A welding and insulating tool for square spiral copper bar coil

Abstract

The application discloses a welding and insulating tool for square spiral copper bar coil, relates to the welding technology field of synchronous generator salient pole rotor coil, and comprises a base fixedly connected to the outer wall of the top of a workbench through a bolt, a back-shaped top frame arranged above the base, a positioning back plate, a copper bar and an upward adjusting structure, the upward adjusting structure comprises an adjusting lead screw and a lead screw pair threadedly connected with the adjusting lead screw, a plurality of detachable positioning clamps are mounted on the positioning back plate and the copper bar can be fastened through the positioning clamps, and a guide column is fixedly connected to each corner position of the back-shaped top frame. The application guarantees the consistency and neatness of the welding size by directly positioning the coil inner cavity, guarantees that the copper bar is basically not deformed by laying insulating materials layer by layer and gradually pulling apart the gap without affecting the remaining coils, and effectively improves the welding and laying efficiency and quality of the square spiral copper bar coil.

Description

Technical Field

[0001] This invention relates to the field of welding technology for salient pole rotor coils of synchronous generators, and particularly to a welding and insulation laying fixture for square spiral copper busbar coils. Background Technology

[0002] Some synchronous generators use a square helical structure for their salient-pole rotor coils (see...). Figure 4 As shown), each layer of coil in the spiral structure is composed of four long strip copper busbars welded together. This type of coil generally has many layers, up to about 100 layers. One to two layers of narrow strip thin insulation are also required between the layers, with an insulation thickness of about 0.2 mm.

[0003] The manufacturing difficulties of this type of coil are all caused by its spiral structure. The coil layers are connected in series, causing twisting and deformation of the copper busbars during welding and insulation installation. Furthermore, it makes it difficult to arrange the coils neatly, thus affecting the coil height and internal cavity dimensions. During welding, special butt joint structures or local clamping at the weld joint are generally used to ensure the perpendicularity of the two welded copper busbars, indirectly achieving consistent internal cavity dimensions. However, there is no good way to avoid deformation of the copper busbars. When laying the insulation layer, the conventional method is to pull the coil apart like a spring and then lay it layer by layer. This method causes severe deformation of the copper busbars. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a new method and tooling for the two processes of welding and insulation laying of square spiral copper busbar coils. By directly positioning the inner cavity of the coil, the consistency and neatness of the welding dimensions are ensured. By laying insulation layer by layer with gaps, the copper busbar is kept essentially undeformed without affecting the remaining coils.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A welding and insulation laying fixture for square spiral copper busbar coils includes a base fixed to the outer wall of the top of the workbench by bolts, a U-shaped top frame disposed above the base, a positioning plate, a copper busbar, and an upward adjustment structure. The upward adjustment structure includes an adjustment screw and a screw pair threadedly connected to the adjustment screw. Several detachable positioning clamps are installed on the positioning plate, and the copper busbar can be fastened by the positioning clamps.

[0006] As a preferred technical solution of the present invention, guide columns are fixedly connected at the four corners of the U-shaped top frame, and the bottom outer walls of the four guide columns are fixedly connected to the top outer wall of the workbench.

[0007] As a preferred technical solution of the present invention, the positioning plate is provided with four guide holes adapted to the guide posts, and the inner walls of the four guide holes are slidably connected to the outer walls of the four guide posts respectively.

[0008] By adopting the above technical solution, the stability of the positioning plate during the upward adjustment process can be guaranteed by the guiding cooperation between the four guide pillars and the four guide ports on the positioning plate.

[0009] As a preferred technical solution of the present invention, the bottom end of the adjusting screw is provided with a bearing seat, the bearing seat is fixedly connected to the top outer wall of the workbench by bolts, and the adjusting screw is rotatably connected to the bearing seat.

[0010] By adopting the above technical solution and by setting the bearing housing, the stability of the adjusting screw rotation during adjustment can be guaranteed.

[0011] As a preferred technical solution of the present invention, the positioning plate is provided with a through hole, the adjusting screw passes through the through hole vertically, and the screw pair is fixedly connected to the top outer wall of the positioning plate by bolts.

[0012] By adopting the above technical solution, the lead screw can be rotated and adjusted to move the positioning plate up an appropriate distance to facilitate the welding of the next layer of copper busbars.

[0013] As a preferred embodiment of the present invention, the positioning fixture includes a concave seat that engages with the positioning plate and a locking bolt threaded to the top of the concave seat.

[0014] By adopting the above technical solution, the concave seat after being engaged with the positioning plate can support the placed copper busbar. The copper busbar can be positioned by tightening the locking bolt, and the concave seat can be removed from the positioning plate by unscrewing the locking bolt.

[0015] The beneficial effects of this invention are as follows: This invention provides a novel method and tooling for the welding and insulation laying processes of square spiral copper busbar coils. The method utilizes a positioning plate and a positioning clamp to synergistically position the inner cavity of the coil on the copper busbar. Moving the positioning clamp causes the welded coil layers to fall onto the base, while rotating the adjusting screw moves the positioning plate upwards, achieving layer-by-layer separation and gradually completing the welding of the spiral structure. This also facilitates insulation laying. By directly positioning the inner cavity of the coil, the consistency and neatness of the welded dimensions are ensured. Furthermore, the method of laying insulation layer by layer without affecting the remaining coils ensures that the copper busbar remains largely undeformed, effectively improving the welding and laying efficiency and quality of square spiral copper busbar coils. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.

[0017] Figure 1 This is a three-dimensional structural diagram of the welding and positioning of the first layer of the spiral coil of the present invention; Figure 2 This is a three-dimensional structural diagram of the welding and positioning of the second layer of the spiral coil of the present invention; Figure 3 This is a schematic diagram of the three-dimensional structure of the welded spiral coil of the present invention; Figure 4 This is a three-dimensional structural diagram of the square spiral copper busbar coil of the present invention.

