Epoxy phase shift change structure cast in split mode

Abstract

The utility model discloses a split pouring epoxy phase-shifting change structure, which relates to the technical field of transformers and comprises an epoxy phase-shifting change body, and the epoxy phase-shifting change body comprises a plurality of epoxy phase-shifting change units arranged along the height direction. The epoxy phase-shifting unit comprises an inner insulator, the phase-shifting coil is coaxially wound on the inner insulator, the plurality of connecting terminals are connected with the phase-shifting coil, and the inner insulator, the phase-shifting coil and the plurality of connecting terminals are embedded in the protective shell; the problems that in a traditional epoxy pouring phase-shifting change structure, troubleshooting of problem points is difficult, the reworking cost is high, die filling is complex, and sleeving adjustment is inconvenient are solved, so that the production efficiency of a transformer is improved, the production cost is reduced, and the maintainability of a product is enhanced.

Description

Technical Field

[0001] This utility model relates to the field of transformer technology, specifically to a split-cast epoxy phase-shifting transformer structure. Background Technology

[0002] Traditional phase-shifting converter coils typically employ an integral epoxy casting process. This involves first wrapping a mesh plate around an inner mold according to the phase-shifting converter design, then winding the coil on the mesh plate, and finally inserting the entire coil into an outer mold for epoxy resin casting and curing.

[0003] However, after the transformer is cast, its coil becomes a single, integral structure. When a transformer malfunctions, the integrated coil makes it difficult to quickly locate the problem. Even if the problem is found, the cast body needs to be broken open for repairs, which not only increases the difficulty of repairs but also easily damages the coil, potentially rendering the entire coil unusable and resulting in high repair costs.

[0004] Meanwhile, during the casting process, the space from the coil root to the mold panel is extremely narrow, typically only about 50mm, while the number of secondary terminals connected to the coil is numerous, reaching dozens, and must be connected within this space. This dense terminal connection not only makes operation difficult and prone to connection problems, but also increases assembly time and the probability of errors.

[0005] In addition, during the assembly process, the coil is usually tied with a strap and put on in one go. If there is a misalignment in the assembly, it needs to be re-lifted and adjusted, which is cumbersome and inefficient. Utility Model Content

[0006] The purpose of this invention is to provide a split-cast epoxy phase-shifting transformer structure to solve the problems of difficult troubleshooting, high rework costs, complex mold assembly, and inconvenient assembly and adjustment in traditional epoxy cast phase-shifting transformer structures, thereby improving the production efficiency of transformers, reducing production costs, and enhancing product maintainability.

[0007] The above-mentioned optimized structure of this utility model is achieved through the following technical solution: a split-cast epoxy phase change structure, including an epoxy phase change body, wherein the epoxy phase change body includes a plurality of epoxy phase change units arranged along the height direction;

[0008] The epoxy phase-shifting unit includes internal insulation;

[0009] A phase-shifting transformer coil, which is coaxially wound on the inner insulation;

[0010] Multiple connection terminals, wherein the multiple connection terminals are connected to the phase-shifting transformer coil;

[0011] The protective shell has the inner insulation, the phase-shifting coil, and a plurality of the connection terminals embedded therein.

[0012] In some embodiments, the protective shell includes an annular portion, wherein the inner insulation and the phase-shifting coil are coaxially embedded in the annular portion;

[0013] The square portion is connected to one side of the circular portion, and the square portion is provided with a plurality of the connecting terminals.

[0014] In some embodiments, the protective shell is made of epoxy resin casting.

[0015] In some embodiments, the connection terminal is a copper terminal.

[0016] In some embodiments, the epoxy phase change unit further includes two fixing holes, which are symmetrically disposed at both ends of the square portion.

[0017] In some embodiments, the epoxy phase change unit further includes a limiting boss, which is disposed on the top of the protective shell;

[0018] A limiting groove is provided at the bottom of the protective shell and is inserted into and engaged with the limiting boss.

[0019] In some embodiments, the cross-section of the limiting groove is an isosceles trapezoid.

