Method of winding transformer coil interlayer insulation and end insulation

Abstract

This invention discloses a method for winding interlayer and end insulation of transformer coils, relating to the field of transformer technology. It includes the following steps: Material preparation: clamping the finished low-voltage coil onto two four-jaw chucks; starting the winding machine switch to evenly wind the first layer of conductor onto the low-voltage coil; when the conductor is wound to the last turn of the first layer, pressing the beginning of the insulating paper tape from the unwinding mechanism under the conductor, the unwinding mechanism will move towards the other end of the coil as the winding machine continues to rotate; the unwinding mechanism leads the conductor unwinding mechanism to the end of the coil and performs end insulation winding; when the second layer of conductor has 1-2 turns remaining, the insulating paper tape begins winding from the end insulation towards the other side of the coil. This method for winding interlayer and end insulation of transformer coils changes the traditional installation mode of layer and end insulation in high-voltage coil winding. By replacing manual operation with mechanical automation, it greatly reduces the labor intensity and production costs of workers; at the same time, the layer and end insulation are wound from the same insulating paper tape, resulting in high integrity of the high-voltage coil and greatly improving production efficiency and product quality.

Description

Technical Field

[0001] This invention relates to the field of transformer technology, and in particular to a method for winding interlayer insulation and end insulation for high-voltage coils of transformers with narrow-pitch end insulation. Background Technology

[0002] The traditional high-voltage coil winding process involves placing the wound low-voltage coil on a specialized winding device, followed by manual pulling and winding of the coil and laying of insulation materials. In particular, the processes of layer insulation and end insulation have many problems.

[0003] Traditional layer insulation installation involves wrapping a single piece of insulating cardboard around the coil after one layer of high-voltage coil wire is wound, securing it at multiple points. As the wire continues to wind, the insulation is pressed under the wire layer. Each layer of insulation requires machine downtime, wasting significant time. Similarly, end insulation requires stopping the machine after shutdown and applying layers of insulation along the outer edge of the coil wire. Depending on the wire thickness, multiple layers of end insulation are needed, each requiring secure bonding. Layer insulation installation is separate from end insulation installation. After the product is wound, there are gaps between the end insulation and the wire layer, resulting in poor overall integrity. Furthermore, the manual operation mode leads to high labor costs, long processing times, and requires a high level of experience and skill from workers, resulting in low production efficiency. Summary of the Invention

[0004] The purpose of this invention is to provide a method for winding interlayer and end insulation of transformer coils specifically for high-voltage coil winding, which changes the winding mode of interlayer and end insulation in the traditional high-voltage coil winding process, reduces costs, and improves the winding efficiency of interlayer and end insulation of high-voltage coils.

[0005] To achieve the above-mentioned objectives, the technical solution adopted by this invention is as follows: A method for winding interlayer insulation and end insulation of a transformer coil, comprising the following steps: Material preparation: The finished low-voltage coil and electromagnetic wire are lifted in the waiting area. The low-voltage coil is lifted onto the winding machine and clamped onto two four-jaw chucks. The electromagnetic wire is placed onto the unwinding wheel of the wire unwinding mechanism. With the tension of the entire equipment reduced, the conductor unwinding mechanism begins to feed out a portion of the conductor. Bend the beginning of the conductor to 90° and wrap the beginning with insulation as required; First layer of winding: Use tape to attach the first layer of end insulation cardboard to the low-voltage coil, and leave a starting position for fixing; Use tape to secure the wire tip to the low-voltage coil; Start the winding machine switch, and at the same time, the wire unwinding mechanism moves from one side of the gantry to the other side under the drive of the linear drive unit, so that the wire is evenly wound on the low voltage coil. When the equipment is running and there are 2-3 turns of the first layer of conductor remaining, stop the equipment and use tape to stick the end insulation cardboard of the other side of the first layer to the low voltage coil; When the conductor is wound to the last turn of the first layer, the beginning of the insulating paper tape led out by the insulating paper tape unwinding mechanism is pressed under the conductor. As the winding machine continues to rotate, the insulating paper tape unwinding mechanism will move to the other end of the coil. After the first layer of conductor is laid, the winding continues in the opposite direction. At this time, the insulating paper tape will be wound synchronously with the conductor. The unwinding mechanism of the insulating paper tape and the unwinding mechanism of the conductor move to the other side at different speeds. The unwinding mechanism of the insulating paper tape is faster and reaches the end of the coil ahead of the unwinding mechanism of the conductor. It then winds the end insulation in place at the end insulation point. When there are 1-2 turns left in the second layer of wire, start winding the insulating paper tape from the end insulation point towards the other side of the coil. After the second layer of wire is completed, start winding in the opposite direction. Before the third layer of wire is completed, the insulating paper tape will also arrive at the other end insulation point in advance for in-situ winding; And so it goes.

