Transformer coil winding method and device

Abstract

The present invention discloses a transformer coil winding method and device, the winding method comprising: determining the winding parameters and coil parameters of the coil to be wound; the coil to be wound comprises a reverse coil and a normal coil; based on the winding parameters and coil parameters, using electromagnetic wire to wind the reverse coil from the outside to the inside on an inner mold; after the reverse coil is wound, based on the coil parameters, using electromagnetic wire to wind the normal coil on the inner mold from the inside to the outside above the reverse coil; repeating the above steps, the reverse coil and the normal coil are continuously wound upward alternately until the winding parameters are met, thereby obtaining the coil to be wound. By determining the winding parameters and coil parameters of the coil to be wound, the present invention can realize the sequential winding of the reverse coil and the normal coil of the coil to be wound, and directly winding the reverse coil from the outside to the inside on the inner mold, thereby avoiding the process of pre-winding and then flipping the coil when manually winding the reverse coil in the traditional process, simplifying the winding process while also improving the winding efficiency of the transformer coil.

Description

Technical Field

[0001] The present invention relates to the technical field of transformers, and in particular to a transformer coil winding method and device. Background Art

[0002] A transformer pancake coil is composed of several positive pancakes and negative pancakes stacked axially, and each positive pancake or negative pancake is made up of several turns of electromagnetic wire wound in the width direction. Among them, when winding the positive pancake, the winding order is from the inner turn to the outer turn, and the negative pancake is wound from the outer turn to the inner turn. The electromagnetic wire is bent between the positive pancake and the negative pancake to achieve a continuous transition between the positive pancake and the negative pancake; that is, the transformer coil is repeatedly wound in the order of "negative pancake-positive pancake-negative pancake-positive pancake" until the entire transformer coil is completed.

[0003] When traditionally winding a positive cake manually, the winding die is rotated to pull the electromagnetic wire and wind it on the die from inner turns to outer turns to form a positive cake. When winding a reverse cake, the electromagnetic wire of the required length for a cake must be pre-wound on the winding die, and then the coil of the cake is disassembled, and the outer turn coil is turned layer by layer to the innermost layer, and this process is repeated until the innermost turn coil is turned to the outermost layer to form a reverse cake.

[0004] Therefore, manually winding the coil cannot be achieved by directly winding from the outer turn to the inner turn to form a reverse pancake. The process of pre-winding and then flipping the pancake cannot effectively improve the winding efficiency. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, the purpose of the present invention is to provide a transformer coil winding method and device, which can replace manual coil winding and does not require the process of pre-winding and then flipping the coil to obtain a reverse coil, thereby effectively improving the winding efficiency.

[0006] In order to solve the above problems, the present invention is implemented according to the following scheme:

[0007] A transformer coil winding method is provided, comprising:

[0008] Determine the winding parameters and coil parameters of the coil to be wound; the coil to be wound includes a reverse coil and a forward coil;

[0009] Based on the winding parameters and coil parameters, use the electromagnetic wire to wind the inner mold from the outside to the inside to form the reverse pancake;

[0010] After the reverse coil is wound, based on the coil parameters, use the electromagnetic wire to wind the positive coil from the inside to the outside of the inner mold on top of the reverse coil.

[0011] Repeat the above steps, and continuously and alternately wind the reverse and forward coils upward until the winding parameters are met, thereby obtaining the coil to be wound.

[0012] Compared with the prior art, the transformer coil winding method of the present invention has the following beneficial effects: by determining the winding parameters and coil parameters of the coil to be wound, the reverse coil and the normal coil of the coil to be wound can be wound in sequence, and the reverse coil can be wound directly from the outside to the inside of the inner mold, avoiding the process of pre-winding and then flipping the coil when manually winding the reverse coil in the traditional process, simplifying the winding process while improving the winding efficiency of the transformer coil.

[0013] Optionally, the winding parameters include:

[0014] The number of turns of the pancake is used to indicate the number of turns of the pancake;

[0015] The number of reverse cakes is used to indicate the number of reverse cakes in the coil to be wound;

[0016] The number of turns of the positive cake is used to indicate the number of turns of the winding positive cake;

[0017] The number of positive biscuits is used to indicate the number of positive biscuits in the coil to be wound.

[0018] Optionally, the coil parameters include electromagnetic wire thickness and electromagnetic wire width.

