Apparatus and method for manufacturing components of a transformer system

Abstract

This 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 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) 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 solidify 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). This disclosure also relates to a method for at least partially manufacturing at least one component (50) of a transformer system.

Description

Background Technology

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

[0002] During the casting process, casting material in a substantially liquid state 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 can then solidify (e.g., harden) within the mold. The solidified portions (also referred to as castings) are ejected from or removed from the mold after solidification.

[0003] Casting materials can be actively solidified by cooling and / or heating the casting material in the mold. For example, curable materials (such as resins and / or other thermosetting materials) can be used as casting materials. After the curable material has been introduced into the mold, the curable material can be at least partially cured (e.g., crosslinked) by applying heat to it, so that the curable material is at least partially solidified.

[0004] In the known prior art, the corresponding mold, which includes the casting material, is typically placed at least partially in a heated environment (e.g., inside a convection oven) to at least partially solidify the casting material.

[0005] In known prior art, applying heat to the casting material is performed in a relatively inefficient manner. This can lead to relatively high energy consumption, thereby increasing the cost of manufacturing the corresponding parts. In particular, energy prices often fluctuate in response to changes and / or events such as economic and / or crises, which can lead to energy price increases. Indeed, energy prices have recently risen relatively significantly. Therefore, due to the aforementioned relatively high energy consumption, the economics of manufacturing parts by casting and curing are relatively susceptible to rising energy prices. This can also reduce the sustainability of casting and curing when using equipment and processes known from the prior art.

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

[0007] The above aspects have not been solved or at least not adequately solved in the existing technology.

[0008] Therefore, this disclosure describes one or more aspects of addressing one or more of the disadvantages identified above.

[0009] This disclosure relates to an apparatus according to the first aspect of this disclosure.

[0010] According to the second aspect, a method is described in this disclosure.

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

[0012] Various exemplary embodiments of this disclosure are provided with features that will become readily apparent from the following description when understood in conjunction with the accompanying drawings. Exemplary apparatuses are disclosed herein according to various embodiments. However, it should be understood that these embodiments are presented by way of example and not limitation, and that various modifications can be made to the disclosed embodiments while remaining within the scope of this disclosure, as will be apparent to those skilled in the art who read this disclosure.

[0013] Therefore, this 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 methods. The specific order or hierarchy of steps in the disclosed methods or processes may be rearranged based on design preferences while remaining within the scope of this disclosure. Therefore, those skilled 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, this disclosure is not limited to the specific order or hierarchy presented. Summary of the Invention

[0014] In the following, exemplary embodiments of this disclosure will be described. It should be noted that, unless otherwise stated or obvious, some aspects of any of the described embodiments may also be found in some other embodiments. However, for the sake of understanding, each aspect will be described in detail only upon its first mention, and any repeated descriptions of the same aspect will be omitted.

[0015] The apparatus according to a first aspect of this disclosure can be configured for at least partially manufacturing at least one component, particularly at least one component of a transformer system. The apparatus may include at least one mold. The mold may be configured to at least partially contain at least one insulating material, particularly at least one electrically insulating material. The at least one insulating material may be configured to at least partially insulate at least one conductor, particularly at least one electrical conductor, and in particular, to electrically insulate it.

[0016] The at least one mold may include one or more cavities configured to at least partially and / or at least temporarily accommodate or receive the at least one insulating material, particularly accommodating or receiving both the at least one insulating material and the at least one conductor simultaneously.

[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 it when the at least one insulating material is at least partially disposed in the at least one mold and the at least one heating element is operatively coupled to at least one section of the at least one mold. In curing apparatuses and processes known from the prior art, the corresponding mold comprising 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 primarily on thermal convection via atmospheric gases (e.g., air) in 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 this disclosure, allows 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. Therefore, thermal convection, which is a resistance to heat transfer, is substantially eliminated or at least reduced in the heat transfer from the heat generated by the at least one heating element to the at least one insulating material.

