A winding device for large transformer production

Abstract

The application relates to the technical field of transformer winding equipment, and particularly provides a winding device for large transformer production, which comprises a main frame, a copper foil unwinding assembly, an insulation layer unwinding assembly, an end insulation unwinding assembly, a winding main unit and a compression roller assembly are arranged on the main frame, the compression roller assembly comprises a front compression roller and a rear compression roller, in the copper foil winding process, the copper foil first passes through the front compression roller and then passes through the rear compression roller, the middle part of the copper foil can be compacted first to drive air between layers, and the edges of the copper foil on both sides can be compacted to discharge residual air, the problem of air retention between copper foil layers in the foil winding process is effectively improved, the internal bubble defects of the coil are reduced, the risk of local discharge of the winding in the transformer operation process is reduced, and the insulation reliability of the foil type coil is improved.

Description

Technical Field

[0001] This invention relates to the field of transformer winding equipment technology, and in particular to a winding device for the production of large transformers. Background Technology

[0002] The copper foil windings of large power transformers are the core component for energy conversion, and the winding quality directly determines the transformer's insulation performance, conductivity, and operational reliability. Currently, existing winding equipment used in large transformer production still faces many practical production challenges in the copper foil winding process.

[0003] During copper foil layer winding, tension fluctuations during the unwinding process can easily cause the copper foil to loosen, resulting in loose adhesion between adjacent copper foil layers after winding, and air can easily become trapped between layers. This residual air can cause partial discharge during transformer operation, reducing the reliability of winding insulation and potentially leading to transformer failure. Currently, conventional clamping rollers mostly use a synchronous clamping method, which easily forces air into the copper foil layers during clamping, making it difficult to effectively expel interlayer gas and ensuring the density of the winding.

[0004] Meanwhile, during the unwinding and conveying process, copper foil is highly susceptible to the adhesion of metal debris, dust, and other impurities. If these impurities are rolled into the winding layers along with the copper foil, they will increase the interlayer contact resistance and reduce the winding's conductivity. Furthermore, hard impurities can puncture the insulation layer, causing insulation defects and posing a significant safety hazard to the transformer. Existing equipment lacks a targeted online cleaning structure and mostly relies on manual wiping and cleaning beforehand. This makes continuous impurity removal during the winding process impossible, resulting in low cleaning efficiency and inconsistent cleaning effects. Summary of the Invention

[0005] Therefore, it is necessary to provide a winding device for large transformer production to address the problem that the adjacent copper foil layers are not tightly bonded during the winding process of current winding equipment, and that air is easily trapped between the layers.

[0006] The above objectives are achieved through the following technical solutions:

[0007] A winding device for manufacturing large transformers, comprising:

[0008] A main frame, on which a copper foil unwinding assembly, an insulating layer unwinding assembly, an end insulating unwinding assembly, a winding main unit, and a pressure roller assembly are provided;

[0009] The copper foil unwinding assembly is used to carry the copper foil roll and can passively release the copper foil; the insulation layer unwinding assembly is used to output the interlayer insulation material; and the end insulation unwinding assembly supplies end insulation material to both ends of the coil being wound.

[0010] The winding host unit can rotate and provide winding traction force. The copper foil unwinding assembly is dragged by the winding traction force of the winding host unit to release the copper foil. The copper foil, interlayer insulation material and end insulation material are pulled and transported to the winding host unit.

[0011] The pressure roller assembly includes a front pressure roller and a rear pressure roller arranged sequentially along the rotation direction of the winding main unit; the front pressure roller presses and tightens the copper foil wound on the middle region of the winding main unit, and the rear pressure roller presses and tightens the copper foil wound on both sides of the winding main unit.

[0012] The front pressure roller first applies pressure to the middle of the copper foil, driving the air between the copper foil layers to both sides of the copper foil. Then, the rear pressure roller presses the edges of the copper foil on both sides to expel the residual air between the copper foil layers.

[0013] Furthermore, there are two rear pressure rollers and one front pressure roller. The axes of the two rear pressure rollers and one front pressure roller are parallel to each other, and the one front pressure roller and the two rear pressure rollers are arranged in a triangular pattern.

[0014] Furthermore, both the front and rear pressure rollers are provided with multiple high-pressure air holes, which are evenly distributed along the axial and circumferential directions of the front and rear pressure rollers. The multiple high-pressure air holes spray air onto the copper foil surface to remove impurities and help flatten the copper foil.

[0015] Furthermore, the pressure roller assembly also includes a floating swing arm. One end of the floating swing arm is hinged to the main frame, and the other end of the floating swing arm is connected to the front pressure roller and the rear pressure roller. The floating swing arm can conformally retract outward as the outer diameter of the coil on the winding main unit increases, so that the front pressure roller and the rear pressure roller are always in contact with the outer surface of the coil.

