A transformer high-voltage coil winding device

Abstract

This invention provides a transformer high-voltage coil winding device, including a high-voltage winding machine, an electromagnetic wire unloading rack, and an insulation layer unloading rack. The high-voltage winding machine is equipped with a winding spindle for synchronously winding electromagnetic wire from the electromagnetic wire unloading rack and insulating material from the insulation layer unloading rack onto the coil frame according to a preset number of turns, layers, and interlayer arrangement rules, forming a high-voltage coil with an interlayer insulation structure. The electromagnetic wire unloading rack is located on one side of the high-voltage winding machine for supporting and stably releasing the electromagnetic wire. The insulation layer unloading rack is located below the high-voltage winding machine or in the vicinity of the wire inlet path for supporting and supplying the insulating material. The transformer high-voltage coil winding device provided by this invention solves the problems of easy deviation, lack of tension, and easy unraveling of the insulating material during use.

Description

Technical Field

[0001] This utility model relates to the field of dry-type transformer production equipment, and in particular to a transformer high-voltage coil winding device. Background Technology

[0002] In the transformer manufacturing process, the winding quality of the high-voltage coil directly affects the electrical performance and operational stability of the product. To improve the insulation performance and mechanical strength of the coil, it is often necessary to simultaneously wrap a layer of insulating material (such as mesh cloth) as a reinforcing insulation material during the winding process.

[0003] However, in existing winding devices, the insulation material is typically unwound directly from the roll and wound onto the coil frame, lacking effective tension control and guiding mechanisms. This leads to the insulation material being prone to misalignment, wrinkling, and even breakage during actual operation, severely affecting the uniformity of coating and insulation performance. Simultaneously, due to the loose structure of the insulation roll itself and the lack of constant tension support, unwinding is likely to occur during the unwinding process, resulting in material waste, increased manual intervention frequency, and reduced production efficiency. Furthermore, traditional devices rely heavily on operators' experience to manually adjust the fabric direction and tension, making it difficult to ensure process consistency.

[0004] Therefore, there is an urgent need to design a new transformer high-voltage coil winding device to solve the technical problems of insulation materials easily deviating, lacking tension, and easily disintegrating during use. Utility Model Content

[0005] To overcome the technical problems mentioned in the background art, this utility model provides a transformer high-voltage coil winding device.

[0006] A transformer high-voltage coil winding device includes a high-voltage winding machine, an electromagnetic wire feeding rack, and an insulation layer feeding rack; The high-voltage winding machine is equipped with a winding spindle, which is used to synchronously wind the electromagnetic wire from the electromagnetic wire feeding rack and the insulating material from the insulating layer feeding rack onto the coil frame according to the preset number of turns, number of layers and interlayer arrangement rules, to form a high-voltage coil with an interlayer insulation structure. The electromagnetic wire feeding rack is located on one side of the high-voltage winding machine and is used to support and stably release the electromagnetic wire. The insulation layer feeding rack is located below the high-voltage winding machine or in the vicinity of the wire inlet path, and is used to carry and supply the insulation material.

[0007] Optionally, the high-voltage winding machine further includes a wire laying mechanism; The wire laying mechanism is located in front of the winding spindle and is used to guide the electromagnetic wire to be evenly arranged along the axial direction of the coil skeleton during the winding process, ensuring that there is no overlap or gap between adjacent turns.

[0008] Optionally, the electromagnetic wire feeding rack is equipped with a tension control mechanism; The tension control mechanism is used to maintain a constant tension in the electromagnetic wire during the unwinding process.

[0009] Optionally, the tension control mechanism includes a magnetic powder brake.

[0010] Optionally, the insulating material includes a mesh fabric.

[0011] Optionally, the insulation layer feeding rack includes a feeding bracket, a feeding shaft, a baffle, and a clamping plate; The feeding shaft is horizontally mounted on the feeding bracket and is used to rotatably support the insulating material roll. The baffle is fixedly sleeved on one or both ends of the unwinding shaft to limit the insulating material roll in the axial direction and prevent the insulating material roll from moving laterally during the unwinding process. The clamping plate is located at the front edge of the feeding bracket and is fixed upward at an inclined angle to initially compress and guide the insulating material released from the feeding shaft.

[0012] Optionally, the clamping plate is provided with an insulating material fixing mechanism, which is used to clamp and fix the end of the remaining insulating material to the clamping plate after the insulating material roll is unwound and cut, so as to facilitate quick positioning and retrieval during the next winding operation.

[0013] Optionally, the insulating material fixing mechanism includes a spring clip, quick clamp, or magnetic clamp.

