High-voltage winding and dry-type transformer

Abstract

Disclosed in the present application is a high-voltage winding, the high-voltage winding comprising a winding body, a high-voltage coil and a high-voltage insulating layer. A conductive wire is wound on the winding body to form the high-voltage coil, the high-voltage coil comprises a plurality of coil segments, and the high-voltage insulating layer wraps the high-voltage coil and the winding body. A support member is provided between any two adjacent coil segments, each support member comprising a plurality of support blocks and a fixing ring, the fixing ring being provided with a plurality of first snap-fit recesses, and the support blocks being fixed on the fixing ring by means of the first snap-fit recesses. The high-voltage winding of the present application is provided with the support members for fixing the relative position of the coil, thereby avoiding displacement of the coil during movement and transportation, mold assembly, and forming stages of the high-voltage winding. Also disclosed in the present application is a dry-type transformer.

Description

A high-voltage winding and a dry-type transformer Technical Field

[0001] This application relates to the field of dry-type transformer technology, and more specifically to a high-voltage winding and a dry-type transformer. Background Technology

[0002] Currently, for high-voltage windings of dry-type transformers with either wire-wound or foil-wound coils, spacers are required between adjacent coils to prevent displacement during transport, mold assembly, and molding. Traditional methods of placing and securing these spacers between coils are difficult, posing a risk of displacement or even detachment, requiring additional binding, which is cumbersome. Furthermore, the spacer dimensions need to be customized according to the spacing between adjacent coils of different high-voltage winding specifications, increasing costs. In addition, during the high-voltage winding molding stage, the spacers are susceptible to displacement due to the stress of the molding insulation medium, leading to coil shifting and affecting the quality of the high-voltage winding. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the purpose of this application is to provide a high-voltage winding in which a support is provided between any two adjacent coil sections. The support has a simple and reliable structure, is easy and flexible to install, and can fully abut against the high-voltage coil, effectively avoiding coil displacement problems caused by support displacement or even detachment, thus ensuring the quality of the high-voltage winding.

[0004] To achieve the above objectives, the technical means adopted in this application are as follows: A high-voltage winding, comprising a winding body, a high-voltage coil, and a high-voltage insulation layer, wherein a conductor is wound on the winding body to form a high-voltage coil, the high-voltage coil comprising several coil segments, and the high-voltage insulation layer enclosing the high-voltage coil and the winding body; a support member is provided between any two adjacent coil segments, the support member comprising several support blocks and a fixing ring, the fixing ring being provided with several first slots, and the support blocks being fixed to the fixing ring through the first slots. The support member is used to abut the coil, preventing the coil from shifting during the transfer, transportation, mold assembly, and forming process of the high-voltage winding.

[0005] Preferably, the support block includes at least one hollow portion, through which the support block is engaged with the first slot. The hollow portion can reduce the impact force of the silicone rubber on the support during injection, preventing damage to the support due to excessive injection pressure; the hollow portion can also make the fixation of the support block and the fixing ring more secure and less prone to falling off.

[0006] Preferably, the sum of the groove depth of the first slot and the depth of the hollowed-out portion is equal to the ring width of the fixing ring. This ensures that the support block can abut against the outer circumference of the winding body.

[0007] Preferably, the support block abuts against the outer circumferential surface of the winding body, and the top of the hollowed-out portion abuts against the bottom of the first slot. This prevents displacement of the innermost wire of the coil and ensures the supporting effect.

[0008] Preferably, the support block is n-shaped and includes a hollow portion.

[0009] Preferably, the support block is H-shaped and includes two hollow sections.

[0010] This allows for the selection of either n-type or H-type support blocks based on the specific structure of the coil winding, making the application of support components more flexible and applicable to a wider range of situations.

[0011] Preferably, the width of the support block matches the width of the first slot. This ensures a tight connection when the support block is engaged in the first slot, preventing it from easily loosening.

[0012] Preferably, a plurality of first slots are disposed on the outer periphery of the fixing ring and are evenly distributed along the circumference of the fixing ring. This allows the support block to be easily fixed to the fixing ring.

[0013] Preferably, the fixing ring is further provided with a plurality of second slots, which are disposed on the inner circumference of the fixing ring and evenly distributed along the circumference of the fixing ring. The arrangement of the second slots facilitates the flow of silicone rubber during the injection of the high-voltage insulating layer.

