Winding method of low-hot-point large-current coil structure

Abstract

The invention provides a low-hot-spot large-current coil structure winding method, and belongs to the technical field of transformers. The invention provides a low-hot-spot large-current coil structure winding method, which comprises the following operation steps: winding at the left end of a winding support frame, winding an upper half coil, winding a first current-sharing upper wire cake of an end current-sharing sub-coil on the winding support frame, taking a remaining wire as a first reserved wire after winding is completed, and taking a second reserved wire as a second reserved wire after winding is completed. A first reserved wire is wound on the right side of a first current-sharing upper wire cake, a continuous sub-coil is wound on the right side of the first current-sharing upper wire cake, a first current-sharing lower wire cake of an end current-sharing sub-coil is wound on a first reserved wire, a lower half coil is wound on the first reserved wire, and a head end connecting wire is connected with all the first current-sharing upper wire cakes and the continuous upper wire cake of the continuous sub-coil. And the tail end connecting wire is connected with all the first uniform lower wire cakes and the continuous lower wire cakes of the continuous sub-coils. According to the winding method of the low-hot-spot large-current coil structure, unbalanced current and hot spots are reduced, the service life is prolonged, and operation is easy and convenient.

Description

Technical Field

[0001] The invention belongs to the technical field of transformers, and in particular relates to a method for winding a high-current coil structure with a low hot spot. Background Art

[0002] In low-voltage, large-capacity transformers, the current on the low-voltage side of the transformer is very large, even up to tens of thousands of amperes. In order to ensure the safety of the transformer, it is necessary to use large-section wires for coil winding, or connect multiple wires in parallel for coil winding. However, when the current reaches a certain level, using large-section wires will cause problems such as excessive coil additional loss and inability to process and manufacture. In order to solve this problem, the general method is to wind multiple groups of identical sub-coils on the axial direction of the core, and connect all the sub-coils in parallel to the current, so that the current in each sub-coil is reduced, reducing the difficulty of manufacturing high-current coils. The multiple groups of axially distributed sub-coils are connected in parallel, and each group of sub-coils is located at a different position of the leakage magnetic field formed by the body of the device. Under the action of the leakage magnetic field, the current in the sub-coil at the end is significantly higher than the current in the sub-coil at other positions, resulting in an unbalanced current distribution phenomenon in the axial direction of the core. The larger the current on the low-voltage side of the transformer and the more sub-coil groups there are, the more serious the unbalanced current distribution phenomenon is, resulting in excessive additional losses and high temperatures in the sub-coils at the end, which seriously raises the hot spot of the high-current coil and causes the hot spot temperature of the coil to exceed the safe value, affecting the safety of transformer operation and shortening the service life of the transformer. Summary of the invention The purpose of the present invention is to provide a method for winding a high-current coil structure with a low hot spot, aiming to solve the problem that the current on the low-voltage side of a low-voltage and large-capacity transformer is large, the sub-coil loss at the end is too large, the temperature is too high, and the hot spot of the high-current coil is increased.

[0003] To achieve the above object, the technical solution adopted by the present invention is: to provide a method for winding a high current coil structure with a low hot spot, comprising the following steps: S1. Winding the coil structure on a winding support frame, winding the upper half of the coil, and winding the first current-sharing upper coil of the end current-sharing sub-coil on the left end of the winding support frame; S2. The winding of the first current-sharing upper wire cake is completed, and the remaining wire is used as the first reserved wire, and the first reserved wire is led to the right side of the first current-sharing upper wire cake; S3, winding a specified number of continuous sub-coils on the right side of the first current-sharing coil; S4, the continuous sub-coil is wound, and the first reserved wire is wound around the first current-sharing lower coil of the end current-sharing sub-coil on the right side of the rightmost continuous sub-coil; S5, winding the lower half coil; S6. The head end connecting wire connects all the first current-sharing upper wire discs with the continuous upper wire discs of the continuous sub-coil, and the tail end connecting wire connects all the first current-sharing lower wire discs with the continuous lower wire discs of the continuous sub-coil.

[0004] In a possible implementation, in step S2, the first reserved conducting wire is wound into a disc and tied to a support bar of a winding support frame.

[0005] In a possible implementation, in step S2, the first reserved conductor is located between two groups of stays of the winding support frame, the first reserved conductor is transposed toward the inside of the winding support frame, and the continuous sub-coil is wound on the outside of the first reserved conductor.

