Boost transformer manufacturing process

Abstract

The invention discloses a boosting transformer manufacturing process. The boosting transformer manufacturing process comprises the following steps that S1, a high-temperature material with the temperature resistance grade of 180 DEG C is used as a manufacturing material of a transformer; s2, a winding process is improved, so that an insulating layer is arranged between winding layers to ensure electrical isolation between the layers; s3, a pin winding process is improved, a direct pin winding mode is adopted, a three-in-one pin winding mode is omitted, and the pin winding process is simplified; s4, the welding time and the welding depth are strictly controlled, so that the welding quality and the reliability of electrical connection are guaranteed; and S5, the oil immersion time and the reverse vacuumizing time are subjected to special requirement treatment, and it is ensured that insulating oil in the transformer is fully immersed and no bubble is left. The high-temperature material with the temperature resistance grade of 180 DEG C is used as the manufacturing material of the transformer, the stability and durability of the transformer in a high-temperature environment are enhanced, the winding process is improved, the insulating layer is added when each layer of coil is wound, interlayer electrical isolation is ensured, interlayer short circuit is effectively prevented, and the insulating performance of the transformer is improved.

Description

Technical Field

[0001] The invention relates to the technical field of step-up transformer production, in particular to a step-up transformer manufacturing process. Background Art

[0002] As a vital equipment in the power system, the performance and quality of the step-up transformer directly affect the stability and safety of the power system. With the continuous development of power technology, higher and higher requirements are placed on the manufacturing process of the step-up transformer. The traditional step-up transformer manufacturing process has been difficult to meet the needs of the modern power system in some aspects. Therefore, it is particularly important to improve and innovate the manufacturing process.

[0003] In the traditional manufacturing process of step-up transformers, the selection of materials is often limited to materials with lower temperature resistance grades, which limits the application of transformers in high temperature environments. At the same time, there are also some shortcomings in the winding process and the foot-binding process, such as insufficient insulation between winding layers, complex foot-binding process and easy loosening, all of which affect the electrical performance and reliability of the transformer.

[0004] In terms of welding, traditional welding processes often make it difficult to accurately control welding time and welding depth, resulting in unstable welding quality and poor electrical connection reliability, which not only affects the performance of the transformer but may also cause safety hazards.

[0005] In addition, oil immersion and back-vacuuming are crucial steps in the transformer manufacturing process. The traditional oil immersion process often makes it difficult to ensure that the insulating oil fully penetrates the transformer components, and it is easy for residual bubbles to affect the insulation performance of the transformer. The back-vacuuming process also lacks scientific control methods, making it difficult to ensure that no bubbles remain inside the transformer. Summary of the invention

[0006] The purpose of the present invention is to solve the above technical problems, thereby providing a step-up transformer manufacturing process; In order to solve the above technical problems, the present invention provides the following technical solutions: The present invention provides a step-up transformer manufacturing process. The following steps are involved: S1: Use high temperature materials with a temperature resistance of 180°C as the manufacturing material of the transformer; S2: Improve the winding process so that there is an insulating layer between the winding layers to ensure electrical isolation between the layers; S3: Improve the foot-binding process, adopt the direct foot-binding method, cancel the three-in-one foot-binding method, and simplify the foot-binding process; S4: Strictly control welding time and welding depth to ensure welding quality and reliability of electrical connection; S5: Special requirements are imposed on the oil immersion time and the vacuum pumping time to ensure that the insulating oil inside the transformer is fully soaked and no bubbles remain.

[0007] Optionally, the specific implementation method of the improved winding process in step S2 is: when winding each layer of coil, first apply a thin layer of insulating paint or stick a layer of insulating film on the coil skeleton, and after it dries or solidifies, wind the next layer of coil, so as to ensure that there is a uniform insulating layer between each layer of coil, thereby achieving electrical isolation between layers. In addition, automated winding equipment is also used, and the automated winding equipment can accurately control the winding tension, speed and thickness of the interlayer insulation layer to ensure the stability and consistency of the winding process.

[0008] Optionally, the S3 step specifically includes the following sub-steps: Prepare the foot-binding materials: select foot-binding tape that meets electrical insulation requirements and has a certain degree of flexibility; b. Direct foot binding operation: Fix one end of the foot wrapping tape to the pin of the transformer or the starting end of the coil, and directly wrap the foot wrapping tape around the pin or coil according to the predetermined winding direction and tightness, ensuring that each layer fits tightly without looseness. During the winding process, check the tension and position of the foot wrapping tape in real time to ensure that the winding is uniform and meets the design requirements; c. End of foot binding: When the foot binding reaches the predetermined length or position, the end of the foot binding is fixed to ensure that the foot binding will not loosen or fall off, and the foot binding is trimmed and arranged as necessary to make the foot binding look neat and beautiful. d. Calculation formula for tightness of foot binding: The tightness of the binding (T) can be calculated by the following formula:

[0009] Among them, Lw is the actual winding length, that is, the total length of the foot wrapping tape on the pin or coil, Lp is the theoretical winding length of the pin or coil, that is, the length that should be wound according to the design requirements, and T represents the percentage of tightness between the foot wrapping tape and the pin or coil. The closer the T value is to 100%, the tighter the foot wrapping is.

