A method for manufacturing an arc suppression coil and an arc suppression coil

Abstract

The application relates to a method for manufacturing an arc-extinguishing coil and the arc-extinguishing coil. In the manufacturing process of the arc-extinguishing coil, a rated winding and a tap winding are wound in two or more sectional coils in the axial direction, and each section of the rated winding and the tap winding is led out in a certain mode. Thus, the number of turns of each layer of each sectional coil of the rated winding and the tap winding is reduced, the interlayer voltage is greatly reduced, the insulation requirement of the insulation filling medium between the two adjacent layers of the sectional coil is reduced, the filling thickness requirement of the insulation medium between the two adjacent layers of the sectional coil is reduced, and on the basis of guaranteeing the voltage resistance capacity of the arc-extinguishing coil, the overall volume is relatively reduced, and the resistance level of the arc-extinguishing coil is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of limiting or suppressing ground fault current, and in particular to a method for manufacturing an arc suppression coil and the arc suppression coil itself. Background Technology

[0002] The selection of the neutral grounding method in a distribution network is closely related to the safety, operational reliability, and economy of the power system, and is a crucial issue that must be considered in the construction of urban and rural power grids. The selection of the grounding method must consider both the existing structure and equipment of the distribution network and the technological limitations of the grounding equipment at the time. Currently, one of the most prevalent grounding methods used in the system is the arc suppression coil grounding method. In arc suppression coil grounding systems, the adjustable-turn arc suppression coil is the most widely used. This type of coil has multiple taps, and an on-load tap changer is used to adjust the taps to change the inductance value, thereby achieving the output of the ground inductive current and realizing automatic tracking compensation.

[0003] With the increasing system load and the gradual increase in voltage level, the capacitive current in the 20kV and 35kV distribution networks has reached as high as 200A. For the adjustable-turn arc suppression coil, the current adjustment range is basically designed to be 50A-200A, with 25 ranges. This places more stringent requirements on the internal insulation structure of the adjustable-turn arc suppression coil.

[0004] In existing arc suppression coil manufacturing processes, both the inner and outer rated windings and tap windings are continuously wound axially to form the required number of turns. After one layer of winding is completed, the second layer is wound back, with an insulating medium laid between adjacent layers. During the continuous winding process, a certain number of taps are led out at different positions axially, resulting in a disc-shaped overall configuration for both the rated winding and the tap windings. However, arc suppression coils manufactured using this method have a relatively high interlayer voltage. To meet the product's withstand voltage requirements, a thick insulating layer is often laid between the layers. This not only increases costs but also results in a larger coil size and poorer heat dissipation. Summary of the Invention

[0005] The purpose of this invention is to provide a method for manufacturing an arc suppression coil, thereby solving the problem of the inability to simultaneously achieve the required voltage withstand capability and size in existing arc suppression coils. Furthermore, this invention also provides an arc suppression coil to address the same issue.

[0006] The arc suppression coil manufacturing method of the present invention includes:

[0007] Wound integral windings and cast integral windings;

[0008] The integral winding comprises: a rated winding, and a tap winding wound on the outer side; the end of the rated winding at its first axial end is led out from the first axial end of the tap winding to form a neutral point tap for connecting the neutral point; and the end of the rated winding at its second axial end is led axially to the first axial end of the tap winding and led out from the first axial end of the tap winding.

[0009] The rated winding and the tap winding are both divided into two or more segmented coils in the axial direction for winding. Each segmented coil of the rated winding and the tap winding is wound with at least two layers. The adjacent ends of the adjacent segmented coils of the rated winding are electrically connected. An insulating medium is provided between each two adjacent layers of the segmented coil.

[0010] Connect the end of the segmented coil near the first axial end of the tap winding to the second end of the rated winding and use it as a tap position. Connect the adjacent ends of every two adjacent segmented coils of the tap winding and use them as tap positions. Lead out the end of the segmented coil away from the first axial end of the tap winding at the second axial end of the tap winding and use it as a tap position.

[0011] Casting the integral winding includes: placing the wound integral winding into a mold for insulation casting.

[0012] The arc suppression coil manufactured using the above-described method has a reduced number of turns in each segment of the rated winding and tap winding, resulting in a lower interlayer voltage. This reduces the insulation requirements of the insulating filler between adjacent layers of the segmented coil and decreases the filler thickness, thereby reducing the overall size while maintaining the arc suppression coil's withstand voltage capability. In particular, the winding and tap lead-out methods of the rated winding and tap winding improve the linearity of the volt-ampere characteristics, making the magnetic field more uniform and regular, and thus resulting in a more orderly distribution of the tap current in the arc suppression coil.

