Coil insulation paper tape winding method and transformer coil winding equipment

Abstract

The invention discloses a coil insulation paper tape winding method, which comprises the following winding steps: step 1, winding tape-shaped insulation paper from the head end to the tail end of an interlayer insulation area along with a wire so as to form interlayer insulation of a current layer; step 2, taking the tail end of the interlayer insulation area of the current layer as an end insulation area, and winding strip-shaped insulation paper in the end insulation area to form end insulation; and 3, leading out the strip-shaped insulation paper to the next layer from the tail end of the interlayer insulation area along with the wire, so that the strip-shaped insulation paper can be wound along with the wire to form the insulation of the next layer. The method is reasonable in step setting, continuous winding can be achieved, the step complexity degree and dependence on personnel ability are reduced, automatic scheme progress is promoted, cost is effectively reduced, and efficiency is effectively improved. The invention further provides transformer coil winding equipment.

Description

Technical Field

[0001] The invention specifically relates to a coil insulation paper tape winding method and transformer coil winding equipment. Background Art

[0002] As the core of the transformer, the coil is made of wires and strip-shaped insulating paper wound according to a specific process to ensure its mechanical, electrical and heat resistance. Therefore, in order to maintain the electrical insulation strength between the wires and avoid breakdown and short circuit of adjacent coils, interlayer insulation must be added between each layer of wires. After normal power-on operation, a voltage difference will be generated between each turn of the wire. Through layer-by-layer arrangement, the voltage difference between the upper and lower layers of wires will increase in a step-like manner.

[0003] In the past, the interlayer insulation of transformer high-voltage coils used traditional wide-width interlayer insulation paper, with constant insulation strength or large changes in insulation gradient within the layer. The wide-width insulation paper between each layer was manually added, which resulted in long labor hours and difficulty in ensuring product consistency. The current idea of ​​using thin strips of insulation paper (or insulation paper tape) to wrap instead of wide-width insulation paper covering can further promote the advancement of coil insulation automatic winding solutions.

[0004] However, the insulation requirement between conductor layers is not that the thickness is always consistent, but that the thickness gradually changes with the voltage difference. In addition, the two ends of the coil need to be wound into the end insulation part. Therefore, the current winding process is either to wind the conductor and the insulation in sequence, or to wind the insulating paper tape and the conductor at the same time (that is, the insulating paper tape is placed under the conductor for winding). At the same time, the strip insulating paper needs to be cut and manually added at least once during each layer of winding to ensure that the interlayer insulation thickness and end insulation meet the requirements. It can be seen that the current winding process is still very cumbersome. Not only does it require a high level of proficiency from the operator, but the steps are trivial and require multiple interruptions. It also requires additional shearing components to assist multiple times, so it is difficult to achieve cost reduction and efficiency improvement. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide a coil insulation paper tape winding method in view of the above-mentioned deficiencies in the prior art. The method has reasonable steps, can achieve uninterrupted winding, reduce the cumbersomeness of the steps and the dependence on the ability of personnel, promote the advancement of automation solutions, effectively reduce costs and improve efficiency. The present invention also provides a transformer coil winding device.

[0006] The present invention provides a method for winding a coil insulating paper tape, comprising a winding step, wherein the winding step comprises:

[0007] The first sub-step: winding the strip insulation paper together with the conductor from the beginning to the end of the interlayer insulation area to form the interlayer insulation of the current layer;

[0008] The second sub-step: taking the tail end of the current interlayer insulation area as the end insulation area, winding the strip insulation paper in the end insulation area to form the end insulation;

[0009] The third sub-step: leading the strip-shaped insulating paper together with the conductor from the tail end of the interlayer insulating area to the next layer, so that the strip-shaped insulating paper can be wound together with the conductor to form the next layer of insulation.

[0010] Furthermore, the first sub-step and the third sub-step use the same first strip-shaped insulating paper to perform uninterrupted winding of each layer of interlayer insulation, and the second sub-step uses the second strip-shaped insulating paper alone to perform the winding of each layer of end insulation; or, the first sub-step, the second sub-step and the third sub-step all use the same first strip-shaped insulating paper to perform uninterrupted winding of each layer of insulation including interlayer insulation and end insulation.

[0011] Furthermore, before the winding step, the method further includes a winding mode selection step, and the winding mode selection step includes:

[0012] Get the wire specifications;

[0013] When the wire specification is not less than the set value, the winding step is performed in the first mode;

[0014] In the winding step performed in the first mode, the first sub-step and the third sub-step use the same first strip-shaped insulating paper to perform uninterrupted winding of the interlayer insulation of each layer, and the second sub-step uses the second strip-shaped insulating paper alone to perform the winding of the end insulation of each layer;

[0015] When the wire specification is smaller than the set value, the winding step is performed in the second mode;

[0016] In the winding step performed using the second mode, the first sub-step, the second sub-step and the third sub-step all use the same first tape-shaped insulating paper to perform uninterrupted winding of each layer of insulation including interlayer insulation and end insulation.

[0017] Furthermore, the first sub-step is used to form a trapezoidal interlayer insulation so that the increase in thickness of the interlayer insulation is consistent with the increase in voltage difference between two layers of conductors.

[0018] Furthermore, in the first sub-step, the strip-shaped insulating paper is wound along with the conductor from the beginning to the end of the interlayer insulation region, specifically comprising:

[0019] According to a set rule, the first strip-shaped insulating paper is gradually moved laterally from the head end to the tail end of the interlayer insulation area during winding;

[0020] So that in the first mode, the first strip-shaped insulating paper is stacked to form the trapezoidal interlayer insulation of the current layer when the current layer of wire is wound, and the number of winding turns of the first strip-shaped insulating paper when forming the interlayer insulation is consistent with the number of winding turns of the wire of the layer; or,

[0021] So that in the second mode, the first strip-shaped insulating paper is stacked to form the insulation of the current layer when the current layer of wire is wound, and the number of winding turns of the first strip-shaped insulating paper when forming insulation is consistent with the number of winding turns of the wire of this layer.

[0022] Furthermore, the first strip-shaped insulating paper is gradually moved laterally from the head end to the tail end of the interlayer insulating region during winding according to a set rule, specifically including:

[0023] The distance y that the first strip of insulating paper moves horizontally from the beginning to the end of the interlayer insulating area when winding the nth turn is obtained by the following first calculation formula:

[0024]

[0025] Among them, h 1 h is the closed thickness of the trapezoidal interlayer insulation, 2 is the opening thickness of the trapezoidal interlayer insulation, L is the width of the interlayer insulation area, H 绝 is the cross-sectional thickness of the first strip-shaped insulating paper, W 绝 is the cross-sectional width of the first strip-shaped insulating paper;

[0026] According to the relationship between the number of winding turns n and the lateral displacement distance y, the first strip-shaped insulating paper is gradually transversely displaced from the head end to the tail end of the interlayer insulating region during winding.

[0027] Furthermore, after the winding mode selection step and before the winding step, the method further includes a specification selection step, and the specification selection step includes:

[0028] The specification S of the first strip-shaped insulating paper is obtained by the following second calculation formula: 截 :

[0029]

[0030] Among them, S 梯 is the axial cross-sectional area of ​​the current layer of trapezoidal interlayer insulation, and N is the number of turns of the first strip-shaped insulating paper forming the current layer of interlayer insulation;

[0031] According to the specification S of the first strip insulating paper 截 Select a paper tape from the standard specification paper tape to obtain the cross-sectional thickness H of the first strip-shaped insulating paper. 绝 and section width W 绝 , thereby obtaining a first strip-shaped insulating paper.

[0032] Further, in the winding step performed in the first mode, in the first sub-step, after the strip-shaped insulating paper is wound along with the conductor from the beginning to the end of the interlayer insulating region, the step further includes: rewinding the first strip-shaped insulating paper at the end of the interlayer insulating region by x turns, wherein N in the second calculation formula is the difference between the number of turns m of the conductor winding and the number of rewinding turns x;

[0033] In the winding step performed using the second mode, the second sub-step is specifically: taking the tail end of the current interlayer insulation region as the end insulation region, winding the first strip-shaped insulation paper around the end insulation region with p turns to form end insulation; wherein p is the conductor thickness H 导 divided by twice the cross-sectional thickness H of the first tape-shaped insulating paper 绝 , N in the second calculation formula is the difference between the number of turns m of the wire winding and the number of turns p of the complex winding.

[0034] Further, in the winding step performed in the first mode, the second sub-step specifically includes:

[0035] When the first strip of insulating paper reaches the end of the interlayer insulating area, the end of the interlayer insulating area is used as the end insulating area.

[0036] The second strip-shaped insulating paper is arranged on the first strip-shaped insulating paper, so that the first strip-shaped insulating paper is arranged under the second strip-shaped insulating paper;

[0037] The second strip-shaped insulating paper is wound together with the first strip-shaped insulating paper at the tail end of the interlayer insulating region, so that the second strip-shaped insulating paper forms end insulation.

[0038] Furthermore, during the execution of the winding step, the method further includes: adjusting the strip-out condition of the strip-shaped insulating paper by acquiring real-time winding data, so that the winding tension of the strip-shaped insulating paper is maintained within a set range.