[0020] In summary, this utility model has the following beneficial effects:

[0021] This type of split-cast epoxy phase-shift transformer structure achieves a split structure for the epoxy phase-shift transformer body by setting multiple epoxy phase-shift transformer units along the height direction. This makes the coil and mold independent units, each with only a few leads. When welding copper terminals, operators can easily reach the leads for operation, and the leads are easily bent during mold assembly without interfering with other leads, simplifying the assembly and fitting process, improving production efficiency. Furthermore, if misalignment occurs during assembly, manual adjustments can be made at any time, making operation more convenient. When the transformer malfunctions and requires rework, only the problematic section needs to be removed for rework, without damaging the overall coil structure. This avoids the situation in traditional integral cast structures where local problems lead to overall scrap, reducing rework costs, shortening rework time, and improving production efficiency. The appropriate number of epoxy phase-shift transformer units can be selected according to the actual needs of the epoxy phase-shift transformer body. Epoxy phase-shift transformer bodies with different coil numbers do not require mold redesign, thus reducing the number of molds, lowering mold manufacturing costs, and expanding the scope of application. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the existing epoxy phase-shifting structure;

[0023] Figure 2This is a schematic diagram of the structure of this utility model;

[0024] Figure 3 This is a schematic diagram of the structure of the epoxy phase-shifting change unit in Embodiment 1 of this utility model;

[0025] Figure 4 This is a cross-sectional schematic diagram of the epoxy phase-shifting unit in Embodiment 1 of this utility model;

[0026] Figure 5 This is a top view of the epoxy phase-shifting unit in Embodiment 2 of this utility model;

[0027] Figure 6 This is a bottom view of the epoxy phase-shifting unit in Embodiment 2 of this utility model.

[0028] In the diagram: 1. Epoxy phase-shifting converter unit; 11. Inner insulation; 12. Phase-shifting converter coil; 13. Connecting terminal; 14. Protective shell; 15. Fixing hole; 16. Limiting boss; 17. Limiting groove. Detailed Implementation

[0029] The technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0030] Example 1:

[0031] refer to Figure 1-4 A modular epoxy phase-shifting transformer structure is disclosed, comprising an epoxy phase-shifting transformer body, which includes multiple epoxy phase-shifting transformer units 1 arranged along the height direction. There can be three epoxy phase-shifting transformer units 1. By designing the epoxy phase-shifting transformer body as a modular structure, the coil and the mold become independent units, each with only a few leads. This allows operators to easily reach and operate during copper terminal welding, and the leads are easily bent during mold assembly without interfering with other leads, simplifying the assembly and fitting process, improving production efficiency. Furthermore, if misalignment occurs during assembly, manual adjustments can be made at any time, making operation more convenient. When the transformer malfunctions and requires rework, only the problematic section needs to be removed for rework, without damaging the overall coil structure. This avoids the situation in traditional modular casting structures where localized problems lead to overall scrap, reducing rework costs, shortening rework time, and improving production efficiency. Furthermore, the appropriate number of epoxy phase-shifting units 1 can be selected according to the actual needs of the epoxy phase-shifting body. Epoxy phase-shifting bodies with different numbers of coils do not require redesigning the mold, thereby reducing the number of molds, lowering mold manufacturing costs, and expanding the scope of application.

[0032] The epoxy phase-shifting unit 1 includes inner insulation 11, a phase-shifting coil 12, multiple connecting terminals 13, and a protective shell 14. The inner insulation 11 serves as the basic support structure for the coil winding and can be a mesh plate wrapped around an inner mold. It can work with cured epoxy resin to form the skeleton and insulation structure of the epoxy phase-shifting unit 1. The phase-shifting coil 12 is coaxially wound on the inner insulation 11. The multiple connecting terminals 13 are connected to the phase-shifting coil 12 and can be welded for fixation; this is existing technology and will not be elaborated further. The connecting terminals 13 can be copper terminals, as copper has good conductivity, ensuring a good electrical connection between the phase-shifting coil and the external circuit, and reducing energy loss. The protective shell 14 embeds the inner insulation 11, the phase-shifting coil 12, and the multiple connecting terminals 13. The height of the inner insulation 11 and the position of the phase-shifting coil 12 on the inner insulation 11 can be adjusted according to actual needs to meet the specific requirements of different epoxy phase-shifting units 1.

[0033] In some embodiments, the protective shell 14 includes an annular portion and a square portion. The annular portion is coaxially embedded with an inner insulation 11 and a phase-shifting coil 12. The square portion is connected to one side of the annular portion and is embedded with a plurality of connection terminals 13. This allows for the relative separation of the phase-shifting coil 12 and the connection terminals 13, provides a reasonable layout space for the connection terminals 13, and enables the centralized arrangement of the connection terminals 13, facilitating subsequent connection with external circuits.

[0034] In some embodiments, the protective shell 14 is made of epoxy resin casting. Epoxy resin has good insulation properties, mechanical strength and chemical corrosion resistance. Using epoxy resin casting for the protective shell can effectively protect the internal electrical components and improve the overall performance and reliability of the transformer.