[0014] This invention integrates a high-voltage winding machine, an electromagnetic wire unloading rack, and an insulation layer unloading rack, achieving synchronous and precise winding of the electromagnetic wire and insulation material, ensuring a stable interlayer insulation structure for the high-voltage coil. The rational layout of the device effectively improves winding efficiency and consistency. Simultaneously, the stable supply and precise arrangement of the insulation material significantly enhance the electrical performance and reliability of the coil. This invention solves the problems of insulation material deviation, lack of tension, and easy unraveling during use. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of a transformer high-voltage coil winding device provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of an insulating layer feeding rack provided in one embodiment of the present invention. Detailed Implementation

[0016] To make the technical problems solved, technical solutions, and beneficial effects of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0017] In the description of this utility model, it should be understood that the terms "longitudinal," "radial," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and 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 a limitation of this utility model. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0018] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0019] like Figure 1 As shown, this embodiment provides a transformer high-voltage coil winding device, including a high-voltage winding machine 01, an electromagnetic wire feeding rack 02, and an insulation layer feeding rack 03; The high-voltage winding machine 01 is equipped with a winding spindle, which is used to simultaneously wind the electromagnetic wire from the electromagnetic wire feeding rack 02 and the insulating material from the insulating layer feeding rack 03 onto the coil frame according to the preset number of turns, number of layers and interlayer arrangement rules, to form a high-voltage coil with an interlayer insulation structure. The electromagnetic wire feeding rack 02 is located on one side of the high-voltage winding machine 01 and is used to support and stably release the electromagnetic wire. The insulation layer feeding rack 03 is located below the high-voltage winding machine 01 or in the vicinity of the wire inlet path, and is used to carry and supply the insulation material.

[0020] Understandably, this embodiment provides a winding device for manufacturing high-voltage coils in dry-type transformers. The device has a compact overall layout and is easy to operate, enabling synchronous and high-precision winding of the electromagnetic wire and insulating material, ensuring that the coil has good electrical performance, mechanical strength, and reliable interlayer insulation.

[0021] Specifically, the winding device mainly includes a high-voltage winding machine 01, an electromagnetic wire feeding rack 02, and an insulation layer feeding rack 03. The three work together to complete the winding of the high-voltage coil.

[0022] The high-voltage winding machine 01 is equipped with a winding spindle, driven by a servo motor, which can precisely control the speed and start / stop. The winding spindle is the core actuator of the winding device. By rotating, it drives the coil frame to rotate, winding the electromagnetic wire and insulation material layer by layer according to a preset program (such as 500 turns, 4 layers, with a layer of mesh cloth added between each layer).

[0023] The electromagnetic wire unwinding rack 02 is located on one side of the high-voltage winding machine 01 and includes an unwinding reel and a rotating shaft. The unwinding reel carries the coiled copper electromagnetic wire and is passively unwound during the winding process.

[0024] The insulation layer feeding rack 03 is located below the high-voltage winding machine 01 or in the vicinity of the wire inlet path, which can save lateral space. The insulation layer feeding rack 03 is used to carry and supply insulation material.

[0025] This embodiment integrates a high-voltage winding machine 01, an electromagnetic wire feeding rack 02, and an insulation layer feeding rack 03, achieving synchronous and precise winding of the electromagnetic wire and insulation material, ensuring that the high-voltage coil has a stable interlayer insulation structure; the device layout is reasonable, effectively improving winding efficiency and consistency; at the same time, the stable supply and precise arrangement of insulation material significantly improve the electrical performance and reliability of the coil.

[0026] Optionally, the high-voltage winding machine 01 also includes a wire laying mechanism; The wire laying mechanism is located in front of the winding spindle and is used to guide the electromagnetic wire to be evenly arranged along the axial direction of the coil skeleton during the winding process, ensuring that there is no overlap or gap between adjacent turns.

[0027] Understandably, the high-voltage winding machine 01 may be equipped with a wire arrangement mechanism (not shown). The wire arrangement mechanism includes a conductor guide wheel and a reciprocating slide table. During the winding process, the guide wheel moves along the axis of the frame with the slide table, guiding the electromagnetic wire to be arranged tightly.

[0028] The wiring mechanism provided in this embodiment significantly improves winding density and consistency, and avoids partial discharge or heat accumulation caused by gaps between turns.

[0029] Optionally, the electromagnetic wire feeding rack 02 is equipped with a tension control mechanism; The tension control mechanism is used to maintain a constant tension in the electromagnetic wire during the unwinding process.