[0039] Furthermore, before the winding step, the method further comprises: leading the strip-shaped insulating paper wound into a paper tape reel to a coil mold on the main shaft;

[0040] The winding step specifically includes:

[0041] The unwinding shaft of the paper tape reel rotates to unwind and the main shaft rotates to rewind, so that the strip-shaped insulating paper is wound into insulation;

[0042] The step of obtaining real-time winding data to adjust the strip-shaped insulating paper strip discharge condition so as to keep the winding tension of the strip-shaped insulating paper within a set range specifically includes:

[0043] Obtain the real-time winding diameter of the paper tape reel and the real-time output speed of the strip insulating paper;

[0044] The rotation speed of the unwinding shaft is adjusted according to the real-time winding diameter and the real-time tape delivery speed so that the winding tension of the tape-shaped insulating paper is maintained within the set range.

[0045] The present invention also provides a transformer coil winding device, comprising a main shaft rotating mechanism, a wire arranging mechanism and an insulating paper supplying mechanism, wherein the wire arranging mechanism and the insulating paper supplying mechanism are respectively used to supply wires and strip insulating paper to the main shaft rotating mechanism, wherein the main shaft rotating mechanism comprises a main shaft, on which a coil mold is arranged, and the main shaft rotating mechanism drives the main shaft to rotate and rewind so that the wires and strip insulating paper are wound onto the coil mold; as the main shaft rotates, the insulating paper supplying mechanism moves together with the wire arranging mechanism relative to the coil mold from the head end to the tail end of the interlayer insulating area, so as to allow the wire arranging mechanism to be wound on the coil mold. When the current conductor layer is formed, the strip insulating paper is wound along with the conductor from the beginning to the end of the interlayer insulating area of ​​the coil mold to form the interlayer insulation of the current layer, and the tail end of the interlayer insulating area of ​​the current layer is used as the end insulating area, and the strip insulating paper is wound in the end insulating area to form the end insulation, and the insulating paper supply mechanism moves relative to the coil mold from the tail end of the interlayer insulating area along with the conductor arrangement mechanism in the opposite direction to lead the strip insulating paper along with the conductor from the tail end of the interlayer insulating area of ​​the coil mold to the next layer, so that the strip insulating paper can be wound along with the conductor to form the insulation of the next layer.

[0046] Furthermore, the insulating paper supply mechanism includes a unwinding shaft and a mechanism frame, the unwinding shaft is rotatably connected to the mechanism frame, and a paper tape reel is provided on the unwinding shaft for rotating and unwinding to supply strip-shaped insulating paper to the main shaft rotation mechanism. The mechanism frame can move along the axial direction of the coil mold to drive the unwinding shaft to move, so that it is wound on the coil mold as the main shaft rotates to form a trapezoidal interlayer insulation, so that the increase in the interlayer insulation thickness is consistent with the increase in the voltage difference between the two layers of conductors.

[0047] Furthermore, the device also includes a controller, which is electrically connected to the mechanism frame and the main shaft respectively, and is used to control the mechanism frame to gradually move horizontally from the head end to the tail end of the interlayer insulation area of ​​the coil mold as the main shaft rotates according to a set rule, so that the strip-shaped insulating paper is stacked to form a trapezoidal interlayer insulation.

[0048] Furthermore, the setting rule is: the lateral displacement distance y of the mechanism frame and the number of rotation and winding turns n of the main shaft satisfy the following first calculation formula:

[0049]

[0050] Among them, h 1 h is the closed thickness of the trapezoidal interlayer insulation, 2 is the opening thickness of the trapezoidal interlayer insulation, L is the width of the interlayer insulation area, H 绝 is the cross-sectional thickness of the first strip-shaped insulating paper, W绝 is the cross-sectional width of the first strip-shaped insulating paper.

[0051] The coil insulation paper tape winding method of the present invention is no longer like the previous winding method, when winding each layer of insulation, the interlayer insulation and the end insulation are each completed at least once to start adding and cutting, but it is directly led out to the next layer, and the tail end of the interlayer insulation area is used as the end insulation area, so that the winding process forms a non-interrupted winding scheme that is only reciprocated in the interlayer insulation area, that is, after the current layer is wound from the head end to the tail end, it is directly introduced into the winding of the next layer. When the next layer is wound, the tail end direction of the previous layer (that is, the aforementioned current layer) is used as the head end direction, and the winding continues from the head end to the tail end (that is, from the perspective of the current layer, the next layer is wound from the tail end to the head end).

[0052] Therefore, in this winding process, there is no need to cut or add the strip insulating paper between the layers, which not only greatly reduces the dependence on the operator's operating proficiency and operating accuracy, but also saves the intermittent operation time, effectively improves the winding efficiency and reduces the winding cost; and the reciprocating winding direction of each layer of the strip insulating paper corresponds to the winding direction of each layer of the wire, avoiding interference caused by the opposite direction, and there is no need to wind the wire and the insulation separately, and can be wound in the forward direction non-interruptedly at the same time. It can be seen that this method further optimizes the winding scheme, makes the steps more concise, and is easy to implement through automated equipment, promoting the advancement of transformer coil automated winding technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 Schematic diagram of stacking of interlayer insulation in the coil insulation paper tape winding method in Example 1 of the present invention;

[0054] Figure 2 1 is a schematic flow chart of a method for winding a coil insulating paper tape in Embodiment 1 of the present invention;

[0055] Figure 3 It is a structural schematic diagram of the insulating paper supply mechanism of the transformer coil winding equipment in Example 3 of the present invention.

[0056] In the figure: 1. Insulating paper supply mechanism; 11. Unwinding shaft; 12. Mechanism frame; 13. Chassis; 14. Paper tape reel; 15. Rocker arm; 16. Pneumatic float rod; 17. Guide wheel. DETAILED DESCRIPTION

[0057] The following will be combined with the accompanying drawings in the present invention to clearly and completely describe the technical solutions in the invention. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of the present invention.

[0058] In the description of the present invention, it should be noted that the terms "upper", "lower" and the like indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings and are only for the convenience and simplification of the description. They do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they should not be understood as limitations on the present invention.

[0059] In the description of the present invention, the terms “first”, “second” and “third” are used for descriptive purposes only and should not be understood as indicating or implying relative importance.

[0060] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "connect", "set", "install", "fix" and the like should be understood in a broad sense, for example, it can be a fixed connection or a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be the internal communication of two elements. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0061] To facilitate understanding of the following implementation methods, the general process of winding the wire and the insulating paper tape together (only the winding of the wire and the paper tape is described, and the rest such as the specification selection, the equipment, and the addition and placement of the whole paper are omitted) is briefly described here: first, multiple turns of wire are wound on the coil mold (assuming that the winding direction is the first direction, and the second direction is opposite to the first direction) to form the first layer of wire layer, and then the end insulation of this layer is wound. When winding the second layer, the insulating paper tape is placed under the wire, and the insulating paper tape and the wire are wound together along the second direction to form the second layer of wire layer. In the process, the insulating paper tape is added and sheared to meet the insulation thickness, and is added and sheared again when the end insulation is finally wound. The third layer is wound in the same way as the second layer. The insulating paper tape is placed under the wire and then the winding begins, except that it is wound along the first direction. By analogy, when the shape of the interlayer insulation (the cross section in the axial direction of the coil mold) is trapezoidal, each wire layer is arranged roughly in a Z shape.

[0062] Example 1

[0063] The coil insulation paper tape winding method of this embodiment includes a winding step, and the winding step includes:

[0064] The first sub-step: winding the strip insulation paper together with the conductor from the beginning to the end of the interlayer insulation area to form the interlayer insulation of the current layer;

[0065] The second sub-step: taking the tail end of the current interlayer insulation area as the end insulation area, winding the strip insulation paper in the end insulation area to form the end insulation;

[0066] The third sub-step: leading the strip-shaped insulating paper together with the conductor from the tail end of the interlayer insulating area to the next layer, so that the strip-shaped insulating paper can be wound together with the conductor to form the next layer of insulation.

[0067] It can be seen that the coil insulation paper tape winding method of the present embodiment is no longer like the previous winding method, when winding each layer of insulation, the interlayer insulation and the end insulation each complete at least one initial addition and cutting. Instead, it adopts a method of directly leading out to the next layer, and uses the tail end of the interlayer insulation area as the end insulation area, so that the winding process forms a non-interrupted winding scheme that only reciprocates within the interlayer insulation area, that is, after the current layer is wound from the head end to the tail end, it is directly introduced into the winding of the next layer. When the next layer is wound, the tail end direction of the previous layer (that is, the aforementioned current layer) is used as the head end direction, and the winding continues from the head end to the tail end (that is, from the perspective of the current layer, the next layer is wound from the tail end to the head end).