[0019] Optionally, the method of winding the inverted pancake from outside to inside of the inner mold using electromagnetic wire based on the winding parameters and coil parameters includes:

[0020] Use magnet wire to wind the first turn of the pancake;

[0021] Adjust the entry position of the electromagnetic wire according to the thickness of the electromagnetic wire, and use the electromagnetic wire to wind the next turn inside the first turn of the inverted pancake;

[0022] Repeat the above steps until the number of turns of the inner mold meets the number of reverse pancake turns, and the reverse pancake winding is completed.

[0023] Optionally, after using electromagnetic wire to wind the inverted cake from the outside to the inside of the inner mold based on the winding parameters and coil parameters, it also includes: retracting the electromagnetic wire outside the inverted cake to make the last turn of the inverted cake fit the inner mold.

[0024] Optionally, after the reverse coil is wound, based on the coil parameters, a positive coil is wound on the inner mold from the inside to the outside using electromagnetic wire above the reverse coil, including:

[0025] Determine the position signal of the last turn of the anti-pancake;

[0026] performing bending processing on the electromagnetic wire according to the position signal;

[0027] Based on the coil parameters, the bent electromagnetic wire is used to wind the positive coil on top of the negative coil.

[0028] Optionally, based on the coil parameters, use the bent electromagnetic wire to wind a positive coil on top of the negative coil, including:

[0029] Adjust the horizontal position of the electromagnetic wire according to its width;

[0030] Based on the horizontal position, use electromagnetic wire to wind the positive cake from the inside to the outside of the inner mold above the negative cake.

[0031] Optionally, after the coil to be wound is obtained, an insulating tape is used to wrap the outer layer of the coil to be wound.

[0032] A transformer coil winding device is also provided, which is applied to the transformer coil winding method, comprising:

[0033] The receiving and sending wire module is used to control the sending and receiving of electromagnetic wires;

[0034] Outer mold module, used to adjust the horizontal position of the electromagnetic wire;

[0035] Direction adjustment module, used to adjust the entry position of the electromagnetic wire;

[0036] The wrapping module is used to wrap the outer layer of the electromagnetic wire.

[0037] Optionally, also include:

[0038] Outer mold positioning module, used to fix the electromagnetic wire;

[0039] The bending module is used to bend the electromagnetic wire. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 is a flow chart of the winding method of the present invention;

[0041] Figure 2 It is a structural schematic diagram of the winding device of the present invention.

[0042] Explanation of the accompanying reference numerals: 1. receiving and sending line module; 101. receiving and sending unit; 102. speed control unit; 2. outer mold module; 3. direction adjustment module; 301. position adjustment unit; 302. angle adjustment unit; 4. wrapping module; 5. outer mold positioning module; 6. bending module; 7. inner mold. DETAILED DESCRIPTION

[0043] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0044] When the following description refers to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present application. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present application as detailed in the appended claims. In the description of the present application, it should be understood that the terms "first", "second", "third", etc. are only used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence, nor can they be understood as indicating or implying relative importance. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to the specific circumstances.

[0045] See also Figure 1 As shown, the present invention provides a transformer coil winding method, comprising:

[0046] S1: Determine the winding parameters and coil parameters of the coil to be wound; wherein, the coil to be wound includes an inverted cake and a positive cake; the winding parameters include the number of inverted cake turns, the number of inverted cakes, the number of positive cake turns and the number of positive cakes; the number of inverted cake turns is used to indicate the number of turns of the inverted cake, that is, how many turns each inverted cake includes; the number of inverted cakes is used to indicate the number of inverted cakes in the coil to be wound, that is, how many inverted cakes the coil to be wound includes; the number of positive cake turns is used to indicate the number of turns of the positive cake, that is, how many turns each positive cake includes; the number of positive cakes is used to indicate the number of positive cakes in the coil to be wound, that is, how many positive cakes the coil to be wound includes; in the coil to be wound, since the inverted cake and the positive cake are axially stacked structures, the number of inverted cake turns in the winding parameters is equal to the number of positive cake turns, and the number of inverted cakes is equal to the number of positive cakes; the coil parameters include the thickness and width of the electromagnetic wire used to wind the coil to be wound.