[0013] Furthermore, when winding the tap-wound segmented coil, an output terminal is connected to the middle section of the conductor of the tap-wound segmented coil to form an independent tap position. This avoids excessively increasing the number of tap-wound segmented coils when a large number of tap positions are required, reducing manufacturing difficulty and simplifying structural design.

[0014] Furthermore, before winding the tap winding outside the rated winding, a pull core extending axially along the rated winding is placed outside the rated winding, so that the pull core is sandwiched between the rated winding and the tap winding. The second end of the rated winding is led axially from the position between the rated winding and the tap winding to the first axial end of the tap winding. After the entire winding is cast and the insulation is cured, the pull core is removed to form an axially continuous heat dissipation channel between the rated winding and the tap winding. This increases the insulation distance between the rated winding and the tap winding, improves the ability to withstand voltage surges, and effectively reduces the temperature rise of the arc suppression coil, enhances the linearity of the arc suppression coil's volt-ampere characteristic curve, and improves the overall performance of the arc suppression coil.

[0015] Furthermore, there are two or more pull cores, and two adjacent pull cores form an axially penetrating aperture with the rated winding and the tap winding. When the second end of the rated winding is led axially to the first axial end of the tap winding, the second end of the rated winding extends along the aperture. In this way, after casting, the insulator can completely enclose the extended portion of the second end, ensuring the insulation performance between the rated winding and the tap winding.

[0016] Furthermore, the rated winding includes 2-4 segmented coils. The number of segmented coils in the rated winding can be selected within this range to balance product cost and performance.

[0017] Furthermore, the tap winding includes 2-12 segmented coils. Selecting the number of segmented coils within this range, based on the different number of tap positions, allows for a better balance between product cost and performance.

[0018] Furthermore, the cores are multiple and evenly arranged in the circumferential direction of the rated winding. This allows the arc suppression coil to form a uniformly distributed heat dissipation channel on the circumference between the rated winding and the tap winding, which is beneficial for the heat dissipation of the arc suppression coil.

[0019] Furthermore, when the second end of the rated winding is led axially to the first axial end of the tap winding, the second end of the rated winding passes through the gap between two adjacent core pulls, and when casting the integral winding, it is cast into the insulating partition between the two heat dissipation channels. In this way, after casting, the insulator can completely wrap the extended portion of the second end, ensuring the insulation performance between the rated winding and the tap winding.

[0020] Furthermore, during the winding of the entire coil, there are gaps between adjacent segments of the rated winding and between adjacent segments of the tap winding. This maintains the air gap length between the segments, thereby improving the voltage withstand capability of the arc suppression coil.

[0021] The arc-suppression coil of the present invention includes an integral winding and an insulator that is cast and encapsulated within the integral winding. The integral winding includes a rated winding and a tap winding, with the rated winding located inside the tap winding. The rated winding includes two or more segmented rated winding coils spaced apart axially. The adjacent ends of two adjacent rated winding segmented coils are connected. The end of the rated winding segmented coil located at the first axial end of the integral winding is led out to form a neutral point tap. The end of the rated winding segmented coil located at the second axial end of the integral winding is connected to the rated winding and the tap winding. The positions between the windings are folded back along the axial direction to the first axial end of the integral winding and led out. The tap winding includes two or more tap winding segmented coils spaced apart axially. The adjacent ends of two adjacent tap winding segmented coils are connected and led out to form a tap position. The end of the first axial end of the tap winding segmented coil at the first axial end of the integral winding is connected to the end of the second axial end of the rated winding segmented coil at the second axial end of the integral winding and led out to form a tap position. The end of the second axial end of the tap winding segmented coil at the second axial end of the integral winding is led out to form a tap position.

[0022] In this invention, the number of turns in each segment of the rated winding and tap winding of the arc suppression coil is reduced, resulting in a lower interlayer voltage. This reduces the insulation requirements of the insulating filler between adjacent layers of the segmented coil and decreases the filler thickness, thereby reducing the overall size while maintaining the withstand voltage capability of the arc suppression coil. In particular, the winding method and tap lead-out method of the rated winding and tap winding improve the linearity of the volt-ampere characteristic, making the magnetic field more uniform and regular, and thus enabling a more orderly distribution of the tap current in the arc suppression coil.

