A shaping device for silicon steel sheet lamination core transformer winding

Abstract

The application discloses a shaping device for silicon steel sheet laminated core transformer winding, relates to the technical field of transformer winding shaping, and is used for pressing and shaping long circular coil winding wound on a winding mold to compact inter-turn gaps and correct the shape, and comprises a machine body, the machine body comprises a presser plate and a force bearing platform. A main limiting mechanism is arranged on the machine body and comprises an upper channel steel plate, a lower channel steel plate and a limiting screw rod. An auxiliary limiting mechanism is arranged on the presser plate and comprises a fixed support, a long shaft limiting assembly, a short shaft limiting assembly and a detection assembly. The device has the advantages that the physical containment limiting of the long shaft limiting assembly, real-time monitoring of the short shaft distance sensor and the long shaft distance sensor and the secondary dynamic rigid support of the support arm effectively inhibit the expansion deformation of the long shaft end and prevent the insulation from being crushed due to excessive pressure and uneven force from above and below, so that the internal quality and shape size precision of the winding are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of transformer winding shaping technology, and in particular to a shaping device for silicon steel sheet laminated core transformer windings. Background Technology

[0002] Transformers are core equipment for electrical energy conversion and transmission in power systems. Among them, silicon steel laminated core transformers are widely used due to their mature structure and stable performance. As one of the core components of a transformer, the manufacturing quality of the windings directly determines the transformer's operational reliability and service life.

[0003] During the winding manufacturing process, after the conductor is wound, it needs to undergo a shaping and pressing process to compact the inter-turn gaps, correct the coil's external dimensions, and ensure the smooth progress of subsequent core assembly and insulation assembly. For oblong (elliptical) windings, their shape consists of two straight sides and semi-circular arcs at both ends. Shaping and pressing are usually carried out using a press in conjunction with upper and lower pressure plates and limiting screws. During pressing, the press plate applies downward pressure, which is transmitted to the coil winding through the upper pressure plate, compressing the axial height of the winding and compacting the inter-turn gaps.

[0004] However, existing winding shaping devices have the following problems in actual production: First, pressure control lacks an effective active protection mechanism. During the clamping process, the mechanical limit of the limiting screw is mainly used to limit the lower limit of the clamping stroke, but the pressure applied by the press may still exceed the withstand limit of the insulation material. The insulation pads inside the winding and the inter-turn insulation are easily crushed under excessive pressure, resulting in a reduction in insulation distance or even insulation damage, which poses a hidden danger of inter-turn short circuit for transformer operation.

[0005] Secondly, when the elongated oval winding is pressed along the short axis, the arcs at both ends along the long axis will expand and deform outward. Existing shaping devices lack physical containment and restraint along the long axis, causing the arcs at the ends of the long axis to bulge outward during the pressing process, resulting in inaccurate coil shape and affecting the smooth progress of subsequent core assembly processes.

[0006] Third, when pressure is applied unidirectionally from top to bottom, the pressure decreases during transmission due to material friction and elastic deformation, resulting in uneven force on the coil and dimensional tilting. Existing shaping devices lack real-time monitoring methods for the uniformity of compression, making it difficult to ensure consistent shaping quality.

[0007] Therefore, there is an urgent need for a shaping device that can monitor the deformation state of the winding in real time, actively prevent insulation crushing, and effectively suppress the expansion of the long shaft and uneven stress distribution, in order to solve the above-mentioned technical problems. Summary of the Invention

[0008] The purpose of this invention is to solve the problems existing in the prior art and to propose a shaping device for the winding of a silicon steel sheet laminated core transformer.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: a shaping device for silicon steel sheet stacked core transformer windings, used to press and straighten the elongated oval coil windings wound on the winding mold, so as to compact the inter-turn gaps and correct the shape, comprising: a machine body, including a press plate and a load-bearing platform that provide downward pressing power.

[0010] The main limiting mechanism is set on the machine body and includes an upper slot steel plate, a lower slot steel plate and a limiting screw; the lower slot steel plate supports the coil winding, the upper slot steel plate is pressed against the top wall of the coil winding, and the limiting screw is used to limit the distance between the upper slot steel plate and the lower slot steel plate.

[0011] An auxiliary limiting mechanism is provided on the machine body and includes a fixed bracket, a long axis limiting component, a short axis limiting component, and a detection component.

