A method for preparing a transformer disk winding with ceramic aluminum wire

Abstract

A method for preparing a pancake-type transformer winding using ceramic aluminum conductors comprises: winding the aluminum conductors onto a winding drum, separating each aluminum conductor with a toothed spacer, the aluminum conductors being clamped into the interdental grooves of the toothed spacer, and the winding drum and the toothed spacer serving as conductors; subjecting the winding drum with the aluminum conductors to micro-arc oxidation / thermoelectrochemical oxidation to form a ceramic aluminum conductor; placing the oxidized winding drum into an insulating drum having comb-type struts on its inner wall, rotating the winding drum in a direction opposite to the winding direction of the ceramic aluminum conductors, causing the ceramic aluminum conductors to be clamped into the comb-type struts one by one to form a pancake, and connecting the pancakes on the insulating drum in series to form a pancake-type transformer winding. The method for winding a pancake using ceramic aluminum conductors of the present invention clamps the ceramic aluminum conductors into the comb-type struts in the winding drum in an internal unwinding manner, with the ends of the prefabricated bent ceramic aluminum conductors being tangential to the insulating drum and the winding drum, respectively, thereby cleverly avoiding the problem of excessive bending of the ceramic aluminum conductors during winding.

Description

Technical Field

[0001] The invention relates to a method for preparing a transformer winding, and in particular to a method for preparing a transformer pancake winding by using a ceramic aluminum conductor. Background Art

[0002] Aluminum conductors with ceramic coatings are a new type of conductor, but due to the ceramic coating on their surface, these conductors are very vulnerable to bending (CN2022107568886). When using this conductor for conventional windings, the inevitable large bends can cause the ceramic coating to fall off, affecting its insulation performance, thus limiting its application in transformer windings. Summary of the Invention

[0003] The object of the present invention is to provide a method for preparing a pancake-type winding of a transformer which can avoid significant bending of a ceramic aluminum conductor.

[0004] In order to achieve the above-mentioned purpose of the invention, the technical solution of the present invention is as follows:

[0005] A method for preparing a pancake-type winding of a transformer using ceramic aluminum wires comprises the following steps:

[0006] (1) The aluminum wires are wound on a winding drum, and the aluminum wires are separated by toothed pads. The aluminum wires are stuck in the interdental grooves of the toothed pads. The winding drum and the toothed pads serve as conductors.

[0007] (2) performing micro-arc oxidation / thermal electrochemical oxidation on the winding drum wound with the aluminum wire to form a ceramic aluminum wire;

[0008] (3) Place the oxidized winding drum into an insulating drum with comb-type struts on the inner wall, and rotate the winding drum in the direction opposite to the winding direction of the ceramic aluminum wire so that the ceramic aluminum wire is inserted into the comb-type struts one by one to form a coil. Connect the coils on the insulating drum in series to form a transformer coil winding.

[0009] Furthermore, the toothed pads in step (1) have a clamping structure at both ends, and the types of toothed pads are divided into inner pads, middle pads and an outer pad, and the inner pads, middle pads and outer pads are stacked and clamped in sequence, the inner pads and outer pads are single-sided teeth, the middle pads are symmetrical double-sided teeth, the teeth on the outer pads face the inter-tooth grooves of the middle pads, one of the inner pads is an inner fixed pad, the teeth of the inner fixed pads face the inter-tooth grooves of the middle pads, the inter-tooth grooves of each middle pad are opposite, and the inner pads are fixed on the winding drum; when winding, the inner joint of the aluminum wire is clamped by the teeth of the inner fixed pad in the inter-tooth groove of the middle pad adjacent to the inner pad; after winding is completed, the outer joint of the aluminum wire is clamped by the teeth of the outer pad in the inter-tooth groove of the middle pad adjacent to the outer pad.

[0010] Furthermore, step (2) includes: immersing the winding drum wrapped with the aluminum wire into an electrolyte, placing a cathode in the electrolyte, connecting the winding drum and the cathode to a micro-arc oxidation / thermal electrochemical oxidation power supply respectively, and performing micro-arc oxidation / thermal electrochemical oxidation treatment on the aluminum wire to form a ceramic aluminum wire.