[0016] Furthermore, the front and rear pressure rollers are hollow inside and have an air shaft connected to them in a rotating seal. The air shaft is connected to the floating swing arm. The air shaft is hollow inside and has air holes on its surface. An air pipe is connected to the air shaft and the air pipe is connected to a high-pressure air pump.

[0017] Furthermore, rotating bearings are provided on the outer periphery of both ends of the air shaft, and multiple layers of sealing rings are provided on the outer periphery of the air shaft between the two rotating bearings. The outer ring of the sealing ring rotates and seals against the hollow inner wall of the front and rear pressure rollers, and the inner ring of the sealing ring is fixed on the outer periphery of the air shaft.

[0018] Furthermore, the copper foil unwinding assembly includes a copper foil unwinding base, a copper foil unwinding support bracket, a copper foil air shaft, a copper foil unwinding damping mechanism, and a transition guide roller group;

[0019] The copper foil unwinding base is assembled on the main frame, and the copper foil unwinding support bracket is fixedly installed on the copper foil unwinding base; the copper foil air shaft is rotatably supported on the copper foil unwinding support bracket through the bearing seat, and the copper foil air shaft is used to clamp and fix the copper foil roll.

[0020] The copper foil unwinding damping mechanism is connected to the end of the copper foil air shaft and is used to apply a reverse damping torque to the copper foil air shaft so that the copper foil maintains unwinding tension.

[0021] Furthermore, the insulation layer unwinding assembly includes an insulation unwinding bracket, an insulation air shaft, an insulation damping mechanism, and an insulation guide roller group;

[0022] The insulating unwinding bracket is fixedly installed on the main frame; the insulating air shaft is rotatably supported on the insulating unwinding bracket through a bearing seat, and the insulating air shaft is used to clamp the interlayer insulating material roll.

[0023] The insulating damping mechanism is connected to the end of the insulating air shaft and is used to apply a reverse damping torque to the insulating air shaft to maintain the unwinding tension of the interlayer insulating material.

[0024] After the interlayer insulation material is released by the insulating air shaft, it is guided by the insulating guide roller group, aligned with the copper foil, and then transported together to the winding host unit.

[0025] Furthermore, the end-insulating unwinding assembly includes a mounting base bracket, several sets of unwinding shafts, and a tension damping mechanism;

[0026] The mounting base bracket is equipped with a transverse linear slide rail, and each set of unwinding shafts is equipped with an independent tension damping mechanism.

[0027] Furthermore, the winding host unit includes a drive spindle and an expansion winding die;

[0028] The drive spindle is rotated and assembled on the main frame, the expansion winding mold is fixed on the drive spindle, and copper foil is wound around the outer periphery of the expansion winding mold to form a foil coil.

[0029] The beneficial effects of this invention are:

[0030] This invention employs a partitioned pressing structure with front and rear pressure rollers, which first compacts the middle of the copper foil to expel interlayer air, and then compacts the edges of the copper foil to expel residual air. This effectively improves the problem of air trapped between copper foil layers during the foil winding process, reduces air bubble defects inside the coil, lowers the risk of partial discharge in the winding during transformer operation, and improves the insulation reliability of the foil coil.

[0031] This invention features high-pressure air holes evenly distributed axially and circumferentially on the front and rear pressure rollers. The airflow from these high-pressure air holes removes dust, metal debris, and other impurities from the copper foil surface during the online winding process, preventing hard impurities from being drawn into the interlayer and causing insulation damage. Simultaneously, the high-pressure airflow forms a flexible pressure, pre-compressing and assisting in flattening the copper foil, thus improving copper foil warping in advance and providing a good foundation for subsequent mechanical compaction. This invention overcomes the limitations of traditional methods that rely on manual pre-treatment to clean copper foil, resulting in continuous and stable impurity removal. The two rear pressure rollers have clearance space, and the front and rear air jet areas are separated and do not interfere with each other, preventing airflow collisions and ensuring the blowing and pre-compressing effects. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the structure of a winding device for producing large transformers according to an embodiment of the present invention;

[0033] Figure 2 for Figure 1 Left view of a winding device for producing a large transformer according to one embodiment;

[0034] Figure 3 for Figure 2 A front view of a winding device for producing a large transformer according to one embodiment;

[0035] Figure 4 for Figure 3 A cross-sectional view along AA of a winding device for manufacturing a large transformer provided in one embodiment;

[0036] Figure 5 A schematic diagram of the floating swing arm and pressure roller assembly of a winding device for large transformer production provided in an embodiment of the present invention;

[0037] Figure 6 for Figure 5 A left view of the floating swing arm and pressure roller assembly of a winding device for large transformer production provided in one embodiment;

[0038] Figure 7 for Figure 6 A cross-sectional view along BB of the floating swing arm and pressure roller assembly of the winding device for large transformer production provided in one embodiment;

[0039] Figure 8 for Figure 7 A partial enlarged view of the floating swing arm and the X part of the pressure roller assembly of the winding device for large transformer production provided in one embodiment;

[0040] Figure 9 An exploded view of the floating swing arm and pressure roller assembly of a winding device for large transformer production provided in an embodiment of the present invention.