[0012] The long axis limiting component is used to physically contain and limit the coil winding at both ends along the long axis, suppressing the outward expansion and deformation of the arc at the end of the long axis during the pressing process; the short axis limiting component is used to provide dynamic rigid support on both sides of the coil winding along the short axis, bearing and diverting the pressing force, and suppressing the winding insulation from being crushed; the detection component is used to monitor the expansion amount along the long axis and the height change at different positions along the short axis of the coil winding in real time.

[0013] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, the lower slot steel plate is installed on the top wall of the load-bearing platform; two limiting screws are provided, which are symmetrically fixed to the top wall of the lower slot steel plate and penetrate through the upper slot steel plate, and the distance between the upper slot steel plate and the lower slot steel plate is adjusted and limited by the nuts.

[0014] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, the long axis limiting component includes a central positioning seat and two arc-shaped limiting plates; the fixed bracket is fixedly connected to the machine body, and the front side wall of the fixed bracket is provided with a guide rail; the central positioning seat is elastically slidably connected to the guide rail of the fixed bracket, and the central positioning seat is T-shaped, with its front end end matching the slot in the middle of the winding mold.

[0015] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, two arc-shaped limiting plates are fixedly connected to the left and right ends of the central positioning seat, and are symmetrically arranged at both ends of the long axis of the coil winding.

[0016] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, the inner side of the arc-shaped limiting plate is an arc-shaped surface that fits with the arc of the end of the long axis of the coil winding, and its center height is aligned with the centerline of the coil winding; the top wall of the arc-shaped limiting plate is lower than the bottom wall of the upper channel steel plate, and the bottom wall is higher than the top wall of the lower channel steel plate.

[0017] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, the short shaft limiting assembly includes mounting seats that are symmetrically fixed on a fixed bracket. Each mounting seat has a support arm that is symmetrically hinged to its top and bottom walls. A limiting block fixedly installed on the mounting seat is provided on the right side of the left support arm and the left side of the right support arm. A pushing block slidably installed on the mounting seat is provided on the left side of the left support arm and the right side of the right support arm.

[0018] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, the four support arms have an initial state and a triggered state. In the initial state, the two support arms on the left mounting base are in a V-shape with the opening facing left, and the two support arms on the right mounting base are in a V-shape with the opening facing right. In the triggered state, the support arms on both the left and right mounting bases rotate and change to a straight line facing up and down.

[0019] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, the detection components include short-axis distance sensors installed on the top and bottom walls of two arc-shaped limiting plates, and long-axis distance sensors installed on the arc-shaped side walls of the two arc-shaped limiting plates near the coil windings.

[0020] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, both the short-axis distance sensor and the long-axis distance sensor are laser displacement sensors; the laser beam of the short-axis distance sensor is vertically aligned with the bottom wall of the upper channel steel plate and the top wall of the lower channel steel plate; the laser beam of the long-axis distance sensor is horizontally aligned with the outer arc surface of the long axis end of the coil winding.

[0021] In the above-mentioned shaping device for silicon steel sheet stacked core transformer windings, the short axis distance sensor is used to monitor the height change and compaction uniformity of the short axis of the coil winding in real time; the long axis distance sensor is used to monitor the deformation and expansion amount in the long axis direction of the coil winding in real time.

[0022] Compared with existing technologies, the advantages of this invention are as follows: 1. This device uses the physical containment and limiting of the long axis limiting component, the real-time monitoring of the short axis ranging sensor and the long axis ranging sensor, and the secondary dynamic rigid support formed by the support arm rotating from a V-shape to a straight shape. The three work together to effectively suppress the expansion deformation of the long axis end, prevent insulation crushing caused by excessive pressure and uneven force, and ensure the internal quality and dimensional accuracy of the winding.

[0023] 2. By triggering the push block to drive the support arm to rotate from a V-shape to a vertical straight shape, the upper and lower ends of the support arm press against the upper and lower channel steel plates, forming a two-stage dynamic rigid support. This directly diverts the downward pressure from the press plate to the lower channel steel plate, instantly stopping the coil winding from being subjected to further pressure. This avoids the hidden dangers of excessive pressure causing the insulation pad to collapse and the inter-turn insulation to break down, which are common in traditional forming processes, thus ensuring the internal quality of the winding.

