Device and method for manufacturing component of transformer system

Abstract

The present disclosure relates to an apparatus (10) for at least partially manufacturing at least one component (50) of a transformer system. The apparatus (10) may include: at least one mold (12) configured to at least partially accommodate at least one insulating material (52) configured to at least partially insulate at least one conductor (54); and at least one heating element (22) configured to be coupled to the at least one mold (12) and configured to heat the at least one insulating material (52) to at least partially cure the at least one insulating material (52) when the at least one insulating material (52) is at least partially disposed in the at least one mold (12). The present disclosure also relates to a method for at least partially manufacturing at least one component (50) of a transformer system.

Description

Background Art

[0001] Casting is widely used in various technical fields to manufacture several components. For example, one or more components of a transformer system may be at least partially manufactured by one or more casting processes (eg, epoxy resin reaction molding).

[0002] During the casting process, a substantially liquid casting material is typically introduced into a mold. The mold may include one or more cavities having one or more desired shapes and receiving the casting material. The casting material may then solidify (e.g., cure) within the mold. The solidified part(s), also referred to as a casting, is ejected or released from the mold after solidification.

[0003] The casting material can be actively solidified by cooling and / or heating the casting material in the mold. For example, a curable material (such as a resin and / or other thermosetting material) can be used as the casting material. After the curable material has been introduced into the mold, heat can be applied to the curable material to at least partially solidify (e.g., crosslink) the curable material.

[0004] In the known prior art, the respective mold comprising the casting material is usually at least partially placed in a heated environment (eg in a convection oven) in order to at least partially solidify the casting material.

[0005] In the known prior art, heat is applied to the casting material in a relatively inefficient manner. This can result in relatively high energy consumption, which can increase the costs of manufacturing the corresponding components. In particular, energy prices are often subject to change, for example in response to economic and / or crisis events, which can lead to rising energy prices. Indeed, energy prices have recently risen significantly. Therefore, due to the relatively high energy consumption mentioned above, the economics of manufacturing components by casting and curing are relatively susceptible to rising energy prices. This can reduce the sustainability of casting and curing when using the devices and processes known from the prior art.

[0006] Furthermore, the devices and processes known from the prior art may result in relatively non-uniform solidification of the cast material, for example due to differences in convective heat transfer within the heated environment, as may occur, for example, when several parts are randomly placed in a solidification chamber. This may result in one or more defects in the cast part, such as variability and / or dispersion in performance parameters and / or defects (such as cracks in the cast material).

[0007] The above aspects have not been addressed or at least not adequately addressed in the prior art.

[0008]

[0011] Accordingly, the present disclosure describes one or more aspects that address one or more of the above-identified disadvantages.

[0009] The present disclosure relates to an apparatus according to a first aspect of the disclosure.

[0010] According to a second aspect, this disclosure describes a method.

[0011] The above and other aspects and embodiments thereof are described in more detail in the drawings, the description and the claims.

[0012] Various exemplary embodiments of the present disclosure are directed to providing features that will become readily apparent by reference to the following description when taken in conjunction with the accompanying drawings. According to various embodiments, exemplary devices are disclosed herein. However, it should be understood that these embodiments are presented by way of example and not limitation, and that various modifications may be made to the disclosed embodiments while remaining within the scope of the present disclosure as will be apparent to those skilled in the art reading this disclosure.

[0013] Therefore, the present disclosure is not limited to the exemplary embodiments and applications described and illustrated herein. Additionally, the specific order and / or hierarchy of steps in the methods disclosed herein are merely exemplary approaches. Based on design preferences, the specific order or hierarchy of steps of the disclosed methods or processes can be rearranged while remaining within the scope of the present disclosure. Therefore, one of ordinary skill in the art will understand that the methods and techniques disclosed herein present various steps or actions in a sample order, and unless expressly stated otherwise, the present disclosure is not limited to the specific order or hierarchy presented. Summary of the Invention

[0014] Hereinafter, exemplary embodiments of the present disclosure will be described. It should be noted that, unless otherwise stated or apparent, some aspects of any of the described embodiments may also be found in some other embodiments. However, to increase understandability, each aspect will be described in detail only when first mentioned, and any repeated description of the same aspect will be omitted.

[0015] The apparatus according to the first aspect of the present disclosure can be configured to at least partially manufacture at least one component, in particular at least one component of a transformer system. The apparatus can include at least one mold. The mold can be configured to at least partially contain at least one insulating material, in particular at least one electrically insulating material. The at least one insulating material can be configured to at least partially insulate, in particular electrically insulate, at least one conductor, in particular at least one electrical conductor.

[0016] The at least one mold may comprise one or more cavities configured to at least partially and / or at least temporarily accommodate or receive the at least one insulating material, in particular to simultaneously accommodate or receive the at least one insulating material and the at least one conductor.

[0017] The apparatus may further include at least one heating element. The at least one heating element may be configured to be coupled to at least one section of the at least one mold. The at least one heating element may be configured to heat the at least one insulating material to at least partially cure the at least one insulating material when the at least one insulating material is at least partially disposed within the at least one mold and the at least one heating element is operably coupled to at least one section of the at least one mold. In curing apparatuses and processes known from the prior art, a respective mold containing the casting material is at least partially placed in a heated environment (e.g., within a convection oven) to at least partially cure the casting material. In other words, curing apparatuses and processes known from the prior art rely at least primarily on heat convection from atmospheric gases (e.g., air) within the heated environment to transfer heat to the casting material.

[0018] In contrast, configuring the at least one heating element to be coupled to at least one section of the at least one mold according to the present disclosure can allow the heat generated by the at least one heating element to be substantially conducted from the at least one heating element to the at least one insulating material, for example, via one or more walls of the at least one mold. Thus, convection heat, which acts as a resistance to heat transfer, is substantially eliminated or at least reduced in the transfer of heat generated by the at least one heating element to the at least one insulating material.