[0047] S2: Based on the winding parameters and coil parameters, use the electromagnetic wire to wind the inner mold from the outside to the inside to form an inverted pancake, including: using the electromagnetic wire to wind the first turn of the inverted pancake; adjusting the entry position of the electromagnetic wire according to the thickness of the electromagnetic wire to avoid interference between the electromagnetic wire and the previous turn, and then using the electromagnetic wire to wind the next turn inside the first turn of the inverted pancake; repeating the above steps until the number of turns wound on the inner mold meets the number of turns of the inverted pancake, that is, when the number of turns wound on the inner mold is equal to the number of turns of the inverted pancake, the inverted pancake winding is completed.

[0048] The present invention does not require the process of pre-winding and then flipping the cake when winding the reverse cake. Therefore, when winding the reverse cake from the outside to the inside of the inner mold, extra space will be reserved in advance for winding, that is, after the reverse cake is wound, there is extra space between the last turn of the reverse cake and the inner mold, that is, after the reverse cake is wound, it is necessary to retract the electromagnetic wire outside the reverse cake so that the last turn of the reverse cake is fitted to the inner mold, that is, the innermost turn of the reverse cake is fitted to the inner mold, so as to ensure that the structure of the reverse cake is compact and stable, and avoid excess electromagnetic wire affecting the winding of the subsequent positive cake; and by fitting the innermost turn of the reverse cake to the inner mold, the gap inside the coil can be reduced, the axial size of the coil can be made more uniform, and at the same time a flat base surface is provided for the winding of the positive cake, thereby improving the overall quality and winding accuracy of the wound coil.

[0049] S3: After the reverse cake is wound, based on the coil parameters, the electromagnetic wire is used to wind the positive cake from the inside to the outside of the inner mold above the reverse cake, including: first determining the position signal of the last turn of the reverse cake, performing bending processing according to the position signal, and based on the coil parameters, using the bent electromagnetic wire to wind the positive cake above the reverse cake.

[0050] In order to ensure that the starting point of the positive cake winding is closely connected with the reverse cake, avoid winding overlap or gaps, and improve winding accuracy and efficiency, it is necessary to accurately determine the end position of the last turn of the reverse cake; therefore, by obtaining a position signal indicating the end position of the reverse cake, the electromagnetic wire is bent according to the position signal, that is, the electromagnetic wire is bent at the end position of the last turn of the reverse cake to accurately adjust the position of the electromagnetic wire and ensure that the starting point of the positive cake winding is the end position of the last turn of the reverse cake.

[0051] In order to ensure that the positive cake fits on top of the negative cake and is wound from the inside to the outside, the width of the electromagnetic wire needs to be used as the basis for adjusting the horizontal position of the electromagnetic wire, that is, the width of the electromagnetic wire is used as the horizontal height required to rise for winding the positive cake based on the horizontal position of the electromagnetic wire when winding the negative cake; therefore, based on the coil parameters, using the bent electromagnetic wire to wind the positive cake above the negative cake includes: adjusting the horizontal position of the electromagnetic wire according to the width of the electromagnetic wire, and based on the horizontal position, using the electromagnetic wire to wind the positive cake from the inside to the outside of the inner mold above the negative cake.

[0052] When winding the reverse cake, the length of the electromagnetic wire for winding one reverse cake has been determined, and the only difference between the reverse cake and the normal cake is the winding direction. The length of the electromagnetic wire for winding the reverse cake is equal to the length of the electromagnetic wire for winding the normal cake, that is, when winding the normal cake, it also includes determining the length of the electromagnetic wire for winding the normal cake based on the length of the electromagnetic wire for winding the reverse cake, and the winding of the normal cake is performed from the inside to the outside of the inner mold, that is, when winding the normal cake, there will be no electromagnetic wires other than the reverse cake when winding the normal cake, that is, there is no need to retract the electromagnetic wires other than the normal cake after winding the reverse cake.

[0053] S4: Repeat the above steps, and the reverse and positive cakes are continuously wound upward alternately until the winding parameters are met to obtain the coil to be wound. In the transformer coil, it is composed of several positive cakes and reverse cakes stacked axially, and the transformer coil is repeatedly wound in the order of "reverse cake-positive cake-reverse cake-positive cake", and the winding parameters of the coil to be wound are determined in step S1, that is, the number of reverse cakes and positive cakes required to be wound when winding the coil to be wound is limited. Therefore, when the winding parameters are met, the number of reverse cakes wound is equal to the number of reverse cakes in the winding parameters, and the number of positive cakes wound is equal to the number of positive cakes in the winding parameters. Because the number of reverse cakes is equal to the number of positive cakes, that is, the number of times the above steps are repeated is equal to the number of reverse cakes and the number of positive cakes.