[0024] 3. The two arc-shaped limiting plates of the long axis limiting assembly physically contain and limit both ends of the coil winding along its long axis. The inner arc-shaped surface of the limiting plate fits against the arc at the end of the long axis of the coil winding, thereby suppressing the outward expansion and deformation of the arc at the end of the long axis during the pressing process. At the same time, the long axis distance sensor monitors the amount of deformation and expansion along the long axis in real time. When the expansion exceeds a preset threshold, a secondary dynamic rigid support is triggered to further prevent irreversible plastic deformation at the end of the long axis, ensuring that the coil's external dimensions meet the core assembly requirements.

[0025] 4. The short-axis ranging sensor monitors the height changes of the coil winding at four positions along the short axis in real time. It determines left-right skew by comparing the upper left and upper right, and lower left and lower right, and determines vertical uniformity by comparing the upper left and lower left, and upper right and lower right. When any data deviation exceeds a preset threshold, the PLC control system triggers a secondary dynamic rigid support to promptly correct uneven force distribution on the upper and lower parts of the coil caused by unidirectional pressure, preventing coil tilting. Attached Figure Description

[0026] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, wherein:

[0027] Figure 1 This is a schematic diagram of the overall structure;

[0028] Figure 2 This is a schematic diagram of the overall front structure;

[0029] Figure 3 This is a schematic diagram of the overall side structure;

[0030] Figure 4 This is a schematic diagram of the coil winding structure;

[0031] Figure 5 A partial structural exploded view of the main limiting mechanism and the auxiliary limiting mechanism;

[0032] Figure 6 A partial structural diagram of the auxiliary limiting mechanism and coil winding;

[0033] Figure 7 A top view of the auxiliary limiting mechanism;

[0034] Figure 8 This is a structural diagram before the secondary dynamic rigid support is triggered.

[0035] Figure 9 This is a schematic diagram of the structure after the secondary dynamic rigid support is triggered.

[0036] In the diagram: 100, winding mold; 200, coil winding; 1, machine body; 11, press plate; 12, load-bearing platform; 2, main limiting mechanism; 21, upper channel steel plate; 22, lower channel steel plate; 23, limiting screw; 3, auxiliary limiting mechanism; 31, fixed bracket; 32, long axis limiting assembly; 321, center positioning seat; 322, arc-shaped limiting plate; 33, short axis limiting assembly; 331, mounting seat; 332, support arm; 333, limiting block; 334, pushing block; 34, detection assembly; 341, short axis ranging sensor; 342, long axis ranging sensor. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Reference Figures 1 to 5 A shaping device for silicon steel sheet laminated core transformer windings is disclosed. This device is used to press and straighten an elongated oval coil winding 200 wound on a winding mold 100 to compact the inter-turn gaps and correct the overall dimensions. It mainly includes a machine body 1, which includes a press plate 11 providing downward pressing power and a support platform 12. The press plate 11 is driven by a hydraulic system and can move vertically up and down; the support platform 12 is fixed to the ground or equipment base to withstand the reaction force generated during the pressing process.

[0039] The main limiting mechanism 2 is mounted on the machine body 1 and includes an upper channel steel plate 21, a lower channel steel plate 22, and limiting screws 23. The lower channel steel plate 22 is installed on the top wall of the load-bearing platform 12 to support the coil winding 200; the upper channel steel plate 21 is located on the top wall of the coil winding 200 and is pressed against the top surface of the coil winding 200 as the press plate 11 is pressed down. There are two limiting screws 23, which are symmetrically fixed to the top wall of the lower channel steel plate 22 and pass through the upper channel steel plate 21 and are adjusted by nuts. By turning the nuts, the minimum distance between the upper channel steel plate 21 and the lower channel steel plate 22 can be adjusted, thereby limiting the lower limit of the pressing stroke and forming a first-level rigid limit.

[0040] It should be noted that after installation and adjustment, the position of the nut on the limit screw 23, which provides a primary rigid limit, determines the lower limit of the clamping stroke. If the nut loosens due to vibration, the limit will fail. Therefore, it is preferable to add an anti-loosening structure, such as double nut locking or thread-locking adhesive, at the nut of the limit screw 23.