[0010] Optionally, the strict control of welding time and welding depth in step S4 is specifically achieved by setting reasonable welding parameters, including welding current I, welding voltage U and welding speed v, and according to the formula

[0011] Where Q is the welding heat input, R is the weld resistance, and t is the welding time. The welding heat input is calculated to ensure that the welding heat input is within the predetermined range, thereby ensuring the welding quality and the reliability of the electrical connection. At the same time, the optimal welding depth d is determined through actual welding tests. The depth d should meet the minimum cross-sectional area requirements required for electrical connection, and the compliance of the welding depth is verified by non-destructive testing methods.

[0012] Optionally, the step S5 specifically includes the following sub-steps: a. Pre-oil treatment: Place the transformer components in an oil immersion tank and use standard insulating oil for preliminary immersion to remove impurities and moisture on the surface of the components; b. Determine the oil immersion time: According to the material, structure and size of transformer components and the properties of insulating oil, the optimal oil immersion time is determined through experiments; The oil immersion time Timm can be calculated by the following formula:

[0013] Where, k is the oil immersion coefficient, V is the volume of the transformer component, and S is the wetting speed of the insulating oil on the surface of the component; c. Oil immersion process monitoring: During the oil immersion process, regularly check the temperature of the insulating oil and the penetration of the components to ensure that the oil immersion is uniform and sufficient; d. Oil immersion post-treatment: After the oil immersion is completed, take out the transformer components, drain the excess insulating oil, and carry out necessary cleaning and inspection.

[0014] Optionally, the step S5 further includes: performing special processing on the back-vacuuming time to ensure that no bubbles remain inside the transformer, specifically including the following sub-steps: a. Vacuum pump preparation: Select a vacuum pump that meets the requirements and ensure that its performance is stable and can meet the needs of back-vacuuming.

[0015] b. Determine the back-vacuum time: According to the internal volume of the transformer, the complexity of the structure and the required vacuum degree, the optimal back-vacuuming time is determined through experiments; The back-vacuum time T can be calculated by the following formula:

[0016] in: t is the back-vacuum time in seconds (s), V is the volume inside the transformer in cubic meters ( m3) or liter (L), P 0 is the initial pressure, that is, the pressure inside the transformer when the vacuum is started, in Pascal (Pa) or millibar (mbar). Pf is the final required vacuum degree, in units of P 0 is the same, Q is the vacuum pump's extraction rate in cubic meters per second ( m 3 / s ) or liters per second (L / s); c. Back-vacuum process monitoring: During the vacuum pumping process, the pressure changes inside the transformer are monitored in real time to ensure that the vacuum degree meets the design requirements; d. Back-vacuum post-processing: After the vacuum back-evacuation is completed, turn off the vacuum pump, maintain the vacuum state inside the transformer for a period of time, then slowly fill in the insulating oil to the specified liquid level, and perform necessary leak detection and testing.

[0017] Optionally, during the oil immersion process of step S5, ultrasonic-assisted oil immersion technology is also added to accelerate the infiltration and penetration of the insulating oil into the transformer components through the vibration of ultrasound, effectively remove tiny bubbles and impurities inside the components, improve the oil immersion efficiency and penetration quality, ensure that the insulating oil inside the transformer fully and evenly penetrates into each component, and enhance the insulation performance and voltage resistance of the transformer.

[0018] In summary, the present invention has the following beneficial effects: The present application uses a high-temperature material with a temperature resistance level of 180°C as a manufacturing material for the transformer, which enhances the stability and durability of the transformer in a high-temperature environment, broadens its application range, improves the winding process, adds an insulating layer when winding each layer of coils, ensures electrical isolation between layers, effectively prevents short circuits between layers, and improves the insulation performance of the transformer. The direct foot-binding method is adopted, and the three-in-one foot-binding method is cancelled, which simplifies the foot-binding process, reduces the operation steps, and improves the manufacturing efficiency. The foot-binding tightness is calculated by a formula to ensure that the foot-binding belt fits tightly with the pin or coil, thereby enhancing the stability and reliability of the electrical connection. Strictly control welding time and welding depth. By setting reasonable welding parameters and calculating welding heat input, the consistency and stability of welding quality are ensured. The optimal welding depth is determined through actual welding tests and verified by non-destructive testing methods, which further ensures the reliability and safety of electrical connections. Special requirements are imposed on the oil immersion time and the back-vacuum pumping time. The oil immersion time and the back-vacuum pumping time are calculated by formulas to ensure that the insulating oil inside the transformer is fully penetrated and no bubbles remain. Ultrasonic-assisted oil immersion technology is added during the oil immersion process to use the vibration of ultrasonic waves to accelerate the infiltration and penetration of the insulating oil, effectively removing tiny bubbles and impurities inside the components and improving the oil immersion efficiency and penetration quality. DETAILED DESCRIPTION

