A voltage transformer coil winding assembly and a winding assembly method

Abstract

This invention provides a voltage transformer coil winding assembly assembly and method, belonging to the field of transformer manufacturing and assembly technology. The voltage transformer coil winding assembly assembly includes a winding mechanism and an assembly mechanism. The winding mechanism includes a winding machine, with baffles fixed on the main shaft of the winding machine. Insulating cylinders with clearance fit are installed between adjacent baffles. The assembly mechanism includes an elastic insulating support plate. The voltage transformer coil winding assembly method includes component installation and wire fixing, coil winding, secondary coil and core installation, and primary coil installation and fixing to the elastic insulating support plate. The beneficial effects are that the insulating cylinder can move slightly along the axial direction, reducing the impact of uneven axial force and ensuring that the width of each wound coil is consistent. The elastic insulating support plate provides reliable support for the coil, prevents rotation, and avoids the insulating cylinder end face protruding from the coil end face, eliminating material waste caused by cutting an extra section of the insulating cylinder.

Description

Technical Field

[0001] This invention belongs to the field of transformer manufacturing and assembly technology, specifically relating to a voltage transformer coil winding assembly assembly and winding assembly method. Background Technology

[0002] In modern power systems, voltage transformers are of paramount importance. Based on the principle of electromagnetic induction, they transform high voltage on the primary side into standard low voltage on the secondary side according to a specific transformation ratio. These low voltage signals are used by metering equipment to ensure accurate electricity measurement and provide a basis for electricity billing; they also provide critical signals for protection equipment, enabling rapid response when system voltage is abnormal, ensuring the safe and stable operation of the power system, and are an important component of power system monitoring and protection.

[0003] In the current manufacturing process of voltage transformers, the winding stage employs a method of simultaneously winding multiple insulating cylinders. During operation, the insulating cylinders are securely mounted on the main shaft, and when the main shaft begins to rotate, the insulating cylinders rotate synchronously. During this process, the conductors are wound sequentially onto the surface of the insulating cylinders according to a pre-set program, completing the initial coil fabrication. After winding, in the assembly stage, to effectively prevent the primary coil from rotating circumferentially relative to the secondary coil, a common practice is to cut the two ends of the primary coil insulating cylinder into special structures protruding from the coil end faces, and then clamp them onto the iron core end faces, thus achieving the anti-rotation purpose.

[0004] However, this winding and assembly method has many drawbacks. During the winding stage, due to differences in tension, speed, and other factors among the individual conductors, the forces exerted on the insulating cylinder by the multiple conductors are uneven, causing the insulating cylinder to bear additional axial forces. This directly results in inconsistent coil widths, making it difficult to guarantee product consistency and stability, and significantly affecting product quality. During the assembly stage, the protruding ends of the insulating cylinder from the coil end face cause significant material waste, increasing production costs. These defects not only raise production costs but also limit further improvements in product quality and the expansion of production scale. Summary of the Invention

[0005] This invention addresses the problems of inconsistent coil widths and wasted insulation material caused by existing winding and assembly methods. It provides a voltage transformer coil winding and assembly assembly component and method that can ensure consistent coil widths and avoid waste of insulation material.

[0006] To solve the above problems, the technical solution adopted by the present invention is as follows: a voltage transformer coil winding assembly assembly, including a winding mechanism and an assembly mechanism. The winding mechanism includes a winding machine, and the assembly mechanism includes a core clamp. A baffle is fixedly connected to the outer wall of the main shaft of the winding machine. A V-groove is provided on the outer circumferential surface of the baffle. An insulating cylinder is clamped between adjacent baffles. The insulating cylinder can rotate synchronously with the baffle. The outer diameter of the insulating cylinder is larger than the outer diameter of the baffle. Both ends of the insulating cylinder are respectively clearance-fitted with the baffles on both sides. Insulating cable ties are tied to the side walls of the insulating cylinder. An elastic insulating support plate is provided on the core clamp. The elastic insulating support plate can pass through the inner wall of the insulating cylinder and the insulating cable ties to support and fix the insulating cylinder. Both ends of the elastic insulating support plate can be fixed on the core clamp.

[0007] During the coil winding process, the main shaft of the winding machine drives the baffles to rotate, and adjacent baffles cause the insulating cylinder to rotate synchronously. By installing multiple baffles and insulating cylinders on the main shaft of the winding machine, multiple coils can be wound synchronously, significantly improving production efficiency. It is worth mentioning that the two ends of the insulating cylinder are fitted with the baffles on both sides with a clearance fit. This means that if the forces applied to the insulating cylinder by multiple wires are uneven during winding, the insulating cylinder can move slightly axially. This adaptive axial movement effectively mitigates the effects of uneven axial forces, ensuring that each wound coil has a consistent width, greatly improving the winding quality of the coils and providing a more stable and reliable foundation for subsequent product applications.