[0019] For example, compared to known prior art solutions, particularly those employing convection ovens, this improves the efficiency and / or effectiveness of heat transfer from the at least one heating element to the at least one insulating material. Furthermore, compared to the prior art, the at least one heating element described herein reduces the overall heat mass being heated, such as the material of the oven and / or the amount of air within the oven, which can be omitted according to this disclosure. Moreover, configuring the at least one heating element to be coupled to the at least one mold according to this disclosure allows heat to be applied to the at least one insulating material in a more localized (e.g., closer and / or more direct) manner. This reduces energy consumption in the manufacturing process and thus lowers costs. For example, when casting and curing transformer system components using known apparatus and processes, such as for curing insulation material for transformer system windings, the manufacture of these transformer system components may require relatively large ovens and / or relatively large amounts of heat, and these transformer components may 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 offers significant advantages compared to the prior art, as described above.

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

[0021] Compared to known prior art solutions (e.g., convection ovens), configuring the at least one heating element to be coupled to the at least one mold allows for more precise customization and / or targeting of heat application via the at least one heating element. For example, this allows for changing and / or individually configuring heat application. For example, this allows for applying more heat to at least one first region than to at least one second region, for example, by appropriately arranging and / or operating the heating elements(s). For example, this allows for providing more heat, for example, 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 experiencing greater heat loss during curing, such as 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, for example, at higher temperatures and / or for longer durations.

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

[0023] Alternatively, the apparatus described herein can be implemented in an already available mold (e.g., a mold already used in solutions known from the prior art), where the mold is placed in an oven for curing. Thus, an available mold can be modified, for example, by connecting the at least one heating element to the corresponding mold, to provide an apparatus 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 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. Optionally, 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 may be configured to at least partially contain both the at least one conductor and the at least one insulating material simultaneously, for example, such that when the at least one conductor and the at least one insulating material are at least partially contained / received within the at least one mold, the at least one insulating material may be heated and at least partially cured. This allows the at least one insulating material to at least partially cure, i.e., solidify, thereby placing it in a state where 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 segment of the at least one conductor. This allows 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, for use as an (electrically) insulating conductor assembly, e.g., an (electrically) insulating winding of a transformer. Therefore, it may not be necessary to (further) assemble the at least one conductor and the at least one insulating material. Alternatively, the at least one insulating material may be cast and cured in 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, for example, 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 can form at least one (electrically) insulating conductor.

[0027] The apparatus described herein can be configured to at least partially manufacture several different components of a transformer system. For example, the apparatus can be configured to at least partially manufacture one or more insulated windings of a transformer system. The one or more windings may 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 other components of a transformer system, such as any conductive components, particularly electrically conductive components, including insulating materials, especially electrical insulating materials.

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

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

[0031] The at least one heating element may 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 may 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 may 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 may be manufactured such that the at least one heating element may be at least partially disposed within the at least one wall. For example, the at least one wall may be made of a plurality of wall layers, wherein the at least one heating element may be at least partially disposed between adjacent wall layers.

[0032] The transformer can be configured as any type of transformer. For example, the transformer can be configured as a traction transformer, particularly for use on railway vehicles, specifically to supply power to railway vehicles. Alternatively or additionally, the transformer can 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 multiple mold segments assembled and / or integrally formed. For example, the at least one mold may include at least one outer mold segment and at least one inner mold segment. At least one cavity may be defined between the at least one outer mold segment and the at least one inner mold segment. The at least one cavity may be configured to receive / accommodate the at least one insulating material.

[0035] The at least one mold, more specifically the at least one cavity, may be at least partially exposed to the environment. Alternatively, the at least one mold, more specifically the at least one cavity, may be enclosed to protect it from environmental influences.

[0036] When the at least one insulating material is introduced into the at least one mold, it may be in a substantially liquid state. When the at least one insulating material is introduced into the at least one mold, it may be preheated and / or partially precured.