[0019] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the new embodiments of the system. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Example: The present invention provides a step-up transformer manufacturing process. The following steps are involved: S1: Use high temperature materials with a temperature resistance of 180°C as the manufacturing material of the transformer; S2: Improve the winding process so that there is an insulating layer between the winding layers to ensure electrical isolation between the layers; S3: Improve the foot-binding process, adopt the direct foot-binding method, cancel the three-in-one foot-binding method, and simplify the foot-binding process; S4: Strictly control welding time and welding depth to ensure welding quality and reliability of electrical connection; S5: Special requirements are imposed on the oil immersion time and the vacuum pumping time to ensure that the insulating oil inside the transformer is fully soaked and no bubbles remain.

[0021] This application selects high-temperature materials with a temperature resistance level of 180°C as the manufacturing material for the transformer. This choice is made based on the need for the transformer to work in a high-temperature environment. Traditional materials cannot withstand the long-term effects of high-temperature environments, which can easily lead to material aging, performance degradation, and even failure. High-temperature materials with a temperature resistance level of 180°C can maintain stable performance in high-temperature environments, thereby improving the stability and durability of the transformer.

[0022] The winding process is one of the key steps in transformer manufacturing, which directly affects the electrical performance and structural stability of the transformer. The present application improves the winding process to ensure that there is a uniform insulation layer between each layer of coils, thereby achieving electrical isolation between layers. This improvement effectively prevents the occurrence of interlayer short circuits and improves the electrical safety of the transformer. At the same time, the present application also uses automated winding equipment that can accurately control the winding tension, speed and thickness of the interlayer insulation layer, which not only improves the stability and consistency of the winding process, but also reduces human errors, further ensuring the winding quality.

[0023] The foot binding process is another important process in transformer manufacturing. It is related to the fixation of the transformer pins or coils and the reliability of the electrical connection. The present application improves the foot binding process by adopting a direct foot binding method, eliminating the traditional three-in-one foot binding method and simplifying the foot binding process. During the foot binding process, the present application also checks the tension and position of the foot binding belt in real time to ensure that the winding is uniform and meets the design requirements, effectively preventing the risk of the foot binding loosening or falling off, and improving the reliability of the foot binding.

[0024] Welding is an indispensable process in transformer manufacturing, which is related to the reliability and stability of electrical connections. This application ensures welding quality by strictly controlling welding time and welding depth. Specifically, this application sets reasonable welding parameters such as welding current, welding voltage, and welding speed, and calculates welding heat input based on these parameters to ensure that the welding heat input is within a predetermined range. At the same time, the optimal welding depth is determined through actual welding tests, and the depth should meet the minimum cross-sectional area requirements required for electrical connections. These measures jointly ensure the reliability and stability of welding quality.

[0025] Oil immersion and back-vacuuming are the last two key processes in the transformer manufacturing process, which directly affect the insulation performance and safety of the transformer. This application has special requirements for the oil immersion time and back-vacuuming time.

[0026] During the oil immersion process, the present application ensures that the insulating oil fully penetrates the transformer components to remove impurities and moisture on the surface of the components and improve the insulation performance. At the same time, ultrasonic-assisted oil immersion technology is also added to accelerate the infiltration and penetration of the insulating oil into the transformer components through the vibration of ultrasonic waves, effectively removing tiny bubbles and impurities inside the components.

[0027] During the back-vacuuming process, this application selected a vacuum pump that met the requirements and determined the optimal back-vacuuming time through experiments based on the internal volume of the transformer, the complexity of the structure and the required vacuum degree. This measure ensured that there were no bubbles remaining inside the transformer, thereby improving the insulation performance and safety.

[0028] Optionally, the specific implementation method of the improved winding process in step S2 is: when winding each layer of coil, first apply a thin layer of insulating paint or stick a layer of insulating film on the coil skeleton, and after it dries or solidifies, wind the next layer of coil, so as to ensure that there is a uniform insulating layer between each layer of coil, thereby achieving electrical isolation between layers. In addition, automated winding equipment is also used, and the automated winding equipment can accurately control the winding tension, speed and thickness of the interlayer insulation layer to ensure the stability and consistency of the winding process.

[0029] When winding each layer of coil, by applying a uniform layer of insulating paint, the electrical connection between adjacent coil layers can be effectively isolated. The insulating paint has excellent electrical insulation and heat resistance, and can maintain a stable insulation effect during the long-term operation of the transformer. In addition to the insulating paint, you can also choose to stick a thin and tough insulating film as interlayer isolation. The insulating film usually has an extremely high breakdown voltage and good mechanical strength, and can withstand the electrical and mechanical stress generated by the transformer during operation.

[0030] Whether applying insulating paint or sticking insulating film, it can ensure the electrical isolation between each layer of coils, effectively prevent the occurrence of interlayer short circuit, greatly improve the electrical safety of the transformer, and reduce failures and damage caused by interlayer short circuit.

