A flexible insulator fully encapsulated dry-type transformer winding structure and manufacturing method

Abstract

The application discloses a kind of elastic insulator full encapsulation dry-type transformer winding structure and manufacturing method, dry-type transformer winding structure includes center winding column, the outer periphery of center winding column is equipped with a plurality of coils that are sequentially connected in series, a plurality of coils constitute the winding of transformer, coil is wound from electromagnetic wire;A plurality of intermediate pads are provided between adjacent coils;The both ends of winding are respectively provided with a plurality of end pads, and the end pads are arranged along the outer periphery of center winding column;End pad, coil, intermediate pad and center winding column surface are encapsulated with elastic insulator.Using the application can simplify the manufacturing difficulty of winding, optimize heat dissipation, reduce cost, while the elastic insulator is effectively filled and fused, and the transformer has good temperature resistance and noise reduction quality.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of elastic insulator full encapsulation dry-type transformer winding structure and manufacturing method, belong to dry-type transformer technical field. BACKGROUND

[0002] Traditional dry-type transformer mainly has three kinds: non-encapsulated impregnated type, epoxy resin casting type, epoxy resin winding type, wherein non-encapsulated impregnated type is the insulation system of electromagnetic wire insulation and air gap, transformer volume is slightly large, easy to absorb moisture;Epoxy resin casting type and winding type are all encapsulated by epoxy resin, and the insulation performance is stable, but epoxy resin is rigid body after curing, and there is cracking risk under extreme climate with large temperature difference.

[0003] To solve the problems of easy moisture absorption of non-encapsulated dry-type transformer and easy cracking of epoxy resin encapsulated dry-type transformer, elastic insulator encapsulated dry-type transformer is proposed. However, this kind of product needs to use rigid epoxy glass fiber insulating cylinder, end ring and comb-shaped support bar for support and protection. This structure is complex, poor in heat dissipation and high in cost, and the epoxy cylinder and comb-shaped support bar are easy to have surface discharge risk after absorbing moisture in later period. SUMMARY

[0004] The present application aims to overcome the deficiencies in the prior art, and provides a kind of elastic insulator full encapsulation dry-type transformer winding structure and manufacturing method, which can simplify the manufacturing difficulty of winding, optimize heat dissipation, improve quality, and reduce cost.

[0005] To achieve the above-mentioned purpose, the present application is realized by using the following technical scheme:

[0006] A kind of elastic insulator full encapsulation dry-type transformer winding structure, comprising a center winding column, a plurality of coils are sequentially connected in series on the outer periphery of the center winding column, the plurality of coils constitute the winding of the transformer, and the coil is wound by electromagnetic wire;

[0007] A plurality of intermediate pads are provided between adjacent coils;

[0008] A plurality of end pads are provided at both ends of the winding, and the end pads are arranged along the outer periphery of the center winding column;

[0009] The end pads, coils, intermediate pads and surface of the center winding column are encapsulated by elastic insulator.

[0010] Optionally, the center winding column is a hollow cylinder, and a plurality of exhaust holes are provided on the circumferential side wall of the center winding column.

[0011] A plurality of heat dissipation channels extending along the winding axis are uniformly arranged on the periphery of the winding, and the heat dissipation channels penetrate through the coils.

[0012] Optionally, the coil is a pie-shaped coil or a layer-shaped coil. The heat dissipation channel can be arranged according to the heat dissipation requirement, and for a small-capacity product, if the heat dissipation area is sufficient, the heat dissipation channel can not be arranged.

[0013] Optionally, the intermediate pads between the adjacent coils are arranged on the same plane, and the end pads at each end of the winding are arranged on the same plane; the intermediate pads and the end pads on the same horizontal plane are uniformly distributed around the center winding column.

[0014] Optionally, the longitudinal section of the intermediate pad is in the shape of 'L', including a short plate and a long plate, the long plate is arranged on the lower coil of the two adjacent coils with the plate surface perpendicular to the center winding column, and the short plate is arranged on the winding of each coil.