[0008] During coil assembly, the elastic insulating support plate passes between the inner wall of the insulating cylinder and the insulating cable tie, thus providing support and fixation for the insulating cylinder. Subsequently, both ends of the elastic insulating support plate are securely fixed to the core clamp. This design not only provides reliable support for the coil, preventing rotation during assembly, but also avoids the need for the end face of the insulating cylinder to protrude beyond the coil end face, as is common in traditional methods. As a result, no extra section is needed at either end of the insulating cylinder, fundamentally eliminating the material waste caused by cutting an extra section of the insulating cylinder. This not only saves production costs but also reduces material loss during production, improving overall production efficiency.

[0009] Furthermore, both sides of the baffle are provided with supporting flanges. The outer diameter of the supporting flange is the same as the inner diameter of the insulating cylinder. A first positioning protrusion is provided on the outer wall of the supporting flange. Positioning grooves are provided at both ends of the insulating cylinder. The bottom of the positioning grooves is arc-shaped and can engage with the first positioning protrusion. The insulating cylinder is placed between two adjacent baffles, and its inner diameter is equal to the outer diameter of the supporting flange, allowing both ends of the insulating cylinder to fit precisely onto the supporting flanges on the baffles on both sides, thus achieving effective support for the insulating cylinder by the baffles. The outer wall of the supporting flange has a first positioning protrusion, and correspondingly, both ends of the insulating cylinder have positioning grooves that engage with the first positioning protrusion. In this way, when the baffle rotates, the baffle can drive the insulating cylinder to rotate synchronously with the help of the coordinated action of the first positioning protrusion and the positioning groove. In addition, the bottom of the positioning groove is arc-shaped. Before winding the coil, when the first positioning protrusion is inserted into the positioning groove, the end of the wire can smoothly enter the interior of the insulating cylinder along the arc-shaped bottom of the positioning groove.

[0010] Furthermore, a groove is provided on the outer wall of the winding machine's main shaft. The length direction of the groove is the same as the axis of the winding machine's main shaft. A through hole is provided at the center of the baffle, and the diameter of the through hole is the same as the diameter of the outer wall of the winding machine's main shaft. A second positioning protrusion is provided on the side wall of the through hole. The second positioning protrusion can slide along the groove and lock. A positioning sleeve is provided between adjacent baffles. The positioning sleeve is fitted onto the outer wall of the winding machine's main shaft. The length of the positioning sleeve is greater than the length of the insulating sleeve, but does not exceed the sum of the length of the insulating sleeve and the height of the supporting flange. When the baffle is fitted onto the outer wall of the winding machine's main shaft, the second positioning protrusion on the baffle can be locked in the groove, restricting the baffle from rotating freely, thereby allowing the winding machine's main shaft to drive the baffle to rotate synchronously. The positioning sleeve is fitted onto the outer wall of the winding machine's main shaft and is located between two adjacent baffles. After locking the winding machine's main shaft, the two ends of the positioning sleeve abut against the baffles on both sides, thereby limiting the positioning of the baffles and preventing the baffles from sliding along the axial direction of the main shaft. In addition, the length of the positioning sleeve is greater than the length of the insulating cylinder, but does not exceed the sum of the length of the insulating cylinder and the height of the support flange. This ensures that there is a clearance fit between the insulating cylinder and the two side baffles, and also ensures that the support flanges of the two side baffles can effectively support the insulating cylinder in the middle.

[0011] Furthermore, four limiting grooves are provided on the side wall of the insulating cylinder. Each of the four limiting grooves is elongated, and their length direction is the same as the axis of the insulating cylinder. The four limiting grooves are evenly distributed at both ends of the insulating cylinder. The two ends of the insulating cable tie can pass through the two limiting grooves at the same end of the insulating cylinder and be tied together. An elastic insulating support plate can pass between the inner wall of the insulating cylinder and the insulating cable tie, providing support and fixing to the insulating cylinder, thereby restricting the insulating cylinder and preventing it from rotating.

[0012] Furthermore, both ends of the elastic insulating support plate are provided with fixing holes, and a through-bolt is provided below the elastic insulating support plate. The two ends of the through-bolt can pass through the fixing holes at both ends of the elastic insulating support plate and be fixedly connected to the iron core clamp. In this way, the through-bolt fixes the elastic insulating support plate to the iron core clamp, thereby fixing the insulating cylinder relative to the iron core clamp and effectively ensuring that the insulating cylinder will not rotate relative to the iron core.

[0013] A method for winding and assembling a voltage transformer coil includes the following steps:

[0014] Step one: Based on the number of coils to be wound simultaneously, following the principle of equipping one set of components for each coil, sequentially install a set of components consisting of a baffle, positioning sleeve, and insulating cylinder onto the main shaft of the winding machine. After all sets are installed, install another baffle on the outermost side and then lock the main shaft of the winding machine. Then, according to the number of coils to be wound, take the corresponding number of wires and sequentially insert the ends of each wire into the insulating cylinder through the corresponding connection between the baffle and the insulating cylinder, and then attach the wires to the outer wall of the insulating cylinder. The number of component sets consisting of baffles, positioning sleeves, and insulating cylinders is determined according to the number of coils to be wound simultaneously, with one set of components corresponding to one coil. By sequentially installing these component sets onto the main shaft of the winding machine, multiple coils can be wound simultaneously. Furthermore, the gap at the connection between the baffle and the insulating cylinder facilitates the entry of the wire ends into the insulating cylinder.