[0006] In a possible implementation, in step S2, a displacement distance of the first reserved wire to the inner side of the winding support frame is greater than or equal to the thickness of the wire.

[0007] In a possible implementation, in step S2, the length of the first reserved wire is greater than the sum of the lengths of the first current-sharing connecting wire and the first current-sharing lower coil of the end current-sharing sub-coil.

[0008] In a possible implementation, in step S3, the upper half coil includes a middle current balancing sub-coil, the second current balancing upper coil of the middle current balancing sub-coil is wound, and the remaining wire is used as a second reserved wire, which leads to the right side of the second current balancing upper coil.

[0009] In a possible implementation, in step S3, the second reserved conductor is located between two groups of stays of the winding support frame, the second reserved conductor is transposed toward the inside of the winding support frame, and the continuous sub-coil is wound on the outside of the second reserved conductor.

[0010] In a possible implementation, in step S3, after the winding of the prescribed number of continuous sub-coils is completed, the second current-sharing lower coil of the middle current-sharing sub-coil is wound on the right side of the continuous sub-coil.

[0011] In a possible implementation, in step S4, when the first current-sharing lower bobbin is wound, the first reserved conducting wire is tightened before winding.

[0012] In a possible implementation, in step S6, the head end connection wire is led out as the head end of the coil structure, and the tail end connection wire is led out as the tail end of the coil structure.

[0013] The beneficial effects of the low hot spot high current coil structure winding method provided by the present invention are: Compared with the prior art, the coil structure is wound on a winding support frame, and the lower half coil is wound after the upper half coil is wound. When the upper half coil is wound, the first current-equalizing upper coil cake of the end current-equalizing sub-coil is first wound. After the first current-equalizing upper coil cake is wound, the wire led out is used as the first reserved wire. The first reserved wire is used to wind the first current-equalizing lower coil cake of the subsequent end current-equalizing sub-coil. The continuous sub-coil is wound close to the right side of the first current-equalizing upper coil cake. After the continuous sub-coil is wound, the first current-equalizing lower coil cake of the end current-equalizing sub-coil is wound close to the right side of the continuous sub-coil. The winding of the upper half coil is completed, and the winding process of the lower half coil is the same as that of the upper half coil. The lower half coil is wound on the right side of the upper half coil. After the upper half coil and the lower half coil are wound, the head end connecting wire connects all the first current-sharing upper wire cakes with the continuous upper wire cakes of the continuous sub-coil, and the tail end connecting wire connects all the first current-sharing lower wire cakes with the continuous lower wire cakes of the continuous sub-coil, so as to wind a high-current coil with a low hot spot, reduce the influence of the transformer body leakage magnetic field on the end coil current, reduce the current flowing in the end coil, reduce the loss and temperature of the transformer, avoid the phenomenon of excessive hot spot of the end coil caused by excessive current, reduce the hot spot of the entire high-current coil, improve the safety and reliability of the transformer, and increase the service life of the transformer. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0015] Figure 1 Schematic diagram of the winding process of the low hot spot high current coil structure winding method provided by the embodiment of the present invention Figure 1 ; Figure 2 Schematic diagram of the winding process of the low hot spot high current coil structure winding method provided by the embodiment of the present invention Figure 2 ; Figure 3 Schematic diagram of the winding process of the low hot spot high current coil structure winding method provided by the embodiment of the present invention Figure 3 ; Figure 4 Schematic diagram of the winding process of the low hot spot high current coil structure winding method provided by the embodiment of the present invention Figure 4 .

