A winding mold for an air-core series reactor and its usage method

Abstract

This invention discloses a winding mold for hollow series reactors and its usage method. It includes a cylindrical support frame with several elongated slots arranged axially on the support frame. The upper ends of the slots are at the same level as the top of the support frame, while the lower ends of the slots are at a higher plane than the bottom of the support frame. A first positioning slot and a second positioning slot, communicating with the slots, are provided on one side of each slot. These slots are used to position the upper and lower star frames, respectively. The invention also includes a central hanger, which passes through the central holes of the upper and lower star frames. The lower end of the central hanger is fixed, while the upper end is threaded. The upper end of the central hanger is secured to the upper star frame with a locking nut. This invention can meet the winding requirements of the product with only a simple arrangement and positioning of the upper and lower star frames. Afterward, the mold can be easily removed or the product taken out for the next processing step. The mold can also be directly used for the next product winding.

Description

Technical Field

[0001] This invention relates to the field of power equipment manufacturing, specifically to a winding mold for a hollow series reactor and its usage method. Background Technology

[0002] The air-core series reactor consists of an upper star frame, a lower star frame, and windings. The windings are composed of epoxy-impregnated glass yarn, insulated electromagnetic wires, and support bars. During processing, the windings require a cylindrical support frame to provide support for the windings and to fix the upper and lower star frames. Finally, the cylindrical support frame is removed.

[0003] A cylindrical support frame typically consists of a main support shaft, supporting cylindrical wooden boards, a height adjustment tube, support columns, and a mold frame locking nut. During reactor winding, the upper star frame, lower star frame, and cylindrical support frame are first assembled and placed on a winding machine for winding. After drying and curing, and cooling, non-product-use components, including the cylindrical support frame, are removed. It can be seen that some tooling accessories of the cylindrical support frame are located inside the product and cannot be removed due to obstruction from the upper and lower star frames. For example, the supporting cylindrical wooden boards need to be broken into fragments that can fall through the gaps in the lower star frame using a hammer and pry bar, requiring fragmentation for removal. Simultaneously, the mold frame columns, which are not bolted to the star frame, need to be removed from bottom to top. The main support shaft, height adjustment tube, etc., need to be removed one by one. Finally, only the upper star frame, lower star frame, and winding remain, allowing for the next processing step.

[0004] Combination Figures 1 to 3 The existing technology is further described below, such as Figure 1 The diagram shown is a structural diagram of a hollow series reactor, where the winding is simplified as a cylindrical tube, consisting of an upper star frame 1, a lower star frame 2, winding 3, and epoxy-impregnated fiberglass binding straps 4. Figure 2 The diagram shows the assembly structure of the winding before winding. It consists of a main support shaft 5, a support round wooden board 6, a height adjustment tube 7, a support column 8, a locking nut on the mold frame 9, an upper star frame 1, and a lower star frame 2. This structure is arranged on the winding machine equipment to perform winding. Figure 3 The diagram shown is of the structure after winding, i.e., in Figure 2 Based on the above, winding 3 and epoxy-impregnated fiberglass binding tape 4 were added. After the winding is cured in the curing oven, the tooling support can be removed to obtain the desired result. Figure 1 The product shown.

[0005] The aforementioned cylindrical support frame requires a large amount of manual labor during processing, has many parts, poor assembly precision, and the supporting cylindrical wooden boards also need to be crushed, resulting in waste of raw materials. At the same time, a large number of tooling accessories are scattered during the dismantling of the mold frame and winding, affecting the on-site working environment, posing safety hazards, and resulting in low overall processing efficiency. Summary of the Invention

[0006] The purpose of this invention is to provide a winding mold and method for power hollow series reactors to solve the problems existing in the prior art. This invention can meet the winding requirements of the product by simply arranging and positioning the upper and lower star frames. After that, the mold can be removed or the product can be taken out through simple operation for the next process. The mold can also be directly used for the next product winding.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A winding mold for a hollow series reactor includes a cylindrical support frame. Several long slots are provided on the support frame along the axial direction. The upper end of the long slots is at the same horizontal plane as the top of the support frame, and the plane where the lower end of the long slots is located is higher than the plane where the bottom of the support frame is located.