[0023] Furthermore, each tap winding segmented coil has leads connected between the two ends of the wire winding that winds the coil to form a tap position. This allows for a larger number of tap positions without excessively increasing the number of tap winding segmented coils, reducing manufacturing difficulty and simplifying structural design.

[0024] Furthermore, an axially penetrating heat dissipation channel is provided within the insulator between the rated winding and the tap winding. The second end of the rated winding is axially led from the position between the rated winding and the tap winding to the axial first end of the tap winding. This increases the insulation distance between the rated winding and the tap winding, enhances the ability to withstand voltage surges, and effectively reduces the temperature rise of the arc suppression coil, thereby improving the linearity of the arc suppression coil's volt-ampere characteristic curve and enhancing the overall performance of the arc suppression coil.

[0025] Furthermore, there are multiple heat dissipation ducts, which are spaced apart in the circumferential direction. The arc suppression coil manufactured in this way can form a uniformly distributed heat dissipation duct on the circumference between the rated winding and the tap winding, which is beneficial to the heat dissipation of the arc suppression coil.

[0026] Furthermore, the end of the rated winding segmented coil located at the second axial end of the integral winding is folded back from the position between two adjacent heat dissipation ducts towards the first axial end of the integral winding, and is encased within an insulating partition formed by the insulator between the two adjacent heat dissipation ducts. This improves the insulation performance between the rated winding and the tap winding while making full use of the space between them, thereby increasing the withstand voltage.

[0027] Furthermore, the rated winding includes 2-4 rated winding segmented coils, and the tap winding includes 2-12 tap winding segmented coils. Selecting the number of rated winding segmented coils and tap winding segmented coils within this range, based on the different number of tap positions, can better balance product cost and performance. Attached Figure Description

[0028] Figure 1 This is a half-sectional schematic diagram of Embodiment 1 of the arc suppression coil of the present invention. For ease of explanation, the figure shows the core pulling used during the casting process.

[0029] In the diagram: 11. First rated winding segmented coil; 110. Front end of the first rated winding segmented coil; 111. Rear end of the first rated winding segmented coil; 12. Second rated winding segmented coil; 121. Front end of the second rated winding segmented coil; 120. Rear end of the second rated winding segmented coil; 123. Fold-back lead-out section; 21. First tap-wound segmented coil; 210. Front end of the first tap-wound segmented coil; 211. Rear end of the first tap-wound segmented coil; 213. Lead-out end of the first tap-wound segmented coil; 22. Second tap-wound segmented coil; 220. 1. Front end of the second tap-wound segmented coil; 221. Rear end of the second tap-wound segmented coil; 223. Lead-out end of the second tap-wound segmented coil; 23. Third tap-wound segmented coil; 230. Front end of the third tap-wound segmented coil; 231. Rear end of the third tap-wound segmented coil; 233. Lead-out end of the third tap-wound segmented coil; 24. Fourth tap-wound segmented coil; 240. Front end of the fourth tap-wound segmented coil; 241. Rear end of the fourth tap-wound segmented coil; 243. Lead-out end of the fourth tap-wound segmented coil; 3. Insulator; 4. Core pulling. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention; that is, the described embodiments are merely some embodiments of the invention, not all embodiments. The components of the embodiments of the invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0031] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0032] It should be noted that relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0033] The features and performance of the present invention will be further described in detail below with reference to embodiments.

[0034] Example 1 of the arc suppression coil of the present invention:

[0035] The half-section structure of the arc suppression coil in this embodiment is as follows: Figure 1 As shown (for ease of explanation, Figure 1 The diagram also shows a core puller (4) used during the casting of the arc suppression coil, which is not part of the arc suppression coil.

[0036] For ease of explanation, we will use Figure 1 The indicated orientation is defined as follows: Figure 1 The left side is the front, which is the first axial end of the arc suppression coil. Figure 1 The right side is the rear, which is the second axial end of the arc suppression coil.

[0037] The arc suppression coil in Example 1 is mainly suitable for 20kV and 35kV neutral point grounding. Therefore, the main specifications and parameters of the arc suppression coil are designed and selected based on the principle of better adapting to the voltage level. Of course, in other examples, if the arc suppression coil is suitable for other voltage levels, the specifications and parameters of the arc suppression coil can also be adjusted accordingly.