[0014] Preferably, the width of the support member is greater than or equal to the loop width of the coil. This allows the support member to better secure the coil and prevents the coil from being higher than the support member, thus preventing the outer coil from shifting due to the lack of constraint from the support member.

[0015] Preferably, the high-voltage insulation layer is made of high-temperature vulcanized silicone rubber or liquid silicone rubber, which improves the overall insulation and mechanical properties of the high-voltage winding.

[0016] This application also provides a dry-type transformer, including an iron core, a low-voltage winding and a high-voltage winding, wherein the low-voltage winding is sleeved outside the iron core and the high-voltage winding is sleeved outside the low-voltage winding.

[0017] The beneficial effects of this application are: the high voltage winding of this application can effectively prevent the high voltage coil from shifting during transfer, transportation, mold assembly and forming by setting support members to abut and fix the high voltage coil, thus ensuring the quality of the high voltage winding.

[0018] Meanwhile, the support component of this application is formed by the snap-fit ​​of the support block and the fixing ring, which has a simple and reliable structure, is easy to process, is flexible to install, and does not require additional binding, resulting in high work efficiency. Furthermore, the structure and quantity of the support component can be flexibly selected according to the structure of the high-voltage coil, making it widely applicable. Attached Figure Description

[0019] Figure 1 is a front view of a dry-type transformer 10 according to an embodiment of this application;

[0020] Figure 2 is a top view of a dry-type transformer 10 according to an embodiment of this application;

[0021] Figure 3 is a front view of the assembled iron core 110 according to one embodiment of this application;

[0022] Figure 4 is an enlarged view of point G in Figure 2;

[0023] Figure 5 is a perspective view of a high-voltage coil 1320 wound on a winding body 1310 according to an embodiment of this application.

[0024] Figure 6 is a simplified circuit diagram of the high-voltage coil 1320 according to an embodiment of this application;

[0025] Figure 7 is a perspective view of the high-voltage winding 130 according to an embodiment of this application;

[0026] Figure 8 is a perspective view of several support members 140 according to an embodiment of this application;

[0027] Figure 9 is a perspective view of the fixing ring 1420 according to an embodiment of this application;

[0028] Figure 10 is a perspective view of the support block 1410 according to an embodiment of this application;

[0029] Figure 11 is a perspective view of the support block 1410 according to another embodiment of this application. Detailed Implementation

[0030] As requested, specific embodiments of this application are disclosed herein. However, it should be understood that the embodiments disclosed herein are merely typical examples of this application and may be embodied in various forms. Therefore, the specific details disclosed herein are not intended to be limiting, but merely to serve as the basis for the claims and as a representative basis for teaching those skilled in the art to apply this application differently in practice in any appropriate manner, including employing the various features disclosed herein in combination with features that may not be explicitly disclosed herein.

[0031] As shown in Figures 1-3, the dry-type transformer 10 is a three-phase transformer, consisting of phase A, phase B, and phase C, meaning it comprises three single-phase transformers 100. Depending on the structure of the core 110, the three transformers 100 can be arranged in a linear or triangular configuration, and they can also be symmetrical. Furthermore, this dry-type transformer 10 can also be used as an isolation transformer, a frequency converter, a test transformer, etc.

[0032] In one embodiment, three transformers 100 are arranged in a linear structure. The dry-type transformer 10 includes an iron core 110, three low-voltage windings 120, and three high-voltage windings 130. The iron core 110 includes three columnar iron core bodies 111, an upper yoke 112 located at the upper end of the three columnar iron core bodies 111, and a lower yoke 113 located at the lower end of the three columnar iron core bodies 111. The three low-voltage windings 120 are respectively sleeved on the outer periphery of the three columnar iron core bodies 111, and the three high-voltage windings 130 are respectively sleeved on the outer periphery of the three low-voltage windings 120. That is, the three columnar iron core bodies 111, the three low-voltage windings 120, and the three high-voltage windings 130 are sequentially sleeved from the inside out. The columnar core 111 is composed of multiple layers of silicon steel sheets, which are bound and fixed together with cable ties. The radial cross-section of the columnar core 111 is approximately elliptical, circular, or other shapes, as long as it can be accommodated in the hollow cavity of the low-voltage winding 120; no restrictions are imposed here. The upper yoke 112 and lower yoke 113 are also composed of multiple layers of silicon steel sheets, which fix the three columnar cores 111 together, thereby forming the three-phase core 110 as shown in Figure 3.

