Winding method of low-voltage coil, low-voltage coil and dry-type transformer
By setting two conductors in each group of conductors and fixing them together, the problem of processing difficulty and cost caused by the increase in the volume of a single conductor is solved, and the current carrying capacity and stability of the low-voltage coil are increased.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- GUANGDONG MINGYANG ELECTRIC CO LTD
- Filing Date
- 2026-01-05
- Publication Date
- 2026-04-17
AI Technical Summary
In existing technologies, as the voltage on the low-voltage side of a dry-type transformer remains constant while the current on the low-voltage side increases, the volume of a single conductor busbar increases, leading to increased processing difficulty, higher procurement costs, and longer production cycles.
Two busbars are set in each group of busbars and fixedly connected by fasteners to increase the cross-sectional area of the busbars to increase the current carrying capacity, while keeping the volume of a single busbar unchanged.
By adding conductor busbars, the current carrying capacity of the low-voltage coil is increased, the processing difficulty and procurement cost are reduced, and the volume stability of a single conductor busbar is maintained.
Smart Images
Figure CN121885397A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of transformer technology, and in particular to a method for winding a low-voltage coil, the low-voltage coil, and a dry-type transformer. Background Technology
[0002] In recent years, the capacity of dry-type transformers has been increasing, while the system voltage on the low-voltage side remains unchanged, resulting in a larger and larger phase current in the low-voltage coil. To meet the current carrying capacity requirements of the transformer's low-voltage coil, the volume of a single conductor busbar has been increasing. The increase in the size of a single conductor busbar has the following disadvantages: (1) increased processing difficulty; (2) correspondingly higher procurement price; (3) longer procurement cycle.
[0003] Therefore, it is necessary to improve the winding method of the low-voltage coil while keeping the volume of a single conductor busbar unchanged, in order to meet the current carrying capacity requirements of the transformer's low-voltage coil. Summary of the Invention
[0004] This invention aims to at least partially solve one of the technical problems in the related art. Therefore, one object of this invention is to provide a method for winding a low-voltage coil, a low-voltage coil, and a dry-type transformer, which can increase the current carrying capacity of the low-voltage coil while maintaining the same volume of a single conductor busbar.
[0005] The technical solution adopted in this invention is:
[0006] In a first aspect, the present invention provides a method for winding a low-voltage coil, comprising: fixing a first conductive busbar and a second conductive busbar together, the first conductive busbar and the second conductive busbar forming a first conductive busbar group; using a foil winding machine to wind a first section of foil onto a mold and the first conductive busbar group; after winding is completed, fixing a third conductive busbar onto the first conductive busbar group, and then fixing a fourth conductive busbar onto the third conductive busbar, the third conductive busbar and the fourth conductive busbar forming a second conductive busbar group; using the foil winding machine to wind a second section of foil onto the mold and the second conductive busbar group; after winding is completed, removing the mold, and the low-voltage coil is manufactured.
[0007] The method of fixing the first conductive busbar and the second conductive busbar together to form a first conductive busbar group includes: placing the second conductive busbar on the first conductive busbar, with the second conductive busbar and the first conductive busbar spaced apart; fixing the first conductive busbar and the second conductive busbar together with a first fixing member; and aligning and fixing the first conductive busbar and the second conductive busbar along the width direction with a second fixing member.
[0008] The method of using a foil winding machine to wind the first section of foil onto the mold and the first conductive busbar assembly includes: placing the first conductive busbar assembly on the positioning groove of the mold; welding the first section of foil onto the second conductive busbar; and winding the first section of foil onto the first conductive busbar assembly.
[0009] The process includes: after the winding is completed, fixing the third conductive busbar to the first conductive busbar group, and then fixing the fourth conductive busbar to the third conductive busbar. This includes: after the winding is completed, trial-assembling and positioning the third conductive busbar and the first conductive busbar group; replacing the first fixing member with an insulator and fixing the third conductive busbar to the first conductive busbar group through the insulator; placing the fourth conductive busbar on the third conductive busbar, aligning and fixing the third conductive busbar and the fourth conductive busbar along the width direction using the third fixing member; and replacing the insulator with the first fixing member and fixing the first conductive busbar group and the second conductive busbar group through the first fixing member.