[0015] Step two: After winding interlayer insulating paper around the outer wall of the insulating cylinder, the main shaft of the winding machine drives the baffle to rotate synchronously with the insulating cylinder. Each conductor is wound sequentially on its corresponding insulating cylinder. When the first layer of conductor is wound, interlayer insulating paper is wound around the outside of the wound conductor again, and then the next layer of conductor is wound. This process is repeated until the entire coil is wound. By winding interlayer insulating paper again after each layer of conductor is completed, electrical contact between different layers of conductor and between the conductor and the insulating cylinder is avoided, reducing electrical faults such as leakage and short circuits, and ensuring the safe and stable operation of electrical equipment. Regular winding and interlayer insulation settings make the magnetic field generated by the coil more uniform and stable, improve electromagnetic conversion efficiency, reduce energy loss, and improve the overall performance of the equipment. At the same time, the multi-layer insulation structure increases the coil's withstand voltage, enabling it to operate in higher voltage environments.

[0016] Step three: First, mount the secondary coil onto the winding support portion of the iron core. Use the edges of the winding support portion to hold the inner wall of the secondary coil in place, preventing rotation. Then, install the winding support portion of the iron core and the secondary coil together onto the iron core clamp. This effectively ensures the stable position of the secondary coil on the winding support portion of the iron core, avoiding coil damage and loose electrical connections caused by coil rotation during subsequent operations or equipment operation, thereby improving the reliability and stability of the equipment. This installation method also ensures the relative positional accuracy between the secondary coil and the iron core, which is beneficial for optimizing electromagnetic coupling, improving electromagnetic conversion efficiency, and enabling the equipment to better convert electrical energy into magnetic energy, thus improving the performance of the entire electrical system.

[0017] Step four: First, pass one end of the elastic insulating support plate between the insulating cable tie and the inner wall of the insulating cylinder. Then, place the primary coil around the secondary coil and install the magnetic circuit closure part of the iron core and the winding support part together. Next, bend both ends of the elastic insulating support plate. Then, insert one end of the through-bolt into the iron core clamp from one side, allowing it to pass sequentially through the fixing hole at one end of the elastic insulating support plate, the gap between the secondary coil and the iron core winding support part, and the fixing hole at the other end of the elastic insulating support plate, before exiting from the other side of the iron core clamp. Finally, fix both ends of the through-bolt to the iron core clamp. Passing one end of the elastic insulating support plate between the insulating cable tie and the inner wall of the insulating cylinder provides good support and positioning for subsequent component installation. Placing the primary coil around the secondary coil and installing the magnetic circuit closure part of the iron core and the winding support part ensures the integrity and normal operation of the electromagnetic system, enabling the magnetic circuit to close effectively and improving electromagnetic conversion efficiency. By using through-bolts to pass through the corresponding parts and fix them to the iron core clamp, the various components are firmly connected together, preventing the components from loosening or shifting due to vibration or external force during equipment operation, thereby ensuring the reliability and safety of the equipment.

[0018] Furthermore, in step two, the distance between the starting edge of the first layer of conductors and the baffle, as well as the distance between the ending edge of the first layer of conductors and the baffle, are both limited to a range of 15-20mm. Limiting the distance between the starting edge and the baffle, and the distance between the ending edge and the baffle, to a range of 15-20mm effectively ensures that the cutter will not cut the conductors during operation.

[0019] Furthermore, in step two, the number of turns of the outer conductor cannot exceed the number of turns of the inner conductor. This helps maintain the uniformity and stability of the magnetic field distribution inside the coil, avoids uneven magnetic field distribution due to excessive outer turns, and enables the coil to more efficiently convert electrical energy into magnetic energy, thereby improving the performance and efficiency of the entire electrical equipment.

[0020] Furthermore, in step two, the interlayer insulation paper is wide-width. Once the first layer of conductors is wound, the interlayer insulation paper is simultaneously wrapped around the outside of all wound conductors. The winding machine then automatically controls the cutter to move to the V-groove on the baffle, allowing the cutter to enter the V-groove and cut the interlayer insulation paper between adjacent insulation cylinders. The next layer of conductors is then wound. Once the next layer is finished, the above operation is repeated until the entire coil is wound. Finally, the winding machine automatically controls the cutter to remove excess interlayer insulation paper from both ends of the coil. The wide-width interlayer insulation paper allows all wound conductors to be wound at once, reducing the need for multiple winding operations. The automatic control of the cutter by the winding machine to cut the interlayer insulation paper and remove excess material reduces the tediousness and error of manual operation, accelerating the entire winding process.

[0021] Furthermore, in step four, one end of the elastic insulating support plate is passed between the insulating cable tie and the inner wall of the insulating cylinder. Then, both sides of the elastic insulating support plate are bent inwards, ensuring a tight fit between the elastic insulating support plate and the inner wall of the insulating cylinder. This fit provides additional support to the insulating cylinder, reducing the risk of deformation or displacement due to external vibration or impact. Simultaneously, this operation enhances insulation performance; the elastic insulating support plate itself possesses insulating properties, and the tight fit fills any potential gaps, preventing electrical leakage and improving the safety of equipment operation.