[0009] The number of long slots is the same as the number of star frame arms of the upper and lower star frame. A first positioning slot and a second positioning slot are provided on one side of the long slot, which are connected to the long slot. The first positioning slot and the second positioning slot are used to position the upper and lower star frame, respectively.

[0010] It also includes a central hanger rod, which passes through the central holes of the upper and lower satellite frames. The lower end of the central hanger rod is fixed, and the upper end is threaded. The upper end of the central hanger rod is fastened to the upper satellite frame by a lock nut.

[0011] Furthermore, both the first positioning groove and the second positioning groove include a horizontal groove communicating with the long groove, and a vertical groove communicating with the horizontal groove.

[0012] Furthermore, the width of the horizontal slot is greater than the width of the star frame arm, and the length of the vertical slot is less than or equal to the width of the star frame arm.

[0013] Furthermore, a closed baffle is provided at the bottom of the support frame, and the lower end of the central hanger is fixedly connected to the closed baffle.

[0014] Furthermore, the lower end of the central lifting rod has a threaded structure, and the lower end of the central lifting rod is fastened to the lower star frame by a locking nut.

[0015] Furthermore, a lifting ring is connected to the top of the central lifting rod.

[0016] Furthermore, the number of star carrier arms in the upper star carrier, the number of star carrier arms in the lower star carrier, and the number of long slots are all 6.

[0017] A method for using a winding mold for an air-core series reactor includes the following steps:

[0018] Pass the lower star frame through the central hanger, and at the same time, the star frame arm of the lower star frame is arranged in the corresponding second positioning groove at the lower end of the support frame through the long groove. Pass the upper star frame through the central hanger, and at the same time, the star frame arm of the upper star frame is arranged in the corresponding first positioning groove at the upper end of the support frame through the long groove. Tighten with lock nuts to complete the assembly of the mold frame.

[0019] The assembled mold frame is placed on the winding machine for winding to obtain the wound reactor.

[0020] After the wound reactor is heated and cured, the reactor is separated from the mold.

[0021] Furthermore, the step of arranging the assembled mold frame on the winding machine for winding specifically involves:

[0022] First, a layer of polytetrafluoroethylene film is wrapped around the outer surface of the mold frame;

[0023] Secondly, the insulating layer is wound;

[0024] Next, wind the electromagnetic wire;

[0025] Finally, pay attention to the vertical binding position of the insulation layer according to the winding sheet, and perform vertical binding in a timely manner so that the upper star frame, lower star frame and winding form an effective whole.

[0026] Furthermore, the separation of the winding from the mold frame specifically involves:

[0027] Remove the locking nut to make the reactor and the mold stand relatively independent. Lift the reactor consisting of the upper star stand, lower star stand and windings. Rotate to place the star stand arms of the upper star stand and lower star stand in the long slot, and then it can be taken out as a whole.

[0028] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0029] This invention, by setting long slots and positioning slots on the support frame, can meet the winding requirements of the product with only simple upper and lower star frames arranged and positioned. At the same time, it eliminates the need for height adjustment tubes, supporting round wooden boards, and a large number of supporting columns required in the prior art. After the winding is completed, the upper and lower star frames and the reactor formed by the winding are lifted, and the star frame arms of the upper and lower star frames are rotated to place them in the long slots, so that the whole thing can be taken out. The structure is simple, the operation is convenient, and it can be directly used for the next product winding after use.

[0030] In addition, during the use of this invention, there is no waste of raw materials and no waste (such as broken wooden discs) is generated. At the same time, after the reactor and the mold frame are separated, there are no other large number of scattered parts (such as multiple support columns and fastening support components) at the operation site, which improves the dirty and messy operation environment.

[0031] Furthermore, both the first positioning slot and the second positioning slot include a horizontal slot communicating with the long slot and a vertical slot communicating with the horizontal slot. The width of the horizontal slot is greater than the width of the star frame arm, which facilitates the entry of the upper and lower star frames during rotation. The length of the vertical slot is less than or equal to the width of the star frame arm, which facilitates the lifting work during disassembly.

[0032] Furthermore, the lower end of the central hanger is fixedly connected to the closed baffle at the bottom of the support frame, or the lower end of the central hanger is designed as a threaded structure and fastened with a lock nut, which is simple, practical and highly flexible. Attached Figure Description

[0033] The accompanying drawings are provided to further understand the invention and constitute a part of this invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0034] Figure 1 This is a structural diagram of a hollow series reactor for electric power.