[0035] The specific working principle is as follows:

[0036] According to the existing process, the inner insulation 11 is wrapped on the inner mold, and the corresponding phase-shifting coil 12 is wound on the inner insulation 11. The connection terminal 13 is made of high-purity copper material, and the connection terminal 13 is reliably connected to the output end of the phase-shifting coil 12 by welding process. In this process, since there are few connection terminals 13, it is very convenient to weld the connection terminals 13.

[0037] The inner mold for completing coil winding and terminal connection is placed into the customized outer mold. Its position in the outer mold can be manually adjusted, and the connecting terminal 13 is connected to the bolt of the panel. During this process, since there are few connecting terminals 13, the hand can easily reach over to bend the lead wire without touching other leads.

[0038] Epoxy resin is injected and cured. The mold design is adapted to the structure of the protective shell 14 to ensure that a complete circular and square structure is formed after casting, effectively protecting the internal components. The outer and inner molds are removed, and the formed epoxy phase change unit 1 is polished to obtain the finished epoxy phase change unit 1.

[0039] Based on the actual requirements of the epoxy phase change body, select an appropriate number of epoxy phase change units 1, and stack the prepared epoxy phase change units 1 sequentially according to the design order, ensuring the coaxiality and perpendicularity between each unit. Secure them with iron yoke pads to complete the assembly of one epoxy phase change body.

[0040] Example 2:

[0041] refer to Figure 5-6 The difference between this embodiment and Embodiment 1 is that:

[0042] To improve the connection stability when multiple epoxy phase change units 1 are connected, the epoxy phase change unit 1 also includes two fixing holes 15, a limiting boss 16, and a limiting groove 17. The two fixing holes 15 are symmetrically arranged at both ends of the square part. Multiple epoxy phase change units 1 can be fixed during the installation process by fixing screws and other connecting parts, thereby improving the stability and reliability of the installation.

[0043] The limiting boss 16 is located at the top of the circular and square portions, and the limiting groove 17 is located at the bottom of the circular and square portions, and is inserted into the limiting boss 16. The shapes of the limiting boss 16 and the limiting groove 17 are adapted to the top surface of the protective shell 14. Through the insertion and engagement of the limiting boss 16 and the limiting groove 17, multiple epoxy phase-shifting units 1 can be accurately aligned and positioned when set along the height direction, avoiding relative rotation between multiple epoxy phase-shifting units 1, and ensuring the structural stability and electrical performance of the entire epoxy phase-shifting body.

[0044] In some embodiments, the cross-section of the limiting groove 17 can be an isosceles trapezoid. The cross-sectional shape of the isosceles trapezoid makes it easier for the limiting boss 16 to be inserted into the limiting groove 17, while ensuring the stability after insertion and preventing relative displacement between multiple epoxy phase change units 1, thereby further improving its stability.

[0045] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A split-cast epoxy phase-change structure, characterized in that: Includes an epoxy phase change body, wherein the epoxy phase change body includes a plurality of epoxy phase change units (1) arranged along the height direction. The epoxy phase-shifting unit (1) includes internal insulation (11); A phase-shifting coil (12) is coaxially wound on the inner insulation (11); Multiple connection terminals (13) are connected to the phase-shifting coil (12); The protective shell (14) is embedded with the inner insulation (11), the phase-shifting coil (12), and a plurality of the connection terminals (13).

2. The epoxy phase-change structure with split casting according to claim 1, characterized in that: The protective shell (14) includes an annular portion, and the inner insulation (11) and the phase-shifting coil (12) are coaxially embedded in the annular portion. A square portion is connected to one side of the circular portion, and the square portion is provided with a plurality of the connecting terminals (13).

3. The epoxy phase-change structure with split casting according to claim 1, characterized in that: The protective shell (14) is made of epoxy resin casting.

4. The epoxy phase-change structure with split casting according to claim 1, characterized in that: The connecting terminal (13) is a copper terminal.

5. The epoxy phase-change structure with split casting according to claim 2, characterized in that: The epoxy phase change unit (1) also includes two fixing holes (15), which are symmetrically located at both ends of the square part.

6. The epoxy phase-change structure with split casting according to claim 2, characterized in that: The epoxy phase change unit (1) further includes a limiting boss (16), which is located on the top of the protective shell (14); The limiting groove (17) is located at the bottom of the protective shell (14) and is inserted into the limiting boss (16).

7. The epoxy phase-change structure with split casting according to claim 6, characterized in that: The cross-section of the limiting groove (17) is an isosceles trapezoid.

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