[0022] As can be seen from the above technical solutions, the advantages of this invention are as follows: During coil winding, the main shaft of the winding machine drives the baffles to rotate, and adjacent baffles drive the insulating cylinder to rotate synchronously. By installing multiple baffles and insulating cylinders on the main shaft, multiple coils can be wound synchronously, significantly improving production efficiency. The insulating cylinder's ends are fitted with the baffles on both sides with a clearance fit. When multiple conductors exert uneven forces on the insulating cylinder, the insulating cylinder can move slightly axially, effectively reducing the impact of uneven axial force and ensuring that each wound coil has a consistent width, thus improving winding quality. During coil assembly, the elastic insulating support plate passes through the inner wall of the insulating cylinder and between the insulating cable ties, providing support and fixing to the insulating cylinder. Its two ends are fixed to the iron core clamp, providing reliable support for the coil, preventing rotation, and avoiding the insulating cylinder end face protruding from the coil end face. This eliminates material waste caused by cutting an extra section of the insulating cylinder, saving production costs and improving overall production efficiency. Attached Figure Description

[0023] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1This is a schematic diagram of the winding mechanism in a specific embodiment of the present invention;

[0025] Figure 2 This is a schematic diagram of the baffle structure in a specific embodiment of the present invention;

[0026] Figure 3 This is a schematic diagram of the structure of the insulating cylinder in a specific embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of the assembly mechanism in a specific embodiment of the present invention;

[0028] Figure 5 This is a schematic diagram of the structure of the elastic insulating support plate in a specific embodiment of the present invention.

[0029] In the diagram: 1. Main shaft, 2. Baffle, 21. Support flange, 211. First positioning protrusion, 22. Connecting hole, 221. Second positioning protrusion, 23. V-groove, 3. Positioning sleeve, 4. Insulating cylinder, 41. Positioning groove, 42. Limiting groove, 43. Insulating cable tie, 5. Wire, 6. Interlayer insulating paper, 7. Cutter, 8. Core clamp, 81. Elastic insulating support plate, 811. Fixing hole, 82. Through-core screw, 83. Secondary coil, 84. Primary coil, 85. Winding bearing part, 86. Magnetic circuit closing part. Detailed Implementation

[0030] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this patent, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this patent.

[0031] Example 1: A voltage transformer coil winding assembly includes a winding mechanism and an assembly mechanism. The winding mechanism can simultaneously perform synchronous winding operations on multiple coils. During the winding process, it can effectively reduce the impact of uneven axial force, promote uniform stress on the conductors 5, and thus ensure that each coil has a consistent width, significantly improving the winding quality. The assembly mechanism can firmly fix the primary coil 84, effectively preventing the primary coil 84 from rotating around the secondary coil 83, ensuring the stability and accuracy of the assembly process, and laying a solid foundation for the normal operation of subsequent electrical equipment.

[0032] like Figure 1As shown, in this specific embodiment, the winding mechanism adopts the following structure: The winding mechanism includes a winding machine, which is an existing device. A groove is provided on the outer wall of the main shaft 1 of the winding machine. The groove is rectangular in shape, and its length direction is exactly the same as the axis direction of the main shaft 1 of the winding machine. Specifically, the groove has two opposite sides, which are parallel to each other, and both sides are perpendicular to the bottom surface of the groove.

[0033] like Figure 2 As shown, a baffle 2 is fitted onto the outer wall of the main shaft 1 of the winding machine. The baffle 2 is generally circular. A through hole 22 is provided at the center of the baffle 2, and the diameter of the through hole 22 is exactly the same as the diameter of the outer wall of the main shaft 1 of the winding machine, that is, the side wall of the through hole 22 of the baffle 2 fits against the outer wall of the main shaft 1 of the winding machine. At the same time, a second positioning protrusion 221 is provided on the side wall of the through hole 22. The size of the second positioning protrusion 221 is adapted to the slide groove, and the second positioning protrusion 221 can be engaged in the slide groove and slide along the slide groove. Therefore, the baffle 2 can slide along the axial direction of the main shaft 1 of the winding machine, and due to the cooperation between the second positioning protrusion 221 and the slide groove, when the main shaft 1 of the winding machine rotates, the baffle 2 will rotate synchronously with the main shaft 1 of the winding machine.

[0034] In addition, a positioning sleeve 3 is provided between adjacent baffles 2, and the positioning sleeve 3 is fitted onto the outer wall of the main shaft 1 of the winding machine. The inner diameter of the positioning sleeve 3 is the same as the diameter of the outer wall of the main shaft 1 of the winding machine, which allows the inner wall of the positioning sleeve 3 to fit snugly against the outer wall of the main shaft 1 of the winding machine, and the positioning sleeve 3 can slide freely on the main shaft 1 of the winding machine. By selecting positioning sleeves 3 of different lengths, the distance between adjacent baffles 2 can be flexibly controlled. If several sets of coils need to be wound simultaneously, several positioning sleeves 3 are installed, and the number of baffles 2 needs to be one more than the number of positioning sleeves 3. The main shaft 1 of the winding machine is fitted with cylinders at both ends. When the main shaft 1 of the winding machine is locked, that is, when the axial preload is applied to the cylinders on the main shaft 1 by the hydraulic device, the cylinders at both ends of the main shaft 1 will exert force on the baffle 2 and the positioning sleeve 3 in the middle, so that the adjacent baffle 2 and the positioning sleeve 3 abut against each other tightly, thereby fixing the position of the baffle 2 and the positioning sleeve 3 and ensuring that the position of the baffle 2 and the positioning sleeve 3 is stable during the winding process. Since the baffle 2 and the second positioning protrusion 221 are integral structures, the position of the second positioning protrusion 221 can be limited by applying force to the cylinder, so that the second positioning protrusion 221 is locked on the slide groove.