[0033] A core clamp 150 is provided on the outer side of the core 110 to hold the core 110. The core clamp 150 can be a channel steel piece or a hollow tube piece, and there is no limitation. There are four core clamps 150, two of which are symmetrically located on both sides of the upper end of the core 110 and above the high-voltage winding 130; the other two are symmetrically located on both sides of the lower end of the core 110 and below the high-voltage winding 130.

[0034] Referring to Figures 2 and 4, the low-voltage winding 120 includes copper foil 121, a low-voltage insulation layer 122, and a support bar 123, with the copper foil 121 and the low-voltage insulation layer 122 alternately arranged. The copper foil 121 is formed by winding a whole sheet of copper foil, and the low-voltage insulation layer 122 is overlapped with the copper foil 121 and wound together. The low-voltage winding 120 is provided with at least one heat dissipation channel, which is located between adjacent copper foils 121 and low-voltage insulation layers 122, and the support bar 123 is located within the heat dissipation channel to support and isolate adjacent copper foils 121 and low-voltage insulation layers 122.

[0035] The low-voltage insulation layer 122 is made of polyimide impregnated paper, specifically SHS-P diphenyl ether prepreg material. It is made by impregnating polyimide film and polysulfone fiber nonwoven soft composite material with diphenyl ether resin and then baking. Of course, the low-voltage insulation layer can also be made of DMD insulation paper or silicone rubber film, or other insulation materials, depending on the insulation heat resistance level of the dry-type transformer.

[0036] The insulating support strip 123 is made of glass fiber impregnated with epoxy resin or aramid fiber impregnated with epoxy resin, without limitation. Furthermore, the insulating support strip 123 is an I-shaped strip for better mechanical stability. Of course, the insulating support strip can also be a square or other shaped strip, as long as it serves a supporting and insulating function.

[0037] As shown in Figures 5-7, the high-voltage winding 130 includes a winding body 1310, a high-voltage coil 1320, and a high-voltage insulation layer 1330. A conductor is wound around the winding body 1310 to form the high-voltage coil 1320, which comprises several coil segments. The high-voltage insulation layer 1330 encloses the high-voltage coil 1320 and the winding body 1310. Specifically, the winding body 1310 is a support cylinder structure, and it is a hollow cylinder, which can be a hollow round cylinder, a hollow elliptical cylinder, or other hollow cylindrical body. Several coil segments are arranged at intervals along the axial direction of the winding body 1310.

[0038] The winding body 1310 is a hollow tube formed by winding and curing glass fiber impregnated with epoxy resin or by pultrusion. It can also be a hollow tube formed by pultrusion winding of glass fiber or aramid fiber impregnated with epoxy resin, or a hollow tube formed by winding and curing of aramid fiber impregnated with epoxy resin or by pultrusion, or it can be made of other composite materials, which are not limited here.

[0039] Taking phase A transformer 100 as an example, a high-voltage coil 1320 is formed by circumferentially winding a conductor around the outer circumferential surface of the winding body 1310. Specifically, the high-voltage coil 1320 is spaced apart along the axial direction of the winding body 1310, and the conductor forms two output ends at the beginning and end after winding, namely the first output end D and the second output end X. Six taps are led out from the middle of the winding body 1310 along its axial direction, namely tap 2, tap 3, tap 4, tap 5, tap 6 and tap 7. The six taps are used to connect to the tap changer.

[0040] In one application scenario, the high-voltage coil 1320 includes four coil segments: a first coil segment 1321, a second coil segment 1322, a third coil segment 1323, and a fourth coil segment 1324. Further, along the axial direction of the winding body 1310, the extension length of each coil segment of the high-voltage coil 1320 is defined as the width of the coil.

[0041] In one embodiment, all four coil segments are foil-wound coils. The conductor is a thin, wide conductive foil. Interlayer insulation material is provided between any two adjacent layers of conductive foil in each coil segment. That is, the conductive foil and interlayer insulation material are overlapped and wound together to form a foil-wound coil. The conductive foil can be copper foil or aluminum foil, etc., and the interlayer insulation material can be silicone cloth, electrical composite material, fiberglass mesh, etc., as long as it meets the interlayer insulation performance requirements of the high-voltage winding 130 and different heat resistance levels; no restrictions are imposed here.