[0015] Optionally, the center winding column, the intermediate pad, the end pad and the elastic insulator are made of silicone rubber products with a Shore hardness greater than 70°.

[0016] Optionally, an adhesive layer is arranged between the end pad, the coil, the intermediate pad and the elastic insulator.

[0017] A manufacturing method of a dry-type transformer winding structure fully encapsulated by an elastic insulator, comprising the following steps:

[0018] A hollow cylindrical center winding column is made;

[0019] A plurality of coils connected in series are wound on the outer periphery of the center winding column using electromagnetic wires, and the plurality of coils constitute the winding of the transformer, and during the winding process, intermediate pads are arranged between the adjacent coils;

[0020] End pads are arranged at both ends of the winding;

[0021] After the winding process and the pad installation are completed, a mold is arranged outside the winding structure, liquid material of the elastic insulator is poured into the mold, and the elastic insulator is solidified to obtain a fully encapsulated dry-type transformer winding.

[0022] Optionally, during the winding process, a plurality of groups of air channel plates extending in the axial direction of the winding are uniformly arranged in the circumferential direction of the winding, and a permeable insulator is wrapped on the outer periphery of the air channel plate; after the encapsulation and solidification of the elastic insulator, the air channel plate is removed, so that the original position of each group of air channel plates forms a heat dissipation channel extending in the axial direction of the winding.

[0023] Optionally, before encapsulation, an adhesion-promoting primer is coated on the surface of the end pad, the coil and the intermediate pad.

[0024] Compared with the prior art, the present application has the following beneficial effects:

[0025] The application provides a kind of elastic insulator encapsulated dry-type transformer winding structure, without rigid inner cylinder, end ring, comb support protection support, improve the compatibility with elastic insulator, optimize the heat dissipation structure, make the transformer have good high temperature resistance and noise reduction effect, while shorten the production period, effectively reduce cost.The elastic insulator in the winding of the application can be effectively filled and fused, so that the transformer has good temperature resistance, noise reduction quality. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 It is the structure schematic diagram of one embodiment of the elastic insulator fully encapsulated dry-type transformer winding structure of the application.

[0027] Figure 2 It is the axial cross-sectional schematic diagram of the elastic insulator fully encapsulated dry-type transformer winding structure. Figure 1

[0028] Figure 3 It is the center winding column flat structure schematic diagram in one embodiment of the elastic insulator fully encapsulated dry-type transformer winding structure of the application.

[0029] Figure 4 It is the intermediate pad structure schematic diagram in one embodiment.

[0030] Figure 5 It is the structure schematic diagram of the second embodiment of the elastic insulator fully encapsulated dry-type transformer winding structure of the application.

[0031] In the figure: 1, center winding column; 2, end pad; 3, pie-shaped coil; 4, intermediate pad; 41, short plate; 42, long plate; 5, elastic insulator; 6: layer type coil. DETAILED DESCRIPTION

[0032] The application will be further described below in combination with the drawings. The following examples are only used to more clearly illustrate the technical solutions of the application, and cannot be used to limit the protection scope of the application.

[0033] ​In the description of the present application, it needs to be understood that the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second" and the like are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined with "first", "second" and the like can be explicitly or implicitly included one or more. In the description of the present application, unless otherwise specified, the meaning of "a plurality of" is two or more.

[0034] In the description of the present application, it needs to be understood that unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connection" should be understood in a broad sense, for example, it can be fixed connection, or detachable connection, or integral connection; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through intermediate medium, or the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood through specific circumstances.