[0035] Supporting flanges 21 are provided on both sides of the baffle 2, and the supporting flanges 21 are generally circular. Figure 3As shown, an insulating cylinder 4 is provided between adjacent baffles 2. The insulating cylinder 4 is a hollow cylinder. The inner diameter of the insulating cylinder 4 is the same as the outer diameter of the supporting flange 21, which allows the two ends of the insulating cylinder 4 to be engaged with the supporting flanges 21 on both sides. Furthermore, the length of the insulating cylinder 4 is less than the length of the matching positioning sleeve 3, which ensures that the two ends of the insulating cylinder 4 are in clearance fit with the two baffles 2, that is, the insulating cylinder 4 can move slightly along the axial direction of the supporting flange 21. At the same time, the sum of the length of the insulating cylinder 4 and the height of the supporting flange 21 is greater than the length of the matching positioning sleeve 3. This design ensures that the insulating cylinder 4 will not fall off the supporting flange 21.

[0036] A first positioning protrusion 211 is provided on the outer wall of the supporting flange 21. The height of the first positioning protrusion 211 is flush with that of the supporting flange 21. Both ends of the insulating cylinder 4 are provided with positioning grooves 41, which are adapted to the first positioning protrusion 211, that is, the first positioning protrusion 211 can be engaged with the positioning groove 41. When the baffle 2 rotates with the main shaft 1 of the winding machine, the baffle 2 will cooperate with the positioning groove 41 through the first positioning protrusion 211, driving the insulating cylinder 4 to rotate synchronously. In addition, the bottom of the positioning groove 41 is arc-shaped. When the first positioning protrusion 211 is fully inserted into the positioning groove 41, there will be a gap between the first positioning protrusion 211 and the bottom of the positioning groove 41. This design facilitates the smooth entry of the end of the wire 5 into the interior of the insulating cylinder 4 along the arc-shaped bottom of the positioning groove 41.

[0037] A V-shaped groove 23 is provided on the outer circumferential surface of the baffle 2. The outer wall diameter of the insulating cylinder 4 is larger than the outer diameter of the baffle 2, which can ensure that the interlayer insulating paper 6 between each layer of the coil will not be wrapped on the outer wall of the baffle 2, thus making it easier to remove the coil later.

[0038] Four limiting grooves 42 are provided on the side wall of the insulating cylinder 4. These four limiting grooves 42 are all elongated, and their length direction is the same as the axial direction of the insulating cylinder 4. The four limiting grooves 42 are evenly distributed at both ends of the insulating cylinder 4. The angle formed between the two limiting grooves 42 located at the same end of the insulating cylinder 4 and the center of the insulating cylinder 4 is between 30° and 90°, and the two ends of the insulating cable ties 43 can pass through these two limiting grooves 42 respectively and be tied together. That is, in this embodiment, there are two insulating cable ties 43. The two ends of the first insulating cable tie 43 pass through the two limiting grooves 42 at one end of the insulating cylinder 4 and are tied together, and the two ends of the second insulating cable tie 43 pass through the two limiting grooves 42 at the other end of the insulating cylinder 4 and are tied together.

[0039] like Figure 4As shown, in this specific embodiment, the assembly mechanism adopts the following structure: The assembly mechanism includes a core clamp 8, which is an existing device and has the function of clamping and fixing the core. An elastic insulating support plate 81 is provided on the core clamp 8. The elastic insulating support plate 81 is elastic and has an overall elongated shape. The elastic insulating support plate 81 can pass between the inner wall of the insulating cylinder 4 and the insulating cable tie 43, thereby providing support and fixing for the insulating cylinder 4.

[0040] like Figure 5 As shown, both ends of the elastic insulating support plate 81 are provided with fixing holes 811, and a through-bolt 82 is disposed below it. The two ends of the through-bolt 82 can pass through the fixing holes 811 at both ends of the elastic insulating support plate 81, and are fixedly connected to the iron core clamp 8 by means of bolts. In this embodiment, a total of four fixing holes 811 are evenly distributed at both ends of the elastic insulating support plate 81, two at each end. There are two through-bolts 82. One end of one through-bolt 82 passes through one of the fixing holes 811 at one end of the elastic insulating support plate 81, and then extends to pass through one of the fixing holes 811 at the other end of the elastic insulating support plate 81. The other through-bolt 82 passes through the remaining fixing hole 811 at one end of the elastic insulating support plate 81, and similarly extends to pass through the remaining fixing hole 811 at the other end of the elastic insulating support plate 81.