[0037] The at least one heating element may be configured to be connected 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 allows 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. Therefore, thermal convection, which is a resistance to heat transfer, can be substantially eliminated or at least reduced in the heat transfer from the at least one heating element to the at least one insulating material. The at least one heating element may be directly or indirectly attached 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 there is substantially no air gap between the at least one heating element and the at least one mold, and particularly 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 facing 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 elements 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 facing and / or 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 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 cavities being configured to receive / 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 may be configured as a flat heating element, particularly a strip heating element or a ribbon heating element. For example, the at least one heating element may be configured as a thick film heater or a thin film heater.

[0043] The at least one heating element can be configured to generate various amounts of heat. For example, the at least one heating element can have a maximum output heating power of at least 1 kW, particularly at least 2 kW, particularly at least 3 kW, particularly at least 4 kW, particularly at least 5 kW, particularly at least 6 kW, particularly at least 7 kW, particularly at least 8 kW, particularly at least 9 kW, particularly at least 10 kW or greater. The at least one heating element can have a maximum output heating power density per surface of the at least one heating element of at least 500 W / m². 2 Especially at least 1 kW / m 2 Especially at least 1.5 kW / m 2 Especially at least 2 kW / m 2 Especially at least 2.5 kW / m 2 Especially at least 3 kW / m 2 Especially at least 3.5 kW / m 2 Especially at least 4 kW / m 2 Especially at least 4.5 kW / m 2 Especially at least 5 kW / m 2 Especially at least 5.5 kW / m 2 Especially at least 6 kW / m 2 Especially at least 6.5 kW / m 2 Especially at least 7 kW / m 2 Especially at least 7.5 kW / m 2 Especially at least 8 kW / m 2 In particular, at least 8.5 kW / m 2 Especially at least 9 kW / m 2 Especially at least 9.5 kW / m 2 Especially at least 10 kW / m 2 Or larger.

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

[0045] The at least one heating element can be configured to heat to temperatures of at least 150°C, particularly at least 175°C, particularly at least 200°C, particularly at least 225°C, particularly at least 250°C, particularly at least 275°C, particularly 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 a more uniform and / or more consistent application of the heat generated by the heating element to the at least one insulating material. For the purpose of storing and / or distributing at least a portion of the heat generated by the at least one heating element, the at least one stabilizing element may 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 allows 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 may be made of a variety of other materials, for example, materials with relatively high heat capacity and / or relatively high thermal conductivity.

[0047] The at least one stabilizing element may be connected to each other. 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 the 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 the 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 device may further include at least one thermally insulating element configured to at least partially thermally insulate at least one or more sections of the at least one mold. This reduces heat loss, thereby providing more efficient and / or more effective heating / curing of the at least one insulating material. The at least one thermally insulating element may be at least partially disposed on the exterior and / or surface of the at least one mold. Alternatively or additionally, the at least one thermally insulating element may be at least partially disposed on the interior and / or surface of the at least one mold.

[0049] The device 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 heat, in particular, individually, a plurality of segments of the at least one insulating material, for example, such that at least a first segment of the plurality of segments can be heated by at least a first heating element of the plurality of heating elements, and at least a second segment of the plurality of segments can be heated by at least a second heating element of the plurality of heating elements. The plurality of first heating elements and the plurality of second heating elements may be configured to heat the plurality of first segments and the plurality of second segments of the at least one insulating material to different temperatures and / or for different heating durations, respectively.

[0050] The device 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 allows 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 allows for changing and / or individually configuring heat application, as described above.

[0051] The at least one controller can be configured to control the at least one temperature and / or the at least one heating duration, particularly in a closed-loop manner. This allows for more precise and / or targeted heating of the at least one insulating material, for example, based on 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 may be configured to adjust and / or control the at least one temperature and / or the at least one heating duration based on one or more temperature profiles and / or one or more heating duration profiles, respectively. The one or more temperature profiles and / or the one or more heating duration profiles may define the at least one temperature and / or the at least one heating duration over time t. This allows 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 particular application. The device may 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 allow, for example, manual (e.g., by a 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 one or more heating duration profiles can 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 each other. 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 heated for different durations.