[0031] Automated winding equipment can accurately control the tension during the winding process to ensure the tightness and consistency of the coil. Too tight tension will cause the coil to deform or break, while too loose tension may affect the electrical performance and mechanical stability of the coil. Through the precise control of automated equipment, these problems can be avoided and the quality of the coil can be improved.

[0032] Winding speed is also one of the important factors affecting coil quality. Too fast a winding speed may cause uneven insulation between coil layers or generate bubbles, while too slow a winding speed may reduce production efficiency. Automated winding equipment can accurately control the winding speed according to preset parameters to ensure the uniformity and consistency of the coil.

[0033] The thickness of the interlayer insulation layer is directly related to the electrical isolation effect and insulation performance of the transformer. Through automated winding equipment, the thickness of the insulation layer between each layer of coils can be accurately controlled to ensure that it is within the design range, which helps to improve the insulation performance and electrical safety of the transformer.

[0034] The use of automated winding equipment has greatly improved the stability and consistency of the winding process. The traditional manual winding method is easily affected by human factors, such as operating force, speed, experience, etc., resulting in uneven coil quality. Automated equipment can wind according to preset parameters and procedures to ensure that each coil has the same quality and performance.

[0035] The use of automated winding equipment also greatly reduces the occurrence of human errors. During the manual winding process, the operator may suffer from reduced winding quality due to fatigue, lack of concentration, etc., while automated equipment can perform winding work continuously and stably without being affected by human factors, thereby improving the quality and reliability of the coil.

[0036] Optionally, the S3 step specifically includes the following sub-steps: Prepare the foot-binding materials: select foot-binding tape that meets electrical insulation requirements and has a certain degree of flexibility; b. Direct foot binding operation: Fix one end of the foot wrapping tape to the pin of the transformer or the starting end of the coil, and directly wrap the foot wrapping tape around the pin or coil according to the predetermined winding direction and tightness, ensuring that each layer fits tightly without looseness. During the winding process, check the tension and position of the foot wrapping tape in real time to ensure that the winding is uniform and meets the design requirements; c. End of foot binding: When the foot binding reaches the predetermined length or position, the end of the foot binding is fixed to ensure that the foot binding will not loosen or fall off, and the foot binding is trimmed and arranged as necessary to make the foot binding look neat and beautiful. d. Calculation formula for tightness of foot binding: The tightness of the binding (T) can be calculated by the following formula:

[0037] Among them, Lw is the actual winding length, that is, the total length of the foot wrapping tape on the pin or coil, Lp is the theoretical winding length of the pin or coil, that is, the length that should be wound according to the design requirements, and T represents the percentage of tightness between the foot wrapping tape and the pin or coil. The closer the T value is to 100%, the tighter the foot wrapping is.

[0038] In electrical equipment or lines, foot wraps, as an insulating layer, must have good electrical insulation properties to prevent current leakage or short circuit. Therefore, when selecting foot wraps, you should ensure that their electrical insulation properties meet relevant standards and specifications.

[0039] The foot binding strap needs to have a certain degree of flexibility so that it can fit closely to the object being wrapped during the wrapping process to reduce gaps and looseness. At the same time, flexibility can also improve the adaptability of the foot binding strap so that it can adapt to objects of different shapes and sizes.

[0040] Direct foot binding operation simplifies the traditional three-in-one foot binding process: The traditional method of foot binding includes a combination of multiple steps or components, such as applying glue first, then wrapping the tape, and finally fixing it. This method is relatively cumbersome and inefficient. By adopting the direct foot binding method, unnecessary steps and components are omitted, and the foot binding process is simplified. This operation method is more intuitive and quick, and can significantly improve the efficiency of foot binding.

[0041] During the wrapping process, the tension of the foot binding should be checked in real time to ensure that it is neither too tight nor too loose. If it is too tight, it may cause the foot binding to break or damage the wrapped object, and if it is too loose, it may cause the foot binding to loosen or fall off. At the same time, it is also necessary to check whether the position of the foot binding is correct to ensure that it can cover the area that needs to be protected and meet the design requirements. By checking the tension and position in real time, it can be ensured that the wrapping is uniform and meets the design requirements. The foot binding tightness calculation formula is a method to quantitatively evaluate the quality of foot binding. By calculating the number of winding layers of the foot binding, the gap between each layer, the winding angle and other parameters, a specific tightness value can be obtained. This value can be used as an important basis for evaluating the quality of foot binding. By comparing the tightness values ​​of different foot binding methods, the best foot binding method can be selected.

[0042] The introduction of a formula to calculate the tightness of foot binding can more scientifically evaluate the quality of foot binding, further ensure the reliability of foot binding, and reduce equipment failures or safety accidents caused by loosening or falling off of foot binding.

[0043] Optionally, the strict control of welding time and welding depth in step S4 is specifically achieved by setting reasonable welding parameters, including welding current I, welding voltage U and welding speed v, And according to the formula:

[0044] Where Q is the welding heat input, R is the weld resistance, and t is the welding time. The welding heat input is calculated to ensure that the welding heat input is within the predetermined range, thereby ensuring the welding quality and the reliability of the electrical connection. At the same time, the optimal welding depth d is determined through actual welding tests. The depth d should meet the minimum cross-sectional area requirements required for electrical connection, and the compliance of the welding depth is verified by non-destructive testing methods.