[0041] Example 2: A method for winding and assembling the voltage transformer coil as described in Example 1, comprising the following steps:

[0042] Step 1: Install the component and secure it with wire 5;

[0043] First, based on the number of coils to be wound simultaneously, a set of components is provided for each coil wound. Each set of components consists of a baffle 2, a positioning sleeve 3, and an insulating cylinder 4. These component sets are sequentially installed on the main shaft 1 of the winding machine. During installation, it is crucial to ensure the accurate positioning of each component. The positioning sleeve 3 is fitted onto the outer wall of the main shaft 1, and the insulating cylinder 4 is secured at both ends to the supporting flanges 21 of the adjacent baffle 2. The baffle 2 is installed through the second positioning protrusion 221 on the side wall of the connecting hole 22, which engages with the sliding groove on the outer wall of the main shaft 1. It is ensured that the second positioning protrusion 221 is properly engaged within the sliding groove, laying the foundation for the subsequent sliding of the baffle 2 along the axis of the main shaft 1 and its synchronous rotation. After all component sets are installed, an additional baffle 2 is installed on the outermost side of the main shaft 1 of the winding machine to complete the entire installation structure.

[0044] Subsequently, cylinders are fitted onto both ends of the winding machine spindle 1, ensuring a tight fit between the two ends of the spindle 1. After fitting, the winding machine spindle 1 is locked by applying axial preload to the cylinders on the spindle 1 using a hydraulic device. The cylinders at both ends of the spindle 1 exert force on the intermediate baffle 2 and positioning sleeve 3, causing adjacent baffles 2 and positioning sleeves 3 to abut against each other, thus fixing their positions and ensuring stability during winding. Alternatively, threads can be provided at the end of the winding machine spindle 1, and a nut connected to these threads can be installed. Tightening the nut applies axial preload to the cylinders, fixing the positions of the baffles 2 and positioning sleeves 3. Since the baffle 2 and the second positioning protrusion 221 are integral structures, applying force to the cylinders limits the position of the second positioning protrusion 221, locking it onto the groove.

[0045] Then, according to the determined number of coils to be wound, take the corresponding number of wires 5. Insert the end of each wire 5 sequentially into the insulating cylinder 4 through the corresponding connection point between the baffle 2 and the insulating cylinder 4, ensuring smooth insertion and avoiding bending or jamming. After insertion, use a suitable adhesive material to bond the portion of the wire 5 outside the insulating cylinder 4 to the outer wall of the insulating cylinder 4, accurately fixing the position of the wire 5 at the beginning of the winding process and providing a reliable guarantee for the smooth progress of subsequent winding work.

[0046] Step 2: Coil winding;

[0047] Interlayer insulating paper 6 is wound around the outer wall of the insulating cylinder 4. A wide-width interlayer insulating paper 6 is selected to meet winding requirements. During winding, ensure the insulating paper adheres tightly to the outer wall of the insulating cylinder 4 without wrinkles or gaps. After winding, start the winding machine. The main shaft 1 of the winding machine begins to rotate. Since the baffle 2 rotates synchronously with the main shaft 1, and the insulating cylinder 4, through the cooperation of the first positioning protrusion 211 on the outer wall of the supporting flange 21 and the positioning grooves 41 at both ends of the insulating cylinder 4, also rotates synchronously with the baffle 2. Each conductor 5 is wound sequentially on its corresponding insulating cylinder 4. When winding the first layer of conductor 5, the distance between its starting edge and the baffle 2, as well as the distance between the ending edge of the first layer of conductor 5 and the baffle 2, must be strictly controlled, both within the range of 15-20mm. This distance range control has a significant impact on the subsequent operation of the cutter 7 and the overall quality of the coil.

[0048] Once the first layer of conductor 5 is wound, immediately wrap all wound conductors 5 with wide interlayer insulation paper 6. During the winding process, ensure the interlayer insulation paper 6 covers the conductors 5 evenly and adheres tightly to them. After winding, the winding machine automatically controls the cutter 7 to begin operation. The cutter 7 moves to the pre-set V-groove 23 on the baffle 2 and precisely inserts into the V-groove 23, cutting the interlayer insulation paper 6 between adjacent insulation cylinders 4. After cutting, the winding of the next layer of conductor 5 begins. The process of winding interlayer insulation paper 6 and cutting with the cutter 7 is repeated after each layer of conductor 5 is completed, continuing in this cycle until the entire coil is wound. Finally, the winding machine automatically controls the cutter 7 to remove excess interlayer insulation paper 6 from both ends of the coil. During this removal process, ensure the accuracy of the cutter 7's operation to avoid accidentally cutting the conductors 5. At the same time, during the entire winding process, it is essential to ensure that the number of turns of the outer layer wire 5 is not greater than the number of turns of the inner layer wire 5. This is a key requirement to ensure the stability of the coil's electromagnetic performance.