[0038] The arc suppression coil includes a rated winding and a tap winding. The rated winding is located inside the tap winding. After the rated winding and the tap winding are wound to form an integral winding, they are wrapped by an insulator 3 made of epoxy resin by pouring epoxy resin. Of course, the taps of the rated winding and the tap winding are led out from the insulator 3.

[0039] Structurally, the main difference between the arc suppression coil of this embodiment and the existing arc suppression coil, namely the main improvement of the present invention, lies in the winding method and tap lead-out method of the rated winding and tap winding, and the structure of the insulator 3 formed by casting is also different.

[0040] Referring to the accompanying drawings, the rated winding includes two rated winding segmented coils spaced apart axially, namely the first rated winding segmented coil 11 and the second rated winding segmented coil 12. Preferably, in this embodiment, the two rated winding segmented coils are substantially identical, including the same number of layers and turns. The front end 110 of the first rated winding segmented coil leads out to form a neutral point tap. The rear end 111 of the first rated winding segmented coil is connected to the front end 121 of the second rated winding segmented coil. The rear end 120 of the second rated winding segmented coil is folded back axially and extends from between the rated winding and the tapped winding to the first axial end of the overall winding through the folded-back lead-out section 123.

[0041] Specifically, both rated winding segmented coils have 5 layers. The first rated winding segmented coil 11 is wound from back to front, and after the first layer has been wound to the required number of turns, the second layer is wound from front to back, and so on, with the fifth layer exiting from the front. The second rated winding segmented coil 12 is wound from front to back, and after the first layer has been wound to the required number of turns, the second layer is wound from back to front, and so on, with the fifth layer exiting from the rear. This facilitates the connection of adjacent ends of the two rated winding segmented coils.

[0042] The tap winding includes four axially spaced segmented coils: a first segmented coil 21, a second segmented coil 22, a third segmented coil 23, and a fourth segmented coil 24. Similar to the rated winding, in this embodiment, preferably, the four segmented coils are substantially identical, including the same number of layers and turns. Each segmented coil is wound starting from the front; after the first layer reaches the required number of turns, the second layer is wound from back to front until the required number of layers is completed. Each tap-wound segmented coil has a front end and a rear end. Adjacent ends of two adjacent tap-wound segmented coils are connected and led out to form a tap position. Specifically, the rear end 211 of the first tap-wound segmented coil is connected and led out to form a tap position, the rear end 221 of the second tap-wound segmented coil is connected and led out to form a tap position, the rear end 221 of the second tap-wound segmented coil is connected and led out to form a tap position, and the rear end 231 of the third tap-wound segmented coil is connected and led out to form a tap position.

[0043] In addition, each tap winding segmented coil also has a tap winding segmented coil lead-out end that is connected to a wire at a certain position in the middle layer of the tap winding segmented coil and leads outward. This lead-out end constitutes a tap position, that is, the first tap winding segmented coil lead-out end 213 constitutes a tap position, the second tap winding segmented coil lead-out end 223 constitutes a tap position, the third tap winding segmented coil lead-out end 233 constitutes a tap position, and the fourth tap winding segmented coil lead-out end 243 constitutes a tap position.

[0044] For the tap-wound segmented coils located at both ends of the overall winding axis, namely the first tap-wound segmented coil 21 and the fourth tap-wound segmented coil 24 in this embodiment, the front end 210 of the first tap-wound segmented coil is connected to the rear end 120 of the second rated winding segmented coil to form a tap position, and the rear end 241 of the fourth tap-wound segmented coil forms a tap position independently.

[0045] It should be noted that during the winding of each segmented coil, an insulating medium is laid between adjacent layers. The insulating medium includes insulating paper and insulating mesh. After the entire winding is completed, during vacuum casting, the flowing epoxy resin can enter the coil layers through the gaps in the insulating mesh to achieve interlayer insulation. These are all existing mature technologies, and will not be elaborated on in detail in this article.

[0046] As can be seen from the above description, in this embodiment, both the rated winding and the tap winding are wound in segments to form axially spaced segmented coils. This reduces the number of turns in each segmented coil, thereby lowering the interlayer voltage between adjacent layers of each segmented coil, reducing the interlayer insulation requirements, and allowing for a reduction in the thickness of the interlayer insulation medium, thus reducing the overall volume of the arc suppression coil. Furthermore, the segmented winding of the tap winding to form axially spaced segmented coils makes it easier to set the tap position, avoiding overvoltage issues at the tap outlet and resulting in a more orderly tap current distribution.