[0057] The at least one controller and / or the at least one heating element may 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 elements may be heated to a higher temperature than one or more second sections of that one of the at least one heating elements. Alternatively or additionally, multiple at least one heating element may be provided, and one or more first heating elements of the multiple heating elements may be heated to a higher temperature than one or more second heating elements of the multiple heating elements.

[0058] The at least one heating element can be configured to be electrically driven.

[0059] The at least one mold may be made at least partially, and particularly entirely, of metal. However, the at least one mold may be made of any suitable (multiple) materials, such as one or more composite materials. The at least one mold may be made by one or more suitable manufacturing methods, such as 3D printing. The at least one mold may be made of one or more materials having 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 thereof, may be configured for vacuum casting.

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

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

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

[0064] The method may include:

[0065] (a) At least one insulating material is arranged at least partially in at least one mold, the at least one insulating material being configured to at least partially insulate at least one conductor.

[0066] The method may further include:

[0067] (b) When the at least one insulating material is at least partially arranged in the at least one mold, the at least one insulating material is heated by at least one heating element connected to the at least one mold to at least partially cure the at least one insulating material.

[0068] 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 may be adjusted by at least one controller.

[0069] The at least one temperature can be sensed by at least one temperature sensor. Data related to the at least one temperature can be provided to the at least one controller.

[0070] 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 curves and / or one or more heating duration curves, respectively.

[0071] Multiple sections of the insulating material can be selectively heated, particularly in a manner that is independent of each other, such that these multiple sections of the insulating material can be heated to different temperatures and / or heated for different durations.

[0072] Different amounts of heat and / or different heating durations can be applied to multiple sections of the insulation material.

[0073] The following list of aspects provides alternatives and / or additional features of this disclosure:

[0074] 1. An apparatus for at least partially manufacturing at least one component, particularly at least one component of a transformer system, the apparatus comprising:

[0075] At least one mold configured to at least partially contain at least one curable material, particularly at least one insulating material configured to at least partially insulate at least one conductor; and

[0076] At least one heating element is configured to be coupled to the at least one mold and configured 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.

[0077] 2. The apparatus according to aspect 1, wherein the at least one mold includes at least one mold wall, and the at least one heating element is arranged to conduct heat to the at least one mold wall.

[0078] 3. The apparatus according to aspect 2, wherein the at least one heating element is configured to be disposed on at least one outer surface of the at least one mold wall.

[0079] 4. The apparatus according to any of the foregoing aspects, wherein the at least one heating element is configured as a flat heating element, particularly a strip heating element or a ribbon heating element.

[0080] 5. The apparatus according to any of the foregoing aspects further includes 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, wherein, in particular, the at least one stabilizing element is made of at least one ceramic material.

[0081] 6. The apparatus according to any of the foregoing aspects further includes at least one thermally insulating element configured to at least partially thermally insulate at least one or more sections of the at least one mold, particularly wherein the at least one thermally insulating element is at least partially disposed on the exterior and / or exterior of the at least one mold.

[0082] 7. An apparatus according to any of the foregoing aspects, comprising a plurality of the at least one heating element configured to heat a plurality of sections of the at least one curable material.

[0083] 8. The apparatus according to any of the foregoing aspects further includes 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.

[0084] 9. The 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, particularly in a closed-loop manner.

[0085] 10. The apparatus according to aspect 8 or 9 further includes 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.

[0086] 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.

[0087] 12. The 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 a plurality of sections of the curable material in a manner particularly independent of each other, particularly such that the plurality of sections of the curable material are heated to different temperatures and / or heated for different durations.

[0088] 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 multiple sections of the curable material.

[0089] 14. The apparatus according to any of the foregoing aspects, wherein the at least one heating element is configured to be electrically driven.

[0090] 15. An apparatus according to any of the foregoing aspects, wherein the at least one mold is at least partially, and in particular entirely, made of metal.

[0091] 16. The apparatus according to any of the foregoing aspects, wherein the at least one mold is configured for vacuum casting.

[0092] 17. The apparatus according to any of the foregoing aspects, wherein the at least one curable material comprises at least one resin, particularly at least one epoxy resin.

