Production process of air-core reactor

Abstract

The invention discloses a production process of an air-core reactor. The production process comprises the following steps: processing incoming copper bars; the wire is wound into a coil; drying and curing the coil after paint dipping; foot pad machining and painting are conducted on the incoming steel material; manufacturing an insulating part from a supplied material; assembling the insulating part, the coil and the foot pad to the transformer body; installing a clamping piece on the transformer body; and carrying out appearance treatment and packaging on the transformer body. The production process of the air-core reactor is used for producing the air-core reactor, an existing production process is changed while the quality of a finished product is guaranteed, pseudo soldering is avoided, an insulation area is not affected, grading section gaps do not affect the radial size of a coil, insulation is staggered, it is guaranteed that the coil is not polluted, and the production efficiency is improved. And sharp corners, burrs, weld beading, oxides and the like at the welding position can be easily removed.

Description

Technical Field

[0001] The invention relates to the technical field of reactors, and in particular to a production process of air-core reactors. Background Art

[0002] Reactors are also called inductors. They actually provide inductance in electrical circuits. Compared with iron-core reactors, which may have large currents causing changes in the saturated inductance of the core, the inductance of air-core reactors is only related to the size, number of turns and connection method. When the above conditions remain unchanged, the inductance is a constant and has nothing to do with the current. Therefore, air-core reactors have better linearity and are used in a wider range of occasions. Conventional reactor windings are of poor quality, the production process is complicated, and it is easy to leave process residues in the finished product. Summary of the invention

[0003] An object of the present invention is to provide a production process of an air-core reactor to solve the problems existing in the prior art.

[0004] To achieve this object, the present invention adopts the following technical solutions:

[0005] A production process for an air-core reactor comprises the following steps:

[0006] Step 1: Processing of copper bar materials;

[0007] Step 2: Winding the wire into a coil;

[0008] Step 3: The coil is dipped in paint and then dried and cured;

[0009] Step 4: Process and paint the steel materials for foot pads;

[0010] Step 5: Insulation parts production;

[0011] Step 6: Assemble the insulating parts, coils and feet to the body of the device;

[0012] Step 7: Install the clamp on the body of the device;

[0013] Step 8: Process the appearance and package the device.

[0014] As a preferred technical solution, in step one, an argon arc welder is used for welding, wherein the argon arc welder uses a cerium tungsten electrode to ensure a reliable ignition arc of 30-35V, the nozzle diameter of the argon arc welder is 10-20mm, the distance between the nozzle and the copper busbar is 8-14mm, and the argon arc welding flow rate is ensured to be 8-15 liters / minute.

[0015] As a preferred technical solution, in step one, the welding gun of the argon arc welding machine is placed above the copper busbar to be welded, the cold arc length is maintained at 2-3 mm, the start button is pressed to ignite the arc, and welding is performed after preheating. When welding is completed, the start button is released and the welding gun can be removed only after the arc is extinguished and the gas lag delay ends.

[0016] As a preferred technical solution, in step 2, a winding mold is installed, and the wire is wound in the direction specified in the drawing. The length of the remaining lead reaches the size specified in the drawing, and the damaged insulation of the lead is peeled off and rewrapped with crepe paper.

[0017] As a preferred technical solution, when winding to the rising layer of the wire in step 2, interlayer insulation is placed, the width of which is greater than the radial height of the wire but not exceeding the insulation at both ends, and the layers of insulating paper between the interlayer insulation are staggered. When winding to the coil airway, the airway strip is placed, the wire is tightened during the winding process, and after the coil is wound, a half-folded layer of glass cloth tape is wrapped around the outer surface.

[0018] As a preferred technical solution, in step two, a winding mold is installed, and the wire is wound in the direction specified in the drawing. The length of the remaining lead is adjusted to the size specified in the drawing. For the damaged insulation part of the lead, each lead should be wrapped with a layer of non-woven fabric, and then the lead wire should be re-wrapped with insulation as a whole.

[0019] As a preferred technical solution, in step 2, a cloth tape is embedded, passed under the wire turns, and the end and wire turns are locked by a glass cloth tape. At the end of winding, four glass cloth tapes are embedded again to firmly bind the end and the hard end ring.

[0020] As a preferred technical solution, in step 2, the insulation layer of the wire to be welded is removed, the wire is fixed on the platform, the wire is welded, the insulation layer of the wire end is removed, the branch wire is wrapped with water-soaked asbestos cloth, the terminal is screwed onto the screw, and clamped with tongs, the welding surface of the terminal is heated to a nearly molten state, an appropriate amount of borax is added, and the phosphor copper electrode is melted on the welding part to make it sufficient for welding, cooled with water, the welding surface is corrected with a file, the asbestos cloth is peeled off, and the terminal leads are tied with glass cloth tape after cleaning.