[0068] Therefore, in this winding process, there is no need to cut or add the strip insulating paper between the layers, which not only greatly reduces the dependence on the operator's operating proficiency and operating accuracy, but also saves the intermittent operation time, effectively improves the winding efficiency and reduces the winding cost; and the reciprocating winding direction of each layer of the strip insulating paper corresponds to the winding direction of each layer of the wire, avoiding interference caused by the opposite direction, and there is no need to wind the wire and the insulation separately, and can be wound in the forward direction non-interruptedly at the same time. It can be seen that this method further optimizes the winding scheme, makes the steps more concise, and is easy to implement through automated equipment, promoting the advancement of transformer coil automated winding technology.

[0069] In this embodiment, two optional specific winding schemes are provided for non-interrupted winding:

[0070] The first sub-step and the third sub-step use the same first strip-shaped insulating paper to perform uninterrupted winding of the inter-layer insulation of each layer, and the second sub-step uses the second strip-shaped insulating paper alone to perform the winding of the end insulation of each layer;

[0071] That is, the interlayer insulation and the end insulation are wound separately, and the first strip-shaped insulating paper is wound along with the conductor from the head end to the tail end of the interlayer insulation area to form the interlayer insulation of the current layer, and the first strip-shaped insulating paper of the interlayer insulation is not cut off, but directly led out from the tail end of the interlayer insulation area to the next layer, so that the first strip-shaped insulating paper can be wound along with the conductor to form the interlayer insulation of the next layer; during the process, the second strip-shaped insulating paper is wound at the tail end of the interlayer insulation area to form the end insulation; therefore, the winding process of the interlayer insulation forms a reciprocating non-interrupted winding scheme alone, which is suitable for the case where the conductor width is large, and can prevent quality problems caused by excessive spiral inclination of the conductor during winding.

[0072] Alternatively, the first sub-step, the second sub-step and the third sub-step all use the same first tape-shaped insulation paper to perform uninterrupted winding of each layer of insulation including interlayer insulation and end insulation.

[0073] That is, the interlayer insulation and the end insulation are wound together or in sequence, the first strip-shaped insulating paper is wound along with the conductor from the beginning to the end of the interlayer insulation area to form the interlayer insulation of the current layer, and is not cut off. The first strip-shaped insulating paper is continued to be wound at the end of the interlayer insulation area to form the end insulation. After that, the first strip-shaped insulating paper is still not cut off, but is directly led out from the end of the interlayer insulation area to the next layer, so that the first strip-shaped insulating paper can be wound along with the conductor to form the insulation of the next layer; therefore, the winding process of the entire insulation (including the interlayer insulation and the end insulation) forms an overall reciprocating non-interrupted winding scheme, which is suitable for the case where the conductor width is small.

[0074] It can be seen that this embodiment has two winding schemes to choose from, one is to use the first strip-shaped insulating paper for interlayer insulation winding, and use the second strip-shaped insulating paper to form end insulation; the other is to use the first strip-shaped insulating paper to wind interlayer insulation and stack end insulation. Therefore, not only a non-interrupted winding scheme is provided, but also two different non-interrupted winding schemes are specifically divided, further enriching and optimizing the automatic winding process.

[0075] In this embodiment, before the winding step, the method further includes a winding mode selection step, and the winding mode selection step includes:

[0076] Get the wire specifications;

[0077] When the wire specification is not less than the set value, the winding step is performed in the first mode;

[0078] The winding step performed in the first mode is the aforementioned first solution, that is, the first sub-step and the third sub-step use the same first strip-shaped insulating paper to perform uninterrupted winding of the inter-layer insulation of each layer, and the second sub-step uses the second strip-shaped insulating paper alone to perform the winding of the end insulation of each layer;

[0079] When the wire specification is smaller than the set value, the winding step is performed in the second mode;

[0080] The winding step performed in the second mode is the aforementioned second solution, and the first sub-step, the second sub-step and the third sub-step all use the same first strip-shaped insulating paper to perform uninterrupted winding of each layer of insulation including interlayer insulation and end insulation.

[0081] That is, the solution of this embodiment also includes a solution selection step, so that the non-interrupted winding solution can be specifically selected according to the specific situation. In this embodiment, the wire width W used for winding 导When the wire width is ≥4mm (i.e. the set value of the wire specification), the first mode is preferred to prevent quality problems caused by excessive wire spiral inclination. 导 When the diameter is less than 4 mm, the second mode is preferred. This classification is not absolute, and the setting value of the wire specification can be flexibly selected in engineering applications.

[0082] In this embodiment, the strip-shaped insulating paper (whether the first strip-shaped insulating paper or the second strip-shaped insulating paper) can be a single-layer paper supplied by a paper tape reel, or a double-layer paper stacked together supplied by two paper tape reels.

[0083] In this embodiment, when the direction of the head and tail ends of the current interlayer insulation is opposite to the direction of the head and tail ends of the next interlayer insulation, the first sub-step is used to form a trapezoidal interlayer insulation (the thickness of the thickest part of the trapezoid is called the open thickness, and the thickness of the thinnest part is called the closed thickness) so that the increase in the thickness of the interlayer insulation is consistent with the increase in the voltage difference between the two layers of wires.

[0084] The coil after winding includes a conductor layer, interlayer insulation and end insulation, and the conductor layer and the interlayer insulation have end insulation at both ends. The conductor layer and the interlayer insulation are alternately distributed layer by layer, and each layer of interlayer insulation is located between two conductor layers. The voltage difference between the two layers of conductor gradually increases with the winding direction of the conductor. The greater the voltage difference, the thicker the thickness of the interlayer insulation. The general structure of the coil is basically the same as the coil currently on the market, so this embodiment does not provide drawings. The difference is that the interlayer insulation of each layer of the coil or the interlayer insulation and the end insulation can be formed by winding with the same first strip of insulating paper.

[0085] The interlayer insulation is formed by winding the first strip-shaped insulating paper with the wire, and the wire and the first strip-shaped insulating paper are wound on the surface of the coil mold on the main shaft through the rotational movement of the main shaft of the winding machine (the transformer coil winding equipment in Example 3). The overall winding process of the wire is arranged in a "Z" shape (or zigzag) in the radial direction. Assuming that the voltage difference between each turn of the wire is equal to Ua after power-on operation, and the number of turns of each layer of wire is m, the upper and lower layers of wires are connected at the head end of each layer. The minimum voltage difference is Ua, and the maximum voltage difference is 2mUa at the end of each layer. In order to meet the voltage difference between the upper and lower layers of wires, this embodiment sets the corresponding interlayer insulation thickness at different voltage differences, so that the interlayer insulation is arranged in a trapezoidal shape. And the openings of the two adjacent trapezoids are reversed, so the overall structure of the coil is more regular after stacking.

[0086] In this embodiment, in the first sub-step, the strip-shaped insulating paper is wound along with the conductor from the head end to the tail end of the interlayer insulating region, specifically comprising: gradually moving the first strip-shaped insulating paper laterally from the head end to the tail end of the interlayer insulating region as the winding proceeds according to a set rule;

[0087] So that in the first mode, the first strip-shaped insulating paper is stacked to form the trapezoidal interlayer insulation of the current layer when the current layer of wire is wound, and the number of winding turns of the first strip-shaped insulating paper when forming the interlayer insulation is consistent with the number of winding turns of the wire of the layer; or,

[0088] In the second mode, the first strip of insulating paper is stacked to form the insulation of the current layer (including interlayer insulation and end insulation) at the same time as the winding of the current layer of wire is completed, and the number of winding turns of the first strip of insulating paper when forming insulation is consistent with the number of winding turns of the wire of this layer. (Since there is no interlayer insulation when the first layer of wire is wound, the corresponding relationship between the wire layer and the interlayer insulation in this embodiment is that the interlayer insulation between the first and second layers of wire is wound synchronously with the second layer of wire, and so on; and the end insulation is the end insulation of the current layer corresponds to the end insulation of the tail end of the current layer and the end insulation of the head end of the next layer, so the stacked thickness of the end insulation is twice the thickness of the wire H 导 ).

[0089] That is, no matter it is the first mode or the second mode, in the uninterrupted winding process, the total number of turns of the first strip-shaped insulating paper in the current layer is consistent with the number of turns of the conductor.

[0090] When combined with the winding equipment, since the coil mold is set on the main shaft, the wire and the strip insulating paper are supplied to the coil mold through other components, so the coil mold rotates with the main shaft to realize the winding and winding of the wire and the strip insulating paper, and the number of rotations of the coil mold is directly related to the number of winding turns. The number of winding turns of each layer of the first strip insulating paper in this embodiment is consistent with the number of winding turns of the wire, so that the wire and interlayer insulation / insulation of this layer can be completed at the same time and with the same number of turns, and the coil mold itself can be rotated and wound, so there is no need for manual assistance and addition, which is convenient for the setting of mechanical equipment.