[0035] Embodiment 1

[0036] As shown in Figures 1 to 4 , a full encapsulation dry-type transformer winding structure of elastic insulation body includes a hollow cylindrical center winding column 1, the center winding column 1 of the embodiment is curled by silica gel plate, referring to Figure 3 , a plurality of rows of exhaust holes are arranged on the side wall of the center winding column 1;

[0037] As shown in Figure 1 , a plurality of series pie-shaped coils 3 are sleeved on the outer periphery of the center winding column 1, the plurality of pie-shaped coils 3 constitute the winding of the transformer, the pie-shaped coil 3 is composed of wound electromagnetic wire, and the electromagnetic wire can be selected from polyimide enameled wire, double glass silk covered wire, polyimide film covered wire or aramid paper covered wire.

[0038] Four end pads 2 are arranged on the two ends of the winding and uniformly distributed along the outer periphery of the center winding column 1.

[0039] The intermediate pad 4 is used for partition between the pie-shaped coils 3, and 8-16 intermediate pads 4 are arranged between the adjacent pie-shaped coils 3 and uniformly distributed along the outer periphery of the center winding column 1, referring to Figure 4As shown, the longitudinal section of the intermediate spacer 4 is in "L" shape, including a short plate 41 and a long plate 42, which are placed vertically and horizontally respectively, and the short plate 41 is close to the side wall of the center winding column 1, and each pancake coil 3 is arranged on the short plate 41. The long plate 42 is placed on the lower pancake coil 3 in the two adjacent pancake coils 3 with the plate surface perpendicular to the center winding column 1.

[0040] In order to facilitate mass production, the end spacer 2 and the intermediate spacer 4 can be made into multiple fixed specifications to adapt to products of various capacities.

[0041] According to the heat dissipation needs, the winding periphery can be uniformly provided with a plurality of heat dissipation channels extending along the winding axis, and each heat dissipation channel penetrates each coil for improving the heat dissipation of the transformer.

[0042] The surface of the center winding column 1, the end spacer 2, the pancake coil 3 and the intermediate spacer 4 is encapsulated with an elastic insulator 5; an adhesive layer is arranged between the end spacer 2, the pancake coil 3, the intermediate spacer 4 and the elastic insulator 5, the adhesive layer is a tackifier primer, and the adhesive layer can improve the adhesion of the elastic insulator.

[0043] In combination Figure 1 And Figure 2 In the axial direction of the center winding column 1, each end spacer 2 is in the same straight line with one intermediate spacer 4 in each layer, and in addition, the end spacer 2 directly contacts with the body pressing block and the spacer during the assembly of the later transformer, so as to form the overall fixation to the winding.

[0044] The center winding column 1, the intermediate spacer 4, the end spacer 2 and the elastic insulator 5 are preferably made of silicone rubber products, and the Shore hardness of the intermediate spacer 4 and the end spacer 2 is 70°-75°, and if the mechanical strength of the winding is higher, the intermediate spacer 4 and the end spacer 2 can also be made of polyimide, epoxy resin forming materials with higher hardness.

[0045] The manufacturing method of the dry-type transformer winding structure encapsulated by the elastic insulator of the embodiment includes the following steps:

[0046] S1, a hollow cylindrical center winding column 1 is made;

[0047] S2, several pie-shaped coils 3 are wound in series on the outer periphery of the central winding column 1 using electromagnetic wire, and the pie-shaped coils 3 constitute the winding of the transformer. During winding, intermediate spacers 4 are installed between adjacent pie-shaped coils 3; according to the need for heat dissipation, a plurality of groups of air channel plates can also be arranged along the winding, and a permeable insulator is wrapped around the outer periphery of the air channel plate. The permeable insulator can be selected as a coarse sand type glass fiber cloth, and the air channel plate is clamped on the radial plane of each layer of coils, so that after the subsequent air channel plate is removed, a heat dissipation air channel extending along the axis of the winding and penetrating through each coil can be formed. When winding the first turn, the intermediate spacer 4 is placed on the lower pie-shaped coil 3 in sequence, the long plate 42 of the intermediate spacer 4 is placed on the lower pie-shaped coil 3, and the short plate 41 is attached to the side of the central winding column 1. The short plate 41 of the intermediate spacer 4 can be effectively prevented from falling off by pressing it with the first turn of wire.