[0047] Of course, the above embodiments are mainly designed for a voltage level of 35kV, taking into account manufacturing costs and product performance. For other voltage levels or other usage requirements, the number of rated winding group split coils can be 3 or 4. Depending on the number of tap positions, the number of tap winding group segmented coils can be 2, 7, 9, 12, etc., and can be selected within the range of 2-12. The total number of taps led out from each tap winding group segmented coil can be 2 to 5. The number of taps led out from the middle section of each tap winding group segmented coil is no more than 3. The taps on both sides of each tap winding group segmented coil are independent taps.

[0048] A heat dissipation channel is formed between the rated winding and the tap winding, and the heat dissipation channel axially penetrates the insulator 3. There are multiple heat dissipation channels, which are evenly distributed in the circumferential direction. This not only improves the insulation withstand voltage between the rated winding and the tap winding, but also helps to dissipate heat from the arc suppression coil. The fold-back lead-out section 123 is cast inside the insulating partition between two adjacent heat dissipation channels, which not only ensures the insulation withstand voltage performance, but also makes full use of space and reduces the overall volume of the arc suppression coil.

[0049] To ensure the stability of the overall structure and the insulation between different segmented coils during the winding process, there is a certain distance between each pair of adjacent tapped winding segmented coils, and there is a certain distance between the two rated winding segmented coils.

[0050] The above embodiments are one preferred embodiment of the present invention, and other preferred embodiments are also included. For example, in other embodiments, the insulating portion between the rated winding and the tap winding is a solid structure with an internal insulating pad layer, eliminating the need for a heat dissipation duct, thus reducing the distance between them. Alternatively, in a preferred embodiment, each tap winding segmented coil has two tap positions formed only at both ends, while no tap positions are led out in the middle section of the tap winding segmented coil. Alternatively, in other preferred embodiments, the rear end of the second rated winding segmented coil is folded back from the inside of the rated winding and led to the axial first end of the rated winding. Alternatively, in other preferred embodiments, when the number of layers in the segmented coil is even, priority is given to ensuring that the front and rear ends of two adjacent segmented coils are adjacent, and the winding start position of the first layer or the lead-out position of the last layer is adjusted. For example, when the rated winding segmented coil has one layer, the end of the first rated winding segmented coil is located near the end of the second rated winding segmented coil, and it can be folded back from the position between the rated winding and the tap winding and led to the axial first end of the rated winding. Alternatively, in other preferred embodiments, the folded-back lead-out section is disposed close to the inner wall surface of the heat dissipation duct, and protrudes from the inner wall of the heat dissipation duct.

[0051] Example 1 of the arc suppression coil manufacturing method of the present invention:

[0052] The manufacturing method of the arc suppression coil mainly includes two steps: the first is the process of winding the integral winding, and the second is the process of casting the integral winding. Winding the integral winding includes winding a rated winding and a tap winding. The rated winding is located inside the tap winding; therefore, the rated winding is wound first, and then the tap winding is wound on the outside. Before winding the tap winding outside the rated winding, a pull core 4 extending axially along the rated winding is placed outside the rated winding, so that the pull core 4 is sandwiched between the rated winding and the tap winding. After the integral winding is cast and the insulation 3 is cured, the pull core 4 is removed to form an axially continuous heat dissipation channel between the rated winding and the tap winding. Specifically, both the rated winding and the tap winding are wound in two or more segments along the axial direction. Each segment of the rated winding and the tap winding is wound with at least two layers. The adjacent ends of adjacent segments of the rated winding are electrically connected, and an insulating medium is provided between each pair of adjacent layers of the segmented winding.

[0053] The specific settings for different taps on its rated winding and tap winding are as follows:

[0054] The end of the rated winding is led out from the first axial end of the tap winding to form a neutral point tap for connecting the neutral point. The end of the rated winding is led axially to the first axial end of the tap winding and led out from the first axial end of the tap winding. Moreover, each segment coil of the tap winding has three leads. Two of the three leads are the two ends of the corresponding segment coil, and the other is led out from the middle of the corresponding segment coil and is used as a tap position. The end of the segment coil at the first axial end of the tap winding is connected to the second end of the rated winding and is used as a tap position. The adjacent ends of every two adjacent segment coils of the tap winding are connected and are used as a tap position. The end of the segment coil at the second axial end of the tap winding that is away from the first axial end is led out and is used as a tap position.