[0045] The magnitude of the current directly affects the heating speed and temperature distribution of the welding joint. Excessive current may cause overheating of the welding area, resulting in defects such as burn-through and cracks; too small current may cause insufficient heating of the welding joint, resulting in problems such as incomplete fusion and incomplete penetration. The voltage mainly affects the length and stability of the arc. A moderate voltage can ensure stable burning of the arc and obtain good welding quality. Voltage that is too high or too low may cause arc instability and affect the welding process. The welding speed determines the amount of heat received by the welding joint per unit time. A welding speed that is too fast may cause insufficient heating of the welding joint, resulting in defects such as incomplete fusion and incomplete penetration; a welding speed that is too slow may cause overheating of the welding area, resulting in problems such as burn-through and deformation.

[0046] Welding heat input refers to the amount of heat received by a weld per unit length during the welding process. By calculating the welding heat input, the heating degree and cooling rate of the weld joint can be evaluated, thereby predicting the structure and performance of the weld joint. Reasonable welding heat input can ensure the stability of the welding process and prevent welding defects caused by overheating or overcooling.

[0047] Determine the optimal welding depth through actual welding tests: Welding depth refers to the penetration depth of the weld in the parent material. Sufficient welding depth can ensure the minimum cross-sectional area required for electrical connection, thereby enhancing the load-bearing capacity of the electrical connection. Through actual welding tests, the formation of welds under different welding parameters can be observed, the welding depth can be measured, and the mechanical properties of the welded joint can be evaluated. Through multiple tests and comparisons, the welding parameter combination for obtaining the best welding depth can be determined. The application of non-destructive testing methods verifies the compliance of the welding depth and further ensures the reliability of welding quality: Nondestructive testing is a method of detecting internal or surface defects without destroying the object being tested. Commonly used nondestructive testing methods include ultrasonic testing, X-ray testing, magnetic particle testing, etc.

[0048] Through non-destructive testing methods, the welding depth can be accurately measured and verified to see if it meets the design requirements. Non-destructive testing can also detect other defects in welded joints, such as cracks, lack of fusion, and incomplete penetration, thereby comprehensively evaluating the welding quality. The application of non-destructive testing methods can promptly detect and eliminate defects in welded joints, and prevent equipment failures or safety accidents caused by defects.

[0049] Verifying the compliance of welding depth through non-destructive testing can further guarantee the reliability of welding quality and ensure the stability and safety of electrical connections.

[0050] Setting reasonable welding parameters and calculating welding heat input, determining the optimal welding depth through actual welding tests, and verifying the compliance of welding depth by applying non-destructive testing methods are important measures to ensure the stability of the welding process and the reliability of welding quality. The implementation of these measures can effectively prevent the occurrence of welding defects and improve the load-bearing capacity and safety of electrical connections.

[0051] Optionally, the step S5 specifically includes the following sub-steps: a. Pre-oil treatment: Place the transformer components in an oil immersion tank and use standard insulating oil for preliminary immersion to remove impurities and moisture on the surface of the components; b. Determine the oil immersion time: According to the material, structure and size of transformer components and the properties of insulating oil, the optimal oil immersion time is determined through experiments; The oil immersion time Timm can be calculated by the following formula:

[0052] Where, k is the oil immersion coefficient, V is the volume of the transformer component, and S is the wetting speed of the insulating oil on the surface of the component; c. Oil immersion process monitoring: During the oil immersion process, regularly check the temperature of the insulating oil and the penetration of the components to ensure that the oil immersion is uniform and sufficient; d. Oil immersion post-treatment: After the oil immersion is completed, take out the transformer components, drain the excess insulating oil, and carry out necessary cleaning and inspection.

[0053] Pre-oil treatment is a preparatory step before the transformer components are immersed in oil. Its main purpose is to remove impurities and moisture on the surface of the components. The presence of impurities and moisture will affect the oil immersion effect, reduce the performance of the insulating oil, and even cause the transformer to malfunction during operation. Pre-oil treatment will use specific cleaning agents and processes to thoroughly clean the surface of the components. During the cleaning process, it is necessary to ensure that the cleaning agent is compatible with the component material and will not cause corrosion or damage. After cleaning, the components need to be dried to completely remove surface moisture and provide a good foundation for subsequent oil immersion. Through pre-oil treatment, the surface of the components becomes clean and dry, providing a good foundation for the subsequent oil immersion process, which helps to ensure the smooth progress of the oil immersion process and improve the oil immersion effect and the performance of the insulating oil.

[0054] According to the material, structure and size of transformer components and the properties of insulating oil, the optimal oil immersion time is determined through experiments: Considerations: The material, structure and size of transformer components will affect the effect and time of oil immersion. The properties of insulating oil, such as viscosity, density, flash point, etc., will also affect the oil immersion time.