[0016] In the figure: 100, upper half coil; 200, lower half coil; 300, head end connecting wire; 400, tail end connecting wire; 500, winding support frame; 110, end current equalizing sub-coil; 111, first current equalizing upper wire cake; 113, first current equalizing connecting wire; 114, first current equalizing lower wire cake; 115, first reserved conductor; 120, continuous sub-coil; 122, continuous upper wire cake; 124, continuous lower wire cake; 510, support bar. DETAILED DESCRIPTION In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0017] Please refer to Figures 1 to 4A low hot spot high current coil structure includes an upper coil 100, a lower coil 200, a head end connection line 300 and a tail end connection line 400, the upper coil 100 includes an end current equalizing sub-coil 110 and a continuous sub-coil 120, the end current equalizing sub-coil 110 includes a first current equalizing upper wire cake 111 and a first current equalizing lower wire cake 114, the first current equalizing upper wire cake 111 is arranged at the uppermost end of the upper coil 100, the first current equalizing lower wire cake 114 is arranged at the lowermost end of the upper coil 100, the first current equalizing upper wire cake 111 and the first current equalizing lower wire cake 114 are connected through a first current equalizing connection line 113, the continuous sub-coil 120 is arranged between the first current equalizing upper wire cake 111 and the first current equalizing lower wire cake 114, the lower coil 200 includes The end current-equalizing sub-coil 110 and the continuous sub-coil 120, the uppermost end of the lower half coil 200 is provided with a first current-equalizing upper wire cake 111, and the lowermost end of the lower half coil 200 is provided with a first current-equalizing lower wire cake 114. The continuous sub-coil 120 of the lower half coil 200 is arranged between the first current-equalizing upper wire cake 111 and the first current-equalizing lower wire cake 114. The continuous sub-coil 120 includes a continuous upper wire cake 122 and a continuous lower wire cake 124. The head end connecting line 300 and the tail end connecting line 400 are arranged along the height direction of the upper half coil 100 and the lower half coil 200. The head end connecting line 300 connects all the first current-equalizing upper wire cakes 111 and the continuous upper wire cake 122, and the tail end connecting line 400 connects all the first current-equalizing lower wire cakes 114 and the continuous lower wire cake 124. A first current-sharing head is led out from the first current-sharing upper wire cake 111, and the other end of the first current-sharing head is connected to the head end connection line 300. A first current-sharing tail is led out from the first current-sharing lower wire cake 114, and the other end of the first current-sharing tail is connected to the tail end connection line 400. A continuous head is led out from the continuous upper wire cake 122, and the other end of the continuous head is connected to the head end connection line 300. A continuous tail is led out from the continuous lower wire cake 124, and the other end of the continuous tail is connected to the tail end connection line 400. The upper half coil 100 also includes a middle current-sharing sub-coil, which is arranged between the first current-sharing upper wire cake 111 and the first current-sharing lower wire cake 114. The middle current-sharing sub-coil includes a second current-sharing upper wire cake and a second current-sharing lower wire cake. The second current-sharing upper wire cake and the second current-sharing lower wire cake are connected by a second current-sharing connection line, and multiple groups of middle current-sharing sub-coils are nested.

[0018] Please refer to Figures 1 to 4 A specific implementation method of a low hot spot high current coil structure winding method provided by the present invention is now described, including the following steps: S1, winding the coil structure on the winding support frame 500, winding the upper half coil 100, and winding the first current-sharing upper coil 111 of the end current-sharing sub-coil 110 on the left end of the winding support frame 500; S2, the winding of the first current-sharing upper wire cake 111 is completed, and the remaining wire is used as the first reserved wire 115, and the first reserved wire 115 is led to the right side of the first current-sharing upper wire cake 111; S3, winding a predetermined number of continuous sub-coils 120 on the right side of the first current-sharing coil 111; S4, the continuous sub-coil 120 is wound, and the first reserved conductor 115 is wound around the first current-sharing lower coil 114 of the end current-sharing sub-coil 110 on the right side of the rightmost continuous sub-coil 120; S5, winding the lower half coil 200; S6. The head end connecting line 300 connects all the first current-sharing upper wire discs 111 and the continuous upper wire discs 122 of the continuous sub-coil 120 , and the tail end connecting line 400 connects all the first current-sharing lower wire discs 114 and the continuous lower wire discs 124 of the continuous sub-coil 120 .