[0011] Furthermore, step (2) includes: immersing the winding drum wrapped with the aluminum wire into a stainless steel barrel containing an electrolyte, and connecting the winding drum and the stainless steel barrel to a micro-arc oxidation / thermo-electrochemical oxidation power supply respectively, performing micro-arc oxidation / thermo-electrochemical oxidation treatment on the aluminum wire to form a ceramic aluminum wire.

[0012] Furthermore, step (3) includes: placing the oxidized winding drum into an insulating drum having a comb-type support bar on the inner wall, rotating the winding drum in a direction opposite to the winding direction of the ceramic aluminum wire, so that the ceramic aluminum wire is clamped into the comb-type support bar one by one to form a wire cake, and connecting the wire cakes on the insulating drum in series to form a transformer pancake winding; when the winding drum rotates in the opposite direction, the tooth-shaped pads between the ceramic aluminum wires fall off one by one, and the tooth-shaped pads are recovered and reused.

[0013] Compared with the prior art, the present invention has the following beneficial technical effects:

[0014] The method of winding a bobbin with a ceramic aluminum conductor of the present invention clamps the ceramic aluminum conductor into a comb-type support bar in the winding drum in the form of internal unwinding, and the two ends of the prefabricated bent ceramic aluminum conductor are tangent to the insulating drum and the winding drum respectively, which cleverly avoids the problem of excessive bending amplitude of the ceramic aluminum conductor during winding. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 1 is a top view of a device for preparing a pancake-type winding of a transformer in Example 1 of the present invention;

[0016] Figure 2 This is a top view of the aluminum wire after it is wound on the winding drum;

[0017] Figure 3 It is a diagram of the type of pad strips of the present invention;

[0018] Figure 4 yes Figure 2 AA section view in;

[0019] Figure 5 yes Figure 2 BB cross-section view in. DETAILED DESCRIPTION

[0020] The technical solutions of the present invention will be described clearly and completely below in conjunction with the accompanying drawings and specific embodiments. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are also within the scope of protection of the present invention.

[0021] Example 1:

[0022] A method for preparing a pancake-type winding of a transformer using ceramic aluminum wires comprises the following steps:

[0023] (1) The aluminum conductors are wound on the winding drum, and the aluminum conductors are separated by toothed pads. The aluminum conductors are clamped in the inter-tooth grooves of the toothed pads. The winding drum and the toothed pads are conductors; the toothed pads have a clamping structure at both ends. The types of toothed pads are divided into inner pads, middle pads and an outer pad. The inner pads, middle pads and outer pads are stacked and clamped in sequence. The inner pads and outer pads are single-sided teeth, the middle pads are symmetrical double-sided teeth, and the teeth on the outer pads face the middle pads. The intertooth grooves of the padding strips, one of the inner padding strips is an inner fixed padding strip, the teeth of the inner fixed padding strip face the intertooth grooves of the middle padding strips, the intertooth grooves of each middle padding strip are opposite, and the inner padding strips are fixed on the winding drum; when winding, the inner layer joint of the aluminum wire is clamped by the teeth of the inner fixed padding strip in the intertooth groove of the middle padding strip adjacent to the inner layer padding; after the winding is completed, the outer layer joint of the aluminum wire is clamped by the teeth of the outer padding strip in the intertooth groove of the middle padding strip adjacent to the outer layer padding.

[0024] (2) The winding drum wrapped with the aluminum wire is immersed in a stainless steel barrel filled with electrolyte, and the winding drum and the stainless steel barrel are respectively connected to a micro-arc oxidation / thermoelectrochemical oxidation power supply to perform micro-arc oxidation / thermoelectrochemical oxidation treatment on the aluminum wire to form a ceramic aluminum wire (the specific method of micro-arc oxidation / thermoelectrochemical oxidation can be referred to patent CN2022104775920).