[0010] The process of using the foil winding machine to wind the second foil segment onto the mold and the second conductive busbar assembly includes: welding the second foil segment onto the fourth conductive busbar; and winding the second foil segment onto the second conductive busbar assembly.
[0011] The process includes: after the winding is completed, the mold is removed, and the low-voltage coil is completed. This includes: replacing the first fixing component with the insulator; after the winding is completed, the second fixing component, the third fixing component, and the mold are removed, and the low-voltage coil is completed.
[0012] Secondly, the present invention provides a low-voltage coil, comprising: a first conductive busbar assembly, including a first conductive busbar and a second conductive busbar fixedly connected; a first foil segment welded and wound onto the first conductive busbar assembly; a second conductive busbar assembly disposed above the end segment of the first foil segment, including a third conductive busbar and a fourth conductive busbar, the second conductive busbar assembly being fixedly connected to the first conductive busbar assembly by a first fixing member; and a second foil segment welded and wound onto the second conductive busbar assembly.
[0013] The second conductive bus is disposed on top of the first conductive bus, and the second conductive bus is spaced apart from the first conductive bus; the first conductive bus and the second conductive bus are fixed together by the first fixing member.
[0014] The third conductive busbar is disposed on top of the second conductive busbar, and the third conductive busbar is spaced apart from the second conductive busbar; the fourth conductive busbar is disposed on top of the third conductive busbar, and the fourth conductive busbar is spaced apart from the third conductive busbar; each conductive busbar has a corresponding positioning hole, the first fixing member passes through the positioning hole of each conductive busbar, and the third conductive busbar and the fourth conductive busbar are fixed together by the first fixing member.
[0015] Thirdly, the present invention provides a dry-type transformer, wherein a low-voltage coil is included, the low-voltage coil being manufactured using the winding method described above.
[0016] The beneficial effects of this invention are:
[0017] This invention improves upon existing low-voltage coil winding methods by incorporating two conductor bars in each group of conductor bars, compared to the current method of using only one conductor bar per group. This increases the cross-sectional area of the conductor bars, thereby increasing the current carrying capacity of the low-voltage coil. Furthermore, the volume of a single conductor bar remains unchanged, without increasing the complexity of the manufacturing process.
[0018] Furthermore, each of the multiple conductive bars has a corresponding positioning hole. The first fixing member passes through the positioning hole of each conductive bar and fixes the two conductive bars of each group of conductive bars together. At the same time, the first fixing member fixes the multiple groups of conductive bars together, which facilitates construction.
[0019] In addition, other fasteners are used during the winding process to align and fix the two conductive bars along the width direction, ensuring the structural stability of each set of conductive bars. Attached Figure Description
[0020] Figure 1 This is a schematic flowchart of an embodiment of the low-voltage coil winding method of the present invention;
[0021] Figure 2 yes Figure 1 A flowchart illustrating an embodiment of step S11;
[0022] Figure 3 yes Figure 1 A schematic diagram of the structure of an embodiment of step S11;
[0023] Figure 4 yes Figure 1 A flowchart illustrating an embodiment of step S12;
[0024] Figure 5 yes Figure 1 A schematic diagram of the structure of an embodiment of step S12;
[0025] Figure 6 yes Figure 1 A flowchart illustrating an embodiment of step S13;
[0026] Figure 7 yes Figure 1 A schematic diagram of the structure of an embodiment of step S13;
[0027] Figure 8 This is a perspective view of an embodiment of the low-voltage coil of the present invention;
[0028] Figure 9 yes Figure 8 A three-dimensional view from another angle;
[0029] Figure 10 This is an exploded structural diagram of an embodiment of the low-voltage coil of the present invention. Detailed Implementation
[0030] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other.