[0019] The present invention provides a method for winding a high-current coil structure with a low hot spot. Compared with the prior art, the coil structure is wound on a winding support frame 500. After the upper half coil 100 is wound, the lower half coil 200 is wound. When the upper half coil 100 is wound, the first current-sharing upper wire cake 111 of the end current-sharing sub-coil 110 is first wound. After the first current-sharing upper wire cake 111 is wound, the wire led out is used as the first reserved wire 115. The first reserved wire 115 is used for winding the first current-sharing lower wire cake 114 of the subsequent end current-sharing sub-coil 110. The continuous sub-coil 120 is wound closely to the right side of the first current-sharing upper wire cake 111. After the continuous sub-coil 120 is wound, the first current-sharing lower wire cake 114 of the end current-sharing sub-coil 110 is wound closely to the right side of the continuous sub-coil 120. The upper half coil 100 is wound. The winding process of the lower coil 200 is consistent with that of the upper coil 100. The lower coil 200 is wound on the right side of the upper coil 100. After the winding of the upper coil 100 and the lower coil 200 is completed, the head end connecting line 300 connects all the first current-sharing upper wire cakes 111 with the continuous upper wire cakes 122 of the continuous sub-coil 120, and the tail end connecting line 400 connects all the first current-sharing lower wire cakes 114 with the continuous lower wire cakes 124 of the continuous sub-coil 120, so as to wind a high-current coil with a low hot spot, reduce the influence of the transformer body leakage magnetic field on the end coil current, reduce the current flowing in the end coil, reduce the loss and temperature of the transformer, avoid the phenomenon of excessively high coil hot spots caused by excessive current in the end coil, reduce the hot spots of the entire high-current coil, improve the safety and reliability of the transformer, and increase the service life of the transformer.

[0020] For details, please refer to Figure 1In step S1, the winding support frame 500 is placed horizontally, and the large current coil structure is wound from the left end to the right end of the winding support frame 500. The lower half coil 200 is wound on the right side of the upper half coil 100. First, the first current equalizing upper coil 111 of the end current equalizing sub-coil 110 of the large current coil structure is wound.

[0021] For details, please refer to Figure 1 In step S2, after the winding of the first current-sharing upper coil 111 is completed, there is a wire remaining at the tail end of the first current-sharing upper coil 111, and the remaining wire is used as the first reserved wire 115. The length of the first reserved wire 115 is greater than the sum of the lengths of the first current-sharing connecting wire 113 of the end current-sharing sub-coil 110 and the first current-sharing lower coil 114. The first reserved wire 115 is transposed toward the inner side of the winding support frame 500, and the transposition distance is greater than or equal to the thickness of the wire. The transposed first reserved wire 115 is located at the winding Between the two groups of struts 510 of the wire support frame 500, the first reserved conductor 115 extends along the length direction of the strut 510 to the right side of the first current equalizing upper wire cake 111, and the first reserved conductor 115 extends to the position of the first current equalizing lower wire cake 114 of the end current equalizing sub-coil 110. The first reserved conductor 115 is wound into a disc, and a binding tape is used to pass through the center of the disc around which the first reserved conductor 115 is wound, and the disc around which the first reserved conductor 115 is wound is tied to the strut 510 of the winding support frame 500.

[0022] For details, please refer to Figure 2In step S3, a continuous sub-coil 120 is wound on the right side of the first current-equalizing upper wire cake 111, and the continuous sub-coil 120 is wound in contact with the right side of the first current-equalizing upper wire cake 111. A specified number of continuous sub-coils 120 are wound. During the winding process, the continuous sub-coil 120 is wound on the outside of the first reserved conductor 115; when the upper half coil 100 contains a middle current-equalizing sub-coil, a second current-equalizing upper wire cake of the middle current-equalizing sub-coil is wound at the position where the continuous sub-coil 120 needs to be wound. The second current-equalizing upper wire cake is wound in contact with the continuous sub-coil 120 and is wound on the outside of the first reserved conductor 115. After the second current-equalizing upper wire cake is wound, the remaining wire is used as the second reserved wire. The length of the second reserved wire is greater than the sum of the lengths of the second current-equalizing connecting wire of the middle current-equalizing sub-coil and the wire of the second current-equalizing lower wire cake. The second reserved wire is wound toward The inner side of the wire support frame 500 is transposed, and the transposition distance is greater than or equal to the thickness of the wire. After the transposition, the second reserved wire is located between the two groups of struts 510 of the winding support frame 500, and the second reserved wire extends to the right side of the second current equalizing upper wire cake along the length direction of the strut 510. The second reserved wire extends to the position of the second current equalizing lower wire cake of the middle current equalizing sub-coil, and the second reserved wire is wound into a disc. A binding tape is used to pass through the center of the disc wound with the second reserved wire, and the disc wound with the second reserved wire is tied to the strut 510 of the winding support frame 500. The continuous sub-coil 120 or other middle current equalizing sub-coil wire cakes are continued to be wound on the right side of the second current equalizing upper wire cake. When winding the second current equalizing lower wire cake of the middle current equalizing sub-coil, the second reserved wire is tightened, the binding of the second reserved wire is released, and the second current equalizing lower wire cake is wound.