[0055] For more details, see the following combination Figure 1 Explanation:

[0056] Step 1: Rated winding

[0057] As attached Figure 1 As shown, during the winding process, the rated winding is first wound, and the rated winding is evenly divided into a first rated winding segmented coil 11 and a second rated winding segmented coil 12. The first rated winding segmented coil 11 is wound, starting from outside the mold, with the rear end 111 of the first rated winding segmented coil in the figure as the starting point, winding forward along the mold axis, maintaining the same direction, until fully wound and leading out the front end 110 of the first rated winding segmented coil, forming a neutral point tap. Then, with the front end 121 of the second rated winding segmented coil in the figure as the starting point, winding backward along the mold axis, maintaining the same direction, until fully wound and leading out the rear end 120 of the second rated winding segmented coil. The rear end 120 of the second rated winding segmented coil is folded back axially from the inner side of the rated winding and led to the first end of the rated winding axis. The rear end 111 of the first rated winding segmented coil and the front end of the second rated winding coil are pressed together with copper foil and soldered to form an insulating encapsulation.

[0058] Step 2: Laying the core puller 4

[0059] Once the rated winding is completed, the rated winding and the tap winding need to be separated. This is done by evenly arranging cores 4 in the outer circumferential direction of the rated winding, with both ends of the cores 4 protruding beyond the end faces of the rated winding. The rear end head 120 of the second rated winding segmented coil is folded back axially from the inner side of the rated winding and led to the first axial end of the rated winding between two adjacent cores 4. Then, the tap winding begins to be wound outside the cores 4.

[0060] Step 3: Tap-connect winding

[0061] The tap windings are wound sequentially from front to back (left to right in the diagram) and from inside to outside (bottom to top in the diagram). The tap windings are evenly divided into four tap winding segment coils along the axial direction, with an air gap between each segment coil. During the winding process, each segment coil is connected to a lead-out end at a certain position in the middle layer, forming a tap position. The adjacent ends of two adjacent segment coils are crimped with copper foil and soldered to form a tap position. The rear end of the last segment coil is led out independently as a tap position. The front end of the first segment coil is crimped with copper foil and soldered to the rear end 120 of the second rated segment coil, forming a tap position.

[0062] Step 4: Overall Casting

[0063] The completed winding is placed into a vacuum casting equipment for epoxy resin casting. During the casting process, each tap is left exposed and the entire winding is completely encapsulated. After the casting is completed and cured, core 4 is removed, thus forming a heat dissipation channel between the rated winding and the tap winding.

[0064] It should be noted that during the above process, insulating paper, insulating mesh, and other insulating media are laid between adjacent layers when each segmented coil is wound. This process is a mature existing technology and will not be described in detail. Of course, insulating paper, insulating mesh, and other insulating media are also laid between the rated winding and core 4, and between the tap winding and core 4.

[0065] The arc suppression coil manufacturing method of the present invention also includes other preferred embodiments. For example, when only two tap positions are needed at both ends of each tap-wound segmented coil, the lead-out ends are not connected to form tap positions during the winding process of the tap-wound segmented coil; for example, when there is no need to set up a heat dissipation duct, after the rated winding is completed, multiple layers of insulating paper or insulating mesh can be wound and laid on its outer side, and then the tap winding is wound on the outer side; the rear end of the second rated winding segmented coil can also be folded back and led out from the gap between adjacent cores after the cores are arranged; during the winding process of each tap-wound segmented coil, two or three lead-out ends are connected at a certain position in the middle layer to form two or three tap positions respectively.

[0066] The arc suppression coils produced by the above methods can effectively improve their withstand voltage performance and enhance the linearity of their volt-ampere characteristics. The even distribution of the rated windings ensures that the windings are evenly distributed around the outside of the iron core, resulting in a more uniform and regular magnetic field. Furthermore, the distribution of the tap current in the arc suppression coil is more orderly, reducing overall losses, decreasing the coil's size, improving production efficiency, and lowering production costs.