[0091] In this embodiment, according to a set rule, the first strip-shaped insulating paper is gradually moved laterally from the head end to the tail end of the interlayer insulating region during winding, specifically including:

[0092] The following first calculation formula is used to obtain the distance y that the first strip-shaped insulating paper moves horizontally from the head end to the tail end along the axial direction of the coil when winding the nth turn:

[0093]

[0094] Among them, h 1 h is the closed thickness of the trapezoidal interlayer insulation, 2 is the opening thickness of the trapezoidal interlayer insulation, L is the width of the interlayer insulation area, (L can be obtained by the wire width W 导 , the number of turns m of the conductor winding in this layer is determined by the axial coefficient k, L = W 导 ×m×k), H 绝 is the cross-sectional thickness of the first strip-shaped insulating paper, W 绝is the cross-sectional width of the first strip of insulating paper; according to the relationship between the number of winding turns n and the lateral displacement distance y, the first strip of insulating paper is gradually lateralized from the head end to the tail end of the interlayer insulating region during winding. According to the formula, the change of the lateral displacement distance is fast at first and then slow, and after the motion synthesis with the rotation of the winding, it presents a variable pitch motion trajectory.

[0095] Specifically, the interlayer insulation is arranged in a trapezoidal shape. According to the required coil height and the interlayer voltage difference between the upper and lower layers of adjacent wires, the required end-to-end trapezoidal insulation thickness (i.e., the narrower closed thickness and the wider open thickness) can be obtained. Figure 1 As shown, the cross section of the interlayer insulation in the axial direction is trapezoidal, and the trapezoidal area can be divided into a rectangular area S 矩形 and the area of ​​the triangle S 三角 , assuming that when the nth turn is wound, the distance that the first strip of insulating paper moves horizontally from the head end to the tail end along the axial direction of the coil is y, then the insulating area formed by the stacking of n turns of the first strip of insulating paper can be obtained according to the aforementioned area relationship Figure 1 After summarizing the formulas in the above, the arrangement method of trapezoidal insulation can be calculated by the following formula, and finally the first calculation formula mentioned above is obtained:

[0096]

[0097] Among them, S 梯 ' is the axial cross-sectional area of ​​the trapezoidal interlayer insulation formed by stacking n turns of the first strip-shaped insulating paper, S 截 is the specification of the first strip-shaped insulating paper. (Except for the expression "nth turn" in the above content, "n turns" refers to the length from the first turn to the nth turn, for example S 梯 ' is the area of ​​the trapezoid formed by stacking n turns of paper tape together).

[0098] In this embodiment, after the winding mode selection step and before the interlayer insulation winding step, the method further includes a specification selection step, which includes: obtaining the specification S of the first strip-shaped insulation paper by the following second calculation formula: 截 :

[0099]

[0100] Among them, S 梯 is the axial cross-sectional area of ​​the current layer of trapezoidal interlayer insulation, and N is the number of turns of the first strip-shaped insulation paper forming the current layer of interlayer insulation; that is, the trapezoidal insulation area is obtained according to the required trapezoidal insulation size, and then the cross-sectional area of ​​a single turn of the first strip-shaped insulation paper is obtained according to the number of turns;

[0101] According to the specification S of the first strip insulating paper 截 Select a paper tape from the standard specification paper tape to obtain the cross-sectional thickness H of the first strip-shaped insulating paper. 绝 and section width W绝 , thereby obtaining the first strip-shaped insulating paper. For example, according to the cross-sectional thickness specifications of the interlayer insulating paper (strip-shaped insulating paper) commonly used in the workshop, which are 0.08mm and 0.13mm, if combined with the two overlapping and splicing schemes, there are several thicknesses of 0.08mm, 0.13mm, 0.16mm, 0.21mm, and 0.26mm to choose from, and the width is between 15mm-40mm. According to the requirements for the cross-sectional width to prevent the broken strip (generally speaking, a width of <15mm is extremely likely to cause the first strip-shaped insulation to break during use), the thickness specification can be selected (i.e., selected from a single sheet or selected from multiple overlapping schemes). In this embodiment, when the scheme of overlapping two first strip-shaped insulating papers is selected, the two sheets completely overlap in the width direction. In other implementation schemes, a 50% to 100% overlap method can also be selected depending on the specific situation.

[0102] In this embodiment, in the specification selection step, when obtaining the specification S of the first strip-shaped insulating paper, 截 Then, we also include: Substituting n=1 into the formula Verify that when the lateral displacement y of the first turn of the first strip of insulating paper is greater than the conductor width W 导 When , it indicates that the specification S of the first strip insulating paper 截 If the selected solution is feasible and can ensure that the two layers of wires at that location do not touch, or the paper tape does not interfere with the wires, then the winding steps can be continued.

[0103] In this embodiment, in the winding step performed in the first mode, in the first sub-step, after the strip-shaped insulating paper is wound along with the conductor from the beginning to the end of the interlayer insulation region, the step further includes: rewinding x turns at the end of the interlayer insulation region, wherein N in the second calculation formula is the difference between the number of turns m of the conductor winding and the number of rewinding turns x. The operation of rewinding several turns at the end can not only increase the insulation strength of the opening (i.e., the end with a larger thickness) of the interlayer insulation, but also return the position of the strip-shaped insulating paper to the correct position by rewinding in situ, which is convenient for the winding of the next layer. Generally, 2-3 turns of rewinding are required at the end.

[0104] In the winding step performed in the second mode, the second sub-step is specifically as follows:

[0105] Taking the tail end of the current interlayer insulation region as the end insulation region, winding the first strip-shaped insulation paper around the end insulation region by p turns to form end insulation;

[0106] Where p is the conductor thickness H 导 divided by twice the cross-sectional thickness H of the first tape-shaped insulating paper 绝, N in the second calculation formula is the difference between the number of turns m of the wire winding and the number of turns p of the double winding. That is, the stacking of the end insulation is completed in the form of double winding. That is, the interlayer insulation winding steps are the same as those in scheme 1. When winding to the tail end, it will not move anymore, and the winding will be repeated at the original place until the layer of wire is wound in place. At this time, the stacking forms the end insulation between this layer and the next layer. When the wire is raised, it moves horizontally to the bottom of the wire in the direction of the wire travel, and starts the winding of the next layer of interlayer insulation.

[0107] In this embodiment, in the winding step performed in the first mode, the second sub-step specifically includes:

[0108] When the first strip of insulating paper reaches the end of the interlayer insulating area, the end of the interlayer insulating area is used as the end insulating area.

[0109] The second strip-shaped insulating paper is arranged on the first strip-shaped insulating paper, so that the first strip-shaped insulating paper is arranged under the second strip-shaped insulating paper;

[0110] The second strip-shaped insulating paper is wound together with the first strip-shaped insulating paper at the tail end of the interlayer insulating region, so that the second strip-shaped insulating paper forms end insulation.

[0111] In this embodiment, the width of the interlayer insulation area is slightly wider than the winding area of ​​the wire, so the tail end of the interlayer insulation area has a certain width relative to the wire winding area. This area is used as the end insulation winding area outside the wire, and the first mode can add end insulation here. This winding method only requires adding end insulation, and the end insulation and interlayer insulation can be wound with the wire at the same time. The interlayer insulation winding and the end insulation winding are completed during the rotation of the coil main shaft. Therefore, there is no need to stop the coil main shaft (i.e., the winding shaft) to perform winding, and the operation layout is more reasonable.

[0112] Specifically, in the first mode, the first strip of insulating paper is wound with a variable pitch along the conductor (according to a set program), and when it reaches the end (the number of turns has been set), the coil spindle will stop, prompting manual addition of end insulation;

[0113] At this time, the end insulation is manually added on top of the first strip of insulation paper, and as the coil main shaft rotates one circle, the end insulation is added. That is, the first strip of insulation paper is always below the end insulation, and the first strip of insulation paper between the current layer and the next layer can be kept continuous (unbroken).

[0114] During the winding process, many factors need to be considered in the design of the tension control system. A slight change in speed will cause a significant fluctuation in tension. If the tension is too small, the strip of insulation paper will loosen when the spindle drives the strip of insulation paper forward, affecting the tightness of the next layer of coils. If the tension is too large, the strip of insulation paper will deform or even break, requiring manual processing, reducing production quality and efficiency. Therefore, the winding tension of the strip of insulation paper must be kept uniform to obtain better winding quality. The main factors that cause tension fluctuations during transformer insulation winding are as follows:

[0115] (1) Influence of transformer coil mold geometry

[0116] The geometric shapes of most transformer coil molds are non-circular cross-sectional structures such as oblong or elliptical. Since the long and short sides change alternately during the rotation of the mold (the angular velocity remains unchanged, and the linear velocity changes periodically), the radius decreases when rotating to the long side, and the tangential speed of the strip insulating paper decreases. When rotating to the short side, the radius increases, and the tangential speed of the strip insulating paper increases. The speed fluctuation causes a large change in the tension of the strip insulating paper.

[0117] (2) Influence of changes in strip insulation paper unwinder, spindle diameter and inertia

[0118] As the strip insulation paper unwinder conveys the strip insulation paper to the next part, the paper reel diameter and inertia gradually decrease, and the spindle diameter and inertia continue to increase. If under a fixed torque or constant speed, the tension of the strip insulation paper will change with the change of diameter and inertia, resulting in uneven tension.