[0023] For details, please refer to Figure 3 In step S4, after the continuous sub-coil 120 and the middle current-sharing sub-coil are wound, the first reserved conductor 115 is tightened, the binding of the first reserved conductor 115 is released, and the first current-sharing lower coil 114 is wound.

[0024] For details, please refer to Figure 4 In step S5 , the lower coil 200 is wound, and the winding method of the lower coil 200 is consistent with the winding method of the upper coil 100 .

[0025] For details, please refer to Figure 4 In step S6, the head end connecting line 300 and the tail end connecting line 400 are arranged along the length direction of the upper half coil 100 and the lower half coil 200. The head end connecting line 300 connects the first current equalizing head ends of all the first current equalizing upper line cakes 111 and the continuous head ends of the continuous upper line cakes 122, and the tail end connecting line 400 connects the first current equalizing tail ends of all the first current equalizing lower line cakes 114 and the continuous tail ends of the continuous lower line cakes 124.

[0026] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for winding a high current coil structure with a low hot spot, characterized in that: The steps are as follows: S1. Winding the coil structure on a winding support frame, winding the upper half of the coil, and winding the first current-sharing upper coil of the end current-sharing sub-coil on the left end of the winding support frame; S2. The winding of the first current-sharing upper wire cake is completed, and the remaining wire is used as the first reserved wire, and the first reserved wire is led to the right side of the first current-sharing upper wire cake; S3, winding a specified number of continuous sub-coils on the right side of the first current-sharing coil; S4, the continuous sub-coil is wound, and the first reserved wire is wound around the first current-sharing lower coil of the end current-sharing sub-coil on the right side of the rightmost continuous sub-coil; S5, winding the lower half coil; S6. The head end connecting wire connects all the first current-sharing upper wire discs with the continuous upper wire discs of the continuous sub-coil, and the tail end connecting wire connects all the first current-sharing lower wire discs with the continuous lower wire discs of the continuous sub-coil.

2. A method for winding a high current coil structure with a low hot spot as claimed in claim 1, characterized in that: In step S2, the first reserved conductor is wound into a disc and tied to the stays of the winding support frame.

3. A method for winding a high current coil structure with a low hot spot as claimed in claim 1, characterized in that: In step S2, the first reserved conductor is located between two groups of stays of the winding support frame, the first reserved conductor is transposed to the inside of the winding support frame, and the continuous sub-coil is wound on the outside of the first reserved conductor.

4. A method for winding a low hot spot high current coil structure as claimed in claim 3, characterized in that: In step S2, the displacement distance of the first reserved wire to the inner side of the winding support frame is greater than or equal to the thickness of the wire.

5. A method for winding a low hot spot high current coil structure as claimed in claim 1, characterized in that: In step S2, the length of the first reserved wire is greater than the sum of the lengths of the first current-sharing connecting wire and the first current-sharing lower coil of the end current-sharing sub-coil.

6. A method for winding a low hot spot high current coil structure as claimed in claim 1, characterized in that: In step S3, the upper half coil includes a middle current balancing sub-coil, the second current balancing upper coil of the middle current balancing sub-coil is wound, and the remaining wire is used as a second reserved wire, which is led to the right side of the second current balancing upper coil.

7. A method for winding a low hot spot high current coil structure as claimed in claim 6, characterized in that: In step S3, the second reserved conductor is located between two groups of stays of the winding support frame, the second reserved conductor is transposed toward the inside of the winding support frame, and the continuous sub-coil is wound on the outside of the second reserved conductor.

8. A method for winding a low hot spot high current coil structure as claimed in claim 7, characterized in that: In step S3, after the winding of the specified number of continuous sub-coils is completed, the second current-sharing lower coil of the middle current-sharing sub-coil is wound on the right side of the continuous sub-coil.

9. A method for winding a low hot spot high current coil structure as claimed in claim 1, characterized in that: In step S4, when the first current-sharing lower coil is wound, the first reserved conducting wire is tightened before winding.

10. A method for winding a low hot spot high current coil structure as claimed in claim 1, characterized in that: In step S6, the head end connection wire is led out as the head end of the coil structure, and the tail end connection wire is led out as the tail end of the coil structure.

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