[0031] Example 1
[0032] Please see Figure 1 , Figure 1 This is a schematic flowchart of an embodiment of the low-voltage coil winding method of the present invention. Figure 1 As shown, the winding method includes the following steps:
[0033] S11: The first conductive busbar and the second conductive busbar are fixedly connected, and the first conductive busbar and the second conductive busbar form a first conductive busbar group;
[0034] like Figure 2 As shown, step S11 includes the following steps:
[0035] S111: The second conductive bus is disposed on top of the first conductive bus, and the second conductive bus is disposed at an interval from the first conductive bus.
[0036] like Figure 3 As shown, the first conductive bus group 1 includes a first conductive bus 11 and a second conductive bus 12. The width of the second conductive bus 12 is slightly smaller than the width of the first conductive bus 11.
[0037] S112: The first conductive busbar and the second conductive busbar are fixed together by a first fastener;
[0038] like Figure 3 As shown, the first fixing member 13 includes two sets of screws (only one set is shown in the figure) and two sets of nuts (not shown in the figure). Both the first conductive bus 11 and the second conductive bus 12 are provided with positioning holes. The positioning holes of the first conductive bus 11 and the second conductive bus 12 are aligned, and then the first conductive bus 11 and the second conductive bus 12 are fixedly connected by screws.
[0039] S113: The first conductive bar and the second conductive bar are aligned and fixed along the width direction using a second fastener.
[0040] like Figure 3 As shown, the second fastener 14 includes a first screw 141, a second screw 142, a first washer 143, a second washer (not shown), a first nut 144, a second nut (not shown), a third nut 145, and a fourth nut (not shown).
[0041] The first conductive busbar 11 and the second conductive busbar 12 are sandwiched between the first screw 141 and the second screw 142. A first gasket 143 is disposed at one end of the first conductive busbar 11 and the second conductive busbar 12 in the width direction, and a second gasket is disposed at the other end of the first conductive busbar 11 and the second conductive busbar 12 in the width direction.
[0042] The first washer 143 and the second washer each have two through holes (not shown in the figure). The first screw 141 passes through the first through hole of the first washer 143 and the first through hole of the second washer. The second screw 142 passes through the second through hole of the first washer 143 and the second through hole of the second washer. Tighten the first nut 144 to one end of the first screw 141 and the first washer 143, and tighten the third nut 145 to one end of the second screw 142 and the first washer 143, thereby aligning and fixing one end of the first conductive bus 11 and one end of the second conductive bus 12. Tighten the second nut to the other end of the first screw 141 and the second washer, and tighten the fourth nut to the other end of the second screw 142 and the second washer, thereby aligning and fixing the other end of the first conductive bus 11 and the other end of the second conductive bus 12.
[0043] S12: The first section of foil is wound onto the mold and the first conductive busbar using a foil winding machine;
[0044] like Figure 4 As shown, step S12 includes the following steps:
[0045] S121: Place the first conductive busbar assembly on the positioning groove of the mold;
[0046] like Figure 5 As shown, the mold 2 is provided with a positioning groove 21, and the first conductive busbar 1 is placed on the positioning groove 21.
[0047] S122: Solder the first foil segment onto the second conductive bus;
[0048] like Figure 5 As shown, the starting end of the first foil 3 is welded to the second conductive busbar 12.
[0049] S123: The first foil segment is wound onto the first conductive busbar.
[0050] Start the foil winding machine to wind the first section of foil onto the first conductive busbar group 1.
[0051] S13: After the winding is finished, the third conductive busbar is fixed to the first conductive busbar group, and then the fourth conductive busbar is fixed to the third conductive busbar. The third conductive busbar and the fourth conductive busbar form the second conductive busbar group.
[0052] The structure of the third conductive bus (not shown in the figure) is the same as that of the first conductive bus 11, and the structure of the fourth conductive bus (not shown in the figure) is the same as that of the second conductive bus 12.
[0053] like Figure 6 As shown, step S13 includes the following steps:
[0054] S131: After the winding is completed, the third conductive busbar is trial-assembled and positioned with the first conductive busbar group;
[0055] like Figure 7 As shown, the positioning hole of the third conductive busbar is aligned with the positioning hole of the first conductive busbar group 1, and the third conductive busbar is aligned with the first conductive busbar group 1 in the width direction.