[0019] For example, this can improve the efficiency and / or effectiveness of heat transfer from the at least one heating element to the at least one insulating material compared to known prior art solutions, particularly prior art solutions employing convection ovens. Furthermore, compared to the prior art, the at least one heating element described herein can reduce the overall thermal mass being heated, such as the material of the oven and / or the amount of air within the oven, which can be eliminated according to the present disclosure. Furthermore, configuring the at least one heating element to be coupled to the at least one mold according to the present disclosure can allow heat to be applied to the at least one insulating material in a more localized manner (e.g., closer and / or more direct). This can reduce energy consumption and, therefore, costs in the manufacturing process. For example, when using known apparatus and processes to cast and cure transformer system components, such as for curing insulation material for transformer system windings, the manufacture of the transformer system components can require relatively large ovens and / or relatively large amounts of heat. These transformer components can be relatively large and / or require relatively large amounts of insulation material (e.g., hundreds of kilograms of insulation material). Therefore, the apparatus described herein can provide significant advantages compared to the prior art, as described above.

[0020] Furthermore, the solution proposed herein may reduce the heating time of the device described herein, for example, compared to conventional oven systems known from the prior art, for example by providing for applying heat to the at least one insulating material in a more localized and / or more direct manner and / or by reducing the thermal mass, as described above.

[0021] Configuring the at least one heating element to be coupled to the at least one mold may also allow for more precise customization and / or targeting of heat application via the at least one heating element, as compared to known prior art solutions (e.g., convection ovens). For example, this may allow for varying and / or individually configuring heat application. For example, this may allow for applying more heat to at least one first region than to at least one second region, e.g., by arranging and / or operating the heating element(s) accordingly. For example, this may allow for providing more heat, e.g., at a higher temperature and / or for a longer duration, to one or more sections of the at least one insulating material within the at least one mold (e.g., one or more sections of the at least one insulating material that experience greater heat loss during curing, e.g., one or more peripheral sections of the at least one insulating material within the at least one mold) than to one or more other sections.

[0022] Furthermore, configuring the at least one heating element to be coupled to the at least one mold can provide a more consistent, uniform, reliable, and / or repeatable curing process, for example, due to applying heat to the at least one insulating material in a closer and / or more direct manner. Furthermore, configuring the at least one heating element to be coupled to the at least one mold can provide a more controllable curing process, for example, by allowing control of the curing front of the insulating material in the mold, which can allow control of residual stresses in the mold after the curing process. This can improve the quality of the cast component and / or can reduce defects in the cast component.

[0023] Furthermore, the device described herein can be implemented into already available molds (e.g., molds already used in solutions known from the prior art), for example, where the molds are placed in an oven for curing. Thus, an available mold can be modified, for example, by coupling the at least one heating element to the respective mold, to provide a device according to one of the configurations described herein.

[0024] The apparatus described herein can be configured to fully cure the at least one insulating material. Alternatively or additionally, the apparatus described herein can be configured to only partially cure the at least one insulating material. For example, the apparatus described herein can be configured to partially cure the at least one insulating material, such that the partially cured at least one insulating material can be removed in a partially cured state. Alternatively, the partially cured at least one insulating material can then be fully cured, for example, in a different process.

[0025] The at least one mold can be configured to at least partially simultaneously accommodate the at least one conductor and the at least one insulating material. For example, while the at least one conductor and the at least one insulating material are at least partially accommodated / received within the at least one mold, the at least one insulating material can be heated and at least partially cured. This can allow the at least one insulating material to at least partially cure, i.e., solidify, into a state in which the at least one insulating material at least partially surrounds the at least one conductor, such that the at least one insulating material can provide insulation, e.g., electrical insulation, to at least one section of the at least one conductor. This can allow the at least one insulating material and the at least one conductor to be removed from the at least one mold after the at least one insulating material has at least partially cured, as an (electrically) insulated conductor assembly, such as an (electrically) insulated winding of a transformer. Thus, (further) assembly of the at least one conductor and the at least one insulating material may not be required. Alternatively, the at least one insulating material can be cast and cured within the at least one mold, removed from the at least one mold, and assembled with the at least one conductor outside the at least one mold, e.g., by at least partially inserting the at least one conductor into the at least one cured insulating material.

[0026] In other words, the at least one conductor and the at least one insulating material may form at least one (electrically) insulated conductor.

[0027] The apparatus described herein can be configured to, at least in part, manufacture a number of different components of a transformer system. For example, the apparatus can be configured to, at least in part, manufacture one or more insulated windings of a transformer system. The one or more windings can include at least one electrical conductor (i.e., the at least one conductor described herein) and at least one electrical insulating material (i.e., the at least one insulating material described herein).

[0028] Alternatively or additionally, the apparatus described herein may be configured to at least partially manufacture several further components of a transformer system, for example any conductive component, in particular electrically conductive component, comprising insulating material, in particular electrically insulating material.

[0029] The at least one heating element can be configured to be coupled to any section of the at least one mold. For example, the at least one heating element can be configured to be coupled to at least one wall of the at least one mold, for example, at least one wall of the at least one mold that at least partially defines one or more mold cavities (the one or more mold cavities being configured to at least partially accommodate or receive the at least one insulating material, in particular, simultaneously accommodate or receive the at least one insulating material and the at least one conductor), in particular on at least one side of the at least one wall facing away from the one or more mold cavities and / or on at least one side of the at least one wall facing the one or more mold cavities. For example, the at least one heating element can be configured to be coupled to at least one side wall of the at least one mold. Alternatively or additionally, the at least one heating element can be configured to be coupled to at least one top side and / or bottom side of the at least one mold, for example, to one or more end panels of the at least one mold.