[0042] In another embodiment, all four coil segments are wire-wound layered coils. The conductors are continuous conductors, each covered with an insulating layer. This insulating layer can be film-coated, enameled, silk-coated, or other methods. The insulating layer can be a polyimide film or a fiberglass film, or it can be polyester varnish or other insulating materials, or a combination of multiple insulating materials can be used, as long as it meets the heat resistance rating of the high-voltage winding 130°C; no specific limitations are imposed here.

[0043] Furthermore, as shown in Figures 8-11, to make the wire winding more stable, the high-voltage winding 130 also includes several support members 140. A support member 140 is provided between any two adjacent sections of the high-voltage coil 1320. Each support member 140 includes several support blocks 1410 and a fixing ring 1420. The fixing ring 1420 is annular, matching the overall shape of the high-voltage winding 130. The fixing ring 1420 is formed by the mating of two symmetrical semi-annular components of the same shape and size. The mating surfaces of the two semi-annular components are smooth, ensuring that there are no obvious steps or protrusions at the mating point of the fixing ring 1420, thus guaranteeing uniform stress distribution and avoiding localized stress concentration. Each semi-annular component has at least one binding hole 1423 at its mating edges at both ends. When assembling the fixing ring 1420, a strap is used to pass through the corresponding binding holes 1423 on the two semi-annular components and fix the two semi-annular components together, thus forming a complete fixing ring 1420. This ensures the stability and reliability of the fixing ring 1420 during use. For example, if the high-voltage winding 130 is a hollow elliptical cylinder, the fixing ring 1420 is an elliptical ring, formed by the mating of two semi-elliptical ring components; or, if the high-voltage winding 130 is a hollow cylinder, the fixing ring 1420 is a circular ring, formed by the mating of two semi-circular ring components. The fixing ring 1420 has several first slots 1421, and several support blocks 1410 are fixed to the fixing ring 1420 through these first slots 1421. The support component 140 is formed by the snap-fit ​​connection of the support block 1410 and the fixing ring 1420. It has a simple and reliable structure, is easy to process, flexible in installation, and requires no additional binding, resulting in high work efficiency. Several support components 140 work together to effectively abut and fix each section of the high-voltage coil 1320, preventing displacement of the coil during transfer, transportation, mold assembly, and forming stages, thus avoiding any impact on the quality of the high-voltage winding 130.

[0044] The number of coils in the high-voltage coil 1320 is determined based on the voltage level of the high-voltage winding 130; the higher the voltage level, the more coils are required. In this embodiment, considering both the voltage level of the high-voltage winding 130 and manufacturing costs, the high-voltage coil 1320 is configured to include four coil segments. Correspondingly, three support members 140 are provided. In other embodiments, the number of support members can be adjusted according to the number of coils in the high-voltage coil, and no specific limitation is made here.

[0045] The inner diameter of the retaining ring 1420 matches the outer circumference of the winding body 1310, allowing the retaining ring 1420 to be arranged circumferentially around the winding body 1310. Several retaining rings 1420 are spaced apart axially along the winding body 1310, ensuring that a retaining ring 1420 is positioned between any two adjacent coil segments. The radial distance between the outer and inner circumferential walls of the retaining ring 1420 is defined as the ring width of the retaining ring 1420. Several first slots 1421 are arranged on the outer circumference of the retaining ring 1420 and evenly distributed circumferentially, facilitating the fixation of the support block 1410 onto the retaining ring 1420. The circumferential distance between two opposite sides of the first slot 1421 is defined as the slot width of the first slot 1421.