[0055] Experiment to determine the best oil immersion time: In order to ensure the adequacy and uniformity of the oil immersion, it is necessary to determine the optimal oil immersion time through experiments. During the test, the penetration of components at different oil immersion times and the performance changes of the insulating oil can be observed. By comparing and analyzing the test results, the optimal oil immersion time can be determined to ensure the optimization of the oil immersion effect. Monitoring of the oil immersion process ensures the stability of the oil immersion temperature and the penetration of components.

[0056] The oil immersion temperature is one of the key factors affecting the oil immersion effect. Too high or too low a temperature may lead to insufficient or excessive oil immersion. During the oil immersion process, the oil immersion temperature needs to be monitored in real time to ensure that it is stable within the set range. At the same time, the penetration of the components needs to be observed to ensure the smooth progress of the oil immersion process.

[0057] By monitoring the oil immersion process and adjusting the oil immersion temperature, the problem of insufficient or excessive oil immersion can be effectively prevented, which helps to ensure the insulation performance and operational reliability of transformer components. Post-oil immersion processing steps, such as draining excess insulating oil and cleaning inspection, ensure the cleanliness and insulation performance of the transformer interior: After the oil immersion is completed, the excess insulating oil on the surface of the component needs to be drained. This can be achieved through a specific draining process or equipment to ensure that there is no excessive insulating oil remaining on the surface of the component.

[0058] After draining the insulating oil, the components need to be cleaned and inspected. During the cleaning and inspection process, it is necessary to remove oil, dust and other impurities on the surface of the components, and ensure that the cleanliness of the components meets the relevant requirements.

[0059] By draining excess insulating oil and cleaning and checking, the cleanliness and insulation performance of the transformer interior can be ensured, which helps prevent transformer failures or safety accidents caused by impurities or oil stains and improves the operating reliability and service life of the transformer.

[0060] Pre-oil treatment, determining the optimal oil immersion time, monitoring the oil immersion process, and post-oil immersion treatment steps are important measures to ensure the oil immersion effect and insulation performance of transformer components. The implementation of these measures can effectively improve the operating reliability and service life of the transformer and ensure the safe and stable operation of the power system.

[0061] Optionally, the step S5 further includes: performing special processing on the back-vacuuming time to ensure that no bubbles remain inside the transformer, specifically including the following sub-steps: a. Vacuum pump preparation: Select a vacuum pump that meets the requirements and ensure that its performance is stable and can meet the needs of back-vacuuming.

[0062] b. Determine the back-vacuum time: According to the internal volume of the transformer, the complexity of the structure and the required vacuum degree, the optimal back-vacuuming time is determined through experiments; The back-vacuum time T can be calculated by the following formula:

[0063] in: t is the back-vacuum time in seconds (s), V is the volume inside the transformer in cubic meters ( m 3) or liter (L), P 0 is the initial pressure, that is, the pressure inside the transformer when the vacuum is started, in Pascal (Pa) or millibar (mbar). Pf is the final required vacuum degree, in units of P 0 is the same, Q is the vacuum pump's extraction rate in cubic meters per second ( m 3 / s ) or liters per second (L / s); c. Back-vacuum process monitoring: During the vacuum pumping process, the pressure changes inside the transformer are monitored in real time to ensure that the vacuum degree meets the design requirements; d. Back-vacuum post-processing: After the vacuum back-evacuation is completed, turn off the vacuum pump, maintain the vacuum state inside the transformer for a period of time, then slowly fill in the insulating oil to the specified liquid level, and perform necessary leak detection and testing.

[0064] According to the internal volume of the transformer and the required vacuum degree, select a vacuum pump with an appropriate pumping speed. A pumping speed that is too fast may cause damage to the internal structure of the transformer, while a pumping speed that is too slow may prolong the time for back-vacuuming. Ensure that the ultimate vacuum degree of the vacuum pump can meet the requirements of the transformer back-vacuuming. Usually, the transformer back-vacuuming needs to reach a higher vacuum degree to ensure that there are no bubbles remaining inside. Select a vacuum pump that has been verified for a long time and has stable performance to ensure the smooth progress of the back-vacuuming process.

[0065] Consider the compatibility of the vacuum pump and the transformer connection port to ensure that the connection is tight and leak-free. According to the specific structure and size of the transformer, select the appropriate vacuum pump model and specifications and determine the optimal back-vacuum time.

[0066] Through experiments, the pressure changes and bubble residue inside the transformer under different back-vacuuming times were observed. Based on the test results, the optimal back-vacuuming time was determined to ensure that there were no bubbles remaining inside the transformer and the required vacuum degree was achieved.

[0067] The volume and structural complexity of the transformer: the larger the volume and the more complex the structure, the longer the back-evacuation time required.

[0068] Required vacuum degree: The higher the vacuum degree required, the longer the back-vacuuming time.