[0056] S132: Replace the first fixing member with an insulator, and fix the third conductive bus to the first conductive bus group through the insulator;
[0057] The purpose of using insulators is to facilitate positioning.
[0058] S133: Place the fourth conductive busbar on the third conductive busbar, and use a third fastener to align and fix the third conductive busbar and the fourth conductive busbar along the width direction;
[0059] The third and fourth conductive busbars are aligned and fixed along the width direction using a third fastener 41. The structure of the third fastener 41 is the same as that of the second fastener 14.
[0060] S134: Replace the insulator with the first fixing member, and fix the first conductive bus group and the second conductive bus group through the first fixing member.
[0061] After placing the fourth conductive outlet on the third conductive outlet, the insulator is removed and the first fixing member is replaced.
[0062] Each conductive busbar has a corresponding positioning hole. The first fixing member is passed through the positioning hole of each conductive busbar. The first conductive busbar group and the second conductive busbar group are fixed together by the first fixing member. The first conductive busbar and the second conductive busbar are fixed together by the first fixing member. The third conductive busbar and the fourth conductive busbar are fixed together by the first fixing member.
[0063] Among them, a protective cardboard 5 is placed below the third conductive busbar to prevent solder slag from falling into the coil.
[0064] S14: The foil winding machine is used to wind the second foil section onto the mold and the second conductive busbar assembly;
[0065] First, the starting segment of the second foil 6 is welded to the fourth conductive busbar, and then the second foil 6 is wound around the second conductive busbar group 4.
[0066] S15: After winding, remove the mold; the low-voltage coil is now complete.
[0067] like Figure 8 As shown, after the winding is completed, the first fixing member 13 is replaced with the insulator.
[0068] Remove the second fixing component 14, the third fixing component 41, the mold 2, and the protective cardboard 5, and the low-voltage coil is completed.
[0069] Example 2
[0070] Please refer to the following: Figures 8 to 10 The low-voltage coil includes a first conductive busbar group 1, a first foil segment 3, a second conductive busbar group 4, and a second foil segment 6.
[0071] The first conductive busbar group 1 includes a first conductive busbar 11 and a second conductive busbar 12 fixedly connected. The second conductive busbar 12 is disposed on the first conductive busbar 11, and the second conductive busbar 12 is spaced apart from the first conductive busbar 11; the first conductive busbar 11 and the second conductive busbar 12 are fixed together by the first fixing member 13.
[0072] The first foil segment 3 is welded and wound onto the first conductive busbar 1. Preferably, the first foil segment 3 is welded onto the second conductive busbar 12.
[0073] The second conductive busbar group 4 is disposed above the end section of the first foil 3. The second conductive busbar group 4 includes a third conductive busbar 41 and a fourth conductive busbar 42. The second conductive busbar group 4 is fixedly connected to the first conductive busbar group 1 by the first fixing member 13.
[0074] The second foil segment 6 is welded and wound onto the second conductive busbar group 4. Preferably, the second foil segment 6 is welded onto the fourth conductive busbar 42.
[0075] Preferably, the third conductive bus 41 is disposed on the second conductive bus 12, and the third conductive bus 41 and the second conductive bus 12 are disposed at intervals.
[0076] The fourth conductive bus 42 is disposed on the third conductive bus 41, and the fourth conductive bus 42 and the third conductive bus 41 are disposed at intervals.
[0077] Each conductive bar has a corresponding positioning hole. The first fixing member 13 passes through the positioning hole of each conductive bar. The third conductive bar 41 and the fourth conductive bar 42 are fixed together by the first fixing member 13.
[0078] Preferably, the first fixing member 13 is an insulator.
[0079] Example 3
[0080] The present invention also provides a dry-type transformer, which includes a low-voltage coil manufactured using the winding method described in Embodiment 1.
[0081] The above is a detailed description of the preferred embodiments of the present invention. However, the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention. All such equivalent modifications or substitutions are included within the scope defined by the claims of this application.