[0041] Reference Figures 1 to 3 , Figures 5 to 9The auxiliary limiting mechanism 3 is set on the press plate 11 of the press machine, and includes a fixed bracket 31, a long shaft limiting component 32, a short shaft limiting component 33 and a detection component 34.

[0042] The fixed bracket 31 is fixedly connected to the body 1, and a guide rail is provided on its front side wall.

[0043] The long-axis limiting assembly 32 includes a central positioning seat 321 and two arc-shaped limiting plates 322. The central positioning seat 321 is elastically slidably connected to the guide rail of the fixed bracket 31. The central positioning seat 321 is T-shaped, and its front end is adapted to the slot in the middle of the winding mold 100. Specifically, the central positioning seat 321 and the guide rail of the fixed bracket 31 are elastically slidably connected vertically through an elastic element, so that the arc-shaped limiting plates 322 can adaptively float up and down when compressed. The elastic element can be a spring or a disc spring assembly, and its stiffness is selected according to the clamping force of the coil winding 200 to ensure that the arc-shaped limiting plates 322 adaptively adjust with the change of coil height during the clamping process.

[0044] Two arc-shaped limiting plates 322 are fixedly connected to the left and right ends of the central positioning seat 321, and are symmetrically arranged at both ends of the long axis of the coil winding 200. The inner side of the arc-shaped limiting plate 322 is an arc-shaped surface that fits against the arc of the end of the long axis of the coil winding 200, and its center height is aligned with the centerline of the coil winding 200. The top wall of the arc-shaped limiting plate 322 is lower than the bottom wall of the upper channel steel plate 21, and the bottom wall is higher than the top wall of the lower channel steel plate 22, thereby providing physical containment and limitation for the end of the long axis of the coil winding 200, and suppressing the outward expansion and deformation of the arc of the end of the long axis (left side of the left end and right side of the right end) during the pressing process.

[0045] The short-axis limiting assembly 33 includes mounting seats 331 that are symmetrically fixed on the fixed bracket 31. Each mounting seat 331 has a support arm 332 that is symmetrically hinged to its top and bottom walls by a torsion spring. A limiting block 333 fixedly mounted on the mounting seat 331 is provided to the right of the left support arm 332 and to the left of the right support arm 332. A pushing block 334 slidably mounted on the mounting seat 331 is provided to the left of the left support arm 332 and to the right of the right support arm 332.

[0046] The four support arms 332 have an initial state and a triggered state. In the initial state, the two support arms 332 on the left mounting base 331 are in a V-shape with the opening facing left, and the two support arms 332 on the right mounting base 331 are in a V-shape with the opening facing right. In the triggered state, the support arms 332 on both the left and right mounting bases 331 rotate and change to a straight line facing up and down.

[0047] It should be noted that the upper channel steel plate 21 and the lower channel steel plate 22 undergo elastic deformation after being compressed, and the actual distance between them is less than the initial distance. Therefore, in the triggered state, the support arms 332 on the left and right mounting seats 331 rotate and change to a straight shape facing up and down, and the distance from the top wall to the bottom wall of the straight shape is equal to the initial distance between the upper channel steel plate 21 and the lower channel steel plate 22 before the pressure is applied.

[0048] The push block 334 is driven by a servo motor or cylinder. When the detection component 34 detects an abnormality, the servo motor or cylinder instantly drives the push block 334, pushing the support arm 332 to rotate into a vertical straight line perpendicular to the upper channel steel plate 21 and the lower channel steel plate 22, so that the upper and lower ends of the support arm 332 press against the upper channel steel plate 21 and the lower channel steel plate 22, forming a secondary dynamic rigid support. When the support arm 332 is in the triggered state, its upper and lower ends are in rigid contact with the bottom wall of the upper channel steel plate 21 and the top wall of the lower channel steel plate 22, respectively, directly diverting the downward pressure of the press plate 11 to the lower channel steel plate 22, thereby instantly stopping the coil winding 200 from being compressed and preventing the insulation from being crushed. The press plate 11 also stops pressing down.

[0049] It should be noted that, during productization, servo drive solutions with fast response speed and large output torque should be prioritized, and a sealed lubrication structure should be adopted for the torsion spring hinge to ensure long-term reliable operation. In addition, the support arm 332 needs to withstand the huge downward pressure of the press plate 11 when it is triggered. Its material strength, hinge shaft diameter, and rigidity of the limit block 333 must all undergo strict force verification to prevent the support arm 332 from plastic deformation or breakage under pressure.