[0035] Figure 2 This is a diagram of the combined structure of the windings before winding in the prior art;

[0036] Figure 3 This is a structural diagram of the wound part in the prior art;

[0037] Figure 4 This is a drawing of the mold frame designed for this invention;

[0038] Figure 5 This is a schematic diagram of the structure after winding using the present invention;

[0039] Figure 6 This is a structural diagram showing the process of removing the mold frame;

[0040] Figure 7 This is a cross-sectional schematic diagram of the support frame of the present invention.

[0041] The components are as follows: 1. Upper star frame; 2. Lower star frame; 3. Winding; 4. Epoxy-impregnated fiberglass binding straps; 5. Main support shaft; 6. Supporting round wooden board; 7. Height adjustment tube; 8. Support column; 9. Locking nut; 10. Support frame; 11. Lifting ring; 12. Central lifting rod. Detailed Implementation

[0042] To enable those skilled in the art to better understand the present invention, the technical solution of the present invention will be further described in detail below with reference to the accompanying drawings. The description is for explanation and not limitation of the present invention.

[0043] It should be noted that the terms "comprising" and "having" and any variations thereof in the specification and claims of this invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such processes, methods, products, or devices.

[0044] Example 1

[0045] like Figures 4-7 A winding mold for a hollow series reactor includes a cylindrical support frame 10. The support frame 10 has several elongated slots arranged axially. The upper ends of the elongated slots are at the same horizontal level as the top of the support frame 10, and the plane containing the lower ends of the elongated slots is higher than the plane containing the bottom of the support frame 10. The number of elongated slots is consistent with the number of star frame arms of the upper star frame 1 and the lower star frame 2. The number of star frame arms of the upper star frame 1, the lower star frame 2, and the number of elongated slots are all 4, 6, or 8. In this embodiment, there are 6. A first positioning slot and a second positioning slot are provided on one side of each elongated slot, communicating with the slot. The first positioning slot and the second positioning slot are respectively used for positioning the upper star frame 1 and... The lower satellite frame 2 is positioned; both the first and second positioning slots include a horizontal slot communicating with the long slot and a vertical slot communicating with the horizontal slot. The width of the horizontal slot is greater than the width of the satellite frame arm, and the length of the vertical slot is less than or equal to the width of the satellite frame arm. It also includes a central lifting rod 12, which passes through the central holes of the upper satellite frame 1 and the lower satellite frame 2. The lower end of the central lifting rod 12 is fixed, and the upper end has a threaded structure. The upper end of the central lifting rod 12 is fastened to the upper satellite frame 1 by a locking nut 9. The bottom of the support frame 10 is provided with a closed baffle. The lower end of the central lifting rod 12 is fixedly connected to the closed baffle, and the top of the central lifting rod 12 is connected to a lifting ring 11.

[0046] The lower end of the central suspension rod 12 is fixedly connected to the closed baffle, which can be done in the following two ways:

[0047] First, the lower end of the central lifting rod 12 is threaded, and the lower end of the central lifting rod 12 passes through the closed baffle. The lower end of the central lifting rod 12 is fastened to the closed baffle by a locking nut 9.

[0048] Second, the lower end of the central hanger 12 is directly welded and fixed to the closed baffle.

[0049] Example 2

[0050] The difference from Embodiment 1 is that the lower end of the central hanger 12 is fixed in a different way. The lower end of the central hanger 12 has a threaded structure, and the lower end of the central hanger 12 is fastened to the lower star frame 2 by a locking nut 9.

[0051] Example 3

[0052] like Figure 4 The diagram shown is of the mold frame designed in this invention. It consists of an upper star frame 1, a locking nut 9, a support frame 10, and a lower star frame 2. During installation, the support frame 10 is fixed, the lower star frame 2 is placed in and rotated to continue downward into the second positioning groove, the upper star frame 1 is then placed in and rotated to continue downward into the first positioning groove, and finally the locking nut 9 is used to tighten it. This assembly can meet the winding requirements.

[0053] like Figure 5 The diagram shown is a schematic of the structure after winding using the present invention, that is, in Figure 4 Based on this, winding 3 and epoxy-impregnated fiberglass binding tape 4 were added.