[0041] in:

[0042] 100. Mainframe rack;

[0043] 200. Winding main unit; 210. Drive spindle; 220. Expansion winding die;

[0044] 300. Pressure roller assembly; 310. Front pressure roller; 320. Rear pressure roller; 330. High-pressure air port; 340. Floating swing arm; 341. Pressure-driven cylinder; 342. Adjusting screw; 350. Air shaft; 360. Vent hole; 370. Air pipe; 380. Rotary bearing; 381. Clamp; 390. Sealing ring;

[0045] 400. Copper foil unwinding assembly; 410. Copper foil unwinding base; 420. Copper foil unwinding support bracket; 430. Copper foil air shaft; 440. Copper foil unwinding damping mechanism; 450. Transition guide roller group;

[0046] 500. Insulation layer unwinding assembly; 510. Insulation unwinding bracket; 520. Insulation air shaft; 530. Insulation damping mechanism; 540. Insulation guide roller assembly;

[0047] 600. End-insulated unwinding assembly; 610. Mounting base bracket; 620. Unwinding shaft. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below through embodiments and in conjunction with the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0049] The component designations used in this document, such as "first" and "second," are merely for distinguishing the described objects and do not have any sequential or technical meaning. The terms "connection" and "linkage" used in this invention, unless otherwise specified, include both direct and indirect connections (linkages). It should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are used only for the convenience of describing the invention and simplifying the description. They 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, and therefore should not be construed as limiting the invention.

[0050] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0051] The following reference Figures 1-9 This invention describes a winding device for producing large transformers.

[0052] A winding device for producing large transformers includes a main frame 100, on which a copper foil unwinding assembly 400, an insulation layer unwinding assembly 500, an end insulation unwinding assembly 600, a winding main unit 200, and a pressure roller assembly 300 are arranged.

[0053] The copper foil unwinding assembly 400 is used to support heavy copper foil rolls and passively release the copper foil. The assembly itself does not have an active feeding power; it relies on external traction to unwind the copper foil. During the unwinding process, it can output wide, thin copper foil, which serves as the conductive core of the transformer's foil coil. The insulation layer unwinding assembly 500 outputs interlayer insulation material, which is made of insulating paper or insulating film. This material is sandwiched between two layers of copper foil to achieve interlayer insulation isolation and prevent short circuits between adjacent copper foil layers. The end insulation unwinding assembly 600 supplies end insulation material to both ends of the coil during winding. This end insulation material is a narrow strip of insulating paper, which is attached to both ends of the coil, filling the gaps at the coil ends and providing insulation protection to the winding ends, thus improving the coil's end withstand voltage capability.

[0054] The winding host unit 200 can rotate and provide winding traction force. During operation, the winding host unit 200 maintains a set speed and rotates continuously. The copper foil unwinding assembly 400 is dragged by the winding traction force of the winding host unit 200 and slowly releases the copper foil. At the same time, the insulation layer unwinding assembly 500 and the end insulation unwinding assembly 600 are also pulled out synchronously. After being guided and transitioned, the copper foil, interlayer insulation material and end insulation material are pulled and transported to the outer periphery of the winding host unit 200. The three materials maintain synchronous feeding speed and are wrapped and stacked layer by layer to form a transformer foil coil.

[0055] The pressure roller assembly 300 includes a front pressure roller 310 and a rear pressure roller 320 arranged sequentially along the rotation direction of the winding main unit 200. Specifically, the front pressure roller 310 and the rear pressure roller 320 are arranged sequentially in the direction in which the copper foil is wound on the winding main unit 200. The copper foil first passes through the front pressure roller 310 and then through the rear pressure roller 320. The front pressure roller 310 presses and wraps the copper foil in the middle area of ​​the winding main unit 200, while the rear pressure roller 320 presses and wraps the copper foil in the two side edge areas of the winding main unit 200. In this embodiment, there is one front pressure roller 310 and two rear pressure rollers 320. One front pressure roller 310 is arranged near the copper foil feed side, and the two rear pressure rollers 320 are placed on the left and right sides respectively. The one front pressure roller 310 and the two rear pressure rollers 320 form a triangular layout, pressing together against the outer surface of the coil. The triangular layout provides stable force and can distribute the pressing load, avoiding excessive local pressure that could damage the thin copper foil.