[0030] In particular, the at least one heating element can be configured to be coupled to the at least one mold directly (i.e., without one or more intermediate components disposed between the at least one mold and the at least one heating element) and / or indirectly (i.e., with one or more intermediate components disposed between the at least one mold and the at least one heating element). The at least one heating element can be configured to be coupled to the at least one mold via various coupling mechanisms. For example, the at least one heating element can be configured to be coupled to the at least one mold via at least one frictional or non-positive connection, at least one form-fit or positive connection, and / or at least one adhesive connection.

[0031] The at least one heating element can be configured to be coupled (e.g., attached or fastened) to at least one section of the exterior and / or interior of the at least one mold. Alternatively or additionally, the at least one heating element can be configured to be integrally coupled to at least one wall of the at least one mold. In other words, the at least one heating element can be at least partially disposed within at least one section of the at least one wall of the at least one mold. For example, the at least one wall of the at least one mold can be manufactured such that the at least one heating element can be at least partially disposed within the at least one wall. For example, the at least one wall can be manufactured from a plurality of wall layers, wherein the at least one heating element can be at least partially disposed between adjacent wall layers.

[0032] The transformer may be configured as any type of transformer. For example, the transformer may be configured as a traction transformer, in particular a traction transformer for use on a railway vehicle, in particular to provide power to the railway vehicle. Alternatively or additionally, the transformer may be configured as a dry-type transformer and / or a liquid-immersed transformer.

[0033] The at least one mold may have any shape and / or any size. In particular, the at least one mold may have a substantially cylindrical shape. However, the at least one mold may have a variety of different shapes.

[0034] The at least one mold may include a plurality of assembled and / or integrally formed mold sections. For example, the at least one mold may include at least one outer mold section and at least one inner mold section. At least one mold cavity may be defined between the at least one outer mold section and the at least one inner mold section. The at least one mold cavity may be configured to accommodate / receive the at least one insulating material.

[0035] The at least one mold, more particularly the at least one mold cavity, may be at least partially open to the environment. Alternatively, the at least one mold, more particularly the at least one mold cavity, may be closed from environmental influences.

[0036] When the at least one insulating material is introduced into the at least one mould, it may be in a substantially liquid state.When the at least one insulating material is introduced into the at least one mould, it may be pre-heated and / or partially pre-cured.

[0037] The at least one heating element may be configured to be coupled to at least one power source, such as an electrical power source.

[0038] The at least one mold or at least one section of the at least one mold may include at least one mold wall. The at least one heating element may be arranged to conduct heat to the at least one mold wall. As described above, this may allow the heat generated by the at least one heating element to be conducted from the at least one heating element to the at least one insulating material via the at least one mold wall. As a result, heat convection, which acts as a heat transfer resistance, may be substantially eliminated from the heat transfer from the at least one heating element to the at least one insulating material or at least reduced in the heat transfer. The at least one heating element may be attached directly or indirectly to at least one surface of the at least one mold wall. The at least one mold wall may at least partially define one or more cavities of the at least one mold, the one or more cavities being configured to receive / accommodate the at least one insulating material.

[0039] In particular, the at least one heating element may be configured to be coupled (e.g. attached or fastened) to the at least one mold such that substantially no air gap exists between the at least one heating element and the at least one mold, in particular between the at least one heating element and the at least one insulating material.

[0040] The at least one heating element may be configured to be disposed on at least one outer surface of the at least one mold wall. The term "outer surface" refers to the surface of the at least one mold wall that faces away from the at least one insulating material when the at least one insulating material is at least partially disposed in the at least one mold. Alternatively or additionally, at least one of the heating element(s) may be configured to be disposed on at least one inner surface of the at least one mold wall. The term "inner surface" refers to the surface of the at least one mold wall that faces toward and / or is in contact with the at least one insulating material when the at least one insulating material is at least partially disposed in the at least one mold.

[0041] The at least one mold, or at least one section of the at least one mold, may include at least one outer mold wall and at least one inner mold wall disposed at least partially within the at least one outer mold wall. One or more mold cavities of the at least one mold may be at least partially defined between the at least one outer mold wall and the at least one inner mold wall, the one or more mold cavities being configured to accommodate / receive the at least one insulating material. The at least one heating element may be configured to be coupled (e.g., fastened, attached, or integrally coupled) to the at least one outer mold wall and / or the at least one inner mold wall.

[0042] The at least one heating element can be configured as a flat heating element, in particular a strip heating element or a belt heating element. For example, the at least one heating element can be configured as a thick film heater or a thin film heater.

[0043] The at least one heating element may be configured to generate various amounts of heat. For example, the at least one heating element may have a maximum output heating power of at least 1 kW, in particular at least 2 kW, in particular at least 3 kW, in particular at least 4 kW, in particular at least 5 kW, in particular at least 6 kW, in particular at least 7 kW, in particular at least 8 kW, in particular at least 9 kW, in particular at least 10 kW or more. The at least one heating element may have a maximum output heating power density per surface of the at least one heating element of at least 500 W / m 2 , in particular at least 1 kW / m 2 , in particular at least 1.5 kW / m 2 , in particular at least 2 kW / m 2 , in particular at least 2.5 kW / m 2 , in particular at least 3 kW / m 2 , in particular at least 3.5 kW / m 2 , in particular at least 4 kW / m 2 , in particular at least 4.5 kW / m 2 , in particular at least 5 kW / m 2 , in particular at least 5.5 kW / m 2 , in particular at least 6 kW / m 2 , in particular at least 6.5 kW / m 2 , in particular at least 7 kW / m 2 , in particular at least 7.5 kW / m 2 , in particular at least 8 kW / m 2 , in particular at least 8.5 kW / m 2 , in particular at least 9 kW / m 2 , in particular at least 9.5 kW / m 2 , in particular at least 10 kW / m 2 or larger.

