A winding device for a split stator coil
By dividing the copper wire bundle into two strands using a stator coil winding device and fixing it with anti-detachment pins, the problem of difficult stator coil winding for low-voltage high-power generators is solved, and the winding efficiency and quality are improved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI MARATHON-GENXIN ELECTRIC CO LTD
- Filing Date
- 2025-06-26
- Publication Date
- 2026-07-07
AI Technical Summary
The large number of copper wires in the stator coils of low-voltage high-power generators makes it difficult to tie the lead copper wires at the ends and they are prone to crossing, which affects the slot fill factor and withstand voltage breakdown. Existing methods are complicated to operate and easily disrupt the coil distribution.
The winding device of the stator coil adopts a split-strand type. The copper wire bundle is divided into two strands by the upper and lower split-strand wheels in the guide unit and fixed during the winding process. Anti-detachment pins are used to prevent slippage, so as to realize the split-strand winding of copper wire.
It achieves effective strand winding of copper wire, avoids crossover, simplifies the operation process, improves slot fill rate and winding neatness, and reduces the risk of copper wire wear.
Smart Images
Figure CN224473174U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to a winding device for a stranded stator coil. Background Technology
[0002] For low-voltage, high-power generators with dispersed winding structures, such as 400V, 50Hz, 2000kW generators, the current reaches 3608A, which is extremely high. Because the stator coils of such generators have a very large number of copper leads—typically over 100 copper wires in a single stator coil—it is extremely difficult to simultaneously bend and secure the leads at the ends. Given the operator's suggestion to divide the leads into two strands for dispersed binding, and considering the size limitations of the copper connectors when installing them at the ends, it is also necessary to divide a large bundle of copper wires into two strands for cold pressing. The traditional method is to directly count the number of copper wires at the end of the bundle and divide it into two strands. However, this method cannot distinguish between the copper wires branching off at both ends of the coil; the two strands may be intertwined and not completely divided, which can easily lead to localized overheating of the cable.
[0003] To ensure that the copper wires within a coil are completely divided into two strands, guaranteeing that the two strands at both ends of the coil are identical and do not cross each other, the current method involves winding the original coil into two separate coils. For example, a coil originally wound with 100 copper wires is wound with 50 copper wires, creating two identical coils. During stator winding, the two coils are then combined into a single complete coil and embedded into a stator slot. This method naturally solves the problem of splitting the coils at both ends because it involves two coils. However, since coils are typically wound in a continuous winding manner, requiring 4-5 turns of copper wire at a time, merging the coils requires turning each turn of copper wire, which is difficult, adds weight to the copper wire, and easily disrupts the distribution of copper wires within the coil. This results in a messy coil embedded in the stator slot, potentially affecting the slot fill factor and even causing wear between the copper wires, leading to withstand voltage breakdown. Utility Model Content
[0004] The purpose of this invention is to overcome the defects of the prior art and provide a winding device for a split-strand stator coil, which meets the requirement of splitting the stator coil at both ends.
[0005] The purpose of this utility model is achieved as follows: a winding device for a stranded stator coil, comprising a wire feeding unit, a guiding unit, and a winding machine;
[0006] The wire feeding unit includes a wire feeding table, a set of copper wire coils arranged outside one side of the wire feeding table, a lead-in wheel that is mounted on the wire feeding table in a one-to-one correspondence with the set of copper wire coils and leads out the set of copper wire coils, and a wire bundle plate mounted on the wire outlet end of the wire feeding table; the guiding unit includes a lateral translation drive mechanism located on the wire outlet side of the wire bundle plate, a translation plate mounted on the lateral translation drive mechanism, a first guide wheel mounted on the front surface of the wire inlet end of the translation plate, and a second guide wheel mounted on the front surface of the wire outlet end of the translation plate.
[0007] The winding machine includes a winding drive motor that is horizontally mounted on the outer rear side of the guide unit and a winding mold mounted on the output shaft of the winding drive motor and located on the outer front side of the guide unit; the winding mold is provided with a plurality of winding grooves horizontally.
[0008] The winding device also includes a stranding device installed in the middle of the translation plate of the guide unit;
[0009] The stranding device includes a pressure plate, a base plate, an upper stranding wheel, a lower stranding wheel, an upper anti-detachment pin, and a lower anti-detachment pin; wherein...
[0010] The pressure plate is disposed on the rear surface of the translation plate;
[0011] The rear surface of the base plate is provided with a groove in the middle, and the base plate is mounted on the front surface of the pressure plate after the groove is engaged with the translation plate;
[0012] The upper split wheel is installed on the upper part of the front surface of the base plate; the lower split wheel is installed on the lower part of the front surface of the base plate.