[0056] In the actual operation of winding transformer foil coils, copper foil, interlayer insulation material, and end insulation material are drawn to the winding host unit 200. As the winding host unit 200 rotates, copper foil is wound layer by layer around the outer circumference of the winding host unit 200 to form a coil. The interlayer insulation material is sandwiched between adjacent copper foil layers, and the end insulation material is attached to the two end faces of the coil. The copper foil that has just finished winding rotates with the coil and first contacts the front pressure roller 310. The front pressure roller 310 applies radial pressure to the middle of the newly attached copper foil, prioritizing the compaction of the middle position of the copper foil and driving the air trapped between the copper foil layers to the left and right sides of the copper foil. As the coil continues to rotate, this section of copper foil that has already undergone pre-compression in the middle then rotates to the rear end. At position 320, two rear pressure rollers 320 press the left and right edges of the copper foil respectively, further expelling the residual air between layers driven to the edge, preventing air from flowing back and remaining between the copper foil layers, and reducing air bubble defects inside the coil. As winding continues, the number of coil layers is continuously added, and the outer diameter of the coil is continuously increased. The pressure roller assembly 300 can float and retract outward, and can always stay close to the outer circle of the coil as the outer diameter of the coil changes, continuously completing the pressing and air venting operation of each layer of copper foil, so that each layer of copper foil can achieve the effect of first venting in the middle and then pressing on both sides, improving the overall winding density of the coil, reducing the risk of partial discharge inside the winding, and finally completing the winding and forming of the transformer foil coil.

[0057] Understandably, the pressure roller assembly 300, which uses a triangular arrangement of one front pressure roller 310 and two rear pressure rollers 320, first presses the middle of the copper foil during winding, driving the air trapped between layers to both sides. Then, the two rear pressure rollers 320 press the edges of the copper foil to completely expel any remaining air. This alleviates the problem of air trapped between copper foil layers during foil winding, reduces air bubble defects inside the coil, lowers the risk of partial discharge during transformer winding operation, and improves the insulation reliability of transformer foil coils. The triangular arrangement of the pressure rollers distributes the force evenly, preventing excessive pressure at a single point from causing wrinkles or damage to the thin copper foil, thus protecting the copper foil itself.

[0058] In a further embodiment, the front pressure roller 310 and the rear pressure roller 320 of the pressure roller assembly 300 are each provided with multiple high-pressure air holes 330, which are evenly distributed along the axial and circumferential directions of the front pressure roller 310 and the rear pressure roller 320. The high-pressure air holes 330 spray air towards the copper foil surface, and the airflow can remove dust, metal debris, and other impurities adhering to the copper foil surface. Simultaneously, the airflow acts on the copper foil surface, assisting in flattening and pre-pressing the copper foil. During actual operation, compressed air is continuously introduced into the internal air passages of the front pressure roller 310 and the rear pressure roller 320, and the gas is sprayed onto the copper foil surface on the outer circumference of the coil through each high-pressure air hole 330. Before the front pressure roller 310 mechanically presses the center of the copper foil, the airflow from the high-pressure air holes 330 first sweeps the central area of ​​the copper foil, removing impurities from the surface. Simultaneously, the airflow creates a flexible pressure to pre-press and pre-flatten the copper foil, ensuring it conforms to the surface and reducing warping. When the copper foil rotates to the rear pressure roller 320, the high-pressure air holes 330 on the rear pressure roller 320 continue to blow air onto both sides of the copper foil. The airflow also applies a flexible pre-pressing force to the edges of the copper foil, blowing any remaining impurities to the sides and causing them to fall off. This prevents impurities from being rolled into the gaps between the copper foil layers and causing damage to the coil insulation. The high-pressure air holes 330, evenly arranged axially and circumferentially, ensure that the airflow covers the entire effective width of the copper foil, guaranteeing uniform blowing, pre-pressing, and flattening effects.

[0059] Specifically, the pressure roller assembly 300 in this embodiment also includes a floating swing arm 340. One end of the floating swing arm 340 is hinged to the main frame 100, and the other end of the floating swing arm 340 is connected to the front pressure roller 310 and the rear pressure roller 320. The floating swing arm 340 can conform to the outer diameter of the coil on the winding main unit 200 as the outer diameter increases, so that the front pressure roller 310 and the rear pressure roller 320 are always in contact with the outer surface of the coil.