[0025] (3) Place the oxidized winding drum into an insulating drum with comb-type struts on the inner wall, and rotate the winding drum in the direction opposite to the winding direction of the ceramic aluminum wire, so that the ceramic aluminum wire is clamped into the comb-type struts one by one to form a coil, and connect the coils on the insulating drum in series to form a transformer coil winding; when the winding drum rotates in the opposite direction, the tooth-shaped pads between the ceramic aluminum wires fall off one by one, and the tooth-shaped pads are recovered and reused.

[0026] The device structure used in the method of the present invention is as follows Figure 1-5As shown, the device comprises an insulating drum 1 and a winding drum 2. The inner wall of the insulating drum 1 has comb-like struts 101. Eight aluminum wires 3 are wound side by side around the winding drum 2, with backing strips 4 placed between each layer of aluminum wires 3. The winding drum 2 and backing strips 4 serve as conductors. The winding drum 2 and backing strips 4 are made of stainless steel. The backing strips 4 are tooth-shaped, and the aluminum wires 3 are retained in the interdental grooves of the tooth-shaped backing strips. The interdental grooves can be rectangular or semicircular in shape; in this embodiment, a semicircular shape is used as an example.

[0027] The toothed pads have snap joints 405 and snap slots (not shown) at both ends, and the matching snap joints 405 and snap slots are located on adjacent pads 4. The pads 4 include an inner pad 404, a middle pad 402, and an outer pad 401. The outer pad 401 and the middle pad 402 have handles 406 at both ends. The inner gasket 404, the middle gasket 402 and the outer gasket 401 are stacked and clamped in sequence. The inner gasket 404 and the outer gasket 401 are single-sided teeth, and the middle gasket 402 is symmetrical double-sided teeth. The teeth on the outer gasket 401 face the inter-tooth groove of the middle gasket 402. One of the inner gaskets is the inner fixed gasket 403. The teeth of the inner fixed gasket 403 face the inter-tooth groove of the middle gasket 402. The inter-tooth grooves of each middle gasket 402 are opposite. The inner gasket 404 and the inner fixed gasket 403 are fixed on the winding drum 2. The inner joint of the aluminum wire 3 is clamped by the teeth of the inner fixed gasket 403 in the inter-tooth groove of the middle gasket 402 adjacent to the inner fixed gasket 403. The outer joint of the aluminum wire 3 is clamped by the teeth of the outer gasket 401 in the inter-tooth groove of the middle gasket 402 adjacent to the outer gasket 401.

[0028] The width of the interdental grooves of the middle layer gasket 402 is greater than the width of the ceramic aluminum wire 3 ′, and the height between the opposite interdental grooves on the middle layer gasket 402 is greater than the thickness of the ceramic aluminum wire 3 ′, so as to minimize the area on the aluminum wire 3 that is shielded by the gasket 4.

[0029] After the aluminum conductor 3 on the winding drum 2 is subjected to micro-arc oxidation / thermoelectrochemical treatment to form a ceramic aluminum conductor 3', the winding drum 2 is placed in the insulating drum 1, and the outer wire ends of the ceramic aluminum conductor 3' on the winding drum 2 are inserted into the comb-type support bar 101 side by side and fixed. Then, the winding drum 2 is rotated in a direction opposite to the winding direction of the ceramic aluminum conductor 3', so that the ceramic aluminum conductor 3' is inserted into the comb-type support bar 101 turn by turn to form a wire cake. As the winding drum 2 rotates, the backing strips 4 between each layer of ceramic aluminum conductor 3' fall off one by one, and the fallen backing strips 4 are recycled and reused. Finally, the wire cakes are connected in series to form a transformer pancake winding.