[0006] Furthermore, the width of the insulating paper tape is greater than the width of the conductor, and the width of the insulating paper tape is the width of the end insulation of the high-voltage coil; the thickness of the conductor is greater than the thickness of the insulating paper tape, and the thickness of the conductor is similar to or equal to the thickness of the insulating paper tape after it is wound in place at the end insulation.

[0007] During the winding process of insulating paper tape on the conductor layer, there will be some overlap, with a thickness of 2 or 3 layers.

[0008] The relationship between the number of turns of the insulating paper tape and the number of turns of the wire is as follows: The conductor is wound with one layer of m+n turns. When the conductor is wound to m turns, the insulating paper tape is wound to another end insulation point after m turns. The conductor continues to be wound to the end of this layer after n turns. The insulating paper tape is wound to the end insulation point with n turns.

[0009] (Thickness of conductor - thickness of insulation layer) divided by n is greater than or equal to the thickness of the insulating paper tape.

[0010] Most high-voltage coil winding processes do not require machine shutdown. However, some processes require machine shutdown: when winding to the oil channel layer, stop the machine, add the oil channel and attach it to the coil, and continue winding; when the coil ends up: release the equipment tension, send the wire out of the coil, fold the wire part out and wrap it with insulation, bring the wire back and attach it to the coil, and continue winding the wire unwinding mechanism.

[0011] To perform the above process, a winding machine, a conductor unwinding mechanism, and an insulating paper tape unwinding mechanism are required. The winding machine is used to fix and clamp the low-voltage coil and drive the coil to rotate to achieve active winding. The wire unwinding mechanism and the insulating paper tape unwinding mechanism are installed on the gantry frame and are driven by a linear drive mechanism to slide horizontally on the linear slide rail of the gantry frame for conveying wires and insulating paper tape. Both the wire unwinding mechanism and the insulating paper tape unwinding mechanism are equipped with a wire unwinding wheel, a guide wheel, and a buffer wheel. The buffer wheel is connected to a buffer cylinder, and the buffer cylinder is equipped with a distance sensor. The speed of the wire unwinding wheel is controlled by a servo motor.

[0012] The beneficial effects of this invention are as follows: This method for winding interlayer and end insulation of transformer coils changes the traditional installation mode of interlayer and end insulation in the high-voltage coil winding process. By replacing manual operation with mechanical automation, the entire winding process is improved, greatly reducing the manual part and lowering the labor intensity and production cost of workers. At the same time, the interlayer and end insulation are wound from the same insulating paper tape, resulting in high integrity of the high-voltage coil and greatly improving production efficiency and product quality. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the winding process of the product to be processed according to the present invention.

[0014] Figure 2 This is a schematic diagram of the device structure for the method of the present invention.

[0015] 1-Wire, 2-Insulating paper tape, 3-End insulation position, 4-Insulating paper tape unwinding mechanism, 5-Insulating paper tape unwinding mechanism, 6-Gantry frame, 7-Winding machine, 11-Unwinding reel, 12-Guide wheel, 13-Buffer wheel, 14-Linear drive unit. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings: This process requires a winding machine, a conductor unwinding mechanism, and an insulating paper tape unwinding mechanism. The winding machine is used to hold low-voltage coils in place and drive the coils to rotate to achieve active winding. It includes a fixed base and a movable base. Both bases are equipped with four-jaw chucks and are driven to rotate by corresponding motors. The movable base moves closer to or away from the fixed base via linear slide rail IV. The wire unwinding mechanism and the insulating paper tape unwinding mechanism are mounted on the gantry frame and are driven by a linear drive mechanism to slide horizontally on the linear slide rails of the gantry frame for conveying wires and insulating paper tape. The gantry frame is equipped with two sets of double parallel linear slide rails, and the wire unwinding mechanism and the insulating paper tape unwinding mechanism are connected to the linear slide rails through sliders. The linear drive mechanism includes a servo motor, a screw, and a nut seat. The screw is parallel to the linear slide rail and is threadedly connected to the nut seat. The screw is connected to the gantry frame through a bearing seat, and the wire unwinding mechanism and the insulating paper tape unwinding mechanism are fixedly connected to the nut seat.

