A double-layered foil coil winding mold structure

Abstract

The application discloses a double-layer foil coil winding mold structure, which comprises a mold core, a mold end plate, a U-shaped support, an outer coil copper bar baffle and a support strut, the mold core is arranged in the center of the winding mold, the inner coil is wound around the periphery of the mold core, the two ends of the mold core are provided with the mold end plate, the mold end plate is connected with the mold core through end plate fixing bolts, the U-shaped support is fixed on the mold end plate through a plurality of groups of end plate fixing bolts, the outer coil copper bar baffle is installed below the U-shaped support through welding, and the support struts are uniformly distributed in a ring shape along the periphery of the inner coil and provide support for the coil winding, the stability and order of the double-layer foil coil winding process are guaranteed through reasonable assembly of the components, and the mold structure is suitable for efficient production of the double-layer foil coil.

Description

Technical Field

[0001] This article belongs to the technical field of coil winding molds, specifically involving a double-layer foil coil winding mold structure. Background Technology

[0002] In the power system, transformers are indispensable equipment, playing a crucial role in converting voltage and current. With the continuous increase in the number of electrical devices in society, the market demand for transformers of various specifications is also increasing. In some places with high requirements for power supply quality, such as large industrial production workshops and precision instrument laboratories, transformer equipment with low input and high output voltage is often required.

[0003] In the manufacturing process of low-voltage, high-current transformers, the coil, as a core component, is crucial to transformer performance due to its winding process and material selection. Currently, the industry typically uses copper foil or aluminum foil as the conductor material for coil fabrication. Furthermore, during the winding process, the primary input outer coil and the secondary output inner coil must be wound separately using independently formed mold cores. After winding, the mold (such as...) is then... Figure 4 (As shown) After dismantling, the wound coils are mounted on the transformer core columns in the radial direction according to their size. However, this traditional production method has significant drawbacks. On the one hand, each of the primary input winding and the secondary output winding requires a mold, which greatly increases the design, processing and manufacturing costs of the molds, putting a lot of pressure on the production investment of enterprises. On the other hand, the molds need to be changed during the winding process, which is not only cumbersome to operate, but also consumes a lot of time, resulting in long production time and low production efficiency, making it difficult to meet the market's demand for rapid production and delivery of transformers.

[0004] Meanwhile, in the production of foil coils for conventional power equipment such as power transformers and reactors, the traditional foil coil winding mold structure also has obvious defects. When it is necessary to produce double-layer coil products with foil windings in both the inner and outer layers, the existing technology still requires the separate production of inner coil molds and outer coil molds. The design, processing and manufacturing costs of the molds are high, further increasing the production input burden of enterprises. In the subsequent assembly process, the inner coil and outer coil must be wound separately before being assembled. After assembly, the two coils need to be fixed. This assembly process not only consumes a lot of manpower and time, but also makes it difficult for the assembled coils to achieve ideal mechanical strength and stability. During equipment operation, problems such as coil loosening and displacement are prone to occur, which in turn affect the overall performance and service life of the power equipment, increasing equipment maintenance costs and safety hazards.

[0005] In summary, existing mold structures used for the production of double-layer foil coils in low-voltage high-current transformers and conventional power equipment generally suffer from problems such as a large number of molds, high costs, and low efficiency. They can no longer meet the development needs of the power equipment manufacturing industry for cost reduction, efficiency improvement, and enhanced product performance. Therefore, developing a mold structure for double-layer foil coil winding that can achieve continuous winding of inner and outer coils, reduce the number of molds used, shorten production time, reduce production costs, and improve coil assembly stability has become an urgent technical problem to be solved in this field. Utility Model Content

[0006] To address the aforementioned issues, this paper proposes a double-layer foil coil winding mold structure. The winding mold includes a mold core, mold end plates, a U-shaped bracket, an outer coil copper busbar baffle, and supporting bars. The mold core is placed at the center of the winding mold, and the inner coil is wound around the outer circumference of the mold core. Mold end plates are located at both ends of the mold core, and the mold end plates are connected to the mold core by end plate fixing bolts. The U-shaped bracket is fixed to the mold end plates by several sets of end plate fixing bolts. The outer coil copper busbar baffle is installed below the U-shaped bracket by welding. The supporting bars are evenly distributed in a ring around the outer circumference of the inner coil. With this structural design, the inner coil can be wound directly on the mold core, while the outer coil is wound synchronously around the outer circumference of the inner coil with the support bars as support, realizing continuous winding of the inner and outer coils and effectively reducing the multiple processes required by the traditional assembly process.