[0044] The at least one heating element or a component of the heating element may be deformable, for example flexible and / or bendable. This may allow the at least one heating element or a component of the heating element to adapt to the shape of the at least one mold, for example, to at least one contour (e.g., inner contour and / or outer contour) of the at least one mold.

[0045] The at least one heating element may be configured to heat to a temperature of at least 150°C, in particular at least 175°C, in particular at least 200°C, in particular at least 225°C, in particular at least 250°C, in particular at least 275°C, in particular at least 300°C.

[0046] The device may further include at least one stabilizing element, configured and arranged relative to the at least one heating element to store and / or distribute at least a portion of the heat generated by the at least one heating element. The at least one stabilizing element can provide for a more uniform and / or consistent application of heat generated by the heating element to the at least one insulating material. To store and / or distribute at least a portion of the heat generated by the at least one heating element, the at least one stabilizing element can be made from a material with a relatively high heat capacity (e.g., ceramic) and / or a material with a relatively high thermal conductivity. This can allow the at least one stabilizing element to store and / or distribute at least a portion of the heat generated by the at least one heating element relatively effectively and / or efficiently. However, the at least one stabilizing element can be made from a variety of other materials, for example, those with relatively high heat capacity and / or relatively high thermal conductivity.

[0047] The at least one stabilizing element may be connected to one another. For example, the at least one stabilizing element may be arranged to contact at least one of the at least one heating element. The at least one stabilizing element may be arranged or configured to be arranged on a side of the at least one heating element facing away from the at least one insulating material when the at least one insulating material is arranged in the at least one mold. Alternatively or additionally, the at least one stabilizing element may be arranged or configured to be arranged on a side of the at least one heating element facing the at least one insulating material when the at least one insulating material is arranged in the at least one mold. In particular, the at least one stabilizing element may be at least partially arranged or configured to be at least partially arranged between the at least one heating element and the at least one insulating material when the at least one insulating material is arranged in the at least one mold.

[0048] The apparatus may further include at least one thermal insulation element configured to at least partially thermally insulate at least one or more sections of the at least one mold. This may reduce heat loss, thereby providing more effective and / or efficient heating / curing of the at least one insulating material. The at least one thermal insulation element may be at least partially disposed at and / or on the exterior of the at least one mold. Alternatively or additionally, the at least one thermal insulation element may be at least partially disposed at and / or on the interior of the at least one mold.

[0049] The apparatus may include a plurality of heating elements, i.e., a plurality of the at least one heating element described above. The plurality of heating elements may be configured to, in particular, heat multiple sections of the at least one insulating material individually, for example, such that at least a first section of the plurality of sections may be heated by at least a first heating element of the plurality of heating elements, and at least a second section of the plurality of sections may be heated by at least a second heating element of the plurality of heating elements. The first heating element(s) and the second heating element(s) may be configured to heat the first section(s) and the second section(s) of the at least one insulating material, respectively, to different temperatures and / or for different heating durations.

[0050] The apparatus may further include at least one controller configured to adjust at least one temperature of at least one section of the at least one heating element and / or at least one temperature of at least one section of the at least one insulating material and / or at least one heating duration of the at least one heating element. This may allow for more precise customization and / or targeting of heat application via the at least one heating element compared to known prior art solutions (e.g., convection ovens). For example, this may allow for varying and / or individually configuring heat application, as described above.

[0051] The at least one controller may be configured to control the at least one temperature and / or the at least one heating duration, in particular in a closed-loop manner. This may allow for more precise and / or targeted heating of the at least one insulating material, for example according to at least one target temperature and / or at least one target heating duration.

[0052] The device may further include at least one temperature sensor configured to sense the at least one temperature and provide data related to the at least one temperature to the at least one controller. The at least one temperature sensor may be configured as a thermocouple. However, any suitable temperature sensor may be used.

[0053] The at least one temperature sensor may be integrated into the at least one heating element, for example as a single coherent unit comprising the at least one temperature sensor and the at least one heating element.

[0054] The at least one controller can be configured to regulate and / or control the at least one temperature and / or the at least one heating duration according to one or more temperature profiles and / or one or more heating duration profiles, respectively. The one or more temperature profiles and / or one or more heating duration profiles can define the at least one temperature and / or the at least one heating duration over time t. This can allow for more precise and / or targeted heating of the at least one insulating material, for example by customizing and / or adapting the at least one temperature and / or the at least one heating duration to suit a respective application. The device can include at least one data storage device configured to store the one or more temperature profiles and / or the one or more heating duration profiles and to allow for manual (e.g., user) and / or automatic selection of at least one of the one or more temperature profiles and / or the one or more heating duration profiles.

[0055] The one or more temperature profiles and / or the one or more heating duration profiles may be configured as predetermined and / or variable profiles.

[0056] The at least one controller and / or the at least one heating element may be configured to selectively heat multiple sections of the at least one insulating material. The at least one controller and / or the at least one heating element may be configured to selectively heat multiple sections of the insulating material independently of one another. The at least one controller and / or the at least one heating element may be configured to selectively heat multiple sections of the at least one insulating material such that the multiple sections of the at least one insulating material are heated to different temperatures and / or for different heating durations.

[0057] The at least one controller and / or the at least one heating element can be configured to apply different amounts of heat and / or different heating durations to multiple sections of the at least one insulating material. For example, one or more first sections of one of the at least one heating element can be heated to a higher temperature than one or more second sections of the one of the at least one heating element. Alternatively or additionally, a plurality of the at least one heating element can be provided, and one or more first heating elements of the plurality of heating elements can be heated to a higher temperature than one or more second heating elements of the plurality of heating elements.

[0058] The at least one heating element may be configured to be electrically powered.