[0021] As a preferred technical solution, in step three, the coil is cleaned and hoisted into the vacuum tank. When the coil is placed, the distance from the heating pipe is not less than 200 mm. The heated steam valve is opened to slowly increase the temperature in the tank. During the preheating period, in order to prevent the iron core from rusting, vacuum is drawn to maintain residual pressure. After preheating, the pressure of the vacuum tank is evenly reduced, and vacuum is continuously drawn until the drying is completed when no condensed water is released from the condenser.

[0022] As a preferred technical solution, in step eight, a label is affixed, a nameplate is installed, a plastic film cover is added, and a wooden box is used for packaging.

[0023] The beneficial effects of the present invention are as follows: providing a production process for an air-core reactor, which is used to produce the air-core reactor, and while ensuring the quality of the finished product, changes the existing production process, does not cause cold welding, does not affect the insulation area, the graded cross-section gap does not affect the radial size of the coil, the insulation is staggered to ensure that the coil is not contaminated, and is easy to remove sharp corners, burrs, weld nodules and oxides at clean welding locations. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention is further described in detail below based on the accompanying drawings and embodiments.

[0025] Figure 1 The present invention is a production process flow chart of an air-core reactor described in an embodiment. DETAILED DESCRIPTION

[0026] The technical solution of the present invention is further described below with reference to the accompanying drawings and through specific implementation methods.

[0027] like Figure 1 As shown in the figure, in this embodiment, the overall process of the production process of an air-core reactor is shown.

[0028] The specific steps include:

[0029] We process copper busbars, cables, electromagnetic wires and various insulating materials into coil insulation parts, and coil-wind copper busbars, cables, electromagnetic wires and coil insulation parts.

[0030] Among them, the copper bar processing adopts WS-500 tungsten electrode argon arc welding machine, auxiliary cooling tools, and the argon arc welding machine uses cerium tungsten electrode to ensure the reliable ignition of 30-35V arc. The nozzle diameter of the argon arc welding machine is 10-20mm, and the distance between the nozzle and the copper bar is 8-14mm. The argon arc welding flow rate is guaranteed to be 8-15 liters / minute. The clean copper bar and copper foil are locked. The welding angle and feed speed can be adjusted. Place the welding gun above the workpiece to be welded, bring the tungsten tip close to the workpiece, and keep the cold arc length at 2-3mm. Press the start button to ignite the arc, and weld after preheating. The welding current selection range is Adjust the use according to the actual situation. At the end of welding, release the start button and wait for the arc to go out. The welding gun can be removed only after the gas delay ends. Choose natural cooling or water cooling. When cooling with water, first cool it with asbestos cloth dipped in water, then cool it with clean water, and then wipe the water marks with a cloth, loosen the clamping device of the copper busbar, clean the sharp corners and burrs of the weld and prepare to wind the coil. If the copper foil needs to be stacked, the lower foil should be welded in the middle of the busbar during welding, and the two layers of foil should be welded separately at staggered positions to ensure the welding quality. The weld should be flat and smooth, and no false welding or leakage welding should occur. The copper foil should not be burned, and the weld nodules should be smoothed with a file.

[0031] Process the welding process of wires and terminal blocks, remove the insulation layer of 50mm long wire to be welded, the welding distance of coil wire should be more than 1.5m from the winding, align the wire and clamp the welding section with tongs, or place it on a special fixed platform.

[0032] For the welding of round wires, if the diameter of the round wire is less than or equal to 1.0mm, it should be welded after twisting. Before twisting, the surface of the welding head should be sanded, decontaminated and painted. Twist the two wires together 15mm-20mm. The wires are required to be tightly combined without sharp corners. Apply tin solder paste to the twisted joints of the wires, heat the electric soldering iron, melt the solder on the electric soldering iron, fill the twisted joints of the wires with molten solder and weld them firmly to ensure that there are no cold or false welds. Use a file and emery cloth to remove the sharp corners and oxides at the welding joints. If the diameter of the round wire is greater than 1mm, it should be flattened appropriately, and then gas welding or lap welding should be used. The flattening degree should be greater than the diameter of the round wire, and the lap length should be 5-10mm. After welding, remove the sharp corners and burrs, sand with sandpaper, and trim to the required size.