[0018] In the diagram: 1. U-shaped top frame; 2. Positioning plate; 3. Base; 4. Copper busbar; 5. Guide column; 6. Adjusting screw; 7. Screw pair; 8. Bearing seat; 9. Positioning fixture. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0020] Reference Figure 1-4 A welding and insulation laying fixture for square spiral copper busbar coils includes a base 3 fixedly connected to the outer wall of the top of the workbench by bolts, a U-shaped top frame 1 set above the base 3, a positioning plate 2, a copper busbar 4, and an upward adjustment structure. Specifically, the upward adjustment structure includes an adjusting screw 6 and a screw pair 7 threadedly connected to the adjusting screw 6. Several detachable positioning clamps 9 are installed on the positioning plate 2, and the copper busbar 4 can be fastened by the positioning clamps 9. Furthermore, guide columns 5 are fixedly connected at the four corners of the top frame 1. The bottom outer walls of the four guide columns 5 are fixedly connected to the top outer wall of the workbench. The positioning plate 2 has four guide holes that are compatible with the guide columns 5. The inner walls of the four guide holes are slidably connected to the outer walls of the four guide columns 5 respectively. In this way, the stability of the positioning plate 2 during the upward adjustment process can be ensured by the guiding cooperation between the four guide columns 5 and the four guide holes on the positioning plate 2. Furthermore, the bottom end of the adjusting screw 6 is provided with a bearing seat 8, which is fixedly connected to the top outer wall of the workbench by bolts. The adjusting screw 6 is rotatably connected to the bearing seat 8. In this way, the setting of the bearing seat 8 can ensure the rotational stability of the adjusting screw 6 during the adjustment process. Furthermore, a through hole is provided on the positioning plate 2, and the adjusting screw 6 passes through the through hole vertically. The screw pair 7 is fixedly connected to the top outer wall of the positioning plate 2 by bolts. In this way, by rotating the adjusting screw 6, the screw pair 7 can drive the positioning plate 2 to move up an appropriate distance to facilitate the welding work of the next layer of copper busbar 4. Furthermore, the positioning fixture 9 includes a concave seat that engages with the positioning plate 2 and a locking bolt threaded to the top of the concave seat. In this way, the concave seat, after engaging with the positioning plate 2, can support the copper busbar 4. The copper busbar 4 can be positioned by tightening the locking bolt, and the concave seat can be removed from the positioning plate 2 by unscrewing the locking bolt.

[0021] The usage process of this invention is as follows: First, as shown in the figure... Figure 1 The base 3, four guide columns 5 and bearing seat 8 are fixedly assembled on the top of the workbench. Then the first layer of copper busbar 4 is arranged on the positioning plate 2. The inner side of the copper busbar 4 is close to the positioning plate 2. Then the positioning clamp 9 is used to fasten the copper busbar 4. At this time, three of the four corners of the coil can be welded. The unwelded corners are used to connect to the next layer to form a spiral structure. Secondly, as Figure 2 By removing the positioning clamp 9, the first layer (already soldered) coil falls into the base 3. The adjusting screw 6 is rotated to move the positioning plate 2 up an appropriate distance. Then the second layer of copper busbars 4 are arranged and soldered. Finally, following the method described above, use tooling to weld the spiral coil layer by layer until all welding is completed, as shown above. Figure 3 As shown, when laying the insulation layer, the entire spiral coil that has been welded is placed on the upper side of the positioning plate 2, and the positioning clamp 9 is removed so that the coil falls layer by layer. At this time, the insulation is laid on the fallen layer. In this way, the insulation is laid layer by layer. During this process, the adjusting screw 6 can also be rotated to realize the coil moving up and down.

[0022] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Moreover, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0023] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A welding and insulation laying fixture for square spiral copper busbar coils, comprising a base (3) fixedly connected to the outer wall of the top of a workbench by bolts and a U-shaped top frame (1) disposed above the base (3), characterized in that, It also includes a positioning plate (2), a copper busbar (4), and an upward adjustment structure; The upward adjustment structure includes an adjustment screw (6) and a screw pair (7) threadedly connected to the adjustment screw (6). Several detachable positioning clamps (9) are installed on the positioning plate (2), and the copper busbar (4) can be fastened by the positioning clamps (9).

2. The welding and insulation laying fixture for square spiral copper busbar coils according to claim 1, characterized in that, The four corners of the spiral top frame (1) are fixedly connected with guide columns (5), and the bottom outer walls of the four guide columns (5) are fixedly connected to the top outer wall of the workbench.

3. The welding and insulation laying fixture for square spiral copper busbar coils according to claim 1, characterized in that, The positioning plate (2) has four guide openings that are adapted to the guide post (5), and the inner walls of the four guide openings are slidably connected to the outer walls of the four guide posts (5).

4. The welding and insulation laying fixture for square spiral copper busbar coils according to claim 1, characterized in that, The bottom end of the adjusting screw (6) is provided with a bearing seat (8), which is fixedly connected to the top outer wall of the workbench by bolts, and the adjusting screw (6) is rotatably connected to the bearing seat (8).

5. The welding and insulation laying fixture for square spiral copper busbar coils according to claim 1, characterized in that, The positioning plate (2) has a through hole, the adjusting screw (6) passes through the through hole vertically, and the screw pair (7) is fixedly connected to the top outer wall of the positioning plate (2) by bolts.

6. The welding and insulation laying fixture for square spiral copper busbar coils according to claim 1, characterized in that, The positioning fixture (9) includes a concave seat that engages with the positioning plate (2) and a locking bolt threaded to the top of the concave seat.

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