[0119] In this embodiment, during the process of executing the winding step, the method further includes: adjusting the tape-out situation of the strip-shaped insulating paper by acquiring real-time winding data, so that the winding tension of the strip-shaped insulating paper is maintained within a set range. Compared with the previous winding with a set unchanged tape-out situation, this embodiment adjusts the tape-out situation by implementing data, so that the tape-out situation and the unwinding situation are adapted in real time to avoid tape-out fluctuations, thereby maintaining the winding tension within a certain range, and is more suitable for the winding of oblong and elliptical coils with long and short axes when rotating, so that each turn of the coil product can be maintained at a set level, thereby improving product quality.

[0120] In this embodiment, before the winding step, the method further includes: leading the strip-shaped insulating paper wound into a paper tape reel to a coil mold on the main shaft; then the winding step specifically includes:

[0121] The unwinding shaft of the paper tape reel rotates to unwind and the main shaft rotates to rewind, so that the strip-shaped insulating paper is wound into insulation;

[0122] By acquiring real-time winding data to adjust the strip-shaped insulating paper discharge situation, so that the winding tension of the strip-shaped insulating paper is maintained within a set range, specifically including: acquiring the real-time winding diameter of the paper tape reel and the real-time strip-shaped insulating paper discharge speed;

[0123] The rotation speed of the unwinding shaft is adjusted according to the real-time winding diameter and the real-time tape delivery speed so that the winding tension of the tape-shaped insulating paper is maintained within the set range.

[0124] The present embodiment provides a method for winding a coil insulating paper tape, which specifically includes steps of a method for controlling the motion of strip insulating paper, and can be used in the technical field of transformer coil production, and is specifically applied to the technical field of automatic winding of strip insulating paper, and particularly relates to a motion control method for trapezoidal insulation winding.

[0125] The present method is used for winding insulating paper tape, and combined with the winding equipment of transformer coil, the general winding process is as follows: Figure 2 As shown, the strip insulation paper arrangement method and the main shaft rotation speed can be calculated according to the coil height and the thickness of the interlayer insulation at the beginning and end, and the corresponding positions of the wire arrangement mechanism and the insulation paper supply mechanism 1 at each moment can be obtained, and they can be reciprocated during the winding process. The interlayer insulation winding process needs to adjust the strip insulation paper unwinding shaft rotation speed according to the real-time winding diameter of the strip insulation paper unwinding shaft and the real-time speed of the first strip insulation paper to keep the strip insulation paper tension unchanged:

[0126] Step 1: Select a strip of insulating paper of appropriate size; that is, according to the conductor size, the number of conductor turns per layer, the axial coefficient (i.e., the tortuosity coefficient), and the required insulation thickness at the maximum and minimum voltage gradients, and then according to the aforementioned second calculation formula, set the basic parameters of the first strip of insulating paper, including the size and quantity of the first strip of insulating paper, and set the starting winding position and the target trapezoidal thickness;

[0127] That is, according to the coil design height and the insulation width at both ends, the strip insulation paper winding height L (that is, the width of the interlayer insulation area, slightly higher than the conductor part height but less than the total coil height) is determined, and then according to the design parameters of the normal layer coil: the closed thickness h of the interlayer insulation 1 , the opening thickness of the interlayer insulation h 2 , the number of turns of each layer of conductor m, the specification S of the strip insulation paper is calculated by the following formula 截 :

[0128]

[0129] The coil parameter settings before winding include the circumference of the main shaft and the length of the major and minor axes, the wire width, thickness, number of winding turns, tension setting, and basic parameters of the strip (including the size, quantity, starting winding position, and target trapezoidal thickness of the strip insulation paper); when setting the winding height of each layer of coil, it is necessary to ensure that the first turn of the strip insulation paper can separate the upper and lower layers of wires, and the width and thickness of the strip insulation paper and whether to wind two layers of strip insulation paper together are selected according to the cross-sectional area of ​​the strip insulation paper;

[0130] The paper tape reel on the strip-shaped insulating paper unwinding shaft (i.e. the strip-shaped insulating paper) is passed through a tension adjustment mechanism (for adjusting the tension) and is wound on the main shaft (coil mold) along with the conductor;

[0131] Step 2: Start winding. During the winding process, the trapezoidal interlayer insulation stacking is completed through step 2.1, and the tension adjustment is completed through steps 2.2 and 2.3;

[0132] After entering the order parameter information, when starting to wind, first set the coordinates of the wiring mechanism according to the starting position of the wire winding. After the first layer of wire winding is completed, end insulation needs to be added; before adding the first strip of insulation paper between the first and second layers, you can also use the wide paper mechanism to add a layer of full paper with a width of the coil height to enhance interlayer insulation. After adding, while winding the first turn of the second layer of wire, the first strip of insulation paper is fed under the wire. As the wire winding spindle rotates, the operator manually adds the end insulation paperboard, and its height is the same as the thickness of the wire;

[0133] Step 2.1: According to the calculation method of the trapezoidal arrangement of interlayer insulation in the first calculation formula, the mathematical relationship between the number of turns n of the strip insulation paper and the current winding height y (i.e., the lateral displacement distance) can be obtained. The arrangement of the strip insulation paper along the axial direction of the coil is achieved by the lateral displacement of the mechanism frame where the unwinding shaft is located, that is, the distance the mechanism frame moves lateraly during one rotation of the equipment spindle. The angular velocity of the equipment spindle can be constant (i.e., n can be determined by the angular velocity), from which the position that the mechanism frame should correspond to at each moment can be derived; specifically, the spindle position state can be obtained through the spindle encoder, and the real-time number of winding turns can be determined based on the position state, and this can be used as the coil winding process axis;

[0134] The winding process is equivalent to designing a variable pitch motion according to a preset trapezoidal insulation thickness; and through the motion synthesis principle, the insulating paper supply mechanism 1 stacks the strip insulating paper according to a preset trapezoidal trajectory;

[0135] Step 2.2: The real-time winding diameter of the tape reel and the real-time speed of the tape out of the tape can be obtained through sensors, etc.;

[0136] Step 2.3: adjusting the rotation speed of the unwinding shaft of the strip insulating paper according to the real-time winding diameter and the real-time speed of the first strip insulating paper, so that the tension of the strip remains unchanged during the winding process on the main shaft; by dynamically controlling the tension of the strip insulating paper, it can be ensured that the tension fluctuation does not exceed ±10%;

[0137] Specifically, the device given in Example 3 describes the structure of the unwinding tension swing arm. After the first strip of insulating paper is unwound from the unwinding shaft, it will pass through multiple guide wheels 17 (including the guide wheel at the top of the unwinding tension swing arm), and then be wound onto the coil mold after being guided by the guide wheels. Therefore, the tension can be further adjusted in combination with the position of the unwinding tension swing arm. The reel diameter of the strip insulating paper unwinding shaft needs to be manually measured and the initial reel diameter needs to be input before winding begins. During the winding process, the incremental encoder at the guide wheel through which the strip insulating paper passes will feedback the strip insulating paper output length information; the strip insulating paper output speed is provided by the strip insulating paper tension unwinding servo motor (or the real-time output speed is determined by the spindle speed), and the absolute encoder at the bottom of the unwinding tension swing rod can also feedback the position of the unwinding tension swing rod, so the real-time output speed can also be fed back through the tension swing rod position fed back by this absolute encoder; the reduced reel diameter value and the real-time output speed are adjusted in real time according to the calculation of the output length information; if the output speed is accelerated, the guide wheel connected to the unwinding tension swing rod will tilt forward, driving the swing rod to swing forward, and the pneumatic float rod connected to the swing rod will provide buffering. The absolute encoder at the bottom of the swing rod will feedback the swing rod position. The servo motor (driving the unwinding shaft) drives the rotation speed of the unwinding shaft according to the above-mentioned swing rod position (real-time tape delivery speed) and the winding diameter value of the insulating paper tape reel which gradually decreases from the initial winding diameter during the winding process, so that the tape delivery line speed of the unwinding shaft and the tape take-up line speed of the take-up shaft are kept within the set difference, thereby achieving real-time adjustment of the tension. The corresponding relationship of the above values ​​can be preset to form a corresponding relationship table or relationship expression, so as to directly adjust according to the corresponding relationship. The specific coefficients and connections of this corresponding relationship can be specifically selected according to various real-time conditions such as the material, size, and working conditions of the paper tape, and are not specifically limited here.

[0138] Step 3: According to the required strip arrangement thickness requirement, the main shaft drives the coil to rotate at a constant adjustable angular velocity, so that the coil cooperates with the reciprocating strip insulation paper unwinder (interlayer insulation supply mechanism) to wind the first strip insulation paper. Specifically, the interlayer insulation supply mechanism can be driven by a servo motor to drive the ball screw to translate in the axial direction and front-to-back direction of the coil after being decelerated by a reducer. When two strip insulation papers are superimposed and wound, when a double layer of strip insulation paper is wound at the same time, the offset servo motor can be driven to change the upper and lower relative positions of the two groups of interlayer insulation supply mechanisms. The upper and lower limits and zero position of the above-mentioned interlayer insulation supply mechanism are sensed by proximity sensors at corresponding positions.