[0030] Understandably, this embodiment provides an electromagnetic wire unwinding rack 02 with a tension control mechanism to maintain constant tension of electromagnetic wire (such as enameled copper wire) during unwinding, so as to avoid problems such as wire damage, uneven winding or poor subsequent processing caused by tension fluctuations.

[0031] In some examples, the tension control mechanism includes a magnetic powder brake.

[0032] The tension control mechanism includes a magnetic powder brake, the input of which is connected to the unwinding shaft. By adjusting the excitation current of the magnetic powder brake, its output braking torque can be changed, thereby automatically adjusting the resistance according to the unwinding speed and wire diameter, so that the electromagnetic wire maintains the set tension during unwinding. This method has a fast response and high control precision, and is suitable for high-speed continuous winding equipment.

[0033] Optionally, the insulating material includes a mesh fabric.

[0034] Understandably, the insulation material can be a mesh fabric. The thickness and mesh size of the mesh fabric can be selected according to actual needs, such as a thickness of 0.15 mm to 0.30 mm and a mesh size of 2 mm × 2 mm. The mesh fabric has good air permeability, mechanical flexibility and tensile strength, is not easily torn during winding, and can effectively fill the gaps between conductors.

[0035] Optionally, such as Figure 2 As shown, the insulation layer feeding rack 03 includes a feeding bracket 031, a feeding shaft 032, a baffle 033, and a clamping plate 034; The feeding shaft 032 is horizontally mounted on the feeding bracket 031 and is used to rotatably support the insulating material roll. The baffle 033 is fixedly sleeved on one or both ends of the unwinding shaft 032 to limit the insulating material roll in the axial direction and prevent the insulating material roll from moving laterally during the unwinding process; The clamping plate 034 is set at the front edge of the feeding bracket 031 and fixed upward at an inclined angle, and is used to initially compress and guide the insulating material released from the feeding shaft 032.

[0036] Understandably, this embodiment provides an insulation layer unwinding rack 03 for use in a transformer high-voltage coil winding device, which is particularly suitable for unwinding flexible strip insulation materials such as fiber mesh cloth. Through a reasonable mechanical structure design, this unwinding rack effectively solves problems such as easy deviation, sagging, and retraction of insulation materials during the unwinding process, improving winding stability and ease of operation.

[0037] Specifically, the insulation layer feeding rack 03 mainly includes a feeding bracket 031, a feeding shaft 032, a baffle 033, and a clamping plate 034. Each component is modularly assembled and fixed as a whole on an independent frame, located in the area adjacent to the wire inlet path below and in front of the winding spindle.

[0038] The feeding bracket 031 includes two vertical columns and a connecting structure between the columns. Each of the two columns is provided with a bearing seat mounting position to support both ends of the feeding shaft 032.

[0039] The unloading shaft 032 can be a high-precision solid steel shaft with a diameter of 25 mm to 40 mm, and its surface is chrome-plated to reduce friction. The unloading shaft 032 is horizontally mounted on the bearing seat of the column, and its two ends are rotatably supported by rolling bearings. The middle of the shaft is used to mount the insulating material drum, which supports passive free rotation for unwinding.

[0040] The baffle 033 is a circular metal disc with an outer diameter slightly larger than the width of the insulating material roll. The baffle 033 is fixedly sleeved on one or both ends of the unwinding shaft 032. The baffle 033 can be locked using a keyway and set screws to prevent axial slippage. The inner surface of the baffle 033 is in close contact with the end face of the roll, providing rigid axial restraint to prevent lateral movement of the roll due to inertia or tension fluctuations during unwinding, thus preventing the insulating material from deviating from its intended path.

[0041] The clamping plate 034 is a flat metal piece, fixedly installed on the front edge of the feeding bracket 031 (i.e., the side near the winding spindle); during installation, it is fixed upward at an angle of 15° to 30° (relative to the horizontal plane), and its upper surface serves as a contact guide surface for the insulating material. The front end of the plate has a rounded transition to avoid scratching the insulating material.

[0042] In one example, during the loading stage, a roll of insulating material (such as a 300 mm wide fiber mesh) is inserted into the unwinding shaft 032, and both sides are limited and locked by baffles 033. During the unwinding stage, the front end of the insulating material is pulled out, allowing it to hang naturally and rest on the upper surface of the inclined clamping plate 034. Because the clamping plate 034 is inclined upwards, the material is slightly compressed under the combined action of gravity and the reaction force of the plate surface, and is smoothly guided along the plate surface to the winding spindle entrance, avoiding shaking or deviation caused by free hanging. After the current winding task is completed, the operator cuts the insulating material and fixes the remaining end on the drum with the spring clips on the clamping plate 034. Since the position and orientation of the clamping plate 034 are fixed, the material can be pulled out directly from the clamping point when the machine is started again, without the need for re-threading, significantly improving the material changing efficiency.