[0054] like Figure 6 As shown, when removing the tooling, first remove the locking nut 9 on the mold frame, then lift the reactor so that the upper star frame 1 and the lower star frame 2 reach the rotatable position, that is, the horizontal slot position. Rotate to place the upper star frame 1 and the lower star frame 2 in the long slot, and then the whole thing can be taken out.

[0055] like Figure 7 The diagram shown is a cross-sectional view of the support frame 10 used in this invention (this is a structural diagram of the support frame 10 with a closed baffle at the bottom).

[0056] The following process is involved in its use:

[0057] First, assembly: Before use, the support frame 10 for winding the dry-type air-core reactor needs to be simply assembled with the upper star frame 1 and the lower star frame 2 before winding can begin. First, the lower star frame 1 is passed through the central hanger 12 of the mold frame and simultaneously positioned in the corresponding second positioning slot at the lower end of the mold frame via the long slot on the support frame 10. Then, the upper star frame 2 is passed through the central hanger 12 of the support frame 10 and simultaneously positioned in the corresponding first positioning slot at the upper end of the support frame 10 via the long slot on the support frame 10. Finally, the upper star frame 1, the lower star frame 2, and the support frame 10 are connected and secured using the locking nut 9 on the support frame 10. The assembly of the support frame 10 with the upper star frame 1 and the lower star frame 2 is complete. Figure 4 As shown, the next step, winding the coil, can then be performed.

[0058] Second, winding: The assembled mold frame is placed on a vertical rotary winding machine. According to the winding sheet requirements, qualified film-coated electromagnetic wire (aluminum or copper) is loaded onto the winding machine's pay-off frame. The wire diameter is measured and verified. Firstly, in... Figure 4The outer surface of the mold frame shown is wrapped with a layer of polytetrafluoroethylene film, which facilitates quick and efficient demolding. Wrapping method: Wrap from bottom to top, overlapping 10-15mm per half-overlap. The wrapping must be tight and adhered firmly, without any gaps or unevenness. After wrapping, the joints should be sealed with transparent tape. Next, the insulation layer is wound. During insulation layer winding, the fiberglass yarn should be free of fuzz, with a smooth, flat surface, uniform thickness, and density; the insulation layer should be free of gaps, exposed yarn, or bulging yarn. The coil should be wound within 4 hours after the bottom wrapping is completed. Third, the magnet wire is wound. Epoxy resin adhesive must be applied between the wires. Check the wire diameter and weight according to the winding sheet. After the winding machine counter is zeroed, begin starting the wire. According to the arm number, winding direction, and lead length required by the winding sheet, fix the lead wire to the second or third lead arm (clockwise) of the winding mold frame, and begin winding the coil at the required starting height. When the product diameter is less than or equal to 1m, the winding speed should not exceed 45 rad / min; when the product diameter is greater than 1m but less than 2m, the winding speed should not exceed 40 rad / min; when the product diameter is greater than or equal to 2m, the winding speed should not exceed 20 rad / min. Finally, according to the winding sheet, pay attention to the vertical binding position of the insulation layer, and promptly use epoxy-impregnated fiberglass binding tape 4 for vertical binding, so that the upper star frame 1, lower star frame 2, and winding form an effective whole. Figure 5 As shown.

[0059] Third, separation of the mold frame and reactor (i.e., removal of the mold frame): After the wound reactor undergoes a high-temperature curing process, the cured reactor is vertically lifted by a crane using a special lifting ring 11 at the top and placed on the ground covered with an insulating mat in the demolding area. Figure 5 As shown, the locking nut 9 on the mold frame is removed, leaving the reactor and mold frame without any fasteners, essentially separated and in a relatively independent state. Then, a crane is used with a special lifting tool to evenly distribute the force on the upper star frame 1, lifting the reactor consisting of the upper star frame 1, lower star frame 2, and windings. The upper star frame 1 and lower star frame 2 are rotated until their corresponding long and short arms are simultaneously positioned in the long slot, allowing for complete removal. Using this mold frame, there is no waste of raw materials in this process, and no waste (such as broken wooden discs) is generated. Furthermore, after the windings and mold frame are separated, there are no other large amounts of scattered parts at the work site (such as multiple support columns or fasteners), improving the cleanliness and tidiness of the work environment. Finally, the reactor is vertically lifted off the mold frame using a lifting tool for shaping. Figure 6 As shown.