[0139] After the winding method of this embodiment is applied to coil winding, the overall process of coil winding can be roughly summarized as follows: select the specifications of the strip insulation paper according to the parameter requirements of each layer of the coil, and calculate the trapezoidal insulation arrangement method between layers; enter the order parameter information of the coil, and calculate the travel position of the strip insulation paper mechanism at each moment according to the set parameters; adjust the unwinding speed to keep the tension of the strip insulation paper constant, and wind it in conjunction with the wire; after the wire layer and insulation are wound, wind the coil with a non-weft tape on the outermost layer of the coil to fix the coil, and wrap it with a plastic film to prevent damage during lifting. The flow chart is as follows Figure 2 shown.

[0140] During the winding process, the displacement speed of the strip insulation paper can be adjusted according to the angular velocity change law of the coil mold, and the position accuracy and coverage of the strip insulation paper can be monitored and adjusted in real time, reducing the amount of insulation material used and improving the winding efficiency and product quality of the product during the manufacturing process.

[0141] Example 2

[0142] This embodiment provides a practical application example of the method in Embodiment 1. Specifically, taking the 6TBC.600.U90076.1 drawing as an example, according to the design drawing, the number of turns of the normal layer is 37.5 turns, the number of turns of the first layer is 35.5 turns, the number of turns of the second layer is 36.5 turns, and the number of turns of the 17th layer is 34 turns. According to the wire width of 3.8mm and the axial coefficient of 1.01, the height of the wired part of the coil is about 148mm. Assuming the coil height is 148mm, the small end of the strip-shaped insulating paper end insulation is 10mm, and the large end is 13.5mm. According to the requirements, the interlayer insulation closed thickness h of the normal layer 1 0.1mm, interlayer insulation opening thickness h 2 It is 0.58mm, and a whole piece of paper needs to be manually added to the first and last layers to enhance the insulation strength.

[0143] Since the first strip of insulating paper is wound together with the conductor, the winding speed is the rotation speed of the main shaft, and in order to form a trapezoidal insulating structure, the lateral movement distance of the insulating paper supply mechanism 1 (the mechanism frame 12) before winding to the end of each layer is always greater than the lateral movement distance of the conductor arrangement mechanism, so the first strip of insulating paper is added under the conductor when each layer is wound. The lateral movement speed of the mechanism frame 12 is fast at first and then slow, and the lateral movement speed of the conductor arrangement mechanism is always uniform.

[0144] This embodiment adopts the first mode for the winding step. First, the winding height L (i.e., the width of the interlayer insulation area) of the first strip-shaped insulating paper is selected as 146mm according to the normal layer. Regarding the setting of the number of turns of the first strip-shaped insulating paper, in order to ensure that the first strip-shaped insulating paper does not need to be broken when it is wound to the end of each layer, the operator continues to manually add the end insulation and then rise to the next layer to achieve continuous winding. The first strip-shaped insulating paper and the wire need to complete the winding of each layer at the same time, that is, the number of winding turns of each layer of the first strip-shaped insulating paper must be equal to the number of turns of each layer of the wire. At the same time, in order to increase the insulation strength at the opening and return the position of the first strip-shaped insulating paper to the correct position, it is necessary to rewind 2-3 turns at the end, and because the number of turns of the special layer is less than the normal layer, the number of turns rewound at the end after winding the trapezoidal insulation may be less than the normal layer, so when calculating, the number of turns N of the first strip-shaped insulating paper is selected as 37.5-3=34.5 turns (i.e., the number of rewinding turns is 3).

[0145] Calculate the cross-sectional area of ​​the required strip insulation paper according to the formula of the cross-sectional area of ​​the interlayer insulation;

[0146]

[0147] According to the thickness specifications of the interlayer insulation paper used in the workshop, which are 0.08mm and 0.13mm, if two layers are overlapped, there are several thicknesses to choose from, such as 0.08mm, 0.13mm, 0.16mm, 0.21mm, and 0.26mm. Since the strip insulation paper is more likely to break at the corners of the rising layer and the oil channel support when it is narrow, try to choose a width of more than 15mm. Based on this, 1.439÷0.08≈18mm, the coverage of the interlayer insulation is 146+18=164mm, which is greater than the coil height of 148mm and less than the total coil height of 148+10+10=168mm, so the first strip insulation paper with a width of 18mm and a thickness of 0.08mm can be selected for winding.

[0148] Since the interlayer insulation is located between the two conductor layers, there is no need to add strip insulation paper when the first conductor layer is wound. It is only necessary to ensure that the paper discharge mechanism and the wire discharge mechanism are located at the same end when the first conductor layer is wound.

[0149] When the second layer is wound, the sum of the turns of the first two layers is 36.5+35.5=72, and the sum of the turns of the two normal layers is 37.5*2=75. According to the voltage difference principle of the "S" type wire arrangement, the ratio of the voltage difference change between the two wire layers is consistent with the ratio of the insulation thickness change. The thickness of the interlayer insulation opening of the second layer can be set to According to the trapezoidal insulation arrangement method formula:

[0150]

[0151] A curve of the lateral displacement distance y of the mechanism frame 12 with respect to the number of winding turns n can be drawn. The main shaft rotates 360° every time around one turn. Since the main shaft rotation speed is constant, the real-time lateral speed of the mechanism frame 12 can be calculated from the slope of the curve.

[0152] When the number of turns of the strip insulation paper is n=1, the current lateral winding distance y≈12.09 can be obtained. This distance is greater than the conductor width, that is, the first turn of the paper tape moves faster than the conductor, so it can be used; when n=2, y≈21.51; when n=3, y≈29.50, until n=33.5, y≈146.1, at this time the trapezoidal insulation structure is wound, the paper discharge mechanism stops moving horizontally, and the strip insulation paper is stacked in place for 3 turns to complete the winding of this layer. The winding of the normal layer can be obtained in the same way.

[0153] Example 3

[0154] The transformer coil winding equipment of this embodiment includes a main shaft rotating mechanism, a wire arranging mechanism and an insulating paper supply mechanism 1. The insulating paper supply mechanism 1 may include an interlayer insulation supply mechanism and an end insulation supply mechanism. The wire arranging mechanism, the interlayer insulation supply mechanism and the end insulation supply mechanism are respectively used to supply wires, a first strip of insulating paper and a second strip of insulating paper to the main shaft rotating mechanism (that is, the insulating paper supply mechanism 1 is used to supply strip insulating paper).

[0155] The main shaft rotation mechanism comprises a main shaft, on which a coil mold is arranged, and the main shaft rotation mechanism drives the main shaft to rotate and rewind so that the conductor and the strip-shaped insulating paper are wound onto the coil mold;

[0156] As the main shaft rotates, the insulating paper supply mechanism 1 moves from the head end to the tail end of the interlayer insulation area relative to the coil mold together with the wire arranging mechanism, so that when the wire arranging mechanism forms the current wire layer on the coil mold, the strip insulating paper is wound from the head end to the tail end of the interlayer insulation area of ​​the coil mold together with the wire to form the interlayer insulation of the current layer, and the tail end of the interlayer insulation area of ​​the current layer is used as the end insulation area, and the strip insulating paper is wound in the end insulation area to form the end insulation, and,

[0157] The insulating paper supply mechanism 1 moves in the opposite direction from the tail end of the interlayer insulating region of the coil mold together with the wire arrangement mechanism, so as to lead the strip insulating paper together with the wire from the tail end of the interlayer insulating region of the coil mold to the next layer, so that the strip insulating paper can be wound together with the wire to form the insulation of the next layer;

[0158] When the controller selects the second mode to execute the winding step according to the instruction, only the interlayer insulation supply mechanism of the insulating paper supply mechanism 1 is used to complete the above-mentioned paper supply and winding of the entire insulation; when the controller selects the first mode to execute the winding step according to the instruction, the interlayer insulation supply mechanism of the insulating paper supply mechanism 1 is used to complete the above-mentioned paper supply and winding of the interlayer insulation, and the end insulation supply mechanism is set at the end insulation area of ​​the coil mold, so that the second strip-shaped insulating paper can be wound in the end insulation area of ​​the coil mold as the main shaft rotates to form end insulation.

[0159] That is, the insulating paper supply mechanism 1 in the device of this embodiment cooperates with the rotation of the main shaft to adopt the coil insulating paper tape winding method in Example 1 to wind the interlayer insulation and end insulation on the coil mold.

[0160] The insulating paper supply mechanism 1 can also be called a strip insulating paper control servo system, and the spindle rotation mechanism can also be called a spindle rotation servo system, which is used to drive the winding machine spindle to rotate, and cooperate with the strip insulating paper control servo system to use the motion synthesis principle to enable the strip insulating paper mechanism to stack a trapezoidal insulation thickness preset by the program through variable pitch motion.

[0161] In this embodiment, the interlayer insulation supply mechanism of the insulating paper supply mechanism 1 includes a reel 11 and a mechanism frame 12. The reel 11 is rotatably connected to the mechanism frame 12. A paper tape reel 14 is provided on the reel 11 for rotating and unwinding to supply the first strip of insulating paper to the main shaft rotation mechanism. The mechanism frame 12 can move along the axial direction of the coil mold to drive the reel 11 to move, so that it is wound on the coil mold as the main shaft rotates to form a trapezoidal interlayer insulation, so that the increase in the interlayer insulation thickness is consistent with the increase in the voltage difference between the two layers of conductors.