[0050] The detection assembly 34 includes a short-axis distance sensor 341 installed in the middle of the top and bottom walls of the two arc-shaped limiting plates 322, and a long-axis distance sensor 342 installed in the middle of the arc-shaped side walls of the two arc-shaped limiting plates 322 near the coil winding 200.

[0051] Both the short-axis ranging sensor 341 and the long-axis ranging sensor 342 are laser displacement sensors. The laser beam of the short-axis ranging sensor 341 is vertically aligned with the bottom wall of the upper channel steel plate 21 and the top wall of the lower channel steel plate 22, and is positioned at four locations: upper left, upper right, lower left, and lower right. This is used to monitor the height change and compression uniformity of the short axis of the coil winding 200 in real time. Specifically, by comparing the upper left and upper right (to determine if there is left-right skew), the lower left and lower right (to determine if there is left-right skew), the upper left and lower left (to determine if the top-bottom is uniform), and the upper right and lower right (to determine if the top-bottom is uniform), it is determined whether the coil winding 200 tilts or experiences uneven force during the compression process.

[0052] It should be noted that: when comparing the top left and top right, if the difference exceeds a preset left / right skew threshold, the coil winding 200 is determined to be skewed in the left / right direction. Similarly, when comparing the bottom left and bottom right, if the difference exceeds the left / right skew threshold, the coil winding 200 is determined to be skewed in the left / right direction. The left / right skew threshold is set based on the maximum allowable left / right tilt of the coil winding 200, typically ranging from 0.5% to 1% of the coil's design height.

[0053] Comparing the top left and bottom left, if the difference exceeds a preset vertical uniformity threshold, the coil winding 200 is determined to be under uneven force in the vertical direction. Similarly, comparing the top right and bottom right, if the difference exceeds the vertical uniformity threshold, the coil winding 200 is determined to be under uneven force in the vertical direction. The vertical uniformity threshold is set based on the maximum allowable vertical thickness difference of the coil winding 200, typically ranging from 0.5% to 1% of the coil's designed height.

[0054] The laser beam of the long axis distance sensor 342 is aligned with the outer arc surface of the long axis end of the coil winding 200 to monitor the amount of deformation and expansion of the coil winding 200 in the long axis direction in real time.

[0055] It should be noted that the allowable range of the long axis expansion should be determined based on the design dimensions of the coil winding 200 and the core assembly clearance requirements. The long axis expansion should be controlled within 1% to 2% of the coil design dimensions. The specific preset threshold value needs to be calculated based on the winding specifications and core column dimensions.

[0056] The short-axis ranging sensor 341 and the long-axis ranging sensor 342 are respectively connected to the PLC control system (an external, mature device). The PLC control system determines whether to trigger the push block 334 to switch from the initial state to the triggered state based on the real-time data from the short-axis ranging sensor 341 and the long-axis ranging sensor 342.

[0057] When any of the following conditions occur, the PLC control system determines it to be abnormal and triggers the push block 334 to switch from the initial state to the triggered state: the difference between the upper left and upper right exceeds the left and right deviation threshold, the difference between the lower left and lower right exceeds the left and right deviation threshold, the difference between the upper left and lower left exceeds the upper and lower uniformity threshold, the difference between the upper right and lower right exceeds the upper and lower uniformity threshold, and the long axis expansion exceeds the expansion amount preset threshold.

[0058] The specific operating steps of the shaping device for the silicon steel sheet laminated core transformer winding are as follows: Insert the coil winding 200. Place the elongated oval coil winding 200, wound on the winding mold 100, onto the lower slot steel plate 22. The short axis of the coil winding 200 corresponds to the vertical direction, and the long axis corresponds to the horizontal left-right direction. Insert the front end of the center positioning seat 321 into the slot in the middle of the winding mold 100 to achieve center positioning. Press the upper slot steel plate 21 onto the horizontal top wall of the coil winding 200. After the limiting screw 23 passes through the upper slot steel plate 21, adjust the nut height so that the upper slot steel plate 21 is tightly against the top wall of the coil winding 200, and the lower slot steel plate 22 is tightly against the bottom wall of the coil winding 200.