[0033] For the welding of flat copper wires, it is necessary to use a file to file out a smooth welding plane with an angle of 20° on the two wires to be welded, and then overlap the two welding surfaces together. The two wires are required to be flush, and they are welded together using a resistance welding machine and phosphor copper electrodes. The welding surface must be full of solder without cold or false soldering. Use a file and emery cloth to clean the sharp corners and oxides at the weld.

[0034] For the welding of flat aluminum wires, it is necessary to use a file to file out a smooth welding plane with an angle of 20° for the two welded wires. The welding steps are the same as those for flat copper wires. The two welding surfaces are overlapped together. The two wires are required to be flush and fixed on the welding platform. The temperature of the gas welding is adjusted, the parts to be welded are heated, and they are moved back and forth continuously to prevent the welding parts from melting. When the temperature reaches the welding temperature, the weld position is filled with aluminum welding rods until the weld surface is full and there is no void welding. The sharp corners, weld nodules and oxides at the welding place are removed with a file. The insulating part of the guide damaged during the welding process is removed, and two layers of 0.1*25 glass fiber cloth tape are half-wrapped with a length of 150mm. If the insulation is severely damaged, the wrapping length can be appropriately lengthened. For multiple parallel-wound guides, the welding points should be staggered by 80mm-100mm from each other during welding, and insulation wrapping should be performed separately. Then two layers of paper are used to pad the welding point position to separate adjacent turns.

[0035] When welding the terminal, remove the insulation layer of the wire to be welded with a length of 50mm, wrap and protect the branch wire with water-soaked asbestos cloth, protect the coil with asbestos board, turn the lead wire and branch wire to a horizontal lower position to prevent the flame or solder from contacting the coil body, take the terminal, screw the terminal onto the screw, clamp it with tongs, heat the welding surface of the terminal to a nearly molten state, add an appropriate amount of borax, and melt the phosphor copper electrode at the welding part to make it sufficient for welding, and place the welding part of the terminal close to the guide to be welded to overlap the maximum length , and keep heating until the phosphor bronze solder melts. At this time, clamp the welding part with pliers. Be careful not to dislocate the welding part to avoid cold welding. Cool with water. First pour water on the front of the terminal. Do not pour it directly on the welding part. Allow the weld part to cool gradually. Then cool it completely with water. Use a file to trim the welding surface, remove burrs, sharp corners and weld nodules, etc. Use a metal brush or emery cloth to remove oxides, peel off the protective asbestos cloth, and clean the surface of the coil. Use 0.1*25 glass fiber cloth to tie the terminal leads to 5mm thick on one side.

[0036] The wire is wound into coils, and the copper bus, cable, magnet wire and coil insulation are coiled, including multi-layer cylindrical coil winding and spiral coil winding.

[0037] In the winding of multi-layer cylindrical coils, install the winding mold, wind the wire according to the specified direction, fold it into a 90° protrusion with a tool, and the length of the protrusion should reach the specified size in the drawing. The damaged part of the protrusion insulation should be peeled off and rewrapped with crepe paper. The thickness should be as required by the drawing. Temporarily bind it with glass cloth tape on the mold before winding. When winding to the conductor layer, place interlayer insulation. The number of layers and materials of interlayer insulation should be placed as required by the drawing. The width should be slightly larger than the radial height of the conductor but not more than the insulation at both ends. If the interlayer insulation requires graded placement, pay attention to the graded cross-sectional gap that does not affect the radial size of the coil. The layers of insulation paper between the interlayer insulation are staggered with a staggered distance of 10mm, and the overlapping part at the lap is not less than 10mm. When winding to the coil airway, place the airway strip, and the adjacent rising positions of the conductors should be staggered by one grid to avoid increasing The radial dimension at this place is large. If there is an error in the number of turns, it can be compensated before the branch line comes out. During the winding process, the wire must be tightened to ensure that the number of turns of each layer is consistent with the requirements of the drawing, and the entire coil is firm and tight. When there is a branch line on the outermost layer of the coil, the branch line is led out from the radial direction with the original wire in a loop according to the drawing, with a length of 150mm, and a 0.5mm paper groove is padded near the inner side of the coil at the loop, and 50mm long on both sides of the root are wrapped firmly with a half-folded layer of cloth tape. The root of the tap joint is fixed on the adjacent turns. The lead-out position of the branch line is carried out according to the drawing, with a deviation of no more than 5mm. The end of the coil is led out along the radial original wire, and it is tied with a glass cloth tape when fixed. After the coil is wound, a half-folded layer of glass cloth tape is wrapped on the outer surface, and 2 more layers are wrapped at both ends to strengthen it. The coil is removed and placed on the coil bracket for processing.