[0059] The at least one mold can be made at least partially, and in particular completely, of metal. However, the at least one mold can be made of any suitable material(s), such as one or more composite materials. The at least one mold can be made by one or more suitable manufacturing methods, including, for example, 3D printing. The at least one mold can be made of one or more materials with relatively high thermal conductivity, for example, to provide relatively low heat transfer resistance between the at least one heating element and the at least one insulating material.

[0060] The at least one mold or at least a portion of the at least one mold may be configured for vacuum casting.

[0061] The at least one insulating material may comprise at least one resin, in particular at least one epoxy resin. However, the at least one insulating material may comprise any suitable curable and / or thermosetting material, such as liquid silicone rubber, polyurethane, etc.

[0062] The following describes a method according to the second aspect of the present disclosure. The features, configurations and advantages described above with respect to the apparatus according to the first aspect apply to the method accordingly.

[0063] The method may be configured for at least partially manufacturing at least one component of a transformer system.The method may be performed by the apparatus according to the first aspect according to any configuration described herein.

[0064] The method may include: (a) At least one insulating material is at least partially disposed in at least one mold, the at least one insulating material being configured to at least partially insulate at least one conductor.

[0065] The method may further comprise: (b) heating the at least one insulating material by at least one heating element coupled to the at least one mold to at least partially cure the at least one insulating material while the at least one insulating material is at least partially disposed in the at least one mold.

[0066] At least one temperature of the at least one heating element and / or at least one temperature of the at least one insulating material and / or at least one heating duration of the at least one heating element can be adjusted by at least one controller.

[0067] The at least one temperature may be sensed by at least one temperature sensor.Data related to the at least one temperature may be provided to the at least one controller.

[0068] The at least one temperature and / or the at least one heating duration can be adjusted by the at least one controller according to one or more temperature profiles and / or one or more heating duration profiles, respectively.

[0069] The plurality of sections of insulation material may in particular be selectively heated independently of one another, in particular such that the plurality of sections of insulation material may be heated to different temperatures and / or for different heating durations.

[0070] Different amounts of heat and / or different heating durations may be applied to sections of the insulation material.

[0071] The following list of aspects provides alternative and / or additional features of the present disclosure: 1. A device for at least partially manufacturing at least one component, in particular at least one component of a transformer system, comprising: at least one mold configured to at least partially contain at least one curable material, in particular at least one insulating material configured to at least partially insulate at least one conductor; and At least one heating element is configured to be coupled to the at least one mold and to heat the at least one material to at least partially cure the at least one material when the at least one material is at least partially disposed in the at least one mold.

[0072] 2. Apparatus according to aspect 1, wherein the at least one mould comprises at least one mould wall, and the at least one heating element is arranged to conduct heat to the at least one mould wall.

[0073] 3. The apparatus according to aspect 2, wherein the at least one heating element is configured to be arranged on at least one outer surface of the at least one mold wall.

[0074] 4. The device according to any of the preceding aspects, wherein the at least one heating element is configured as a flat heating element, in particular as a strip-shaped heating element or a ribbon-shaped heating element.

[0075] 5. The device according to any of the preceding aspects, further comprising at least one stabilizing element, which is configured and arranged relative to the at least one heating element to store and / or distribute at least a portion of the heat generated by the at least one heating element, in particular wherein the at least one stabilizing element is made of at least one ceramic material.

[0076] 6. The device according to any of the preceding aspects, further comprising at least one thermal insulation element configured to at least partially thermally insulate at least one or more sections of the at least one mold, in particular wherein the at least one thermal insulation element is at least partially arranged at and / or on the exterior of the at least one mold.

[0077] 7. The apparatus according to any one of the preceding aspects, comprising a plurality of the at least one heating elements configured to heat a plurality of sections of the at least one curable material.

[0078] 8. The device according to any of the preceding aspects, further comprising at least one controller configured to adjust at least one temperature of at least one portion of the at least one heating element and / or at least one temperature of the at least one curable material and / or at least one heating duration of the at least one heating element.

[0079] 9. Apparatus according to aspect 8, wherein the at least one controller is configured to control the at least one temperature and / or the at least one heating duration, in particular in a closed-loop manner.

[0080] 10. The apparatus according to aspect 8 or 9, further comprising at least one temperature sensor configured to sense the at least one temperature and provide data related to the at least one temperature to the at least one controller.

[0081] 11. The apparatus according to any one of aspects 8 to 10, wherein the at least one controller is configured to adjust and / or control the at least one temperature and / or the at least one heating duration according to one or more temperature curves and / or one or more heating duration curves, respectively.

[0082] 12. An apparatus according to any one of aspects 8 to 11, wherein the at least one controller and / or the at least one heating element is configured to selectively heat multiple sections of curable material, in particular independently of each other, in particular so that the multiple sections of curable material are heated to different temperatures and / or are heated for different heating durations.

[0083] 13. The apparatus according to any one of aspects 8 to 12, wherein the at least one controller and / or the at least one heating element is configured to apply different amounts of heat and / or different heating durations to the multiple sections of the curable material.

[0084] 14. The device according to any of the preceding aspects, wherein the at least one heating element is configured to be electrically driven.

[0085] 15. The device according to any of the preceding aspects, wherein the at least one mold is at least partially, in particular completely, made of metal.

[0086] 16. Apparatus according to any one of the preceding aspects, wherein the at least one mould is configured for vacuum casting.

[0087] 17. The device according to any of the preceding aspects, wherein the at least one curable material comprises at least one resin, in particular at least one epoxy resin.

[0088] 18. A method for at least partially manufacturing at least one component of a transformer system, in particular from a device according to any one of the preceding aspects, the method comprising: (c) arranging at least one curable material, in particular at least one insulating material, at least partially in the at least one mold, the at least one insulating material being configured to at least partially insulate the at least one conductor; and (d) heating the at least one curable material by at least one heating element coupled to the at least one mold to at least partially cure the at least one curable material while the at least one curable material is at least partially disposed in the at least one mold.