[0059] Pressure shaping. The press is started, and the press plate 11 moves downward to press against the upper channel steel plate 21, which in turn presses against the top wall of the coil winding 200. As the press plate 11 continues to press down, the coil winding 200 is gradually compressed, and the inter-turn gaps are compacted. The limit screw 23 forms a first-level rigid limit, and the upper channel steel plate 21 is pressed against the nut of the limit screw 23, reaching the lower limit of the stroke.

[0060] Real-time process monitoring. During the clamping process, the detection component 34 operates continuously. The short-axis distance sensor 341 monitors the height changes of the coil winding 200 at four positions along the short axis in real time, and the long-axis distance sensor 342 monitors the expansion of the coil winding 200 along the long axis in real time. The PLC control system receives the above data and performs comparative analysis: if the difference between the upper left and upper right exceeds the left-right skew threshold, the difference between the lower left and lower right exceeds the left-right skew threshold, the difference between the upper left and lower left exceeds the vertical uniformity threshold, the difference between the upper right and lower right exceeds the vertical uniformity threshold, and the long-axis expansion exceeds the preset expansion threshold, then it is judged as abnormal.

[0061] Triggering the secondary dynamic rigid support. When the PLC control system determines that triggering is required, it immediately sends a command to the servo motor or cylinder. The servo motor or cylinder instantly drives the push block 334, pushing the support arm 332 to rotate into a vertical straight line perpendicular to the upper channel steel plate 21 and the lower channel steel plate 22 (e.g., Figure 8 Change to Figure 9 At this time, the upper and lower ends of the support arm 332 respectively press against the bottom wall of the upper channel steel plate 21 and the top wall of the lower channel steel plate 22, forming a secondary dynamic rigid support, which directly diverts the downward pressure of the press plate 11 to the lower channel steel plate 22, instantly stopping the coil winding 200 from being pressed and preventing the insulation from being crushed.

[0062] The press plate 11 rises back, the push block 334 returns to its initial V-shaped state, the support arm 332 retracts under the action of the torsion spring, and the shaped coil winding 200 is taken out.

[0063] It should be noted that during the application of enormous downward pressure by the press plate 11, the fixed bracket 31 and the central positioning seat 321 may also undergo slight elastic deformation, causing displacement of the sensor reference surface. This results in the measurement data including the deformation of the bracket rather than purely reflecting the deformation of the coil winding 200. Therefore, during productization, the rigidity of the fixed bracket 31 and the central positioning seat 321 should be optimized. Ideally, their deformation under maximum clamping force should be verified through finite element analysis to ensure the stability of the sensor's measurement reference.

[0064] Currently, the shaping of the winding conductors after winding is mainly achieved using a simple hydraulic press. This method suffers from drawbacks such as coarse pressure control, lack of real-time monitoring, easy expansion and deformation of the long axis of the elongated coil, and uneven force distribution. This solution, compared to existing technologies, adds structures such as an arc-shaped limiting plate 322, a short-axis distance sensor 341, a long-axis distance sensor 342, a pressing block 334, and a support arm 332. Although this increases equipment costs, it enables real-time monitoring of the clamping force, active suppression of long-axis expansion, and timely prevention of vertical deviation. Furthermore, when the pressure exceeds a safety threshold, a secondary dynamic rigid support instantly diverts the pressure, fundamentally preventing insulation crushing and winding deformation. These structures can be manufactured using conventional machining and hydraulic systems, with mature and easily implemented processes. From a long-term perspective, this solution can significantly improve the consistency and reliability of winding shaping quality, reduce rework and scrap costs caused by insulation defects, and extend the transformer's service life, resulting in significant economic benefits.

[0065] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" 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 this invention and simplifying the description, and are not intended to 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 this invention.