[0060] During actual operation, the hinged part of the floating swing arm 340 can swing freely. The floating swing arm 340 is equipped with a pressure-driven cylinder 341, which continuously applies a clamping force to the floating swing arm 340. As the number of layers increases during the coil winding process, the outer diameter of the coil continuously increases. The outer circle of the coil will exert an outward pushing force on the front pressure roller 310 and the rear pressure roller 320, causing the floating swing arm 340 to swing outward and retract around the hinge point. The pressure-driven cylinder 341 maintains a constant clamping force. Regardless of changes in the outer diameter of the coil, the front pressure roller 310 and the rear pressure roller 320 can continuously adhere to the outer circle of the coil, ensuring that each layer of copper foil can obtain a stable clamping force without any decrease in clamping force or the pressure rollers detaching from the coil surface. This ensures a continuous and stable interlayer air venting and compaction effect. Furthermore, a hinge plate is provided at the connection between the floating swing arm 340 and the front pressure roller 310 and the rear pressure roller 320. The front pressure roller 310 and the rear pressure roller 320 are mounted on the hinge plate. An adjusting screw 342 is provided between the hinge plate and the floating swing arm 340. The adjusting screw 342 is used to adjust the angle between the hinge plate and the floating swing arm 340, thereby changing the angle between the front pressure roller 310 and the rear pressure roller 320. By rotating the adjusting screw 342, the hinge plate can be driven to swing slightly relative to the floating arm 340, thereby synchronously adjusting the contact angle of the front pressure roller 310 and the rear pressure roller 320 relative to the outer circle of the coil. This adapts to the clamping posture adjustment for different copper foil thicknesses and coil diameters. When winding foil coils of different specifications, the contact angle of the pressure rollers can be finely adjusted according to the copper foil thickness and the outer diameter of the coil, allowing the front pressure roller 310 and the rear pressure roller 320 to better fit the outer curved surface of the coil.

[0061] It should be noted that in this embodiment, the front pressure roller 310 and rear pressure roller 320, arranged in a triangular pattern, have a clearance space between the two rear pressure rollers 320 during operation. This prevents the rear pressure roller 320 from obstructing or interfering with the high-pressure gas blown out of the high-pressure air holes 330 on the front pressure roller 310, ensuring the high-pressure gas cleans the copper foil and performs pre-pressing. Specifically, the gas blown out of the high-pressure air holes 330 on the front pressure roller 310 mainly acts on the central area of ​​the copper foil, completing the cleaning of impurities and flexible pre-pressing. The high-pressure gas blown out of the high-pressure air holes 330 on the two rear pressure rollers 320 acts on the left and right edge areas of the copper foil, respectively, completing the cleaning and pre-pressing of the edge areas. The air jet areas of the front pressure roller 310 and the rear pressure roller 320 are separated yet connected, and the airflow does not interfere with each other, preventing airflow collision and cancellation. This allows for segmented cleaning, pre-pressing, and auxiliary flattening of the central and side edges of the copper foil, creating favorable conditions for subsequent mechanical compaction operations.

[0062] Specifically, in this embodiment, both the front pressure roller 310 and the rear pressure roller 320 are hollow structures. An air shaft 350 is rotatably and sealed within both the front and rear pressure rollers 310 and 320. The air shaft 350 serves as the rotational center axis of the front and rear pressure rollers 310 and 320, and is fixedly mounted on the hinge plate of the floating swing arm 340, allowing it to remain stationary. The air shaft 350 is entirely hollow, with ventilation holes 360 on its surface communicating with the internal cavity of the pressure rollers. An air pipe 370 is connected to the outside of the air shaft 350, and the end of the air pipe 370 is connected to a high-pressure air pump. During operation, the high-pressure air pump continuously delivers high-pressure gas into the hollow air shaft 350 through the air pipe 370. The high-pressure gas enters the hollow cavity of the front and rear pressure rollers 310 and 320 through the ventilation holes 360 on the surface of the air shaft 350, and is finally uniformly ejected from the high-pressure air holes 330 on the surface of the pressure rollers. During the winding operation, the front pressure roller 310 and the rear pressure roller 320 rotate around the air shaft 350 as they follow the friction of the copper foil. The air shaft 350 remains fixed. The rotating sealing structure can effectively ensure the sealing of the internal air passage during the rotation of the pressure roller, avoid high-pressure gas leakage, and continuously and stably provide the copper foil surface with air jet purging, pre-pressing and auxiliary flattening functions, ensuring the continuous and stable winding operation.