[0046] The fixing ring 1420 is also provided with a plurality of second slots 1422. These second slots 1422 are arranged on the inner circumference of the fixing ring 1420 and evenly distributed along the circumference of the fixing ring 1420. The distance between two opposite sides of the second slot 1422 along the circumference of the fixing ring 1420 is defined as the slot width of the second slot 1422. In this embodiment, the slot width of the second slot 1422 is greater than the slot width of the first slot 1421. The arrangement of the second slot 1422 facilitates the flow of silicone rubber during the injection of the high-voltage insulation layer 1330, preventing the fixing ring 1420 from shifting due to excessive injection pressure, which could lead to coil displacement and affect the quality of the high-voltage winding 130. The arrangement of the second slot 1422 also facilitates the connection of wires between adjacent coil segments after winding, i.e., connecting the wire of one coil segment to the wire of another adjacent coil segment by passing the wire through the second slot 1422. In other embodiments, the slot width of the second slot can also be adjusted according to the wire specifications, as long as it facilitates the flow of silicone rubber during injection; no limitation is imposed here. It is understandable that the positions of the second slot 1422 and the first slot 1421 on the fixing ring 1420 can correspond to each other. For example, each second slot 1422 and each first slot 1421 can be respectively set on the inner and outer circumferences of the fixing ring 1420. Alternatively, the positions of the second slot 1422 and the first slot 1421 on the fixing ring 1420 can not correspond. For example, each second slot 1422 and each first slot 1421 can be staggered on the inner and outer circumferences of the fixing ring 1420. As long as the arrangement of the second slot 1422 and the first slot 1421 meets the structural strength requirements of the fixing ring 1420, no specific restrictions are imposed here.

[0047] The support block 1410 includes at least one hollow portion 1411, through which the support block 1410 is engaged with the first slot 1421 of the fixing ring 1420. The hollow portion 1411 facilitates the flow of silicone rubber during injection, reduces the impact force of the silicone rubber on the support member 140 during injection, and prevents the support member 140 from being damaged due to high injection pressure, thus affecting the winding quality. The hollow portion 1411 also makes the engagement connection between the support block 1410 and the fixing ring 1420 more secure and less prone to falling off.

[0048] For ease of description, when the support member 140 is installed on the outer periphery of the winding body 1310, the length of the support block 1410 along the axial direction of the winding body 1310 is defined as the thickness of the support block 1410, the length of the support block 1410 along the radial direction of the winding body 1310 is defined as the height of the support block 1410, and the length of the support block 1410 along the circumference of the winding body 1310 is defined as the width of the support block 1410. The width of the support block 1410 matches the groove width of the first slot 1421, ensuring a tight connection when the support block 1410 is engaged in the first slot 1421, preventing loosening and preventing displacement of the high-voltage coil 1320 during transfer, transportation, mold assembly, and forming stages, effectively ensuring the inter-segment distance of the high-voltage coil 1320. If the width of the first slot 1421 is greater than the width of the support block 1410, a gap will remain between the fixing ring 1420 and the support block 1410. During the winding of the wire and the forming of the high-voltage insulation layer 1330, the support block 1410 may easily loosen on the fixing ring 1420, failing to fix the coil and causing the high-voltage coil 1320 to shift, affecting the quality of the high-voltage winding 130. If the width of the first slot 1421 is less than the width of the support block 1410, the support block 1410 cannot be inserted into the first slot 1421 and will also fail to fix the coil. The thickness of the support block 1410 can be designed according to the distance between two adjacent sections of the high-voltage coil 1320, and the height of the support block 1410 can be designed according to the size of the high-voltage coil 1320 it supports; no specific limitations are imposed here.

[0049] The distance from one end of the hollow portion 1411 to the other end along the radial direction of the winding body 1310 is defined as the depth of the hollow portion 1411. The depth of the first slot 1421 along the radial direction of the winding body 1310 is defined as the groove depth of the first slot 1421. The sum of the groove depth of the first slot 1421 and the depth of the hollow portion 1411 is equal to the ring width of the fixing ring 1420. Thus, when the support member 140 is installed on the outer periphery of the winding body 1310, the support block 1410 can abut against the outer peripheral surface of the winding body 1310, thereby preventing the innermost conductor of the coil from shifting and ensuring the support effect.

[0050] In one embodiment, referring to FIG10, the support block 1410 can be an n-shaped block structure, in which case the support block 1410 includes a hollow portion 1411. In another embodiment, referring to FIG11, the support block 1410 can also be an H-shaped block structure, in which case the support block 1410 includes two identical hollow portions 1411. The specific dimensions of the H-shaped support block 1410 and the n-shaped support block 1410 can be adjusted according to the usage requirements, as described above, and will not be repeated here.