[0066] Furthermore, the terms "first," "second," "number one," and "number two" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," "number one," or "number two" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0067] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0068] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A shaping device for silicon steel sheet laminated core transformer windings, used to press and shape elongated oval coil windings wound on a winding mold to compact the inter-turn gaps and correct the shape, characterized in that, include: The machine body includes the press plate and the load-bearing platform that provide downward pressing power; The main limiting mechanism is set on the machine body and includes an upper slot steel plate, a lower slot steel plate and a limiting screw; the lower slot steel plate supports the coil winding, the upper slot steel plate is pressed against the top wall of the coil winding, and the limiting screw is used to limit the distance between the upper slot steel plate and the lower slot steel plate. An auxiliary limiting mechanism is provided on the machine body, including a fixed bracket, a long axis limiting component, a short axis limiting component, and a detection component; The long axis limiting component is used to physically contain and limit the coil winding at both ends along the long axis, suppressing the outward expansion and deformation of the arc at the end of the long axis during the pressing process; the short axis limiting component is used to provide dynamic rigid support on both sides of the coil winding along the short axis, bearing and diverting the pressing force, and suppressing the winding insulation from being crushed; the detection component is used to monitor the expansion amount along the long axis and the height change at different positions along the short axis of the coil winding in real time.

2. The shaping device for silicon steel sheet laminated core transformer windings according to claim 1, characterized in that, The lower channel steel plate is installed on the top wall of the load-bearing platform; there are two limiting screws, which are symmetrically fixed to the top wall of the lower channel steel plate and penetrate through the upper channel steel plate. The distance between the upper channel steel plate and the lower channel steel plate is adjusted and limited by the nuts.

3. A shaping device for silicon steel sheet laminated core transformer windings according to claim 1, characterized in that, The long axis limiting assembly includes a central positioning seat and two arc-shaped limiting plates; the fixed bracket is fixedly connected to the machine body, and the front side wall of the fixed bracket is provided with a guide rail; the central positioning seat is elastically slidably connected to the guide rail of the fixed bracket, and the central positioning seat is T-shaped, with its front end end matching the slot in the middle of the winding mold.

4. A shaping device for silicon steel sheet laminated core transformer windings according to claim 3, characterized in that, The two arc-shaped limiting plates are fixedly connected to the left and right ends of the central positioning seat, and are arranged symmetrically at both ends of the long axis of the coil winding.

5. A shaping device for silicon steel sheet laminated core transformer windings according to claim 4, characterized in that, The inner side of the arc-shaped limiting plate is an arc-shaped surface that fits against the arc at the end of the long axis of the coil winding, and its center height is aligned with the centerline of the coil winding; the top wall of the arc-shaped limiting plate is lower than the bottom wall of the upper channel steel plate, and the bottom wall is higher than the top wall of the lower channel steel plate.

6. A shaping device for silicon steel sheet laminated core transformer windings according to claim 1, characterized in that, The short axis limiting assembly includes mounting seats that are symmetrically fixed on a fixed bracket. Each mounting seat has a support arm that is symmetrically hinged to its top and bottom walls. A limiting block fixed on the mounting seat is provided on the right side of the left support arm and the left side of the right support arm. A pushing block slidably mounted on the mounting seat is provided on the left side of the left support arm and the right side of the right support arm.

7. A shaping device for silicon steel sheet laminated core transformer windings according to claim 6, characterized in that, The four support arms have an initial state and a triggered state; in the initial state, the two support arms on the left mounting base are in a V-shape with the opening facing left, and the two support arms on the right mounting base are in a V-shape with the opening facing right; in the triggered state, the support arms on both the left and right mounting bases rotate and change to a straight line facing up and down.

8. A shaping device for silicon steel sheet laminated core transformer windings according to claim 3, characterized in that, The detection assembly includes short-axis ranging sensors mounted on the top and bottom walls of the two arc-shaped limiting plates, and long-axis ranging sensors mounted on the arc-shaped sidewalls of the two arc-shaped limiting plates near the coil windings.

9. A shaping device for silicon steel sheet laminated core transformer windings according to claim 8, characterized in that, Both the short-axis and long-axis ranging sensors are laser displacement sensors; the laser beam of the short-axis ranging sensor is vertically aligned with the bottom wall of the upper channel steel plate and the top wall of the lower channel steel plate; the laser beam of the long-axis ranging sensor is horizontally aligned with the outer arc surface of the long axis end of the coil winding.

10. A shaping device for silicon steel sheet laminated core transformer windings according to claim 8, characterized in that, The short-axis distance sensor is used to monitor the height change and compression uniformity of the short axis of the coil winding in real time; the long-axis distance sensor is used to monitor the deformation and expansion of the coil winding in the long axis direction in real time.

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