[0069] Monitoring of the back-vacuuming process Real-time monitoring: Use monitoring equipment such as vacuum gauges to monitor the pressure changes inside the transformer in real time to ensure that the vacuum degree gradually decreases during the back-vacuuming process and ultimately meets the design requirements.

[0070] Data Records: Record key data during the back-vacuuming process, such as start time, end time, final vacuum degree, etc. These data will help with subsequent analysis and evaluation, and provide a reference for future back-vacuuming processes.

[0071] Post-vacuum treatment steps Maintain vacuum: After the back-vacuuming is completed, the vacuum state is maintained for a period of time to ensure that the moisture and impurities inside the transformer are fully removed.

[0072] Slowly fill with insulating oil: After confirming that the required vacuum degree has been reached inside the transformer, slowly fill in insulating oil to the specified liquid level. During the filling process, pay attention to controlling the oil speed and oil temperature to avoid impact or damage to the inside of the transformer.

[0073] Perform necessary leak detection and testing: After the oil filling is completed, the transformer is leak tested to ensure that there are no leakage points, and necessary electrical and insulation performance tests are carried out to ensure that the performance of the transformer meets the design requirements.

[0074] Selecting a vacuum pump that meets the requirements, determining the optimal back-vacuuming time, monitoring the back-vacuuming process, and performing post-back-vacuuming processing steps are the key to ensuring the stability and reliability of the transformer back-vacuuming process, which helps to remove air, moisture and impurities inside the transformer, thereby ensuring the transformer's insulation performance and long-term stable operation.

[0075] Optionally, during the oil immersion process of step S5, ultrasonic-assisted oil immersion technology is also added to accelerate the infiltration and penetration of the insulating oil into the transformer components through the vibration of ultrasound, effectively remove tiny bubbles and impurities inside the components, improve the oil immersion efficiency and penetration quality, ensure that the insulating oil inside the transformer fully and evenly penetrates into each component, and enhance the insulation performance and voltage resistance of the transformer.

[0076] The vibration of ultrasound accelerates the infiltration and penetration of insulating oil into transformer components and improves the oil impregnation efficiency. Ultrasonic waves effectively remove tiny bubbles and impurities inside the components and improve the impregnation quality. The application of ultrasonic-assisted oil impregnation technology ensures that the insulating oil inside the transformer fully and evenly penetrates into every component, thereby enhancing the insulation performance and voltage resistance of the transformer.

[0077] The present application uses high-temperature materials with a temperature resistance level of 180°C as the manufacturing material of the transformer, which enhances the stability and durability of the transformer in high temperature environments, broadens its application range, improves the winding process, adds an insulating layer when winding each layer of coils, ensures electrical isolation between layers, effectively prevents short circuits between layers, and improves the insulation performance of the transformer. It adopts a direct foot-binding method, eliminates the three-in-one foot-binding method, simplifies the foot-binding process, reduces the operating steps, and improves manufacturing efficiency. The foot-binding tightness is calculated through a formula to ensure that the foot-binding belt fits tightly with the pin or coil, thereby enhancing the stability and reliability of the electrical connection.

[0078] Strictly control welding time and welding depth, ensure the consistency and stability of welding quality by setting reasonable welding parameters and calculating welding heat input, determine the optimal welding depth through actual welding tests and verify it through non-destructive testing methods, further ensuring the reliability and safety of electrical connections.

[0079] Special requirements are imposed on the oil immersion time and the back-vacuum pumping time. The oil immersion time and the back-vacuum pumping time are calculated by formulas to ensure that the insulating oil inside the transformer is fully penetrated and no bubbles remain. Ultrasonic-assisted oil immersion technology is added during the oil immersion process to use the vibration of ultrasonic waves to accelerate the infiltration and penetration of the insulating oil, effectively removing tiny bubbles and impurities inside the components and improving the oil immersion efficiency and penetration quality.

[0080] Through the above optimization measures, the insulation performance, temperature resistance level, manufacturing efficiency, electrical connection reliability and insulating oil penetration quality of the transformer have been significantly improved. These improvements have jointly enhanced the overall performance of the transformer, making it more stable and reliable during operation, extending its service life and reducing maintenance costs.

[0081] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A step-up transformer manufacturing process, characterized in that: The following steps are involved: S1: Use high temperature materials with a temperature resistance of 180°C as the manufacturing material of the transformer; S2: Improve the winding process so that there is an insulating layer between the winding layers to ensure electrical isolation between the layers; S3: Improve the foot-binding process, adopt the direct foot-binding method, cancel the three-in-one foot-binding method, and simplify the foot-binding process; S4: Strictly control welding time and welding depth to ensure welding quality and reliability of electrical connection; S5: Special requirements are imposed on the oil immersion time and the vacuum pumping time to ensure that the insulating oil inside the transformer is fully soaked and no bubbles remain.