[0054] After the coil to be wound is obtained, the outer layer of the magnet wire is wrapped with an insulating tape so that the outer layer of the magnet wire is wrapped by the insulating layer.

[0055] See also Figure 2 As shown, the present invention also provides a transformer coil winding device, including: a wire receiving and sending module 1, an outer mold module 2, a direction adjustment module 3, a wrapping module 4, an outer mold positioning module 5, a bending module 6 and a control module; the wire receiving and sending module 1 includes a wire receiving and sending unit 101 and a speed control unit 102; the direction adjustment module 3 includes a position adjustment unit 301 and an angle adjustment unit 302; wherein, the wire receiving and sending module 1 is used to control the sending and receiving of the electromagnetic wire; the outer mold module 2 is used to adjust the horizontal position of the electromagnetic wire; the direction adjustment module 3 is used to adjust the entry position of the electromagnetic wire; the wrapping module 4 is used to wrap the outer layer of the electromagnetic wire; the outer mold positioning module 5 is used to fix the electromagnetic wire; the bending module 6 is used to bend the electromagnetic wire; the control module is used to control the wire receiving and sending module 1, the outer mold module 2, the direction adjustment module 3, the wrapping module 4, the outer mold positioning module 5 and the bending module 6.

[0056] The winding method is described in detail in conjunction with the winding device as follows:

[0057] First, when winding the inverted pancake, the control module controls the sending and receiving unit 101 to send the electromagnetic wire to the outer mold positioning module 5, so that the electromagnetic wire fits the outer mold positioning module 5 and rotates into an arc. After the first turn of the inverted pancake is wound, the control module controls the position adjustment unit 301 to move the sending and receiving unit 101 toward the inner mold 7 according to the thickness of the electromagnetic wire. The moving distance is the thickness of the electromagnetic wire, and the angle adjustment unit 302 is controlled to adjust the entry angle of the electromagnetic wire. The entry position of the electromagnetic wire is controlled by the position adjustment unit 301 and the angle adjustment unit 302 to avoid interference between the electromagnetic wire and the previous turn; the control module controls the sending and receiving unit 101 to repeat the above steps until the number of turns wound on the inner mold 7 meets the number of turns of the inverted pancake, that is, when the number of turns wound on the inner mold 7 is equal to the number of turns of the inverted pancake, the inverted pancake winding is completed, and after the inverted pancake winding is completed, the sending and receiving unit 101 is controlled to retract the electromagnetic wire outside the inverted pancake.

[0058] Then, the positive cake is wound, and the receiving and sending unit 101 obtains the position signal of the last turn of the negative cake and sends it to the control module, which controls the bending module 6 to bend the electromagnetic wire. The control module controls the outer mold module 2 to move the outer mold positioning module 5 upward according to the width of the electromagnetic wire. The moving distance is the width of the electromagnetic wire; the receiving and sending unit 101 obtains the wire feeding speed of the electromagnetic wire and sends it to the control module. The control module controls the speed control unit 102 to control the rotation speed of the inner mold 7 according to the wire feeding speed, coil parameters and the radius of the inner mold 7. For example: when the wire feeding speed of the receiving and sending unit 101 is 1000mm / min, the radius of the inner mold 7 is 150, and the reduction ratio of the speed control unit 102 is is 50:1, then when winding the first turn of the positive cake, the speed control unit 102 is obtained to have a rotation speed of 53.05 r / min through geometric calculation, and the speed is adjusted once each turn is completed; the control module controls the position adjustment unit 301 to move the sending and receiving unit 101 toward the inner mold 7 according to the thickness of the electromagnetic wire, and the moving distance is the thickness of the electromagnetic wire, and controls the angle adjustment unit 302 to adjust the entry angle of the electromagnetic wire. The entry position of the electromagnetic wire is controlled by the position adjustment unit 301 and the angle adjustment unit 302 to avoid interference between the electromagnetic wire and the previous turn; the control module controls the sending and receiving unit 101 to repeat the above steps until the number of winding turns meets the number of turns of the positive cake, and the positive cake winding is completed.

[0059] Then the control module controls the outer mold module 2 to move the outer mold positioning module 5 upward according to the width of the electromagnetic wire. The moving distance is the width of the electromagnetic wire. At this time, it is the horizontal position for the next inverted cake to start winding, and the next inverted cake starts to be wound.