[0017] Both the wire unwinding mechanism and the insulating paper tape unwinding mechanism are equipped with a wire unwinding wheel, a guide wheel, and a buffer wheel. The buffer wheel is connected to a buffer cylinder, and the buffer cylinder is equipped with a distance sensor. The speed of the wire unwinding wheel is controlled by a servo motor.

[0018] A method for winding interlayer insulation and end insulation of a transformer coil, comprising the following steps: Material preparation: The finished low-voltage coil and electromagnetic wire are lifted in the waiting area. The low-voltage coil is lifted onto the winding machine and clamped onto two four-jaw chucks. The electromagnetic wire is placed onto the unwinding wheel of the wire unwinding mechanism. With the tension of the entire equipment reduced, the conductor unwinding mechanism begins to feed out a portion of the conductor. Bend the beginning of the conductor to 90° and wrap the beginning with insulation as required; First layer of winding: Use tape to attach the first layer of end insulation cardboard to the low-voltage coil, and leave a starting position for fixing; Use tape to secure the wire tip to the low-voltage coil; Start the winding machine switch, and at the same time, the wire unwinding mechanism moves from one side of the gantry to the other side under the drive of the linear drive unit, so that the wire is evenly wound on the low voltage coil. When the equipment is running and there are 2-3 turns of the first layer of conductor remaining, stop the equipment and use tape to stick the end insulation cardboard of the other side of the first layer to the low voltage coil; When the conductor is wound to the last turn of the first layer, the beginning of the insulating paper tape led out by the insulating paper tape unwinding mechanism is pressed under the conductor. As the winding machine continues to rotate, the insulating paper tape unwinding mechanism will move to the other end of the coil. After the first layer of conductor is laid, the winding continues in the opposite direction. At this time, the insulating paper tape will be wound synchronously with the conductor. The unwinding mechanism of the insulating paper tape and the unwinding mechanism of the conductor move to the other side at different speeds. The unwinding mechanism of the insulating paper tape is faster and reaches the end of the coil ahead of the unwinding mechanism of the conductor. It then winds the end insulation in place at the end insulation point. When there are 1-2 turns left in the second layer of wire, start winding the insulating paper tape from the end insulation point towards the other side of the coil. After the second layer of wire is completed, start winding in the opposite direction. Before the third layer of wire is completed, the insulating paper tape will also arrive at the other end insulation point in advance for in-situ winding; And so it goes.

[0019] Furthermore, the width of the insulating paper tape is greater than the width of the conductor, and the width of the insulating paper tape is the width of the end insulation of the high-voltage coil; the thickness of the conductor is greater than the thickness of the insulating paper tape, and the thickness of the conductor is similar to or equal to the thickness of the insulating paper tape after it is wound in place at the end insulation.

[0020] During the winding process of insulating paper tape on the conductor layer, there will be some overlap, with a thickness of 2 or 3 layers.

[0021] The relationship between the number of turns of the insulating paper tape and the number of turns of the wire is as follows: The conductor is wound with one layer of m+n turns. When the conductor is wound to m turns, the insulating paper tape is wound to another end insulation point after m turns. The conductor continues to be wound to the end of this layer after n turns. The insulating paper tape is wound to the end insulation point with n turns.

[0022] (Thickness of conductor - thickness of insulation layer) divided by n is greater than or equal to the thickness of the insulating paper tape.

[0023] Most high-voltage coil winding processes do not require machine shutdown. However, some processes require machine shutdown: when winding to the oil channel layer, stop the machine, add the oil channel and attach it to the coil, and continue winding; when the coil ends up: release the equipment tension, send the wire out of the coil, fold the wire part out and wrap it with insulation, bring the wire back and attach it to the coil, and continue winding the wire unwinding mechanism.

[0024] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements can be made without departing from the principle of the present invention, and these improvements should also be considered within the scope of protection of the present invention without creative effort.