[0063] It should be noted that, in order to enable the air shaft 350 to rotate and seal with the front pressure roller 310 and the rear pressure roller 320, in this embodiment, rotating bearings 380 are provided on the outer periphery of both ends of the air shaft 350. The rotating bearings 380 are fixed to the outer periphery of the air shaft 350 by clamps 381, and a multi-layer sealing ring 390 is provided on the outer periphery of the air shaft 350 between the two rotating bearings 380. The outer ring of the sealing ring 390 rotates and seals against the hollow inner wall of the front pressure roller 310 and the rear pressure roller 320, and the inner ring of the sealing ring 390 is fixed to the outer periphery of the air shaft 350. The rotating bearings 380 provide radial support, supporting the front pressure roller 310 and the rear pressure roller 320 to rotate flexibly relative to the air shaft 350, thereby reducing the frictional resistance during rotation. The multi-layer sealing rings 390 are arranged sequentially along the axial direction of the air shaft 350 to form multiple independent sealing barriers. The inner ring of the sealing ring 390 remains stationary with the air shaft 350, while the outer ring of the sealing ring 390 rotates relative to the hollow inner wall of the pressure roller. Under the condition of high-speed frictional rotation of the pressure roller, it prevents the internal high-pressure gas from leaking outward from the gap between the air shaft 350 and the pressure roller cavity.

[0064] Understandably, the rotating bearings 380 are arranged on both axial sides of the sealing ring 390 to axially limit the pressure roller, reduce axial movement during operation, prevent axial displacement from pulling and wearing the sealing ring 390, and extend its service life. After the high-pressure gas enters the hollow cavity of the pressure roller through the air shaft 350 and the vent 360, the multi-layer sealing rings 390 confine the high-pressure gas within the cavities between the bearings, ensuring stable jet pressure from the high-pressure air holes 330. This prevents pressure attenuation due to gas leakage, ensuring continuous and stable purging, pre-tightening, and auxiliary leveling operations.

[0065] Specifically, the copper foil unwinding assembly 400 in this embodiment includes a copper foil unwinding base 410, a copper foil unwinding support bracket 420, a copper foil air shaft 430, a copper foil unwinding damping mechanism 440, and a transition guide roller group 450. The copper foil unwinding base 410 is assembled on the main frame 100, and the copper foil unwinding support bracket 420 is fixedly mounted on the unwinding base. The copper foil air shaft 430 is rotatably supported on the copper foil unwinding support bracket 420 through a bearing seat. The copper foil air shaft 430 can be directly fitted and fixed to the copper foil roll, realizing quick assembly and disassembly and stable locking of the copper foil roll. The copper foil unwinding damping mechanism 440 is connected to the end of the copper foil air expansion shaft 430. When the winding host unit 200 pulls the copper foil out, the copper foil unwinding damping mechanism 440 can continuously apply reverse damping torque to the copper foil air expansion shaft 430 to counteract the inertial unwinding speed, so that the copper foil maintains a uniform and stable unwinding tension throughout the process, avoiding looseness, wrinkles, and stretching deformation during the copper foil unwinding process, and ensuring that the copper foil is conveyed flat and stable.

[0066] Specifically, the insulation layer unwinding assembly 500 in this embodiment includes an insulation unwinding bracket 510, an insulation air shaft 520, an insulation damping mechanism 530, and an insulation guide roller group 540. The insulation unwinding bracket 510 is fixedly installed on the main frame 100. The insulation air shaft 520 is rotatably supported on the insulation unwinding bracket 510 through a bearing seat. The insulation air shaft 520 is used to clamp and fix the interlayer insulation material roll, ensuring smooth rotation of the insulation material roll. The insulation damping mechanism 530 is connected to the end of the insulation air shaft 520. During the passive unwinding process of the interlayer insulation material, the insulation damping mechanism 530 applies a stable reverse damping torque to the insulation air shaft 520, effectively maintaining the unwinding tension of the interlayer insulation material and preventing the insulation material from loosening or shaking. After the interlayer insulation material is smoothly released by the insulation air shaft 520, it is precisely guided and limited by the insulation guide roller group 540, so that the interlayer insulation material and the copper foil are aligned in width and synchronized in speed. Finally, it is smoothly transported together with the copper foil to the winding main unit 200 for composite winding.

[0067] Specifically, the end insulation unwinding assembly 600 in this embodiment includes a mounting base bracket 610, several sets of unwinding shafts 620, and a tension damping mechanism (not shown in the figure). The mounting base bracket 610 is equipped with a transverse linear slide rail, which allows for fine adjustment of the overall transverse position. Each set of unwinding shafts 620 is equipped with an independent tension damping mechanism, which can individually control the unwinding tension of a single set of end insulation paper tape, ensuring uniform tension and synchronous output of the end insulation paper tape on both sides. The transverse linear slide rail can adapt to the winding requirements of coils with different width specifications, ensuring that the end insulation paper tape accurately fits the end faces of the coil, improving the insulation protection effect of the coil ends.