[0060] The control module controls the receiving and sending wire module 1, the outer mold module 2, the direction adjustment module 3, the wrapping module 4, the outer mold positioning module 5 and the bending module 6 to repeat the above steps until the winding parameters are met, that is, the number of reverse coils wound is equal to the number of reverse coils in the winding parameters, and the number of positive coils wound is equal to the number of positive coils in the winding parameters. Because the number of reverse coils is equal to the number of positive coils, that is, when the number of times the above steps are repeated is equal to the number of reverse coils and the number of positive coils, the coil to be wound is obtained.

[0061] After obtaining the coil to be wound, the control module controls the wrapping module 4 to wrap the outer layer of the electromagnetic wire with an insulating tape at the wire feeding speed according to the wire feeding speed of the receiving and sending unit 101, so that the outer layer of the electromagnetic wire is wrapped by the insulating layer.

[0062] The present invention can replace the manual winding method and directly wind the inner mold 7 from the outside to the inside, avoiding the process of pre-winding and then turning the cake when manually winding the cake in the traditional process, simplifying the winding process and improving the winding efficiency of the transformer coil.

[0063] The above are only preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application should be included in the scope of protection of the present application.

Claims

1. A transformer coil winding method, characterized in that: include: Determine the winding parameters and coil parameters of the coil to be wound; the coil to be wound includes a reverse coil and a forward coil, and the coil parameters include the thickness and width of the electromagnetic wire; Based on the winding parameters and coil parameters, use electromagnetic wire to wind the inner mold from the outside to the inside to form an inverted cake, and retract the electromagnetic wire outside the inverted cake so that the last turn of the inverted cake fits the inner mold; After the reverse coil is wound, based on the coil parameters, use the electromagnetic wire to wind the positive coil from the inside to the outside of the inner mold on top of the reverse coil. Repeat the above steps, winding the reverse and forward coils alternately upwards until the winding parameters are met, and the coil to be wound is obtained; The method of winding the inverted pancake from the outside to the inside of the inner mold using the electromagnetic wire based on the winding parameters and the coil parameters includes: using the electromagnetic wire to wind the first turn of the inverted pancake; adjusting the electromagnetic wire entry position according to the thickness of the electromagnetic wire, and using the electromagnetic wire to wind the next turn inside the first turn of the inverted pancake; repeating the above steps until the number of turns wound on the inner mold meets the number of turns of the inverted pancake, thereby completing the inverted pancake winding; The method uses electromagnetic wire to wind the positive cake from the inside to the outside of the inner mold above the negative cake based on the coil parameters, including: adjusting the horizontal position of the electromagnetic wire according to the width of the electromagnetic wire; and based on the horizontal position, uses electromagnetic wire to wind the positive cake from the inside to the outside of the inner mold above the negative cake.

2. A transformer coil winding method according to claim 1, characterized in that: The winding parameters include: The number of turns of the pancake is used to indicate the number of turns of the pancake; The number of reverse cakes is used to indicate the number of reverse cakes in the coil to be wound; The number of turns of the positive cake is used to indicate the number of turns of the winding positive cake; The number of positive biscuits is used to indicate the number of positive biscuits in the coil to be wound.

3. A transformer coil winding method according to claim 2, characterized in that: Before winding the positive cake from the inside to the outside of the inner mold using electromagnetic wire on the top of the negative cake based on the coil parameters, the method further includes: Determine the position signal of the last turn of the anti-pancake; The electromagnetic wire is bent according to the position signal.

4. The transformer coil winding method according to claim 1, characterized in that: After obtaining the coil to be wound, use insulating tape to wrap the outer layer of the magnet wire.

5. A transformer coil winding device, applied to a transformer coil winding method according to any one of claims 1 to 4, characterized in that: include: The receiving and sending wire module is used to control the sending and receiving of electromagnetic wires; Outer mold module, used to adjust the horizontal position of the electromagnetic wire; Direction adjustment module, used to adjust the entry position of the electromagnetic wire; The wrapping module is used to wrap the outer layer of the electromagnetic wire.

6. The transformer coil winding device according to claim 5, characterized in that: Also includes: Outer mold positioning module, used to fix the electromagnetic wire; The bending module is used to bend the electromagnetic wire.

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