[0089] 19. The method according to aspect 18, wherein at least one temperature of the at least one heating element and / or at least one temperature of the at least one curable material and / or at least one heating duration of the at least one heating element are regulated by at least one controller.

[0090] 20. The method of aspect 19, wherein the at least one temperature is sensed by at least one temperature sensor and data related to the at least one temperature is provided to the at least one controller.

[0091] 21. The method according to aspect 19 or 20, wherein the at least one temperature and / or the at least one heating duration are adjusted by the at least one controller according to one or more temperature profiles and / or one or more heating duration profiles, respectively.

[0092] 22. A method according to any one of aspects 18 to 21, wherein the multiple sections of the at least one curable material are selectively heated in a manner independent of each other, in particular so that the multiple sections of the at least one curable material are heated to different temperatures and / or are heated for different heating durations.

[0093] 23. The method according to any one of aspects 18 to 22, wherein different amounts of heat and / or different durations of heating are applied to the multiple sections of the at least one curable material. BRIEF DESCRIPTION OF THE DRAWINGS

[0094] The presently disclosed subject matter will be explained in more detail with reference to preferred exemplary embodiments illustrated in the accompanying drawings.

[0095] Figure 1Schematically illustrating in cross-section an apparatus for at least partially manufacturing at least one component of a transformer system according to an embodiment of the present disclosure; Figure 2 Schematically depicts, in a longitudinal sectional view, an apparatus for at least partially manufacturing at least one component of a transformer system according to a further embodiment of the present disclosure; Figure 3 schematically illustrates in cross-section an apparatus for at least partially manufacturing at least one component of a transformer system according to a further embodiment of the present disclosure; Figure 4 schematically illustrates in cross-section an apparatus for at least partially manufacturing at least one component of a transformer system according to a further embodiment of the present disclosure; Figure 5 Components at least partially produced by an apparatus according to any of the configurations described herein are schematically shown in longitudinal cross-section. DETAILED DESCRIPTION

[0096] Figure 1 An apparatus 10 for at least partially manufacturing at least one component of a transformer system according to an embodiment of the present disclosure is schematically shown in cross-section. The apparatus 10 may include at least one mold 12 configured to at least partially contain at least one insulating material configured to at least partially insulate at least one conductor.

[0097] The at least one mold 12 may include a plurality of mold sections that may be assembled and / or integrally formed. Figure 1 As shown in FIG, the at least one mold 12 may include at least one outer mold section 14 and at least one inner mold section 16. The at least one inner mold section 16 may be at least partially disposed within the at least one outer mold section 14.

[0098] The at least one mold 12 may include at least one cavity 18, which may be defined between the at least one outer mold section 14 and the at least one inner mold section 16. The at least one cavity 18 may be configured to house / receive the at least one insulating material.

[0099] The at least one mold 12 (eg, the at least one outer mold segment 14 and / or the at least one inner mold segment 16) may include at least one mold wall 20A, 20B, such as Figure 1 At least one mold side wall 20A, 20B is shown in FIG.

[0100] The apparatus 10 may further include at least one heating element 22 configured to be coupled to the at least one mold 12. The at least one heating element 22 may be configured to heat the at least one insulating material to at least partially cure the at least one insulating material when the at least one insulating material is at least partially disposed in the at least one mold 12 and the at least one heating element 22 is coupled to the at least one mold 12.

[0101] The at least one heating element 22 can be deformable, for example, flexible and / or bendable. This allows the at least one heating element 22 to adapt to the shape of the at least one mold 12, for example, to adapt to at least one contour (e.g., inner contour and / or outer contour) of the at least one mold 12. The at least one heating element 22 can be configured to be electrically powered. The at least one heating element 22 can be configured as a flat heating element, in particular, a strip-shaped heating element or a ribbon-shaped heating element.

[0102] The at least one heating element 22 may be arranged to conduct heat to the at least one mold wall 20A, 20B. For example, the at least one heating element 22 may be directly and / or indirectly attached to the at least one mold wall 20A, 20B. For example, the at least one heating element 22 may be configured to be arranged on at least one outer surface 26 of the mold wall 20A, such as Figure 1 The at least one heating element 22 may extend substantially around the entire circumference of the at least one core 12, as shown in FIG. Figure 1 However, such a configuration is merely exemplary. The at least one heating element 22 may extend only around a portion of the circumference of the at least one core 12. For example, the device 10 may include a plurality of heating elements 22, i.e., a plurality of the at least one heating element 22 described above, distributed around at least a portion of the circumference of the at least one core 12 (see FIG. Figure 4 and corresponding description further below).

[0103] The apparatus 10 may further include at least one thermal insulation element (not shown) configured to at least partially thermally insulate at least one or more sections of the at least one mold 12. This may reduce heat loss, thereby providing more effective and / or efficient heating / curing of the at least one insulation material.

[0104] like Figure 2 As shown in FIG, the device 10 may include a plurality of heating elements 22, i.e., a plurality of Figure 1 The at least one heating element 22 is described. The heating element 22 can be arranged at different positions. In particular, the heating element 22 can be distributed, for example, so that the heating elements 22 are spaced apart from each other.

[0105] like Figure 2 As shown in FIG, the at least one mold 12 may include at least one top member 30 and / or at least one bottom member 32 that may at least partially define or bound the at least one cavity 18.

[0106] As shown in the figures, the at least one heating element 22 can be coupled to or configured to be coupled to at least one mold sidewall 20A, 20B. Alternatively or additionally, at least one of the at least one heating element 22 can be coupled to or configured to be coupled to the at least one top member 30 and / or the at least one bottom member 32.