[0049] Step 3: Install the secondary coil 83 and the iron core;

[0050] First, mount the secondary coil 83 onto the winding support portion 85 of the iron core. During mounting, ensure the center of the secondary coil 83 is aligned with the center of the winding support portion 85 to guarantee accurate installation. After mounting, use the edges of the winding support portion 85 to engage the inner wall of the secondary coil 83. This engaging method effectively prevents the secondary coil 83 from rotating on the winding support portion 85, ensuring its stability in subsequent operations. Then, mount the winding support portion 85 and the secondary coil 83 together onto the iron core clamp 8. During installation, ensure the positioning elements of the iron core clamp 8 accurately align with the relevant parts of the iron core and the secondary coil 83 to achieve a secure installation and provide a reliable foundation for subsequent operations.

[0051] Step 4: Install and fix the primary coil 84 to the elastic insulating support plate 81;

[0052] First, pass one end of the elastic insulating support plate 81 between the insulating cable tie 43 and the inner wall of the insulating cylinder 4. Handle with care during this process to avoid damaging the elastic insulating support plate 81 or the insulating cable tie 43. After passing through, bend both sides of the elastic insulating support plate 81 inwards. Apply appropriate force during bending to ensure a tight fit between the elastic insulating support plate 81 and the inner wall of the insulating cylinder 4, maximizing its supporting and insulating functions. Next, place the primary coil 84 over the secondary coil 83. Ensure the concentricity of the primary coil 84 and the secondary coil 83 during insertion, ensuring accurate alignment. After insertion, install the magnetic circuit closure part 86 of the iron core and the winding support part 85 together. During installation, ensure a tight connection between the magnetic circuit closure part 86 and the winding support part 85 to guarantee the normal operation of the magnetic circuit.

[0053] Next, bend both ends of the elastic insulating support plate 81. The bending angle should be adjusted according to the actual situation to facilitate the subsequent insertion of the through-bolt 82. Then, insert one end of the through-bolt 82 into the iron core clamp 8 from one side, following a predetermined path, passing sequentially through the fixing hole 811 at one end of the elastic insulating support plate 81, the gap between the secondary coil 83 and the iron core winding support part 85, and the fixing hole 811 at the other end of the elastic insulating support plate 81, before exiting from the other side of the iron core clamp 8. During the insertion process, ensure that the through-bolt 82 passes smoothly through each part without jamming or shifting. Finally, fix both ends of the through-bolt 82 to the iron core clamp 8 with bolts.

[0054] As can be seen from the above embodiments, the beneficial effects of the present invention are as follows: When winding the coil, the main shaft of the winding machine drives the baffle to rotate, and the adjacent baffles drive the insulating cylinder to rotate synchronously. By installing multiple baffles and insulating cylinders on the main shaft, multiple coils can be wound synchronously, greatly improving production efficiency. The two ends of the insulating cylinder are fitted with the baffles on both sides with a clearance fit. When multiple wires exert uneven forces on the insulating cylinder, the insulating cylinder can move slightly along the axial direction, effectively weakening the impact of uneven axial force, ensuring that the width of each wound coil is consistent, and improving the winding quality. When assembling the coil, the elastic insulating support plate passes through the inner wall of the insulating cylinder and between the insulating cable tie, providing support and fixing for the insulating cylinder. Its two ends are fixed to the iron core clamp, which not only provides reliable support for the coil and prevents rotation, but also avoids the end face of the insulating cylinder protruding from the end face of the coil, eliminating material waste caused by cutting an extra section of the insulating cylinder, saving production costs, and improving overall production efficiency.

[0055] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A voltage transformer coil winding assembly, comprising a winding mechanism and an assembly mechanism, wherein the winding mechanism includes a winding machine and the assembly mechanism includes a core clamp (8), characterized in that, A baffle (2) is fixedly connected to the outer wall of the main shaft (1) of the winding machine. A V-groove (23) is provided on the outer circumferential surface of the baffle (2). An insulating cylinder (4) is snapped between adjacent baffles (2). The insulating cylinder (4) can rotate synchronously with the baffle (2). The outer diameter of the insulating cylinder (4) is larger than the outer diameter of the baffle (2). The two ends of the insulating cylinder (4) are respectively fitted with the baffles (2) on both sides. An insulating cable tie (43) is tied to the side wall of the insulating cylinder (4). An elastic insulating support plate (81) is provided on the iron core clamp (8). The elastic insulating support plate (81) can be inserted from the inside of the insulating cylinder (4). The insulating cylinder (4) passes through and supports the wall and the insulating cable tie (43), and both ends of the elastic insulating support plate (81) can be fixed on the iron core clamp (8); both sides of the baffle (2) are provided with support flanges (21), the outer wall diameter of the support flange (21) is the same as the inner wall diameter of the insulating cylinder (4), the outer wall of the support flange (21) has a first positioning protrusion (211), both ends of the insulating cylinder (4) are provided with positioning grooves (41), the bottom of the positioning groove (41) is arc-shaped, and the positioning groove (41) can be snapped into the first positioning protrusion (211); A groove is provided on the outer wall of the main shaft (1) of the winding machine. The length direction of the groove is the same as the axis direction of the main shaft (1) of the winding machine. A connecting hole (22) is provided at the center of the baffle (2). The diameter of the connecting hole (22) is the same as the diameter of the outer wall of the main shaft (1) of the winding machine. A second positioning protrusion (221) is provided on the side wall of the connecting hole (22). The second positioning protrusion (221) can slide along the groove and lock. A positioning sleeve (3) is provided between adjacent baffles (2). 3) The positioning sleeve (3) is sleeved on the outer wall of the main shaft (1) of the winding machine. The length of the positioning sleeve (3) is greater than the length of the insulating cylinder (4) and does not exceed the sum of the length of the insulating cylinder (4) and the height of the supporting flange (21). Both ends of the elastic insulating support plate (81) are provided with fixing holes (811). A through-core screw (82) is provided below the elastic insulating support plate (81). Both ends of the through-core screw (82) can pass through the fixing holes (811) at both ends of the elastic insulating support plate (81) and be fixedly connected to the iron core clamp (8).