[0093] 18. A method for manufacturing at least one component of a transformer system, particularly by means of any one of the foregoing aspects, comprising:

[0094] (c) Arranging at least one curable material, particularly at least one insulating material, at least partially in at least one mold, the at least one insulating material being configured to at least partially insulate at least one conductor; and

[0095] (d) When the at least one curable material is at least partially arranged in the at least one mold, the at least one curable material is heated by at least one heating element connected to the at least one mold to at least partially cure the at least one curable material.

[0096] 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 is adjusted by at least one controller.

[0097] 20. The method according to 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.

[0098] 21. The method according to aspect 19 or 20, wherein the at least one temperature and / or the at least one heating duration is adjusted by the at least one controller according to one or more temperature curves and / or one or more heating duration curves, respectively.

[0099] 22. The method according to any one of aspects 18 to 21, wherein a plurality of sections of the at least one curable material are selectively heated in a manner independent of each other, particularly such that the plurality of sections of the at least one curable material are heated to different temperatures and / or heated for different durations.

[0100] 23. The method according to any one of aspects 18 to 22, wherein different amounts of heat and / or different heating durations are applied to multiple sections of the at least one curable material. Attached Figure Description

[0101] The subject matter of this disclosure will be explained in more detail with reference to the preferred exemplary embodiments illustrated in the accompanying drawings.

[0102] Figure 1 A cross-sectional view schematically illustrates an apparatus for at least partially manufacturing at least one component of a transformer system according to an embodiment of the present disclosure;

[0103] Figure 2 A longitudinal sectional view schematically illustrates an apparatus for at least partially manufacturing at least one component of a transformer system according to another embodiment of the present disclosure;

[0104] Figure 3 A cross-sectional view schematically illustrates an apparatus for at least partially manufacturing at least one component of a transformer system according to another embodiment of the present disclosure;

[0105] Figure 4 A cross-sectional view schematically illustrates an apparatus for at least partially manufacturing at least one component of a transformer system according to another embodiment of the present disclosure;

[0106] Figure 5 The components, at least in part, manufactured by the device according to any configuration described herein are shown schematically in longitudinal sectional view. Detailed Implementation

[0107] Figure 1 A cross-sectional view schematically illustrates an apparatus 10 for at least partially manufacturing at least one component of a transformer system according to an embodiment of the present disclosure. 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.

[0108] The at least one mold 12 may include multiple mold segments that can be assembled and / or integrally formed. For example... Figure 1 As shown, 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 arranged at least partially within the at least one outer mold section 14.

[0109] 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 receive / accommodate the at least one insulating material.

[0110] The at least one mold 12 (e.g., the at least one outer mold section 14 and / or the at least one inner mold section 16) may include at least one mold wall 20A, 20B, for example, such as Figure 1 At least one mold sidewall 20A, 20B shown.

[0111] The device 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.

[0112] The at least one heating element 22 may be deformable, such as 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 at least one contour of the at least one mold 12 (e.g., inner contour and / or outer contour). The at least one heating element 22 may be configured to be electrically driven. The at least one heating element 22 may be configured as a flat heating element, particularly a strip heating element or a ribbon heating element.

[0113] 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 disposed on at least one outer surface 26 of the mold wall 20A, such as... Figure 1 As illustrated in the example, the at least one heating element 22 may extend substantially around the entire circumference of the at least one core 12, such as... Figure 1 As shown in the diagram. 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, the plurality of heating elements being distributed around at least a portion of the circumference of the at least one core 12 (see...). Figure 4 (and further corresponding descriptions below).

[0114] The device 10 may further include at least one thermally insulating element (not shown) configured to at least partially thermally insulate at least one or more sections of the at least one mold 12. This reduces heat loss, thereby providing more efficient and / or more effective heating / curing of the at least one insulating material.

[0115] like Figure 2 As shown, the device 10 may include a plurality of heating elements 22, that is, a plurality of the elements mentioned above. Figure 1 The at least one heating element 22 is described. The heating elements 22 may be arranged in different locations. In particular, the heating elements 22 may be distributed, for example, such that the heating elements 22 are spaced apart from each other.