[0048] S3, end spacers 2 are installed at both ends of the winding;

[0049] S4, the surfaces of the end spacers 2, pie-shaped coils 3 and intermediate spacers 4 are coated with a tackifying primer, i.e. an adhesion layer;

[0050] S5, after the outer mold is assembled, the liquid material of the elastic insulator 5 is poured into the entire mold through vacuum pressure and solidified, thereby forming a complete solid winding unit with the central winding column 1, end spacers 2, pie-shaped coils 3 and intermediate spacers 4. The exhaust holes can serve as exhaust channels during pouring of the elastic insulator 5;

[0051] S6, for the air channel plate, the air channel plate is removed, thereby forming a winding heat dissipation channel and improving the heat dissipation of the transformer.

[0052] Example 2

[0053] As shown in Figure 5 , the elastic insulator fully encapsulated dry-type transformer winding structure of the present embodiment includes a hollow cylindrical central winding column 1, and a plurality of rows of exhaust holes are arranged on the side wall of the central winding column 1.

[0054] Different from example 1, in the present embodiment, a plurality of series-connected layer-shaped coils 6 are sleeved on the outer periphery of the central winding column 1, and the layer-shaped coils 6 constitute the winding of the transformer. The layer-shaped coils 6 are composed of wound electromagnetic wire. For a 10kV level winding, 4-6 layers of layer-shaped coils are preferred, and the electromagnetic wire can be selected from polyimide enameled wire, double glass silk covered wire, polyimide film covered wire or aramid paper covered wire.

[0055] Four end spacers 2 are arranged at both ends of the winding, and the end spacers 2 are uniformly distributed along the outer periphery of the central winding column 1.

[0056] The intermediate spacer 4 is used for partition between the layer type coils 6, and 8-16 intermediate spacers 4 are arranged between the adjacent layer type coils 6 along the outer periphery of the center winding post 1. The longitudinal section of the intermediate spacer 4 is in the shape of "L", and includes a short plate 41 and a long plate 42. The short plate 41 and the long plate 42 are arranged vertically and horizontally respectively, and the short plate 41 is close to the side wall of the center winding post 1. The layer type coils 6 are arranged on the short plate 41, and the long plate 42 is arranged on the lower layer type coil 6 of the two adjacent layer type coils 6.

[0057] In order to facilitate mass production, the end spacer 2 and the intermediate spacer 4 can be made into multiple fixed specifications to adapt to products of various capacities.

[0058] The winding can be provided with axial heat dissipation channels along the circumference to improve the heat dissipation of the transformer.

[0059] The surface of the center winding post 1, the end spacer 2, the layer type coil 6 and the intermediate spacer 4 is encapsulated with the elastic insulator 5. An adhesive layer is arranged between the end spacer 2, the layer type coil 6, the intermediate spacer 4 and the elastic insulator 5. The adhesive layer is tackifier primer, and the adhesive layer can improve the adhesion of the elastic insulator.

[0060] In the axial direction of the center winding post 1, each end spacer 2 and one intermediate spacer 4 in each layer are on the same straight line. In addition, the end spacer 2 directly contacts the body pressing block and the spacer during the assembly of the transformer, so that the overall fixation of the winding can be formed.

[0061] The center winding post 1, the intermediate spacer 4, the end spacer 2 and the elastic insulator 5 are preferably made of silicone rubber products. The Shore hardness of the intermediate spacer 4 and the end spacer 2 is 70°-75°. If the mechanical strength of the winding is higher, the intermediate spacer 4 and the end spacer 2 can also be made of polyimide and epoxy resin forming materials with higher hardness.