[0162] In this embodiment, the interlayer insulation supply mechanism can also be provided with a tension adjustment mechanism for adjusting the tension of the first strip-shaped insulating paper. The first strip-shaped insulating paper drawn from the paper tape reel 14 of the unwinding shaft 11 passes through the tension adjustment mechanism and is wound on the main shaft along with the wire.

[0163] The interlayer insulation supply mechanism can also be equipped with a sensor at the paper tape reel 14 to sense the real-time winding diameter of the paper tape reel 14, and sense the real-time speed of the first strip of insulating paper through an encoder, a sensor, etc.; the spindle rotation mechanism can also include a spindle encoder to measure the spindle rotation position state and obtain the number of spindle rotation turns.

[0164] Specifically, an unwinding tension rocker can be set at the position of the unwinding shaft 11 as a tension adjustment mechanism. The unwinding tension rocker can include a rocker 15 and a pneumatic float rod 16. The pneumatic float rod 16 is horizontally arranged, and the outer shell is connected to the mechanism frame 12. The floating rod end is connected to the top of the rocker 15, and the bottom of the rocker 15 is hingedly connected to the mechanism frame 12. An absolute encoder is provided at the bottom of the rocker 15 to sense the swing position of the rocker 15. Guide wheels 17 are also rotatably connected to the top of the rocker 15 and the mechanism frame 12. As a guiding mechanism, the first strip of insulating paper passes around multiple guide wheels 17 and then is wound onto the coil mold. An incremental encoder can be connected to a certain guide wheel 17 to obtain the number of meters of the output tape, thereby obtaining the real-time winding diameter value of the insulating paper tape reel based on the initial winding diameter.

[0165] When the tape delivery speed increases, the guide wheel connected to the unwinding tension swing rod tilts forward, driving the swing rod 15 to swing forward, and the pneumatic float rod 16 connected to the swing rod 15 provides a buffer. The absolute value encoder at the lower end of the swing rod 15 will feedback the position of the swing rod 15. The servo motor (driving the unwinding shaft) drives the rotation speed of the unwinding shaft according to the above-mentioned swing rod position (reflecting the real-time tape delivery speed) and the winding diameter of the insulating paper tape reel that gradually decreases from the initial winding diameter during the winding process, so that the tape delivery line speed of the unwinding shaft and the tape reel line speed of the reel are kept within the set difference, thereby achieving real-time adjustment of the tension. The corresponding relationship of the above numerical values ​​can be preset, so that the adjustment can be made directly according to the corresponding relationship. The specific coefficients and connections of this corresponding relationship can be specifically selected according to various real-time conditions such as the material, size, and working conditions of the paper tape, and are not specifically limited here.

[0166] like Figure 3 As shown, the interlayer insulation supply mechanism can be provided with two groups, and the two groups of interlayer insulation supply mechanisms are respectively used to supply two pieces of first strip-shaped insulating paper, so as to realize the superposition winding of the two, wherein the two groups of interlayer insulation supply mechanisms can be controlled by an independent servo system, and can realize 50%-100% or complete overlap in the width direction to meet the quality requirements of the insulation system, and can also be used separately. The unwinding shaft 11 can adopt an air expansion shaft, and the air expansion is used to achieve the fastening with the paper tape reel, which is convenient for taking and placing. The insulating paper supply mechanism 1 also includes a chassis 13, and the two groups of interlayer insulation supply mechanisms are movably connected to the chassis 13, and the sliding along the coil axis and the sliding direction close to or away from the coil are realized by the cooperation of the slider and the slide rail. The above sliding drive can be realized by the cooperation of the servo motor with a reducer to drive the gear, rack or ball screw. At the same time, the mechanism frame 12 of the two groups of interlayer insulation supply mechanisms is provided with a belt guide wheel, and the relative position of the two groups of belt guide wheels can also be adjusted by the offset servo motor. The upper and lower limit positions and the zero position of each group of interlayer insulation supply mechanisms are sensed by proximity sensors arranged at corresponding positions.

[0167] In this embodiment, the end insulation supply mechanism can be implemented by a mechanical structure, specifically, a rotatable shaft carrying a paper tape reel is used for unwinding, and a main shaft is used for rewinding, but the unwinding is always kept at the end insulation area of ​​the coil mold. Manual unwinding can also be used, and the end insulation winding is realized by cooperating with the main shaft for rewinding.

[0168] In this embodiment, the device also includes a controller (or main controller), which is electrically connected to the mechanism frame 12 and the main shaft respectively, and is used to control the mechanism frame to gradually move horizontally from the head end to the tail end of the interlayer insulation area of ​​the coil mold as the main shaft rotates according to a set rule, so that the strip insulation paper is stacked to form a trapezoidal interlayer insulation.

[0169] The above setting rules are:

[0170] The lateral displacement distance y of the mechanism frame 12 and the number of rotation and winding turns n of the main shaft satisfy the following first calculation formula:

[0171]

[0172] Among them, h 1 h is the closed thickness of the trapezoidal interlayer insulation, 2 is the opening thickness of the trapezoidal interlayer insulation, L is the width of the interlayer insulation area, H 绝 is the cross-sectional thickness of the first strip-shaped insulating paper, W 绝 is the cross-sectional width of the first strip insulating paper. The controller is also used to receive and feedback control signals through the main shaft rotation servo system and the strip insulating paper control servo system, and use the independent servo systems of the two sets of interlayer insulation supply mechanisms to control the overlap amount of the strip insulating paper to ensure an overlap rate of 50%-100%, and monitor and adjust the position accuracy and coverage of the strip insulating paper in real time, so as to improve the winding efficiency and product quality of the product during the production process.

[0173] That is, when each layer is wound into a trapezoidal interlayer insulation, the controller uses the first calculation formula as a basis to control the lateral movement distance of the mechanism frame 12 as the main shaft rotates.

[0174] The PLC of the controller for controlling the spindle at the lower level of the main controller is connected to the main cabinet PLC (of the transformer coil production system) via Ethernet, and the MODBUS-TCP protocol is used to exchange data, such as control instructions, status information, sensor data, etc. The main cabinet PLC communicates with the spindle encoder through the CAN interface to feedback information about the spindle position, speed, etc. The spindle encoder communicates with the upper and lower unwinding screw (i.e., unwinding shaft 11) position encoders (on the two sets of interlayer insulation supply mechanisms) through the CAN bus to achieve data synchronization and control. Similarly, the front and rear unwinding encoders and the unwinding rack cabinet PLC feedback information through the CAN protocol.

[0175] A non-contact sensor can be used to detect the lateral dimensions of the coil (or the coil mold wound with wires and strip-shaped insulating paper), and compared with the preset value of the PLC to adjust the wiring spacing, bending angle, tension value, etc. to form a closed-loop control. The communication can use the ethercat communication protocol and method to combine the spindle position information with the lateral dimension information for analysis and addition.

[0176] The transformer coil winding equipment of this embodiment can also be set up as needed: a strip insulation paper coverage control system, which is used to adjust the distance from the strip insulation paper outlet to the coil entry point, so that the paper tape outlet is 100mm-150mm outside the maximum turning radius of the coil, to prevent interference collision caused by being too close, and to avoid the hysteresis effect caused by the paper tape cantilever being too long when moving due to being too far. The strip insulation paper tension control system dynamically controls the insulation tension of the strip insulation paper through pneumatic floating rod buffering and tension detection, and the tension fluctuation is controlled within ±10%; the auxiliary mechanism is used to control the program to control the spindle to stop slowly when the program presets the broken belt position, and the pneumatic anti-slip component clamps the strip insulation paper to prevent the tension mechanism from causing the strip insulation paper to reverse and recycle.

[0177] The guide wheel used to guide the paper tape in the equipment adopts low damping bearings and low rotational inertia rollers to ensure that the strip insulation paper runs smoothly and the tension is transmitted reliably.

[0178] It is to be understood that the above embodiments are merely exemplary embodiments used to illustrate the principles of the present invention, but the present invention is not limited thereto. For those of ordinary skill in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also considered to be within the scope of protection of the present invention.

Claims

1. A method for winding a coil insulating paper tape, characterized in that: The method comprises a winding step, wherein the winding step comprises: The first sub-step: winding the strip insulation paper together with the conductor from the beginning to the end of the interlayer insulation area to form the interlayer insulation of the current layer; The second sub-step: taking the tail end of the current interlayer insulation area as the end insulation area, winding the strip insulation paper in the end insulation area to form the end insulation; The third sub-step: leading the strip-shaped insulating paper together with the conductor from the tail end of the interlayer insulating area to the next layer, so that the strip-shaped insulating paper can be wound together with the conductor to form the next layer of insulation.

2. The method for winding the coil insulating paper tape according to claim 1, characterized in that: The first sub-step and the third sub-step use the same first strip-shaped insulating paper to perform uninterrupted winding of the inter-layer insulation, and the second sub-step uses the second strip-shaped insulating paper to perform the winding of the end insulation of each layer; or, The first sub-step, the second sub-step and the third sub-step all use the same first strip-shaped insulating paper to perform uninterrupted winding of each layer of insulation including interlayer insulation and end insulation.