2. A step-up transformer manufacturing process according to claim 1, characterized in that: The specific implementation method of the step S2 to improve the winding process is: when winding each layer of coil, first apply a thin layer of insulating paint or stick a layer of insulating film on the coil frame, and after it dries or solidifies, wind the next layer of coil, so as to ensure that there is a uniform insulating layer between each layer of coil, thereby achieving electrical isolation between layers. In addition, automated winding equipment is also used, and the automated winding equipment can accurately control the winding tension, speed and thickness of the interlayer insulation layer to ensure the stability and consistency of the winding process.

3. A step-up transformer manufacturing process according to claim 1, characterized in that: The S3 step specifically includes the following sub-steps: Choose foot wraps that meet electrical insulation requirements and have a certain degree of flexibility; b. Direct foot binding operation: Fix one end of the foot wrapping tape to the pin of the transformer or the starting end of the coil, and directly wrap the foot wrapping tape around the pin or coil according to the predetermined winding direction and tightness, ensuring that each layer fits tightly without looseness. During the winding process, check the tension and position of the foot wrapping tape in real time to ensure that the winding is uniform and meets the design requirements; c. End of foot binding: When the foot binding reaches the predetermined length or position, the end of the foot binding is fixed to ensure that the foot binding will not loosen or fall off, and the foot binding is trimmed and arranged as necessary to make the foot binding look neat and beautiful. d. Calculation formula for tightness of foot binding: The tightness of the binding (T) can be calculated by the following formula: Among them, Lw is the actual winding length, that is, the total length of the foot wrapping tape on the pin or coil, Lp is the theoretical winding length of the pin or coil, that is, the length that should be wound according to the design requirements, and T represents the percentage of tightness between the foot wrapping tape and the pin or coil. The closer the T value is to 100%, the tighter the foot wrapping is.

4. The step-up transformer manufacturing process according to claim 1, characterized in that: The strict control of welding time and welding depth in step S4 is specifically achieved by setting reasonable welding parameters, including welding current I, welding voltage U and welding speed v, and according to the formula Where Q is the welding heat input, R is the weld resistance, and t is the welding time. The welding heat input is calculated to ensure that the welding heat input is within the predetermined range, thereby ensuring the welding quality and the reliability of the electrical connection. At the same time, the optimal welding depth d is determined through actual welding tests. The depth d should meet the minimum cross-sectional area requirements required for electrical connection, and the compliance of the welding depth is verified by non-destructive testing methods.

5. The manufacturing process of a step-up transformer according to claim 1, characterized in that: The S5 step specifically includes the following sub-steps: a. Pre-oil treatment: Place the transformer components in an oil immersion tank and use standard insulating oil for preliminary immersion to remove impurities and moisture on the surface of the components; b. Determine the oil immersion time: According to the material, structure and size of transformer components and the properties of insulating oil, the optimal oil immersion time is determined through experiments; The oil immersion time Timm can be calculated by the following formula: Where, k is the oil immersion coefficient, V is the volume of the transformer component, and S is the wetting speed of the insulating oil on the surface of the component; c. Oil immersion process monitoring: During the oil immersion process, regularly check the temperature of the insulating oil and the penetration of the components to ensure that the oil immersion is uniform and sufficient; d. Oil immersion post-treatment: After the oil immersion is completed, take out the transformer components, drain the excess insulating oil, and carry out necessary cleaning and inspection.

6. A step-up transformer manufacturing process according to claim 5, characterized in that: The step S5 further includes: performing special processing on the back-vacuuming time to ensure that no bubbles remain inside the transformer, which specifically includes the following sub-steps: a. Vacuum pump preparation: Select a vacuum pump that meets the requirements and ensure that its performance is stable and can meet the needs of back-vacuuming. b. Determine the back-vacuum time: According to the internal volume of the transformer, the complexity of the structure and the required vacuum degree, the optimal back-vacuuming time is determined through experiments; The back-vacuum time T can be calculated by the following formula: in: t is the back-vacuum time in seconds (s), V is the volume inside the transformer in cubic meters ( m 3) or liter (L), P 0 is the initial pressure, that is, the pressure inside the transformer when the vacuum is started, in Pascal (Pa) or millibar (mbar). Pf is the final required vacuum degree, in units of P 0 is the same, Q is the vacuum pump's extraction rate in cubic meters per second ( m 3 / s ) or liters per second (L / s); c. Back-vacuum process monitoring: During the vacuum pumping process, the pressure changes inside the transformer are monitored in real time to ensure that the vacuum degree meets the design requirements; d. Back-vacuum post-processing: After the back-vacuuming is completed, turn off the vacuum pump, maintain the vacuum state inside the transformer for a period of time, then slowly fill in the insulating oil to the specified liquid level, and perform necessary leak detection and testing.

7. The manufacturing process of a step-up transformer according to claim 1, characterized in that: During the oil immersion process of step S5, ultrasonic-assisted oil immersion technology is also added. Through the vibration of ultrasound, the infiltration and penetration of insulating oil into transformer components is accelerated, tiny bubbles and impurities inside the components are effectively removed, the oil immersion efficiency and penetration quality are improved, and it is ensured that the insulating oil inside the transformer fully and evenly penetrates into each component, thereby enhancing the insulation performance and voltage resistance of the transformer.

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