[0007] The inner coil is wound on the mold core, which is made of high-strength material. The mold core has excellent compressive strength and dimensional stability, and can maintain its structural shape and not easily deform during the winding process, thus providing a reliable guarantee for the winding accuracy of the inner coil.

[0008] The U-shaped bracket includes parallel vertical support plates and a bottom support horizontal plate for connecting the two vertical support plates. The inner sidewall of the vertical support plate is in contact with the mold end plate, and the bottom support horizontal plate is welded and fixed to the vertical support plate by reinforcing ribs, which further improves the overall structural strength and load-bearing capacity of the U-shaped bracket, ensuring that the outer coil copper busbar baffle can be stably supported during the outer coil winding process, and avoiding positional displacement caused by uneven force.

[0009] The U-shaped bracket is located opposite the copper busbar end face that fixes the internal winding. Its design position can precisely correspond to the feeding direction of the copper busbar, avoiding vertical displacement of the copper busbar during transmission, thereby ensuring uniform interlayer spacing of the double-layer foil coil.

[0010] The mold end plate is placed inside the U-shaped bracket, and the center of the mold end plate is higher than the height of the vertical support plate of the U-shaped bracket. This height difference design provides ample operating space for the turning and stacking of copper busbars.

[0011] The height of the outer coil copper busbar baffle is lower than the thickness of the outer foil type coil copper busbar. The extension direction of the outer coil copper busbar baffle is consistent with the axial direction of the mold core. This design can avoid the continuous feeding of the outer foil type coil copper busbar due to the outer coil copper busbar baffle being too high.

[0012] The support bar is long and its length is matched with the axial length of the inner coil. The support bar is located between the inner coil and the outer foil coil copper busbar to be wound. The support bar provides stable support and protection for the inner coil, preventing the inner coil from deforming under external pressure, and does not excessively occupy the winding space of the outer foil coil copper busbar, thus ensuring the compactness and rationality of the overall structure of the double-layer foil coil.

[0013] Beneficial effects:

[0014] The mold end plate is connected to the mold core using end plate fixing bolts. The U-shaped bracket is fixed to the mold end plate by several sets of end plate fixing bolts, forming a detachable structure. This allows for quick mold assembly and coil winding, effectively reducing the labor intensity of operators and also reducing the probability of production errors caused by complex operations, thus improving the stability of the production process.

[0015] By winding the inner and outer coils together, they form a whole during the winding process, resulting in a tighter bond between them. This effectively improves the mechanical strength of the product, enabling it to better withstand various mechanical stresses during equipment operation. At the same time, the stability of the coils is also greatly enhanced, reducing problems such as coil loosening and displacement, thus strongly guaranteeing the overall quality of the product and the reliable operation of the power equipment.

[0016] By adopting this new type of double-layer foil coil winding mold, when encountering coil products where both inner and outer coils need to be produced using copper or aluminum foil, only one inner coil mold and a U-shaped bracket need to be made. There is no need to make an additional outer coil mold, which can complete the production of both inner and outer windings. This reduces the need for an outer coil mold and effectively lowers the production cost. Attached Figure Description

[0017] Figure 1 This is a front view of a double-layer foil coil winding mold structure;

[0018] Figure 2 This is a top view of a double-layer foil coil winding mold structure;

[0019] Figure 3 This is a side view of a double-layer foil coil winding mold structure;

[0020] Figure 4This is a side view of a conventional foil coil winding die;

[0021] In the diagram: 1. Mold core, 2. Mold end plate, 3. End plate fixing bolt, 4. U-shaped bracket, 5. Outer coil copper busbar baffle, 6. Inner coil, 7. Support bar, 8. Outer foil type coil copper busbar, 9. Copper busbar baffle, 10. Inner foil type coil copper busbar. Detailed Implementation

[0022] To enhance understanding of this utility model, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. These embodiments are only used to explain the present utility model and do not constitute a limitation on the scope of protection of the present utility model.

[0023] 1. Mold core, 2. Mold end plate, 3. End plate fixing bolt, 4. U-shaped bracket, 5. Outer coil copper busbar baffle, 6. Inner coil, 7. Support bar, 8. Outer foil coil copper busbar, 9. Copper busbar baffle, 10. Inner foil coil copper busbar.