[0013] The upper anti-detachment pin is installed on the front surface of the base plate and is located above the upper stranding wheel; the lower anti-detachment pin is installed on the front surface of the base plate and is located below the lower stranding wheel;
[0014] The gaps between the outer surface of the upper anti-detachment pin and the outer surface of the upper stranding wheel, and the gaps between the outer surface of the lower anti-detachment pin and the outer surface of the lower stranding wheel, are both smaller than the diameter of the copper wire.
[0015] The winding device for the above-mentioned split-strand stator coil is characterized in that the upper split-strand wheel and the lower split-strand wheel each include a bolt shaft mounted on the base plate, a spacer mounted in the middle of the bolt shaft, two bearings mounted one in front of the other on the bolt shaft and located at both ends of the spacer, and a grooved wheel fitted on the outer ring of the two bearings.
[0016] The winding device for the above-mentioned stranded stator coil is characterized in that the base plate has upper and lower insertion holes corresponding to the upper and lower anti-detachment pins, and an upper threaded hole perpendicularly connected to the upper insertion hole is opened on the top surface of the base plate, and a lower threaded hole perpendicularly connected to the lower insertion hole is opened on the bottom surface of the base plate; after the upper and lower anti-detachment pins are inserted into the upper and lower insertion holes respectively, the upper and lower anti-detachment pins are locked by two locking screws installed in the upper and lower threaded holes respectively.
[0017] The features of the winding device for the split-strand stator coil of this utility model are:
[0018] 1. By adding a stranding device, mainly composed of an upper stranding wheel and a lower stranding wheel, to the guide unit, the large copper wire bundle is divided into an upper small copper wire bundle and a lower small copper wire bundle in the middle of the guide unit. In this way, the beginning and end of the coil can be tied at the stranding device. The coil can be wound in the normal winding method while the wire is being stranded.
[0019] 2. The entire stranding device is detachable and its installation position can be adjusted. Removing it will not affect the function of the original winding device.
[0020] 3. Anti-detachment pins are installed above the upper stranding wheel and below the lower stranding wheel to prevent the copper wire from slipping. The anti-detachment pins are easy to install and remove, making it convenient to pass the small copper wire bundle through the upper and lower stranding wheels. Attached Figure Description
[0021] Figure 1 This is a side view of the winding device for the stranded stator coil of this utility model;
[0022] Figure 2 This is a top view of the winding device for the stranded stator coil of this utility model;
[0023] Figure 3 This is a perspective view of the stranding device in the winding device of the stranded stator coil of this utility model;
[0024] Figure 4 This is a side view of the stranding device in the winding device of the stranded stator coil of this utility model;
[0025] Figure 5 This is an axial sectional view of the upper or lower stranding wheel in the winding device of this utility model. Detailed Implementation
[0026] The present invention will be further described below with reference to the accompanying drawings.
[0027] Please see Figures 1 to 5 The winding device for the stranded stator coil of this utility model includes a wire feeding unit 1, a guiding unit 2, a winding machine 3, and a stranding device 4.
[0028] The wire feeding unit 1 includes a wire feeding platform 10, a set of copper wire coils 11 symmetrically arranged on one side of the wire feeding platform 10, a row of lead wheels 12 that are installed on the wire feeding platform 10 in a one-to-one correspondence with the set of copper wire coils 11 and lead out the set of copper wire coils 11, and a wire bundle plate 13 installed at the wire outlet end of the wire feeding platform 10.
[0029] The guide unit 2 includes a lateral translation drive mechanism 20 located on the wire outlet side of the cable tray 13, a translation plate 21 mounted on the lateral translation drive mechanism 20, a first guide wheel 22 mounted on the front surface of the wire inlet end of the translation plate 21, and a second guide wheel 23 mounted on the front surface of the wire outlet end of the translation plate 21.
[0030] The winding machine 3 includes a winding drive motor 30 that is horizontally mounted on the outer rear side of the guide unit 2 and a winding mold 31 that is mounted on the output shaft of the winding drive motor 30 and located on the outer square side of the guide unit 2; the winding mold 31 is provided with a plurality of winding grooves horizontally.
[0031] The stranding device 4 is installed in the middle of the translation plate 21 of the guide unit 2; the stranding device 4 includes a pressure plate 41, a base plate 42, an upper stranding wheel 43a, a lower stranding wheel 43b, an upper anti-detachment pin 44a, and a lower anti-detachment pin 44b; wherein...
[0032] The pressure plate 41 is disposed on the rear surface of the translation plate 21;
[0033] The rear surface of the base plate 42 is provided with a groove 420 in the middle. After the base plate 42 is engaged with the translation plate 21 in the groove 420, it is mounted on the front surface of the pressure plate 41 by bolts 40.
[0034] The upper split wheel 43a is installed on the upper part of the front surface of the base plate 42; the lower split wheel 43b is installed on the lower part of the front surface of the base plate 42.