Claims
1. A method for winding a low-voltage coil, characterized in that, include: The first conductive busbar and the second conductive busbar are fixedly connected, and the first conductive busbar and the second conductive busbar form a first conductive busbar group; A foil winding machine is used to wind the first section of foil onto the mold and the first conductive busbar assembly; After the winding is completed, the third conductive busbar is fixed to the first conductive busbar group, and then the fourth conductive busbar is fixed to the third conductive busbar. The third conductive busbar and the fourth conductive busbar form the second conductive busbar group. The second foil segment is wound onto the mold and the second conductive busbar using the foil winding machine. After the winding is completed, the mold is removed, and the low-voltage coil is manufactured.
2. The winding method according to claim 1, characterized in that, The step of fixing the first conductive busbar and the second conductive busbar together to form a first conductive busbar group includes: The second conductive bus is disposed on top of the first conductive bus, and the second conductive bus and the first conductive bus are spaced apart; The first conductive busbar and the second conductive busbar are fixed together using a first fastener; The first conductive bar and the second conductive bar are aligned and fixed along the width direction using a second fastener.
3. The winding method according to claim 2, characterized in that, The step of winding the first foil section onto the mold and the first conductive busbar assembly using a foil winding machine includes: Place the first conductive busbar assembly on the positioning groove of the mold; The first foil segment is welded onto the second conductive busbar; The first foil segment is wound onto the first conductive busbar.
4. The winding method according to claim 3, characterized in that, After the winding is completed, the third conductive busbar is fixed to the first conductive busbar group, and then the fourth conductive busbar is fixed to the third conductive busbar, including: After the winding is completed, the third conductive busbar and the first conductive busbar group are trial-assembled and positioned. Replace the first fixing member with an insulator, and use the insulator to fix the third conductive busbar to the first conductive busbar group; The fourth conductive busbar is placed on the third conductive busbar, and the third conductive busbar and the fourth conductive busbar are aligned and fixed along the width direction using a third fastener; The insulator is replaced with the first fixing member, and the first conductive busbar group and the second conductive busbar group are fixedly connected by the first fixing member.
5. The winding method according to claim 4, characterized in that, The step of winding the second foil section onto the mold and the second conductive busbar using the foil winding machine includes: The second foil segment is welded onto the fourth conductive bus; The second foil segment is wound onto the second conductive busbar.
6. The winding method according to claim 5, characterized in that, After winding is completed, the mold is removed, and the low-voltage coil is manufactured, including: After the winding is completed, the first fixing member is replaced with the insulator; The second fixing member, the third fixing member, and the mold are removed, and the low-voltage coil is completed.
7. A low-voltage coil, characterized in that, include: The first conductive bus group includes a first conductive bus and a second conductive bus that are fixedly connected. The first foil segment is welded and wound onto the first conductive busbar assembly; The second conductive bus group is disposed above the end section of the first foil segment, and includes a third conductive bus and a fourth conductive bus. The second conductive bus group and the first conductive bus group are fixedly connected by a first fastener. The second foil is welded and wound onto the second conductive busbar assembly.
8. The low-voltage coil according to claim 7, characterized in that, The second conductive busbar is disposed on top of the first conductive busbar, and the second conductive busbar and the first conductive busbar are spaced apart; the first conductive busbar and the second conductive busbar are fixed together by the first fixing member.
9. The low-voltage coil according to claim 7, characterized in that, The third conductive bus is disposed on top of the second conductive bus, and the third conductive bus is spaced apart from the second conductive bus. The fourth conductive bus is disposed on top of the third conductive bus, and the fourth conductive bus is disposed at a distance from the third conductive bus; Each conductive bar has a corresponding positioning hole. The first fixing member passes through the positioning hole of each conductive bar, and the third conductive bar and the fourth conductive bar are fixed together by the first fixing member.
10. A dry-type transformer, characterized in that, It includes a low-voltage coil, which is manufactured using the winding method described in any one of claims 1 to 6.