[0043] This embodiment constructs a stable, efficient, and easy-to-use insulation material supply system through the collaborative structure of the feeding bracket 031, feeding shaft 032, baffle 033, and inclined clamping plate 034, which effectively supports the realization of high-quality winding process of high-voltage coil.

[0044] Optionally, the clamping plate 034 is provided with an insulating material fixing mechanism, which is used to clamp and fix the end of the remaining insulating material on the clamping plate 034 after the insulating material roll is unwound and cut, so as to facilitate quick positioning and retrieval during the next winding operation.

[0045] Understandably, the clamping plate 034 integrates an insulation material fixing mechanism (such as a spring clip or magnetic clip) for clamping the cut end of the material. Specifically, after the current winding process is completed, the operator uses scissors or an automatic cutting device to cut the insulation material, and then the remaining end of the insulation material on the roll is firmly clamped to the clamping plate 034 by the insulation material fixing mechanism.

[0046] This embodiment can effectively prevent the ends of the insulating material from shrinking, scattering, or drooping, avoiding the need for re-threading during the next use, and improving operational efficiency and automation.

[0047] Optionally, the insulating material fixing mechanism includes a spring clip, quick clamp, or magnetic clamp.

[0048] Understandably, this embodiment provides an insulation material fixing mechanism for the insulation layer feeding rack 03 in a transformer high-voltage coil winding device. Its purpose is to reliably fix the free ends of the insulation material (such as fiber mesh) after the winding operation is paused or completed, preventing it from retracting, scattering, or sagging, thereby improving the preparation efficiency and operational convenience for the next winding operation. The insulation material fixing mechanism includes, but is not limited to, spring clips, quick-release clamps, or magnetic clamps.

[0049] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A transformer high voltage coil winding apparatus, characterized by, This includes high-voltage winding machines, electromagnetic wire feeding racks, and insulation layer feeding racks; The high-voltage winding machine is equipped with a winding spindle, which is used to synchronously wind the electromagnetic wire from the electromagnetic wire feeding rack and the insulating material from the insulating layer feeding rack onto the coil frame according to the preset number of turns, number of layers and interlayer arrangement rules, to form a high-voltage coil with an interlayer insulation structure. The electromagnetic wire feeding rack is located on one side of the high-voltage winding machine and is used to support and stably release the electromagnetic wire. The insulation layer feeding rack is located below the high-voltage winding machine or in the vicinity of the wire inlet path, and is used to carry and supply the insulation material.

2. The transformer high voltage coil winding apparatus of claim 1, wherein, The high-voltage winding machine also includes a wire laying mechanism; The wire laying mechanism is located in front of the winding spindle and is used to guide the electromagnetic wire to be evenly arranged along the axial direction of the coil skeleton during the winding process, ensuring that there is no overlap or gap between adjacent turns.

3. The transformer high voltage coil winding apparatus of claim 1, wherein, The electromagnetic wire feeding frame is equipped with a tension control mechanism; The tension control mechanism is used to maintain a constant tension in the electromagnetic wire during the unwinding process.

4. The transformer high voltage coil winding apparatus of claim 3, wherein, The tension control mechanism includes a magnetic powder brake.

5. The transformer high-voltage coil winding device according to claim 1, characterized in that, The insulating material includes a mesh fabric.

6. The transformer high-voltage coil winding device according to claim 1, characterized in that, The insulation layer feeding rack includes a feeding bracket, a feeding shaft, a baffle, and a clamping plate; The feeding shaft is horizontally mounted on the feeding bracket and is used to rotatably support the insulating material roll. The baffle is fixedly sleeved on one or both ends of the unwinding shaft to limit the insulating material roll in the axial direction and prevent the insulating material roll from moving laterally during the unwinding process. The clamping plate is located at the front edge of the feeding bracket and is fixed upward at an inclined angle to initially compress and guide the insulating material released from the feeding shaft.

7. The transformer high-voltage coil winding device according to claim 6, characterized in that, The clamping plate is equipped with an insulating material fixing mechanism, which is used to clamp and fix the end of the remaining insulating material to the clamping plate after the insulating material roll is unwound and cut, so as to facilitate quick positioning and retrieval during the next winding operation.

8. The transformer high-voltage coil winding device according to claim 7, characterized in that, The insulating material fixing mechanism includes a spring clip, quick clamp, or magnetic clamp.

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