3. The method for winding the coil insulating paper tape according to claim 2, characterized in that: Before the winding step, the method further includes a winding mode selection step, and the winding mode selection step includes: Get the wire specifications; When the wire specification is not less than the set value, the winding step is performed in the first mode; In the winding step performed in the first mode, the first sub-step and the third sub-step use the same first strip-shaped insulating paper to perform uninterrupted winding of the interlayer insulation of each layer, and the second sub-step uses the second strip-shaped insulating paper alone to perform the winding of the end insulation of each layer; When the wire specification is smaller than the set value, the winding step is performed in the second mode; In the winding step performed using the second mode, the first sub-step, the second sub-step and the third sub-step all use the same first tape-shaped insulating paper to perform uninterrupted winding of each layer of insulation including interlayer insulation and end insulation.

4. The method for winding the coil insulating paper tape according to claim 3, characterized in that: The first sub-step is used to form a trapezoidal interlayer insulation so that the increase in thickness of the interlayer insulation is consistent with the increase in voltage difference between two layers of conductors.

5. The method for winding the coil insulating paper tape according to claim 4, characterized in that: In the first sub-step, the strip-shaped insulating paper is wound along with the conductor from the beginning to the end of the interlayer insulation area, specifically comprising: According to a set rule, the first strip-shaped insulating paper is gradually moved laterally from the head end to the tail end of the interlayer insulation area during winding; So that in the first mode, the first strip-shaped insulating paper is stacked to form the trapezoidal interlayer insulation of the current layer when the current layer of wire is wound, and the number of winding turns of the first strip-shaped insulating paper when forming the interlayer insulation is consistent with the number of winding turns of the wire of the layer; or, So that in the second mode, the first strip-shaped insulating paper is stacked to form the insulation of the current layer when the current layer of wire is wound, and the number of winding turns of the first strip-shaped insulating paper when forming insulation is consistent with the number of winding turns of the wire of this layer.

6. The method for winding the coil insulating paper tape according to claim 5, characterized in that: The step of gradually moving the first strip-shaped insulating paper laterally from the head end to the tail end of the interlayer insulating region according to the set rule during winding specifically includes: The distance y that the first strip of insulating paper moves horizontally from the beginning to the end of the interlayer insulating area when winding the nth turn is obtained by the following first calculation formula: Among them, h1 is the closed thickness of the trapezoidal interlayer insulation, h2 is the open thickness of the trapezoidal interlayer insulation, L is the width of the interlayer insulation area, H 绝 is the cross-sectional thickness of the first strip-shaped insulating paper, W 绝 is the cross-sectional width of the first strip-shaped insulating paper; According to the relationship between the number of winding turns n and the lateral displacement distance y, the first strip-shaped insulating paper is gradually transversely displaced from the head end to the tail end of the interlayer insulating region during winding.

7. The method for winding the coil insulating paper tape according to claim 6, characterized in that: After the winding mode selection step and before the winding step, the method further includes a specification selection step, and the specification selection step includes: The specification S of the first strip-shaped insulating paper is obtained by the following second calculation formula: 截 : Among them, S 梯 is the axial cross-sectional area of ​​the current layer of trapezoidal interlayer insulation, and N is the number of turns of the first strip-shaped insulating paper forming the current layer of interlayer insulation; According to the specification S of the first strip insulating paper 截 Select a paper tape from the standard specification paper tape to obtain the cross-sectional thickness H of the first strip-shaped insulating paper. 绝 and section width W 绝 , thereby obtaining a first strip-shaped insulating paper.

8. The method for winding the coil insulating paper tape according to claim 7, characterized in that: In the winding step performed in the first mode, in the first sub-step, after the strip-shaped insulating paper is wound along with the conductor from the beginning to the end of the interlayer insulation region, the method further includes: Rewind the first tape-shaped insulating paper at the end of the interlayer insulating area with x turns, Wherein, N in the second calculation formula is the difference between the number of turns m of the wire winding and the number of turns x of the double winding; In the winding step performed using the second mode, the second sub-step is specifically: Taking the tail end of the current interlayer insulation region as the end insulation region, winding the first strip-shaped insulation paper around the end insulation region by p turns to form end insulation; Where p is the conductor thickness H 导 divided by twice the cross-sectional thickness H of the first tape-shaped insulating paper 绝 , N in the second calculation formula is the difference between the number of turns m of the wire winding and the number of turns p of the complex winding.

9. The method for winding the coil insulating paper tape according to claim 3, characterized in that: In the winding step performed in the first mode, the second sub-step specifically includes: When the first strip of insulating paper reaches the end of the interlayer insulating area, the end of the interlayer insulating area is used as the end insulating area. The second strip-shaped insulating paper is arranged on the first strip-shaped insulating paper, so that the first strip-shaped insulating paper is arranged under the second strip-shaped insulating paper; The second strip-shaped insulating paper is wound together with the first strip-shaped insulating paper at the tail end of the interlayer insulating region, so that the second strip-shaped insulating paper forms end insulation.

10. The method for winding the coil insulating paper tape according to claim 1, characterized in that: During the process of performing the winding step, the method further comprises: By acquiring real-time winding data to adjust the strip-shaped insulating paper discharge situation, the winding tension of the strip-shaped insulating paper is kept within a set range.

11. The method for winding the coil insulating paper tape according to claim 10, characterized in that: Before the winding step, the method further comprises: leading the strip-shaped insulating paper wound into a paper tape reel to a coil mold on the main shaft; The winding step specifically includes: The unwinding shaft of the paper tape reel rotates to unwind and the main shaft rotates to rewind, so that the strip-shaped insulating paper is wound into insulation; The step of obtaining real-time winding data to adjust the strip-shaped insulating paper strip discharge condition so as to keep the winding tension of the strip-shaped insulating paper within a set range specifically includes: Obtain the real-time winding diameter of the paper tape reel and the real-time output speed of the strip insulating paper; The rotation speed of the unwinding shaft is adjusted according to the real-time winding diameter and the real-time tape delivery speed so that the winding tension of the tape-shaped insulating paper is maintained within the set range.

12. A transformer coil winding device, characterized in that: It comprises a main shaft rotating mechanism, a wire arranging mechanism and an insulating paper supplying mechanism (1). The wire arrangement mechanism and the insulating paper supply mechanism (1) are used to supply wires and strip-shaped insulating paper to the main shaft rotation mechanism respectively. The spindle rotation mechanism comprises a spindle, on which a coil mold is arranged, and the spindle rotation mechanism drives the spindle to rotate and reel so that the conductor and the strip-shaped insulating paper are wound onto the coil mold; As the main shaft rotates, the insulating paper supply mechanism (1) moves with the wire arrangement mechanism from the head end to the tail end of the interlayer insulation area relative to the coil mold, so that when the wire arrangement mechanism forms a current wire layer on the coil mold, the strip insulating paper is wound along with the wire from the head end to the tail end of the interlayer insulation area of ​​the coil mold to form the interlayer insulation of the current layer, and the tail end of the interlayer insulation area of ​​the current layer is used as the end insulation area, and the strip insulating paper is wound in the end insulation area to form the end insulation, and, The insulating paper supply mechanism (1) moves in the opposite direction from the tail end of the interlayer insulating area of ​​the coil mold together with the wire arrangement mechanism, so as to lead the strip insulating paper together with the wire from the tail end of the interlayer insulating area of ​​the coil mold to the next layer, so that the strip insulating paper can be wound together with the wire to form the insulation of the next layer.

13. The transformer coil winding device according to claim 12, characterized in that: The insulating paper supply mechanism (1) comprises an unwinding shaft (11) and a mechanism frame (12). The unwinding shaft (11) is rotatably connected to the mechanism frame (12), and a paper tape reel is provided on the unwinding shaft (11) for rotating and unwinding to supply the strip-shaped insulating paper to the main shaft rotating mechanism. The mechanism frame (12) can move along the axial direction of the coil mould to drive the unwinding shaft (11) to move, so that it is wound on the coil mould as the main shaft rotates to form a trapezoidal interlayer insulation, so that the increase in the thickness of the interlayer insulation is consistent with the increase in the voltage difference between the two layers of conductors.

14. The transformer coil winding device according to claim 13, characterized in that: The invention also includes a controller, which is electrically connected to the mechanism frame (12) and the main shaft respectively, and is used to control the mechanism frame (12) to gradually move laterally from the head end to the tail end of the interlayer insulation area of ​​the coil mold as the main shaft rotates according to a set rule, so that the strip-shaped insulation paper is stacked to form a trapezoidal interlayer insulation.

15. The transformer coil winding device according to claim 14, characterized in that: The setting rule is: The lateral displacement distance y of the mechanism frame (12) and the number of rotation and winding turns n of the main shaft satisfy the following first calculation formula: Among them, h1 is the closed thickness of the trapezoidal interlayer insulation, h2 is the open thickness of the trapezoidal interlayer insulation, L is the width of the interlayer insulation area, H 绝 is the cross-sectional thickness of the first strip-shaped insulating paper, W 绝 is the cross-sectional width of the first strip-shaped insulating paper.

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