[0060] As is known from common technical knowledge, this invention can be implemented through other embodiments that do not depart from its spirit or essential characteristics. Therefore, the disclosed embodiments described above are merely illustrative in all respects and are not the only ones. All modifications within the scope of this invention or its equivalents are included in this invention.

Claims

1. A winding mold for an air-core series reactor, characterized in that, It includes a cylindrical support frame (10), on which a plurality of long grooves are provided along the axial direction. The upper end of the long grooves is on the same horizontal plane as the top of the support frame (10), and the plane where the lower end of the long grooves is located is higher than the plane where the bottom of the support frame (10) is located. The number of long slots is the same as the number of star frame arms of the upper star frame (1) and the lower star frame (2). A first positioning slot and a second positioning slot are provided on one side of the long slot, which are connected to the long slot. The first positioning slot and the second positioning slot are used to position the upper star frame (1) and the lower star frame (2) respectively. It also includes a central hanger (12), which is installed through the central holes of the upper star frame (1) and the lower star frame (2). The lower end of the central hanger (12) is fixed, and the upper end is threaded. The upper end of the central hanger (12) is fastened to the upper star frame (1) by a locking nut (9).

2. The winding mold for a hollow series reactor according to claim 1, characterized in that, Both the first positioning groove and the second positioning groove include a horizontal groove communicating with the long groove, and a vertical groove communicating with the horizontal groove.

3. The winding mold for a hollow series reactor according to claim 2, characterized in that, The width of the horizontal slot is greater than the width of the star-shaped arm, and the length of the vertical slot is less than or equal to the width of the star-shaped arm.

4. The winding mold for a hollow series reactor according to claim 1, characterized in that, The bottom of the support frame (10) is provided with a closed baffle, and the lower end of the central hanger (12) is fixedly connected to the closed baffle.

5. The winding mold for a hollow series reactor according to claim 1, characterized in that, The lower end of the central hanger (12) is threaded, and the lower end of the central hanger (12) is fastened to the lower star frame (2) by a locking nut (9).

6. The winding mold for a hollow series reactor according to claim 1, characterized in that, The top of the central boom (12) is connected to a lifting ring (11).

7. A winding mold for a hollow series reactor according to claim 1, characterized in that, The number of star frame arms of the upper star frame (1), the number of star frame arms of the lower star frame (2), and the number of long slots are all 4, 6, or 8.

8. The method of using the winding mold for an air-core series reactor as described in any one of claims 1-7, characterized in that, Includes the following steps: Pass the lower star frame (1) through the central hanger (12), and at the same time, the star frame arm of the lower star frame (1) is arranged in the second positioning groove corresponding to the lower end of the support frame (10) through the long groove. Pass the upper star frame (2) through the central hanger (12), and at the same time, the star frame arm of the upper star frame (2) is arranged in the first positioning groove corresponding to the upper end of the support frame (10) through the long groove. Secure it with a locking nut (9) to complete the assembly of the mold frame. The assembled mold frame is placed on the winding machine for winding to obtain the wound reactor. After the wound reactor is heated and cured, the reactor is separated from the mold.

9. The method of using the winding mold for a hollow series reactor according to claim 8, characterized in that, The process of arranging the assembled mold frame on the winding machine for winding specifically involves: First, a layer of polytetrafluoroethylene film is wrapped around the outer surface of the mold frame; Secondly, the insulating layer is wound; Next, wind the electromagnetic wire; Finally, pay attention to the vertical binding position of the insulation layer according to the winding sheet, and perform vertical binding in time so that the upper star frame (1), lower star frame (2) and winding (3) form an effective whole.

10. The method of using the winding mold for a hollow series reactor according to claim 8, characterized in that, The separation of the reactor from the mold frame is specifically as follows: Remove the locking nut (9) to make the reactor and the mold stand relatively independent. Lift up the reactor consisting of the upper star frame (1), the lower star frame (2) and the winding (3). Rotate to place the star frame arms of the upper star frame (1) and the lower star frame (2) in the long slot, so that the whole unit can be taken out.

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