[0068] Specifically, the winding host unit 200 in this embodiment includes a drive spindle 210 and an expansion winding mold 220. The drive spindle 210 is rotatably mounted on the host frame 100, providing stable rotational power. The expansion winding mold 220 is mounted and fixed on the drive spindle 210, rotating synchronously with the drive spindle 210, providing a forming substrate and traction power for winding the foil coil. Copper foil and insulating material are wrapped and wound layer by layer around the outer periphery of the expansion winding mold 220, ultimately forming a transformer foil coil with a regular structure and uniform density.

[0069] The specific working process of a winding device for large transformer production provided by the present invention will be described in conjunction with the above embodiments:

[0070] When the equipment is in operation, the copper foil roll, interlayer insulation roll, and end insulation paper tape are first installed on the copper foil unwinding assembly 400, the insulation layer unwinding assembly 500, and the end insulation unwinding assembly 600, respectively. The appropriate unwinding damping force is pre-adjusted through the tension damping mechanism of each assembly to ensure uniform tension and smooth conveying of various materials during the subsequent passive discharge process. At the same time, the high-pressure air pump and pressure drive cylinder 341 are adjusted to the working state to ensure unobstructed air passage of the pressure roller and constant pressure output of the floating swing arm 340.

[0071] After the initial loading and debugging are completed, the winding main unit 200 starts working, driving the main shaft 210 to rotate the expansion winding mold 220 at a constant speed. Relying on the rotational traction force, the copper foil, interlayer insulation material, and end insulation paper tape are simultaneously and passively discharged. The copper foil is precisely guided and conveyed by the transition guide roller group 450, the interlayer insulation material is aligned and attached to the surface of the copper foil by the insulation guide roller group 540, and the end insulation paper tape is aligned to the two ends of the coil. The three materials maintain synchronous feeding speed and precise alignment, and are jointly conveyed to the outer periphery of the expansion winding mold 220 for superimposed wrapping and winding.

[0072] At the instant each layer of material is wound and formed to fit the outer circumference of the coil, a high-pressure air pump continuously supplies air. The high-pressure gas enters the internal cavity of the front pressure roller 310 and the rear pressure roller 320 through the stationary air shaft 350, and is ejected at high speed from the evenly distributed high-pressure air holes 330. The air jet from the front pressure roller 310 first blows away impurities and performs flexible pre-compression and pre-flattening on the middle of the copper foil. The air jet from the rear pressure roller 320 then performs secondary cleaning and pre-shaping on both sides of the copper foil, eliminating the potential for warping, wrinkles, and surface impurities in advance.

[0073] During the continuous rotation of the coil, a front pressure roller 310 and two rear pressure rollers 320 arranged in a triangular pattern sequentially perform zoned mechanical compaction of the copper foil. The front pressure roller 310 compacts the middle of the copper foil, driving interlayer air to both sides, while the rear pressure rollers 320 compact the edges of the copper foil, expelling as much residual interlayer air as possible. The triangular layout ensures uniform compaction force and avoids damaging the thin copper foil. A clearance space is provided between the two rear pressure rollers 320, allowing the front and rear air jet areas to work independently and without interference, ensuring stable and reliable purging and pre-compacting effects.

[0074] As the number of coil winding layers increases, the outer diameter of the coil continuously expands. The outer circle of the coil continuously pushes against the pressure roller, causing the floating swing arm 340 to overcome the cylinder pressure and adaptively retract outwards. Throughout the process, the front pressure roller 310 and the rear pressure roller 320 maintain a tight fit against the outer circle of the coil, ensuring that each layer of copper foil receives constant clamping force and a stable air jet effect. At the same time, the rotating bearings 380 at both ends of the air shaft 350 ensure smooth and flexible rotation of the pressure roller, while the multi-layer sealing rings 390 continuously maintain a high-pressure sealing state in the internal air passage, preventing gas leakage and ensuring stable air jet pressure throughout the process.

[0075] During continuous operation of the entire equipment, the copper foil unwinding assembly 400, the insulation layer unwinding assembly 500, and the end insulation unwinding assembly 600 maintain a passive and uniform feeding speed. Combined with the continuous winding action of the winding main unit 200, this achieves integrated synchronous winding and forming of the copper foil, interlayer insulation, and end insulation. After the entire winding is completed, the equipment stops operating, and the expansion winding mold 220 retracts to completely remove the densely formed, bubble-free, and highly insulating transformer foil coil, completing a single winding operation.