Claims

1. A method for winding interlayer insulation and end insulation of a transformer coil, characterized in that: It includes the following steps: Material preparation: The finished low-voltage coil and electromagnetic wire are lifted in the waiting area. The low-voltage coil is lifted onto the winding machine and clamped onto two four-jaw chucks. The electromagnetic wire is placed onto the unwinding wheel of the wire unwinding mechanism. With the tension of the entire equipment reduced, the conductor unwinding mechanism begins to feed out a portion of the conductor. Bend the beginning of the conductor to 90° and wrap the beginning with insulation as required; First layer of winding: Use tape to attach the first layer of end insulation cardboard to the low-voltage coil, and leave a starting position for fixing; Use tape to secure the wire end to the low-voltage coil; Start the winding machine switch, and at the same time, the wire unwinding mechanism moves from one side of the gantry to the other side under the drive of the linear drive unit, so that the wire is evenly wound on the low voltage coil. When the equipment is running and there are 2-3 turns of the first layer of conductor remaining, stop the equipment and use tape to stick the end insulation cardboard of the other side of the first layer to the low voltage coil; When the conductor is wound to the last turn of the first layer, the beginning of the insulating paper tape led out by the insulating paper tape unwinding mechanism is pressed under the conductor. As the winding machine continues to rotate, the insulating paper tape unwinding mechanism will move to the other end of the coil. After the first layer of conductor is laid, the winding continues in the opposite direction. At this time, the insulating paper tape will be wound synchronously with the conductor. The unwinding mechanism of the insulating paper tape and the unwinding mechanism of the conductor move to the other side at different speeds. The unwinding mechanism of the insulating paper tape is faster and reaches the end of the coil ahead of the unwinding mechanism of the conductor. It then winds the end insulation in place at the end insulation point. When there are 1-2 turns left in the second layer of wire, start winding the insulating paper tape from the end insulation point towards the other side of the coil. After the second layer of wire is completed, start winding in the opposite direction. Before the third layer of wire is completed, the insulating paper tape will also arrive at the other end insulation point in advance for in-situ winding; And so it goes.

2. The method for winding interlayer insulation and end insulation of transformer coils according to claim 1, characterized in that: The width of the insulating paper tape is greater than the width of the conductor, and the width of the insulating paper tape is the width of the end insulation of the high-voltage coil; the thickness of the conductor is greater than the thickness of the insulating paper tape, and the thickness of the conductor is similar to or equal to the thickness of the insulating paper tape after it is wound in place at the end insulation.

3. The method for winding interlayer insulation and end insulation of transformer coils according to claim 1, characterized in that: During the winding process of insulating paper tape on the conductor layer, there will be some overlap, with a thickness of 2 or 3 layers.

4. The method for winding interlayer insulation and end insulation of transformer coils according to claim 1, characterized in that: The relationship between the number of turns of the insulating paper tape and the number of turns of the wire is as follows: The conductor is wound with one layer of m+n turns. When the conductor is wound to m turns, the insulating paper tape is wound to another end insulation point after m turns. The conductor continues to be wound to the end of this layer after n turns. The insulating paper tape is wound to the end insulation point with n turns.

5. The method for winding interlayer insulation and end insulation of transformer coils according to claim 4, characterized in that: (Thickness of conductor - thickness of insulation layer) divided by n is greater than or equal to the thickness of the insulating paper tape.

6. The method for winding interlayer insulation and end insulation of transformer coils according to claim 1, characterized in that: When the winding reaches the oil channel layer, stop the machine, add the oil channel to the coil, and continue winding.

7. The method for winding interlayer insulation and end insulation of transformer coils according to claim 1, characterized in that: Intermediate coil exit: Remove equipment tension, send the wire out of the coil, fold the wire portion out and wrap it with insulation, bring the wire back and stick it in place, then continue winding.

8. The method for winding interlayer insulation and end insulation of transformer coils according to claim 1, characterized in that: To perform the above process, a winding machine, a conductor unwinding mechanism, and an insulating paper tape unwinding mechanism are required. The winding machine is used to fix and hold the low-voltage coil and drive the coil to rotate to achieve active winding. The conductor unwinding mechanism and the insulating paper tape unwinding mechanism are installed on the gantry frame and are driven by a linear drive mechanism to slide horizontally on the linear slide rail of the gantry frame for conveying conductors and insulating paper tape.

9. The method for winding interlayer insulation and end insulation of transformer coils according to claim 8, characterized in that: Both the wire unwinding mechanism and the insulating paper tape unwinding mechanism are equipped with a wire unwinding wheel, a guide wheel, and a buffer wheel. The buffer wheel is connected to a buffer cylinder, and the buffer cylinder is equipped with a distance sensor. The speed of the wire unwinding wheel is controlled by a servo motor.

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