[0116] like Figure 2 As shown, 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 delineate the at least one cavity 18.

[0117] As shown in the figures, the at least one heating element 22 may 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 may 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.

[0118] For example Figure 1 and Figure 2 As shown, the at least one heating element 22 may be attached to or configured to be attached to the at least one mold 12 at its exterior and / or on its exterior. For example, the at least one heating element 22 may be attached to or configured to be attached to the at least one mold 12 on the side of the at least one wall 20A, 20B of the at least one mold 12 facing away from the at least one cavity 18 and / or on the side of the at least one wall 20A, 20B of the at least one mold 12 facing the at least one cavity 18.

[0119] 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 inside and / or on the interior of the at least one mold 12, such as Figure 3 As shown in the image.

[0120] Alternatively or additionally, the at least one heating element 22 may be configured to be integrally connected 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 may be arranged within at least one 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 may be manufactured such that the at least one heating element 22 is arranged within the at least one wall 20A, 20B. For example, the at least one wall 20A, 20B may be made of multiple wall layers, wherein the at least one heating element 22 may be at least partially arranged between adjacent wall layers of the at least one wall 20A, 20B.

[0121] The device 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 connected to the at least one heating element 22, for example wirelessly and / or via a hard connection.

[0122] The at least one controller 34 may 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 may be configured to heat one or more first sections of a heating element 22 to one or more temperatures 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 may be configured such that one or more first heating elements among the plurality of heating elements 22 can be heated to a higher temperature than one or more second heating elements among the plurality of heating elements 22. Alternatively, the device 10 may include a plurality of controllers 34, wherein each controller 34 may be configured to control one or more different heating elements among the plurality of heating elements 22.

[0123] The at least one controller 34 may be configured to adjust and / or control the at least one temperature and / or the at least one heating duration based on one or more temperature profiles and / or one or more heating duration profiles, respectively. The one or more temperature profiles and / or the one or more heating duration profiles may define the at least one temperature and / or the at least one heating duration over time t. This allows 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 particular application. The device 10 (e.g., the at least one controller 34) may 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 allow, for example, manual (e.g., by a 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.

[0124] The device 10 may further include 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, such as Figure 4 As shown in the diagram. The at least one stabilizing element 38 can provide a more uniform and / or more consistent way to apply the heat generated by the at least one heating element 22 to the at least one insulating material. For the purpose of storing and / or distributing at least a portion of the heat generated by the at least one heating element, the at least one stabilizing element 38 may 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 allows 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 may be made of a variety of other materials, for example, materials with a relatively high heat capacity and / or a relatively high thermal conductivity.

[0125] Figures 1 to 4 The features of the embodiments can also be combined in various configurations. For example, the device 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 the outside and / or outside, 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 the inside and / or inside.

[0126] Figure 5Component 50 is schematically shown in a longitudinal sectional view. This component is at least partially manufactured by device 10 according to any of the configurations described herein, for example, as... Figures 1 to 4 As shown in the diagram. Component 50 may include at least one insulating material 52 (e.g., the at least one insulating material described above), which may be received / accommodated in the at least one mold 12 of the device 10, as described above. Component 50 may further include at least one conductor 54, which may also be received / accommodated in the at least one mold 12 of the device 10, as described above. In other words, the at least one mold 12 may be configured to at least partially and / or at least temporarily simultaneously accommodate 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 includes at least one resin, particularly at least one epoxy resin.

[0127] In a substantially liquid state, 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. When the at least one conductor 54 is introduced into the at least one mold 12, the at least one conductor 54 can be in a substantially solid state. 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 solidified by heat generated by the at least one heating element 22 of the device 10, so that the at least one insulating material 52 is at least partially solidified.

[0128] This allows the at least one insulating material 52 to at least partially solidify (i.e., solidify), thereby placing it in a state where the at least one insulating material 52 at least partially surrounds the at least one conductor 54, such that the at least one insulating material 52 can provide insulation, such as electrical insulation, to at least one segment of the at least one conductor 54. Figure 5 As shown in the diagram. In other words, the at least one conductor 54 and the at least one insulating material 52 can form at least one (electrically) insulating conductor. The at least one conductor 54 can be configured to be connected to at least one voltage power source and / or at least one load, for example, via at least one connector (not shown).