2. The voltage transformer coil winding assembly according to claim 1, characterized in that, The insulating cylinder (4) has four limiting grooves (42) on its side wall. The four limiting grooves (42) are all long strips, and the length direction of the limiting grooves (42) is the same as the axial direction of the insulating cylinder (4). The four limiting grooves (42) are evenly distributed at both ends of the insulating cylinder (4). The two ends of the insulating cable tie (43) can pass through the two limiting grooves (42) at the same end of the insulating cylinder (4) and be tied together.

3. A method for winding and assembling a voltage transformer coil, characterized in that, The application in the voltage transformer coil winding assembly as described in claim 1 or 2 includes the following steps: Step 1: Based on the number of coils to be wound simultaneously, and following the principle of equipping a set of components for each coil, install a set of components consisting of baffle (2), positioning sleeve (3), and insulating cylinder (4) on the main shaft (1) of the winding machine in sequence. After all the sets are installed, install another baffle (2) on the outermost side and then lock the main shaft (1) of the winding machine. Then, according to the number of coils to be wound, take the corresponding number of wires (5) and insert the ends of each wire (5) into the insulating cylinder (4) through the corresponding baffle (2) and insulating cylinder (4) in sequence, and then attach the wires (5) to the outer wall of the insulating cylinder (4). Step 2: After the interlayer insulating paper (6) is wrapped around the outer wall of the insulating cylinder (4), the main shaft (1) of the winding machine drives the baffle (2) to rotate synchronously with the insulating cylinder (4). Each wire (5) is wound on the corresponding insulating cylinder (4) in sequence. When the first layer of wire (5) is wound, the interlayer insulating paper (6) is wrapped around the outside of the wound wire (5) again, and then the next layer of wire (5) is wound. The above operation steps are repeated in this way until the winding of the entire coil is completed. Step 3: First, put the secondary coil (83) into the winding support part (85) of the iron core. Use the edge of the winding support part (85) to hold the inner wall of the secondary coil (83) to prevent the secondary coil (83) from rotating on the winding support part (85). Then, install the winding support part (85) of the iron core and the secondary coil (83) together on the iron core clamp (8). Step four: First, pass one end of the elastic insulating support plate (81) through the insulating cable tie (43) and the inner wall of the insulating cylinder (4). Then, put the primary coil (84) on the outside of the secondary coil (83) and install the magnetic circuit closure part (86) of the iron core and the winding support part (85) together. Then, bend both ends of the elastic insulating support plate (81). Then, insert one end of the through-core screw (82) from one side of the iron core clamp (8), so that it passes through the fixing hole (811) at one end of the elastic insulating support plate (81), the gap between the secondary coil (83) and the iron core winding support part (85), and the fixing hole (811) at the other end of the elastic insulating support plate (81). Then, it passes out from the other side of the iron core clamp (8). Finally, fix both ends of the through-core screw (82) on the iron core clamp (8).

4. The voltage transformer coil winding and assembly method according to claim 3, characterized in that, In step two, the distance between the starting edge of the first layer of conductor (5) and the baffle (2), and the distance between the ending edge of the first layer of conductor (5) and the baffle (2) are both limited to the range of 15-20mm.

5. The voltage transformer coil winding and assembly method according to claim 3, characterized in that, In step two, the number of turns of the outer conductor (5) cannot be greater than the number of turns of the inner conductor (5).

6. The voltage transformer coil winding and assembly method according to claim 3, characterized in that, In step two, the interlayer insulating paper (6) is in a wide format. When the first layer of conductor (5) is wound, the interlayer insulating paper (6) is used to wrap around the outside of all the wound conductors (5) at the same time. Then the winding machine automatically controls the cutter (7) to move to the V-groove (23) on the baffle (2) and let the cutter (7) extend into the V-groove (23) to cut the interlayer insulating paper (6) between adjacent insulating cylinders (4). Then the next layer of conductor (5) is wound. After the next layer of conductor (5) is wound, the above operation is repeated until the winding of the entire coil is completed. Finally, the winding machine automatically controls the cutter (7) to cut off the excess interlayer insulating paper (6) at both ends of the coil.

7. The voltage transformer coil winding and assembly method according to claim 3, characterized in that, In step four, one end of the elastic insulating support plate (81) is passed between the insulating cable tie (43) and the inner wall of the insulating cylinder (4), and then both sides of the elastic insulating support plate (81) are bent inward so that the elastic insulating support plate (81) and the inner wall of the insulating cylinder (4) fit tightly together.

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