[0024] like Figure 1 , 2 As shown in Figure 3;

[0025] A double-layer foil coil winding mold structure, the winding mold includes a mold core 1, mold end plates 2, a U-shaped bracket 4, an outer coil copper busbar baffle 5, and supporting bars 7. The mold core 1 is placed at the center of the winding mold, and an inner coil 6 is wound around the outer periphery of the mold core 1. Mold end plates 2 are provided at both ends of the mold core 1. The mold end plates 2 are connected to the mold core 1 by end plate fixing bolts 3. The U-shaped bracket 4 is fixed to the mold end plates 2 by several sets of end plate fixing bolts 3. The outer coil copper busbar baffle 5 is installed below the U-shaped bracket 4 by welding. The supporting bars 7 are evenly distributed in a ring shape along the outer periphery of the inner coil 6. The inner coil 6 is wound on the mold core 1. The mold core 1 adopts... Made of high-strength material, the U-shaped bracket 4 includes parallel vertical support plates and a bottom support horizontal plate for connecting the two vertical support plates. The U-shaped bracket 4 is located opposite the end face of the copper busbar that fixes the internal winding. The mold end plate 2 is placed inside the U-shaped bracket 4. The center position of the mold end plate 2 is higher than the height of the vertical support plate of the U-shaped bracket 4. The height of the outer coil copper busbar baffle 5 is lower than the thickness of the outer foil coil copper busbar 8 to be wound. The extension direction of the outer coil copper busbar baffle 5 is consistent with the axial direction of the mold core 1. The support bar 7 is long and the length of the support bar 7 is adapted to the axial length of the inner coil 6. The support bar 7 is located between the inner coil 6 and the outer foil coil copper busbar 8 to be wound.

[0026] Implementation example;

[0027] First, the inner coil 6 is wound on the mold core 1. After winding, support bars 7 are evenly placed outside the wound inner coil 6. Mold end plates 2 are installed at both ends of the mold core 1. The U-shaped bracket 4 is installed and fixed on the mold end plate 2 by the end plate fixing bolts. The outer coil copper busbar baffle 5 is welded on the bottom surface of the U-shaped bracket 4. After fixing the U-shaped bracket 4 and the outer coil copper busbar baffle 5, the winding of the outer foil coil copper busbar 8 begins. After the inner and outer coils are wound, the end plate fixing bolts 3 are removed, and the mold end plate 2 and U-shaped bracket 4 are removed. Then, the mold core 1 is pulled out from the wound coil. The finished coil can then be assembled. After the inner and outer coils are wound together, the process of assembling and fixing two coils can be reduced in the assembly stage, reducing production time. The mechanical strength of the product after the inner and outer coils are wound together is improved, the product stability is strong, and the overall quality of the product is improved.

[0028] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A double-layer foil coil winding mold structure, characterized in that, The winding mold includes a mold core, a mold end plate, a U-shaped bracket, an outer coil copper busbar baffle, and supporting bars. The mold core is placed at the center of the winding mold, and the inner coil is wound around the outer circumference of the mold core. Mold end plates are provided at both ends of the mold core. The mold end plates are connected to the mold core by end plate fixing bolts. The U-shaped bracket is fixed to the mold end plate by several sets of end plate fixing bolts. The outer coil copper busbar baffle is installed below the U-shaped bracket by welding. The supporting bars are evenly distributed in a ring around the outer circumference of the inner coil.

2. The double-layer foil coil winding mold structure according to claim 1, characterized in that, The inner coil is wound on the mold core, and the mold core is made of high-strength material.

3. The double-layer foil coil winding mold structure according to claim 1, characterized in that, The U-shaped bracket includes parallel vertical support plates and a bottom support horizontal plate for connecting the two vertical support plates.

4. The double-layer foil coil winding mold structure according to claim 1, characterized in that, The U-shaped bracket is located opposite the copper busbar end face that fixes the internal winding.

5. The double-layer foil coil winding mold structure according to claim 1, characterized in that, The mold end plate is placed inside the U-shaped bracket, and the center of the mold end plate is higher than the height of the vertical support plate of the U-shaped bracket.

6. The double-layer foil coil winding mold structure according to claim 1, characterized in that, The height of the outer coil copper busbar baffle is lower than the thickness of the outer foil type coil copper busbar, and the extension direction of the outer coil copper busbar baffle is consistent with the axial direction of the mold core.

7. The double-layer foil coil winding mold structure according to claim 1, characterized in that, The support bar is long and its length is adapted to the axial length of the inner coil. The support bar is located between the inner coil and the copper busbar of the outer foil coil to be wound.

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