[0062] The elastic insulator encapsulated dry-type transformer winding of the above-mentioned embodiment does not need the protection and support of the rigid inner cylinder, the end ring and the comb-shaped support, improves the compatibility with the elastic insulator, and has simple structure, easy operation and smooth heat dissipation. At the same time, the elastic insulator in the winding can be effectively filled and fused, so that the transformer has good temperature resistance and noise reduction quality.

[0063] The above-mentioned is only the preferred embodiment of the present application. It should be noted that those skilled in the art can make several improvements and modifications without departing from the technical principles of the present application. These improvements and modifications should also be considered as the protection scope of the present application.

Claims

1. A dry-type transformer winding structure fully encapsulated with an elastomeric insulator, characterized by: The center winding column is provided with a plurality of coils in series, which form the winding of the transformer, and the coils are wound by electromagnetic wire; A plurality of intermediate blocks are arranged between adjacent coils, and the longitudinal section of the intermediate block is "L" shaped, including a short plate and a long plate, and the long plate is arranged on the lower coil of the two adjacent coils with the plate surface perpendicular to the center winding column, and the short plate is arranged on the side of the center winding column, and each coil is arranged on the short plate; A plurality of end blocks are arranged at both ends of the winding, and the end blocks are arranged along the outer periphery of the center winding column; in the axial direction of the center winding column, each end block is in the same straight line with one intermediate block in each layer; A plurality of heat dissipation channels extending in the axial direction of the winding are uniformly arranged around the winding, and the heat dissipation channels penetrate through each coil; The end blocks, coils, intermediate blocks and the surface of the center winding column are encapsulated with elastic insulator; The manufacturing method of the dry-type transformer winding structure comprises the following steps: A hollow cylindrical center winding column is made; A plurality of coils in series are wound on the outer periphery of the center winding column using electromagnetic wire, and the plurality of coils form the winding of the transformer, and during the winding process, intermediate blocks are installed between adjacent coils, and a plurality of groups of air channel plates extending in the axial direction of the winding are uniformly arranged around the winding, and a permeable insulator is wrapped around the outer periphery of the air channel plate, and intermediate blocks are installed between adjacent coils; End blocks are installed at both ends of the winding; After the winding structure is completed, the mold is installed outside the winding structure, the liquid material of the elastic insulator is poured into the mold, and the elastic insulator is solidified; After the encapsulation and solidification of the elastic insulator, the air channel plate is taken out, so that the original air channel plate forms a heat dissipation channel extending in the axial direction of the winding; The encapsulated dry-type transformer winding is obtained.

2. A flexible insulation fully encapsulated dry-type transformer winding structure according to claim 1, characterized in that: The center winding column is a hollow cylinder, and a plurality of exhaust holes are arranged on the circumferential side wall of the center winding column.

3. A flexible insulation fully encapsulated dry-type transformer winding structure as claimed in claim 1, wherein: The coil is a pie-shaped coil or a layer-shaped coil.

4. A flexible insulation fully encapsulated dry-type transformer winding structure as claimed in claim 2, wherein: The plurality of intermediate blocks between adjacent coils are arranged on the same plane, and the plurality of end blocks at each end of the winding are arranged on the same plane; the intermediate blocks and the end blocks on the same horizontal plane are uniformly distributed around the center winding column.

5. A flexible insulation fully encapsulated dry-type transformer winding structure as claimed in claim 1, wherein: The center winding column, the intermediate blocks, the end blocks and the elastic insulator are made of silicone rubber products, and the Shore hardness is greater than 70°.

6. A flexible insulation fully encapsulated dry-type transformer winding structure as claimed in claim 1, wherein: An adhesive layer is arranged between the end blocks, the coils, the intermediate blocks and the elastic insulator.

7. The elastically insulated fully-encapsulated dry-type transformer winding structure of claim 1, wherein, The manufacturing method of the dry-type transformer winding structure further comprises the step of: before encapsulation, coating a tackifying primer on the surface of the end blocks, coils and intermediate blocks.

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