[0038] In the process of spiral coil winding, install the winding mold, hold the hard insulating cylinder tightly, wind the wire in the specified direction, fold it into a 90° protrusion with a tool, and leave the protrusion length to meet the size specified in the drawing. For the damaged part of the protrusion insulation, wrap each wire with a layer of non-woven fabric, and then re-wrap the insulation of the protruding wire as a whole with a thickness as required by the drawing. Before winding, temporarily bind it with glass cloth on the mold, clamp the coil head with a protrusion clamp, start the winding machine to prepare to wind the first turn of wire, mark the wire transposition before winding, pre-embed four cloth tapes, pass under the wire turns, and lock the protrusion and wire turns securely with the glass cloth tape. A 0.5mm non-woven fabric is placed at the bend of the head. The coil is transposed according to the principle of cross transposition at the specified position of the drawing. Pay attention to strengthening the insulation during transposition to avoid radial size difference. Pay attention to controlling the axial size of the coil during winding. When winding to the last few turns, pre-embed four glass cloth tapes. The method is the same as the beginning. Tie the finished head and the hard end ring firmly. Before cutting the last head, use a temporary tensioning tape to hold the root of the coil, check the coil size, and measure the insulation between the parallel wires. After confirming that the parallel wires are not connected, wrap a layer of semi-dry glass cloth tape around the outside of the coil, remove the coil and place it on the coil bracket for processing.

[0039] After the coil is dipped in paint and dried and solidified, the coil is cleaned and checked to be intact, and then hoisted into a vertical vacuum tank. If it is a horizontal vacuum tank, it is hoisted onto a flat car and pulled into the tank. When the coil is placed, the distance from the heating pipe is not less than 200mm. Place a thermal resistor, one thermal resistor on the top of the coil with its measuring head close to the coil to measure the coil temperature, one thermal resistor in the middle of the coil phases, and one thermal resistor in the tank parallel to half the height of the coil to measure the furnace temperature, check the accuracy of the temperature measurement system, record the number and position of each resistor, record the temperature, vacuum degree, and steam pressure of the heating pipe once an hour during the process, record the amount of condensed water released every hour during vacuuming, and record special matters such as water and power outages to ensure that no one in the tank closes the tank door.

[0040] Open the steam valve of the heating pipe to slowly increase the temperature in the tank. The heating rate shall not exceed 15℃ / h. The temperature difference between the furnace temperature and the core temperature shall be controlled to be no more than 30℃, and the furnace temperature shall be controlled not to exceed 105℃±5℃. During the preheating period, in order to prevent the core from rusting, evacuate the residual pressure to 4.8*10 to the fourth power Pa every hour and maintain it for 15 minutes. Then release the vacuum and continue heating. The preheating time is calculated from the time the temperature measuring element reaches 100℃. After preheating, evenly reduce the pressure of the vacuum tank step by step to 4.8*10 to the fourth power Pa and 2.1*10 to the fourth power Pa and maintain it for the specified time. Evenly reduce the pressure in the vacuum tank to below 1.3*10 to the third power Pa. Continue to evacuate until the condenser is connected. Drying is completed when no condensed water is released for 3 consecutive hours. During the treatment process, when the pressure in the vacuum tank reaches about 2.1*10 fourth power Pa-7.8*10 third power Pa, more water should be released. If no water is released at all or very little water is released during the whole process, and almost no water is released even after the vacuum is increased, although the above-mentioned requirement of no water for 3 consecutive hours is met, it cannot be regarded as the drying process is completed. If necessary, open the tank to find the cause and eliminate the fault. The opening time should not exceed 2 hours. After eliminating the fault, close the tank door as soon as possible, heat to the specified temperature, and use 2 hours to evenly evacuate the vacuum to the original stopping vacuum degree. After drying is completed, stop heating, release the vacuum, open the tank door, take out the device body, and hurry to process and assemble. The retention time in the air should not exceed 8 hours.

[0041] The steel materials are processed and painted for the feet, the insulating parts are made for the incoming materials, and assembled with the above-mentioned body, the insulating parts, coils, and feet are assembled to the body, and the clamps are installed on the body.

[0042] First, make each part, and then perform deburring inspection according to the drawings. Mark the position and size of the qualified and inspected parts, and perform spot welding. After the parts are tested and installed correctly, perform formal welding. After welding, remove the welding slag, deburr the parts, and send them for inspection for surface treatment (pickling, phosphating, painting).