[0035] The upper split wheel 43a and the lower split wheel 43b each include a bolt shaft 431 mounted on the base plate 42, a spacer 432 mounted in the middle of the bolt shaft 431, two bearings 433 mounted one in front of the other on the bolt 431 and located at both ends of the spacer 432, and a grooved wheel 430 fitted on the outer ring of the two bearings 43; the inner and outer ends of the grooved wheel 430 are respectively provided with an inner washer 434 and an outer washer 435; a spring washer 436 is also provided between the outer washer 435 and the thread head of the bolt shaft 431; the material of the grooved wheel 430 is nylon or ABS;
[0036] The upper anti-detachment pin 44a is installed on the front surface of the base plate 42 and is located above the upper stranding wheel 43a; the lower anti-detachment pin 44b is installed on the front surface of the base plate 42 and is located below the lower stranding wheel 43b; the gap h between the outer surface of the upper anti-detachment pin 44a and the outer surface of the upper stranding wheel 43a and the outer surface h of the lower anti-detachment pin 44b and the lower stranding wheel 43b is smaller than the diameter of the copper wire and is 0.5-1mm. The diameter of the copper wire is usually 1.2-1.6mm. The upper anti-detachment pin 44a and the lower anti-detachment pin 44b can prevent the copper wire from slipping out of the groove of the grooved wheel 430.
[0037] The base plate 42 has upper and lower insertion holes corresponding to the upper anti-detachment pins 44a and 44b, respectively. The top surface of the base plate 42 has an upper threaded hole that is perpendicular to the upper insertion hole, and the bottom surface of the base plate 42 has a lower threaded hole that is perpendicular to the lower insertion hole. After the upper anti-detachment pins 44a and 44b are inserted into the upper and lower insertion holes respectively, the upper anti-detachment pins 44a and 44b are locked by two locking screws 45 that are installed in the upper and lower threaded holes respectively.
[0038] In operation, the winding device for the stator coil of this utility model involves winding a set of copper wires 11 around a row of lead wheels 12 one by one. Then, the set of copper wires is gathered into a large copper wire bundle by the wire bundle plate 13. The bundle then enters the guide unit 2 and passes through the first guide wheel 22 and the second guide wheel 23 in sequence. After passing through the first guide wheel 22, the large copper wire bundle 5A is divided into two small copper wire bundles by the upper and lower stranding wheels 43a and 43b, respectively. The two small copper wire bundles 5a pass one by one from the upper side of the upper stranding wheel 43a and the lower side of the lower stranding wheel 43b. The two small copper wire bundles 5a are then led out by the second guide wheel 23 and gathered into a large copper wire bundle 5A again. The large copper wire bundle 5A is then aligned with the winding slots of the winding mold 31. Finally, the winding drive motor 30 drives the winding mold 31 to rotate and wind the large copper wire bundle 5A onto the winding mold 31, thus completing the winding of the stator coil. The motor inside the lateral translation drive mechanism 20 of the guide unit 2 drives the lead screw to move the support plate 21 back and forth, coordinating with the winding mold 31 to move synchronously. After the winding mold 31 rotates to complete the winding of the coil in one winding slot, the two support plates 21 translate by the width of one winding slot, guiding the copper wire bundle to the next winding slot, and continuing to wind the coil in the next winding slot.
[0039] Before winding the coil, count the number of copper wires and divide them into two small copper wire bundles 5a. After passing through the first guide wheel 22 of the guide unit 2, pass them through the upper and lower stranding wheels 43a and 43b of the stranding device 4, respectively. Removing the upper and lower anti-detachment pins 44a and 44b facilitates operation. Then, combine the two small copper wire bundles 5a into a large copper wire bundle 5A and pass it through the second guide wheel 23 of the guide unit 2. Before entering the winding mold 31, at the stranding device 4, first use cable ties to fix the beginning of the coil to secure the strands, and then begin normal coil winding. After the coil winding is completed, at the end of the coil, again at the stranding device 4, use cable ties to secure the end strands of this coil. Then repeat the operation to complete the winding of all coils.
[0040] The upper and lower stranding wheels 43a and 43b of the stranding device 4 are located between the first guide wheel 22 and the second guide wheel 23 of the guide unit 2. They are located on the upper and lower sides of the original large copper wire bundle's travel path, respectively, and are offset by 30-40mm above and below the original large copper wire bundle's travel path. Compared with the position of the original large copper wire bundle, the stranded small copper wire bundles can be separated by 60-80mm of space, so that the beginning and end sections of the coil can be tied at the stranding device 4.