[0051] During installation, the hollow portion 1411 of the support block 1410 is secured to the outside of the fixing ring 1420 through the first slot 1421, and the two sides of the fixing ring 1420 are sandwiched between the hollow portion 1411 on the support block 1410. That is, the hollow portion 1411 of the n-shaped support block 1410 is secured in the first slot 1421, or any one of the hollow portions 1411 of the H-shaped support block 1410 is secured in the first slot 1421, so that the support block 1410 abuts against the outer peripheral surface of the winding body 1310, and the top of the hollow portion 1411 abuts against the bottom of the first slot 1421, ensuring that the support block 1410 and the fixing ring 1420 are tightly connected. By installing several support blocks 1410 in several first slots 1421 on the fixing ring 1420 in the above manner, the assembly of the support member 140 can be completed. The assembly process of support component 140 is simple and efficient.

[0052] Both the support block 1410 and the fixing ring 1420 are made of insulating and high-temperature resistant materials, such as glass fiber reinforced epoxy resin composite board and glass fiber reinforced polyimide composite board, and are formed by milling. The above materials have good high-temperature resistance and electrical insulation properties, and the process is simple and the processing cycle is short.

[0053] The contact surfaces of the support block 1410 and the fixing ring 1420 can be further fixed with an adhesive, preferably a high-temperature resistant adhesive, making the support 140 more stable and reliable, eliminating the need for additional binding, improving work efficiency, and able to withstand the high temperatures during the molding of the high-voltage insulation layer 1330. The support 140 ensures the inter-segment distance of the coil when it is erected in the mold, thereby ensuring the insulation performance of the high-voltage winding 130.

[0054] When the support member 140 is mounted on the winding body 1310, the distance from the farthest end of the support member 140 from the winding body 1310 along the radial direction of the winding body 1310 to the nearest end of the support member 140 from the winding body 1310 is defined as the width of the support member 140. Specifically, when the height of the support block 1410 is less than the ring width of the fixing ring 1420, the width of the support member 140 is equal to the ring width of the fixing ring 1420; when the height of the support block 1410 is equal to the ring width of the fixing ring 1420, the width of the support member 140 is also equal to it; when the height of the support block 1410 is greater than the ring width of the fixing ring 1420, the width of the support member 140 is equal to the height of the support block 1410. Along the radial direction of the winding body 1310, the distance from the outermost outer side of the outermost conductor of the high-voltage coil 1320 to the outer circumference of the winding body 1310 is defined as the coil loop width. The width of the support member 140 is greater than or equal to the loop width of the coil. Thus, in the radial direction of the winding body 1310, the support member 140 can abut against the side wall of the entire high-voltage coil 1320, which can better fix the coil and prevent the outer conductor of the coil from being unsupported by the support member 140 when the loop width of the coil is greater than the width of the support member 140, thereby causing the coil to shift and affecting the quality of the high-voltage winding 130.

[0055] In one application scenario, along the axial direction of the winding body 1310, the width of each segment of the high-voltage coil 1320 is uniform, that is, the two sides of each segment of the coil are flush.

[0056] Referring to Figures 5-7, before the high-voltage coil 1320 is wound, the positions of each coil segment are marked on the winding body 1310, that is, the width of each coil segment and the distance between each coil segment are marked. Then, the support member 140 is installed on the winding body 1310, so that each support member 140 is located in the inter-segment area of ​​each coil segment.

[0057] For ease of description, the upper end of the winding body 1310 is defined as the first end, and the lower end of the winding body 1310 is defined as the second end. Thus, from the first end to the second end of the winding body 1310, the high-voltage coil 1320 sequentially includes the first coil segment 1321, the second coil segment 1322, the third coil segment 1323, and the fourth coil segment 1324.

[0058] In one embodiment, all four coil segments are layered structures, with interlayer insulation material placed between the layers of each coil segment to reduce the voltage difference between them. In this case, interlayer insulation material is placed along the axial direction of the high-voltage winding 130, i.e., the axial direction of the winding body 1310, to prevent the interlayer electric field strength from exceeding the withstand threshold of the insulating film covering the insulated wire. Furthermore, the layered structure in each coil segment provides excellent resistance to lightning strikes, resulting in a more significant economic advantage. The interlayer insulation material can be silicone cloth, fiberglass mesh, electrical composite materials, etc. It can be one layer, two layers, or three layers, depending on the design, and is not limited here.