[0129] Once the at least one insulating material 52 has been at least partially cured, the at least one partially cured insulating material 52 can be removed from the at least one mold 12.

[0130] The apparatus 10 described herein can be configured to at least partially manufacture several 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 turns around at least one winding axis. The winding can be introduced into the at least one mold 12 in a wound state.

[0131] Alternatively or additionally, the device 10 described herein may be configured to at least partially manufacture several other components of a transformer system, such as any conductive components, particularly electrically conductive components, including insulating materials, especially electrical insulating materials.

[0132] While various embodiments of this 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 exemplary architectures or configurations, provided to enable those skilled in the art to understand the exemplary features and functionality of this disclosure. However, such persons will understand that this disclosure is not limited to the illustrated exemplary architectures or configurations, but can be implemented using various alternative architectures and configurations. Additionally, as those skilled in the art will understand, one or more features of one embodiment may be combined with one or more features of another embodiment described herein. Therefore, the breadth and scope of this disclosure should not be limited to any of the exemplary embodiments described above.

[0133] It should also be understood that any reference to elements in this document using names such as "first," "second," etc., generally does not restrict the number or order of those elements. Rather, these names may be used herein as a convenient means of distinguishing between two or more elements or instances of elements. Therefore, references to the first element and the second element do not imply that only two elements may be used, or that the first element must somehow precede the second element.

[0134] 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 can be applied to other embodiments without departing from the scope of this disclosure. Therefore, this disclosure is not intended to be limited to the embodiments shown herein, but is to be endowed with the widest scope consistent with the novel features and principles disclosed herein, as set forth in the appended claims.

Claims

1. An apparatus (10) for at least partially manufacturing at least one component (50) of a transformer system, the apparatus comprising: At least one mold (12), said at least one mold (12) being 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 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), wherein the at least one heating element (22) is flexible and / or bendable.

2. The apparatus (10) according to claim 1, wherein, The at least one mold (12) includes 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 apparatus (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 apparatus (10) according to any one of the preceding claims, wherein, The at least one heating element (22) is configured as a flat heating element, particularly a strip-shaped heating element or a ribbon-shaped heating element.

5. The apparatus (10) according to claim 1, further comprising at least one stabilizing element (38), the at least one stabilizing element being 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), particularly wherein, The at least one stabilizing element (38) is made of at least one ceramic material.

6. The apparatus (10) according to claim 1, the apparatus comprising a plurality of the at least one heating element (22) configured to heat a plurality of sections of the at least one insulating material (52).

7. The apparatus (10) according to claim 1, the apparatus further comprising at least one controller (34) configured to adjust at least one temperature of at least one portion of at least one heating element (22) and / or at least one temperature of at least one insulating material (52) and / or at least one heating duration of at least one heating element (22).

8. The apparatus (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 apparatus (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 multiple sections of the insulating material (52) in a manner particularly independent of each other, such that the multiple sections of the insulating material (52) are heated to different temperatures and / or heated for different durations.

10. The apparatus (10) according to any one of claims 7 or 8, 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 apparatus according to claim 1, wherein, The at least one heating element is configured to be electrically driven.

12. A method for manufacturing at least one component (50) of a transformer system, particularly by means (10) according to any one of the preceding claims, the method comprising: (e) At least one insulating material (52) is arranged at least partially in at least one mold (12), said at least one insulating material being configured to at least partially insulate at least one conductor (54); as well as (f) When the at least one insulating material (52) is at least partially disposed in the at least one mold (12), the at least one insulating material (52) is heated 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), wherein the at least one heating element (22) is flexible and / or bendable.

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 adjusted 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 claim 12, wherein, The multiple sections of the insulating material (52) are selectively heated in a manner that is independent of each other, such that the multiple sections of the insulating material (52) are heated to different temperatures and / or heated for different durations.

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