[0030] The method of the present invention first winds an aluminum conductor 3 onto a winding drum 2 and oxidizes it to form a curved ceramic aluminum conductor 3'. Then, the winding drum 2 is rotated in the opposite direction within the insulating drum 1, causing the ceramic aluminum conductor 3' to engage with comb-shaped stays 101 to form a coil. During coil winding, the ends of the curved ceramic aluminum conductor 3' are tangential to the insulating drum 1 and the winding drum 2, respectively. Compared to conventional winding methods that straighten the wire and then wind it, this winding method significantly reduces the bending amplitude of the ceramic aluminum conductor 3'. By engaging the ceramic aluminum conductor 3' with the comb-shaped stays 101 within the winding drum 1 in an internal unwinding manner, the problem of excessive bending amplitude of the ceramic aluminum conductor 3' during winding is cleverly avoided. The method of the present invention innovatively isolates the aluminum conductor 3 on the winding drum 2 by stacking and engaging toothed strips, facilitating oxidation treatment. Subsequently, during reverse winding, the toothed strips gradually fall off between the winding drum and the insulating drum, allowing for recycling. During the insertion of the ceramic aluminum conductor 3' into the comb-type support bar 101, since the diameter of the ceramic aluminum conductor coil on the bobbin is larger than the diameter of the coil formed on the winding drum 2, the dotted areas on the ceramic aluminum conductor 3' shielded by the pad 4 are staggered in sequence to avoid the formation of short-circuit areas.

Claims

1. A method for preparing a pancake-type transformer winding using ceramic aluminum wire, characterized in that: Including steps: (1) The aluminum wires are wound on a winding drum, and the aluminum wires are separated by toothed pads. The aluminum wires are stuck in the interdental grooves of the toothed pads. The winding drum and the toothed pads serve as conductors. (2) performing micro-arc oxidation / thermal electrochemical oxidation on the winding drum wound with the aluminum wire to form a ceramic aluminum wire; (3) Place the oxidized winding drum into an insulating drum with comb-type struts on the inner wall, and rotate the winding drum in the direction opposite to the winding direction of the ceramic aluminum wire so that the ceramic aluminum wire is gradually clamped into the comb-type struts to form a coil. Connect the coils on the insulating drum in series to form a transformer coil winding. The toothed pads in step (1) have a clamping structure at both ends. The types of toothed pads are divided into inner pads, middle pads and an outer pad. The inner pads, middle pads and outer pads are stacked and clamped in sequence. The inner pads and outer pads are single-sided teeth, and the middle pads are symmetrical double-sided teeth. The teeth on the outer pads face the inter-tooth grooves of the middle pads. One of the inner pads is an inner fixed pad. The teeth of the inner fixed pads face the inter-tooth grooves of the middle pads. The inter-tooth grooves of each middle pad are opposite, and the inner pads are fixed on the winding drum. When winding, the inner joint of the aluminum wire is clamped by the teeth of the inner fixed pad in the inter-tooth groove of the middle pad adjacent to the inner pad. After winding is completed, the outer joint of the aluminum wire is clamped by the teeth of the outer pad in the inter-tooth groove of the middle pad adjacent to the outer pad.

2. The method for preparing a pancake-type transformer winding using ceramic aluminum conductor according to claim 1, characterized in that: Step (2) comprises: immersing the winding drum wrapped with the aluminum wire into an electrolyte, placing a cathode in the electrolyte, connecting the winding drum and the cathode to a micro-arc oxidation / thermal electrochemical oxidation power supply respectively, performing micro-arc oxidation / thermal electrochemical oxidation treatment on the aluminum wire to form a ceramic aluminum wire.

3. The method for preparing a pancake-type transformer winding using ceramic aluminum conductors according to claim 2, characterized in that: Step (2) comprises: immersing the winding drum wound with the aluminum wire into a stainless steel barrel containing an electrolyte, and connecting the winding drum and the stainless steel barrel to a micro-arc oxidation / thermo-electrochemical oxidation power supply respectively, performing micro-arc oxidation / thermo-electrochemical oxidation treatment on the aluminum wire to form a ceramic aluminum wire.

4. The method for preparing a pancake-type transformer winding using ceramic aluminum conductors according to claim 1, characterized in that: Step (3) comprises: placing the oxidized winding drum into an insulating drum having a comb-type support bar on the inner wall, rotating the winding drum in a direction opposite to the winding direction of the ceramic aluminum wire, so that the ceramic aluminum wire is clamped into the comb-type support bar one by one to form a coil, and connecting the coils on the insulating drum in series to form a transformer coil winding; when the winding drum rotates in the opposite direction, the tooth-shaped pads between the ceramic aluminum wires fall off one by one, and the tooth-shaped pads are recovered and reused.

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