[0043] The appearance of the device is processed and packaged, and labels and nameplates are affixed. High-voltage danger labels are affixed to the sides of the coil and the lower middle of the screws next to the phases. Grounding labels are riveted next to the grounding nut. Vertical labels are affixed to the flush terminals on the boss decomposition plate. The body is covered with plastic film to prevent moisture and dust. The process flow card is filled out and sent to the quality inspector for quality inspection. Finally, it is packaged in wooden boxes and the labels are removed.

[0044] It should be stated that the above-mentioned specific implementation methods are only preferred embodiments of the present invention and the technical principles used. Within the technical scope disclosed by the present invention, any changes or substitutions that can be easily thought of by technicians familiar with this technical field should be included in the protection scope of the present invention.

Claims

1. A production process for an air-core reactor, characterized in that: The following steps are involved: Step 1: Processing of copper bar materials; Step 2: Winding the wire into a coil; Step 3: The coil is dipped in paint and then dried and cured; Step 4: Process and paint the steel materials for foot pads; Step 5: Insulation parts production; Step 6: Assemble the insulating parts, coils and feet to the body of the device; Step 7: Install the clamp on the body of the device; Step 8: Process the appearance and package the device.

2. The production process of an air-core reactor according to claim 1, characterized in that: In step one, an argon arc welder is used for welding, wherein the argon arc welder uses a cerium tungsten electrode to ensure a reliable ignition arc of 30-35V, the nozzle diameter of the argon arc welder is 10-20mm, the distance between the nozzle and the copper busbar is 8-14mm, and the argon arc welding flow rate is ensured to be 8-15 liters / minute.

3. The production process of an air-core reactor according to claim 2, characterized in that: In step one, place the welding gun of the argon arc welding machine above the copper busbar to be welded, keep the cold arc length at 2-3mm, press the start button to ignite the arc, and weld after preheating. When welding is finished, release the start button and wait for the arc to extinguish. The welding gun can be removed only after the gas lag delay ends.

4. The production process of an air-core reactor according to claim 1, characterized in that: In step 2, install the winding mold, wind the wire according to the drawing, and leave the lead length to the size specified in the drawing. Strip off the damaged insulation of the lead and rewrap it with crepe paper.

5. The production process of an air-core reactor according to claim 5, characterized in that: When winding to the rising layer of the wire in step 2, place interlayer insulation with a width greater than the radial height of the wire but not exceeding the insulation at both ends. The layers of insulation paper between the interlayer insulation are staggered. When winding to the coil airway, place the airway strip. Tighten the wire during the winding process. After the coil is wound, wrap a half-fold layer of glass cloth tape around the outer surface.

6. The production process of an air-core reactor according to claim 1, characterized in that: In step 2, install the winding mold, wind the wire according to the direction specified in the drawing, and leave a length that meets the size specified in the drawing. For the damaged insulation part of the wire, each wire should be wrapped with a layer of non-woven fabric, and then the wire should be re-wrapped with insulation as a whole.

7. The production process of an air-core reactor according to claim 6, characterized in that: In step 2, pre-embed the cloth tape, pass it under the wire turns, and lock the end and wire turns with the glass cloth tape. At the end of winding, pre-embed four more glass cloth tapes to securely tie the end and the hard end ring.

8. The production process of an air-core reactor according to claim 1, characterized in that: In step 2, remove the insulation layer of the wire to be welded, fix the wire on the platform, weld the wire, remove the insulation layer at the end of the wire, wrap the branch wire with water-soaked asbestos cloth, screw the terminal block onto the screw, clamp it with tongs, heat the welding surface of the terminal block to a nearly molten state, add an appropriate amount of borax, and melt the phosphor copper electrode on the welding part to make it sufficient for welding, cool it with water, correct the welding surface with a file, peel off the asbestos cloth, clean it and tie the terminal lead with glass cloth tape.

9. The production process of an air-core reactor according to claim 1, characterized in that: In step three, clean the coil and hang it into the vacuum tank. When placing the coil, the distance from the heating pipe should be no less than 200mm. Open the heated steam valve to slowly increase the temperature in the tank. During the preheating period, in order to prevent the iron core from rusting, vacuumize and maintain residual pressure. After preheating, evenly reduce the pressure of the vacuum tank and continue to vacuum until the condenser is dry and no condensate is released.

10. The production process of an air-core reactor according to claim 1, characterized in that: In step eight, label the product, install the nameplate, cover it with plastic film, and pack it in a wooden box.

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