[0107] For example Figure 1 and Figure 2 , the at least one heating element 22 can be coupled to or configured to be coupled to the at least one mold 12 at and / or on the exterior of the at least one mold 12. For example, the at least one heating element 22 can be coupled to or configured to be coupled to the at least one mold 12 on a side of the at least one wall 20A, 20B of the at least one mold 12 facing away from the at least one mold cavity 18 and / or on a side of the at least one wall 20A, 20B of the at least one mold 12 facing the at least one mold cavity 18.

[0108] Alternatively or additionally, the at least one heating element 22 may be coupled to or configured to be coupled to the at least one mold 12 at and / or on the interior of the at least one mold 12, such as Figure 3 As shown in .

[0109] Alternatively or additionally, the at least one heating element 22 can be configured to be integrally coupled to the at least one wall 20A, 20B of the at least one mold 12. In other words, the at least one heating element 22 can be disposed within at least a section of the at least one wall 20A, 20B of the at least one mold 12, which is not specifically shown in the figures. For example, the at least one wall 20A, 20B of the at least one mold 12 can be manufactured such that the at least one heating element 22 is disposed within the at least one wall 20A, 20B. For example, the at least one wall 20A, 20B can be manufactured from a plurality of wall layers, wherein the at least one heating element 22 can be at least partially disposed between adjacent wall layers of the at least one wall 20A, 20B.

[0110] The apparatus 10 may further include at least one controller 34 configured to adjust at least one temperature of at least one section of the at least one heating element 22 and / or at least one temperature of at least one section of the at least one insulating material and / or at least one heating duration of the at least one heating element 22. The at least one controller 34 may be communicatively coupled to the at least one heating element 22, e.g., wirelessly and / or via a hardwired connection.

[0111] The at least one controller 34 can be configured to control each heating element 22 individually and / or collectively. The at least one controller 34 and / or the at least one heating element 22 can be configured to heat one or more first sections of a heating element 22 to one or more temperatures that are higher than one or more second sections of the heating element 22. Alternatively or additionally, the at least one controller 34 and / or the plurality of heating elements 22 can be configured such that one or more first heating elements of the plurality of heating elements 22 can be heated to a higher temperature than one or more second heating elements of the plurality of heating elements 22. Alternatively, the apparatus 10 can include a plurality of controllers 34, wherein each controller 34 can be configured to control one or more different heating elements of the plurality of heating elements 22.

[0112] The at least one controller 34 can be configured to regulate and / or control the at least one temperature and / or the at least one heating duration according to one or more temperature profiles and / or one or more heating duration profiles, respectively. The one or more temperature profiles and / or one or more heating duration profiles can define the at least one temperature and / or the at least one heating duration over time t. This can allow for more precise and / or targeted heating of the at least one insulating material, for example, by customizing and / or adapting the at least one temperature and / or the at least one heating duration to suit a respective application. Apparatus 10 (e.g., the at least one controller 34) can include at least one data storage device configured to store the one or more temperature profiles and / or the one or more heating duration profiles and to allow for manual (e.g., user) and / or automatic selection of at least one of the one or more temperature profiles and / or the one or more heating duration profiles.

[0113] The device 10 may further include at least one stabilizing element 38 configured and arranged relative to the at least one heating element 22 to store and / or distribute at least a portion of the heat generated by the at least one heating element 22, such as Figure 4. The at least one stabilizing element 38 can provide for applying heat generated by the at least one heating element 22 to the at least one insulating material in a more uniform and / or consistent manner. To store and / or distribute at least a portion of the heat generated by the at least one heating element, the at least one stabilizing element 38 can be made of a material with a relatively high heat capacity (e.g., ceramic) and / or a material with a relatively high thermal conductivity. This can allow the at least one stabilizing element 38 to store and / or distribute at least a portion of the heat generated by the at least one heating element 22 relatively effectively and / or efficiently. However, the at least one stabilizing element 38 can be made of various other materials, for example, materials with a relatively high heat capacity and / or relatively high thermal conductivity.

[0114] Figures 1 to 4 Features of the embodiments may also be combined in various configurations. For example, the apparatus 10 may include a plurality of heating elements 22, wherein at least one of the plurality of heating elements 22 may be coupled to or configured to be coupled to the at least one mold 12 at and / or on the exterior of the at least one mold 12, and at least one of the plurality of heating elements 22 may be coupled to or configured to be coupled to the at least one mold 12 at and / or on the interior of the at least one mold 12.

[0115] Figure 5 There is schematically shown in longitudinal section a component 50 which is at least partially manufactured by the device 10 according to any of the configurations described herein, for example Figures 1 to 4 . Component 50 may include at least one insulating material 52 (e.g., the at least one insulating material described above), which may be received / contained within the at least one mold 12 of apparatus 10, as described above. Component 50 may further include at least one conductor 54, which may also be received / contained within the at least one mold 12 of apparatus 10, as described above. In other words, the at least one mold 12 may be configured to simultaneously, at least partially and / or at least temporarily, contain or receive the at least one insulating material 52 and the at least one conductor 54. The at least one insulating material 52 may be, or at least include, at least one resin, particularly at least one epoxy resin.

[0116] The at least one insulating material 52 can be introduced into the at least one mold 12, for example, into the at least one cavity 18, while being in a substantially liquid state. The at least one conductor 54 can be in a substantially solid state when introduced into the at least one mold 12. After the at least one insulating material 52 and the at least one conductor 54 have been introduced into the at least one mold 12, the at least one insulating material 52 can be at least partially cured by heat generated by the at least one heating element 22 of the apparatus 10 to at least partially solidify the at least one insulating material 52.

[0117] This may allow the at least one insulating material 52 to at least partially solidify (i.e., cure) so as to be in a state where the at least one insulating material 52 at least partially surrounds the at least one conductor 54 so that the at least one insulating material 52 may provide insulation, e.g., electrical insulation, to at least one section of the at least one conductor 54. Figure 5 In other words, the at least one conductor 54 and the at least one insulating material 52 may form at least one (electrically) insulated conductor. The at least one conductor 54 may be configured to be connected to at least one voltage source and / or at least one load, for example, via at least one connector (not shown).