[0041] The winding device for the stator coil of this utility model allows for adjustment of the installation position of the stranding device 4 on the translation plate 21 after loosening the bolt 40 between the pressure plate 41 and the base plate 42. The entire stranding device 4 can be disassembled after removing the bolt 40 without affecting the coil winding in its original state.
[0042] The winding device for the stator coil of this utility model can also wind two coils simultaneously. Two parallel translation plates 21 are arranged one in front of the other on the guide unit 2. The inlet and outlet ends of each translation plate 21 are respectively installed with a first guide wheel 22 and a second guide wheel 23. The transverse translation drive mechanism 20 drives the two translation plates 21 simultaneously. At the same time, a stranding device 4 is installed on each of the two translation plates 21. On both sides of the wire feeding table 10 of the wire feeding unit 1, a set of copper wire coils 11 corresponding to the two translation plates 21 is arranged. Two rows of copper wire coils 11 corresponding to the two sets of copper wire coils 11 are installed on the wire feeding table. The wires are drawn out by two sets of copper wire coils 11 on the wire guide wheel 12. The multiple copper wires drawn out by the two sets of wire guide wheels 12 are gathered into a large bundle on the wire bundle plate 13. The large bundle of copper wires after exiting the wire bundle plate 13 is divided into two large copper wire bundles 5A, and then enters the first guide wheel 22 on the two translation plates 21 one by one. After being divided into two small copper wire bundles 5a by the stranding device 4 on the two translation plates 21, they enter the second guide wheel 23 on the two translation plates 21 one by one. Finally, they are introduced into the two winding slots of the winding mold 31 that are adapted to the spacing of the two translation plates 21, so as to realize the function of winding two coils at the same time.
[0043] The above embodiments are for illustrative purposes only and are not intended to limit the present invention. Those skilled in the art can make various changes or modifications without departing from the spirit and scope of the present invention. Therefore, all equivalent technical solutions should also fall within the scope of the present invention and should be defined by the claims.
Claims
1. A winding device for a stranded stator coil, comprising a wire feeding unit, a guiding unit, and a winding machine; The wire feeding unit includes a wire feeding table, a set of copper wire coils arranged outside one side of the wire feeding table, a lead-in wheel that is mounted on the wire feeding table in a one-to-one correspondence with the set of copper wire coils and leads out the set of copper wire coils, and a wire bundle plate mounted on the wire outlet end of the wire feeding table; the guiding unit includes a lateral translation drive mechanism located on the wire outlet side of the wire bundle plate, a translation plate mounted on the lateral translation drive mechanism, a first guide wheel mounted on the front surface of the wire inlet end of the translation plate, and a second guide wheel mounted on the front surface of the wire outlet end of the translation plate. The winding machine includes a winding drive motor that is horizontally mounted on the outer rear side of the guide unit and a winding mold mounted on the output shaft of the winding drive motor and located on the outer front side of the guide unit; the winding mold is provided with a plurality of winding grooves horizontally. Its features are, The winding device also includes a stranding device installed in the middle of the translation plate of the guide unit; The stranding device includes a pressure plate, a base plate, an upper stranding wheel, a lower stranding wheel, an upper anti-detachment pin, and a lower anti-detachment pin; wherein... The pressure plate is disposed on the rear surface of the translation plate; The rear surface of the base plate is provided with a groove in the middle, and the base plate is mounted on the front surface of the pressure plate after the groove is engaged with the translation plate; The upper split wheel is installed on the upper part of the front surface of the base plate; the lower split wheel is installed on the lower part of the front surface of the base plate. The upper anti-detachment pin is installed on the front surface of the base plate and is located above the upper stranding wheel; the lower anti-detachment pin is installed on the front surface of the base plate and is located below the lower stranding wheel; The gaps between the outer surface of the upper anti-detachment pin and the outer surface of the upper stranding wheel, and the gaps between the outer surface of the lower anti-detachment pin and the outer surface of the lower stranding wheel, are both smaller than the diameter of the copper wire.
2. The winding device for a split-strand stator coil according to claim 1, characterized in that, The upper and lower split wheels each include a bolt shaft mounted on the base plate, a spacer mounted in the middle of the bolt shaft, two bearings mounted one in front of the other on the bolt shaft and located at both ends of the spacer, and a grooved wheel fitted on the outer ring of the two bearings.
3. The winding device for a split-strand stator coil according to claim 1, characterized in that, The base plate has upper and lower insertion holes corresponding to the upper and lower anti-detachment pins, and an upper threaded hole perpendicularly connected to the upper insertion hole is opened on the top surface of the base plate, and a lower threaded hole perpendicularly connected to the lower insertion hole is opened on the bottom surface of the base plate. After the upper and lower anti-detachment pins are inserted into the upper and lower insertion holes respectively, the upper and lower anti-detachment pins are locked by two locking screws installed in the upper and lower threaded holes respectively.