[0067] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. The scope of patent protection of the present invention shall be determined by the claims. Similarly, any equivalent structural changes made based on the description and drawings of the present invention shall also be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing an arc suppression coil, characterized in that, include: Wound integral windings and cast integral windings; The integral winding includes: winding a rated winding, then winding a tap winding on the outside, leading the end of the first axial end of the rated winding out from the first axial end of the tap winding to form a neutral point tap for connecting the neutral point, and leading the end of the second axial end of the rated winding axially to the first axial end of the tap winding and leading it out from the first axial end of the tap winding. The rated winding and the tap winding are both divided into two or more segmented coils in the axial direction for winding. Each segmented coil of the rated winding and the tap winding is wound with at least two layers. The adjacent ends of the adjacent segmented coils of the rated winding are electrically connected. An insulating medium is provided between each two adjacent layers of the segmented coil. Connect the end of the segmented coil near the first axial end of the tap winding to the second end of the rated winding and use it as a tap position. Connect the adjacent ends of every two adjacent segmented coils of the tap winding and use them as tap positions. Lead out the end of the segmented coil away from the first axial end of the tap winding at the second axial end of the tap winding and use it as a tap position. Casting the integral winding includes: placing the wound integral winding into a mold for insulation casting.

2. The method for manufacturing an arc-suppression coil according to claim 1, characterized in that, in When winding the tap-wound segmented coil, connect the lead end to the middle section of the wire of the tap-wound segmented coil to form an independent tap position.

3. The method for manufacturing an arc-suppression coil according to claim 1 or 2, characterized in that, Before winding the tap winding outside the rated winding, place a core (4) extending along the axial direction of the rated winding outside the rated winding so that the core (4) is sandwiched between the rated winding and the tap winding. The second end of the rated winding is led axially from the position between the rated winding and the tap winding to the first axial end of the tap winding. After the entire winding is cast and the insulation (3) is cured, the core (4) is pulled out to form an axially through heat dissipation channel between the rated winding and the tap winding. There are two or more core pullers (4), and two adjacent core pullers (4) form an axially penetrating hole with the rated winding and the tap winding. When the second end of the rated winding is led axially to the first axial end of the tap winding, the second end of the rated winding extends along the hole.

4. The method for manufacturing an arc-suppression coil according to claim 3, characterized in that, There are multiple core pullers (4) and they are evenly arranged in the circumferential direction of the rated winding.

5. The method for manufacturing an arc suppression coil according to claim 1 or 2, characterized in that, During the winding of the whole winding, there are gaps between adjacent segmented coils of the rated winding and between adjacent segmented coils of the tap winding.

6. The method for manufacturing an arc-suppression coil according to claim 1 or 2, characterized in that, The rated winding consists of 2-4 segmented coils, and the tap winding consists of 2-12 segmented coils.

7. An arc suppression coil, comprising an integral winding and an insulator (3) encasing the integral winding, wherein the integral winding comprises a rated winding and a tap winding, the rated winding being located inside the tap winding, characterized in that, The rated winding includes two or more rated winding segmented coils spaced apart axially. The adjacent ends of two adjacent rated winding segmented coils are connected. The end of the rated winding segmented coil at the first axial end of the overall winding is led out to form a neutral point tap. The end of the rated winding segmented coil at the second axial end of the overall winding is folded back axially to the first axial end of the overall winding and led out. The tap winding includes two or more tap winding segmented coils spaced apart axially. The adjacent ends of two adjacent tap winding segmented coils are connected and led out to form a tap position. The end of the tap winding segmented coil at the first axial end of the overall winding is connected to the end of the rated winding segmented coil at the second axial end of the overall winding and led out to form a tap position. The end of the tap winding segmented coil at the second axial end of the overall winding is led out to form a tap position.

8. The arc suppression coil according to claim 7, characterized in that, Each tap section of the winding coil is connected to the two ends of the wire that winds the coil to form a tap position.

9. The arc suppression coil according to claim 7 or 8, characterized in that, The insulator (3) has an axially penetrating heat dissipation channel located between the rated winding and the tap winding. The second end of the rated winding is led axially from the location between the rated winding and the tap winding to the first axial end of the tap winding.

10. The arc suppression coil according to claim 9, characterized in that, The end of the rated winding segmented coil located at the second axial end of the overall winding is folded back from the position between two adjacent heat dissipation channels to the first axial end of the overall winding and is wrapped in the insulating partition formed by the insulator (3) between the two adjacent heat dissipation channels.

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