[0076] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0077] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A winding device for large transformer production, characterized by, include: A main frame, on which a copper foil unwinding assembly, an insulating layer unwinding assembly, an end insulating unwinding assembly, a winding main unit, and a pressure roller assembly are provided; The copper foil unwinding assembly is used to carry the copper foil roll and can passively release the copper foil; the insulation layer unwinding assembly is used to output the interlayer insulation material; and the end insulation unwinding assembly supplies end insulation material to both ends of the coil being wound. The winding host unit can rotate and provide winding traction force. The copper foil unwinding assembly is dragged by the winding traction force of the winding host unit to release the copper foil. The copper foil, interlayer insulation material and end insulation material are pulled and transported to the winding host unit. The pressure roller assembly includes a front pressure roller and a rear pressure roller arranged sequentially along the rotation direction of the winding main unit; the front pressure roller presses and tightens the copper foil wound on the middle region of the winding main unit, and the rear pressure roller presses and tightens the copper foil wound on both sides of the winding main unit. The front pressure roller first applies pressure to the middle of the copper foil, driving the air between the copper foil layers to both sides of the copper foil. Then, the rear pressure roller presses the edges of the copper foil on both sides to expel the residual air between the copper foil layers.

2. The winding device for large transformer production according to claim 1, characterized by, There are two rear pressure rollers and one front pressure roller. The axes of the two rear pressure rollers and one front pressure roller are parallel to each other, and the one front pressure roller and the two rear pressure rollers are arranged in a triangular pattern.

3. The winding device for large transformer production according to claim 2, characterized in that, Both the front and rear pressure rollers are provided with multiple high-pressure air holes, which are evenly distributed along the axial and circumferential directions of the front and rear pressure rollers. The multiple high-pressure air holes spray air onto the copper foil surface to remove impurities and help flatten the copper foil.

4. The winding device for large transformer production according to claim 3, characterized in that, The pressure roller assembly also includes a floating swing arm. One end of the floating swing arm is hinged to the main frame, and the other end of the floating swing arm is connected to the front pressure roller and the rear pressure roller. The floating swing arm can conform to the outer diameter of the coil on the winding main unit as it increases, so that the front pressure roller and the rear pressure roller are always in contact with the outer surface of the coil.

5. The winding device for large transformer production according to claim 4, characterized by The front and rear pressure rollers are hollow inside and have an air shaft connected to them in a rotating seal. The air shaft is connected to the floating swing arm. The air shaft is hollow inside and has air holes on its surface. An air pipe is connected to the air shaft and the air pipe is connected to a high-pressure air pump.

6. The winding device for large transformer production according to claim 5, wherein Rotary bearings are provided on the outer periphery of both ends of the air shaft. Multiple layers of sealing rings are provided on the outer periphery of the air shaft between the two rotary bearings. The outer ring of the sealing ring rotates and seals against the hollow inner wall of the front and rear pressure rollers, and the inner ring of the sealing ring is fixed on the outer periphery of the air shaft.

7. The winding device for large transformer production according to claim 1, wherein The copper foil unwinding assembly includes a copper foil unwinding base, a copper foil unwinding support bracket, a copper foil air shaft, a copper foil unwinding damping mechanism, and a transition guide roller group; The copper foil unwinding base is assembled on the main frame, and the copper foil unwinding support bracket is fixedly installed on the copper foil unwinding base; the copper foil air shaft is rotatably supported on the copper foil unwinding support bracket through the bearing seat, and the copper foil air shaft is used to clamp and fix the copper foil roll. The copper foil unwinding damping mechanism is connected to the end of the copper foil air shaft and is used to apply a reverse damping torque to the copper foil air shaft so that the copper foil maintains unwinding tension.

8. The winding device for large transformer production according to claim 1, wherein The insulation layer unwinding assembly includes an insulation unwinding bracket, an insulation air shaft, an insulation damping mechanism, and an insulation guide roller group; The insulating unwinding bracket is fixedly installed on the main frame; the insulating air shaft is rotatably supported on the insulating unwinding bracket through a bearing seat, and the insulating air shaft is used to clamp the interlayer insulating material roll. The insulating damping mechanism is connected to the end of the insulating air shaft and is used to apply a reverse damping torque to the insulating air shaft to maintain the unwinding tension of the interlayer insulating material. After the interlayer insulation material is released by the insulating air shaft, it is guided by the insulating guide roller group, aligned with the copper foil, and then transported together to the winding host unit.

9. The winding device for large transformer production according to claim 1, wherein The end-insulated unwinding assembly includes a mounting base bracket, several sets of unwinding shafts, and a tension damping mechanism. The mounting base bracket is equipped with a transverse linear slide rail, and each set of unwinding shafts is equipped with an independent tension damping mechanism.

10. The winding device for large transformer production according to claim 1, wherein The winding host unit includes a drive spindle and an expansion winding mold; The drive spindle is rotated and assembled on the main frame, the expansion winding mold is fixed on the drive spindle, and copper foil is wound around the outer periphery of the expansion winding mold to form a foil coil.

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