (25) comprising a frame, a second shift mechanism (252), and a first guide wheel (251); the frame is connected to the mounting frame (22) for synchronous movement; the second shift mechanism (252) is arranged on the frame, and the second shift mechanism drives the first guide wheel to move so that the first guide wheel changes its position in the axial direction of the rotating shaft in the rotating shaft mechanism; the wire delivered by the feeding mechanism (3) is wound around the first guide wheel (251); a limiting shaft (253) and a wire arrangement shaft (255) for limiting the wire are arranged on the frame; a radial spacing of a predetermined distance exists between the limiting shaft (253) and the winding die (8) on the rotating shaft (7); the angle between the length extension direction of the wire arrangement shaft (255) and the axial direction of the rotating shaft (7) is a, 0<a<90°, The winding method of the fully automatic high voltage coil winding machine comprises the following steps The first step is to wind the wire delivered by the feeding mechanism around the wire guide mechanism and fix it on the winding die on the rotating shaft; The second step is to wind a right-angle triangle area 1 at the head end of the winding mold, and then to cover the wound right-angle triangle area 1 with an insulating layer; The third step is to wind multiple inclined areas along the inclined surface of the right-angle triangle area one toward the tail end of the winding mold, and then wind the right-angle triangle area two at the terminal end of the winding mold in the opposite winding order to the right-angle triangle area one, and cover the right-angle triangle area with an insulating layer.

2. A fully automatic high voltage coil winding machine as claimed in claim 1, characterized in that: The method also includes the step of wrapping an insulating layer around the wound coil.

3. A fully automatic high voltage coil winding machine as claimed in claim 1, characterized in that: A roller (254) is arranged on the frame, and the roller abuts against the peripheral surface of the winding mold arranged on the rotating shaft.

4. A fully automatic high voltage coil winding machine as claimed in claim 1, characterized in that: The frame body is pivotally connected to the mounting frame (22), the frame body is displaced up and down relative to the rotating shaft (7), and a spring (23) is arranged on the mounting frame below the pivotal connection, and the other end of the spring (23) is connected to the frame body.

5. A fully automatic high voltage coil winding machine as claimed in claim 1, characterized in that: The shifting mechanism (21) is a ball screw nut mechanism. The shifting mechanism (21) is located on one side of the rotating shaft and moves the mounting frame (22) along the axial direction of the rotating shaft (7).

6. A fully automatic high voltage coil winding machine as claimed in claim 1, characterized in that: The second shifting mechanism (252) is a ball screw nut mechanism, and the second shifting mechanism moves the guide wheel (251) along the axial direction of the rotating shaft.

7. A fully automatic high voltage coil winding machine as claimed in claim 1, characterized in that: A second guide wheel (24) is arranged on the mounting frame (22), and the wire material transported by the feeding mechanism (3) is passed through the second guide wheel (24) and the first guide wheel (251) in sequence.

8. A fully automatic high voltage coil winding machine as claimed in claim 1, characterized in that: The feeding mechanism (3) comprises a bracket (37), on which are arranged guide wheel three (31), guide wheel four (33), guide wheel five (34), tension adjustment mechanism (32), wire sensor (35), and guide umbrella (36); the wire on the wire drum passes through the guide umbrella (36), wire sensor (35), guide wheel five (34), guide wheel four (33), tension adjustment mechanism (32), wire wheel three (31), and guide wheel one (251) in sequence; The rotating shaft mechanism comprises a main box (1), a power mechanism, a rotating shaft (7) and a tailstock (5). The main box (1) is provided with the power mechanism, the output end of the power mechanism is connected to the rotating shaft (7), the other end of the rotating shaft (7) is provided on the tailstock (5), a winding die (8) is provided on the rotating shaft (7), and baffles are provided at opposite ends of the winding die.

9. A fully automatic high voltage coil winding machine as claimed in claim 8, characterized in that: It also includes a control system connected to the rotating shaft mechanism, the wire mechanism, and the feeding mechanism. The control system includes a control cabinet and an operation panel (61). The operation panel (61) is arranged on the main box (1).

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