[0118] Once the at least one insulating material 52 has at least partially cured, the at least partially cured at least one insulating material 52 may be removed from the at least one mold 12 .

[0119] The apparatus 10 described herein can be configured to at least partially manufacture a number of different components of a transformer system. For example, the apparatus 10 can be configured to at least partially manufacture one or more insulated windings of a transformer system. For example, the at least one conductor 54 can be at least one winding wound one or more times around at least one winding axis. The winding can be introduced into the at least one mold 12 in a wound state.

[0120] Alternatively or additionally, the apparatus 10 described herein may be configured to at least partially manufacture several further components of a transformer system, for example any conductive component, in particular electrically conductive component, comprising insulating material, in particular electrically insulating material.

[0121] Although various embodiments of the present disclosure have been described above, it should be understood that they are presented by way of example only and not by way of limitation. Similarly, various figures may depict example architectures or configurations, which are provided to enable those of ordinary skill in the art to understand the exemplary features and functions of the present disclosure. However, such persons will understand that the present disclosure is not limited to the illustrated example architectures or configurations, but may be implemented using various alternative architectures and configurations. Additionally, as will be understood by those of ordinary skill in the art, one or more features of an embodiment may be combined with one or more features of another embodiment described herein. Therefore, the breadth and scope of the present disclosure should not be limited by any of the exemplary embodiments described above.

[0122] It should also be understood that any reference to an element herein using designations such as "first," "second," etc., does not generally limit the quantity or order of those elements. Rather, these designations may be used herein as a convenient means of distinguishing between two or more elements or instances of an element. Thus, a reference to a first element and a second element does not mean that only two elements may be employed, or that the first element must precede the second element in some manner.

[0123] Various modifications to the embodiments described in this disclosure will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments without departing from the scope of this disclosure. Therefore, the present disclosure is not intended to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the novel features and principles disclosed herein, as recited in the appended claims.

Claims

1. A device (10) for at least partially manufacturing at least one component (50) of a transformer system, the device comprising: at least one mold (12) configured to at least partially contain at least one insulating material (52) configured to at least partially insulate at least one conductor (54); and At least one heating element (22) is configured to be coupled to the at least one mold (12) and to heat the at least one insulating material (52) to at least partially cure the at least one insulating material (52) when the at least one insulating material (52) is at least partially disposed in the at least one mold (12).

2. The device (10) according to claim 1, wherein The at least one mold (12) comprises at least one mold wall (20A, 20B), and the at least one heating element (22) is arranged to conduct heat to the at least one mold wall (20A, 20B).

3. The device (10) according to claim 2, wherein The at least one heating element (22) is configured to be arranged on at least one outer surface (26) of the at least one mold wall (20A, 20B).

4. The device (10) according to any one of the preceding claims, wherein The at least one heating element (22) is configured as a flat heating element, in particular as a strip-shaped heating element or a ribbon-shaped heating element.

5. The device (10) according to any of the preceding claims, further comprising at least one stabilizing element (38), which is configured and arranged relative to the at least one heating element (22) to store and / or distribute at least a portion of the heat generated by the at least one heating element (22), in particular wherein, The at least one stabilizing element (38) is made of at least one ceramic material.

6. The device (10) according to any one of the preceding claims, comprising a plurality of said at least one heating element (22) configured to heat a plurality of sections of said at least one insulating material (52).

7. The device (10) according to any of the preceding claims, further comprising at least one controller (34), the at least one controller being configured to regulate at least one temperature of at least one portion of the at least one heating element (22) and / or at least one temperature of the at least one insulating material (52) and / or at least one heating duration of the at least one heating element (22).

8. The device (10) according to claim 7, wherein The at least one controller (34) is configured to adjust and / or control the at least one temperature and / or the at least one heating duration according to one or more temperature profiles and / or one or more heating duration profiles, respectively.

9. The device (10) according to claim 7 or 8, wherein The at least one controller (34) and / or the at least one heating element (22) are configured to selectively heat a plurality of sections of the insulating material (52), in particular independently of one another, in particular such that the plurality of sections of the insulating material (52) are heated to different temperatures and / or for different heating durations.

10. The device (10) according to any one of claims 7 to 9, wherein The at least one controller (34) and / or the at least one heating element (22) are configured to apply different amounts of heat and / or different heating durations to multiple sections of the insulating material (52).

11. The device according to any one of the preceding claims, wherein The at least one heating element is configured to be electrically powered.

12. A method for at least partially manufacturing at least one component (50) of a transformer system, in particular from a device (10) according to any one of the preceding claims, the method comprising: (e) disposing at least one insulating material (52) at least partially in the at least one mold (12), the at least one insulating material being configured to at least partially insulate the at least one conductor (54); as well as (f) heating the at least one insulating material (52) by at least one heating element (22) coupled to the at least one mold (12) to at least partially cure the at least one insulating material (52) when the at least one insulating material (52) is at least partially disposed in the at least one mold (12).

13. The method according to claim 12, wherein: At least one temperature of the at least one heating element and / or at least one temperature of the at least one insulating material (52) and / or at least one heating duration of the at least one heating element (22) are regulated by at least one controller (34).

14. The method according to claim 13, wherein: The at least one temperature and / or the at least one heating duration are adjusted by the at least one controller (34) according to one or more temperature profiles and / or one or more heating duration profiles, respectively.

15. The method according to any one of claims 12 to 14, wherein The sections of the insulating material (52) are selectively heated, in particular independently of one another, in particular such that the sections of the insulating material (52) are heated to different temperatures and / or for different heating durations.

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