[0059] Specifically, during the winding process, a single conductor is used to wind the fourth section of coil 1324. Within the marked area of ​​the fourth section of coil 1324 on the winding body 1310, the conductor is wound from the first end to the second end of the winding body 1310 until it reaches the marked width and is then tied, forming the first layer of conductor for the fourth section of coil 1324. Interlayer insulation material is then placed on the first layer of conductor. Next, the conductor is wound in a "Z" shape on the interlayer insulation material, i.e., the conductor is pulled back to its original position where the first layer of conductor began winding and then wound above the first layer of conductor until it reaches the marked width, at which point it is tied, and interlayer insulation material is placed again. This process is repeated until the fourth section of coil 1324 is completed. The outer turn of the conductor (i.e., the conductor end) at the second end of the winding body 1310 of the fourth section of coil 1324 forms the second output terminal X exposed outside the high-voltage insulation layer 1330. For ease of description, the inner turn of the coil, i.e. the end where the wire begins to be wound, is defined as the wire start end, and the outer turn of the coil, i.e. the end where the wire is finished to be wound, is defined as the wire end.

[0060] The second section of coil 1322 is wound using another wire. Within the marked area of ​​the second section of coil 1322 on the winding body 1310, the wire is wound from the first end to the second end of the winding body 1310 using the method described above, which will not be repeated here. The difference is that during the winding of the second section of coil 1322, the wire needs to be led out to three taps, namely tap 6, tap 4, and tap 2 as shown in Figure 6. The taps can be led out using the double-fold method, that is, during the coil winding, the wire is folded outward to a certain length at the tap position to form a tap, and an insulation layer is wrapped around the outside of the tap, and then the second section of coil 1322 is continued to be wound; or the taps can be led out using the welding method, that is, during the coil winding, the tap is welded at the tap position, and an insulation layer is wrapped around the weld and the outside of the tap, and then the second section of coil 1322 is continued to be wound.

[0061] After the fourth section coil 1324 and the second section coil 1322 are wound, the winding body 1310 is reversed, so that the first end and the second end of the winding body 1310 are swapped, and then the first section coil 1321 and the third section coil 1323 are wound.

[0062] Before the first section of coil 1321 is wound, the lead end of the wire of the second section of coil 1322 is led out through one of the second slots 1422 on the adjacent fixing ring 1420 and soldered to the lead end of the wire of the first section of coil 1321. After the solder joint is covered with an insulating layer, the wire of the first section of coil 1321 is wound from the second end to the first end of the winding body 1310 in the same "Z" shape. Similar to the fourth section of coil 1324, the outer turn wire end (i.e. the wire end) of the first section of coil 1321 at the first end of the winding body 1310 forms the first outgoing terminal D exposed outside the high voltage insulation layer 1330.

[0063] Before winding the third coil segment 1323, the lead end of the fourth coil segment 1324 is led out through one of the second slots 1422 on the adjacent fixing ring 1420 and welded to the lead end of the third coil segment 1323. After covering the weld with an insulating layer, the lead of the third coil segment 1323 is wound from the second end to the first end of the winding body 1310 in a "Z" shape. Similar to the second coil segment 1322, the lead is also led out to three taps through lead wires, namely tap 3, tap 5, and tap 7 as shown in Figure 6. At this point, the high-voltage coil 1320 is wound. Each coil segment formed by the winding is perpendicular to the axis of the winding body 1310, which makes winding convenient, the lead arrangement is neat, and the mechanical strength is good.

[0064] By winding four coil segments in the above manner, it is possible to simplify and expedite the connection of wires between adjacent coil segments. This allows for closer proximity between the wire ends of the first coil segment 1321, the second coil segment 1322, the third coil segment 1323, and the fourth coil segment 1324, facilitating welding. Furthermore, it also facilitates the extraction of the high-voltage winding 130's output terminals. The wire end of the first coil segment 1321 is located at the first end of the winding body 1310, and the wire end of the fourth coil segment 1324 is located at the second end of the winding body 1310, enabling direct extraction of the first output terminal D and the second output terminal X. Moreover, compared to winding all four coil segments sequentially from the first end to the second end of the winding body 1310, it eliminates the need for additional diagonal wires to connect adjacent coil segments and avoids the need to extract the wire ends from the inner turns of the wire as output terminals of the winding body 1310. This not only facilitates wire connection and extraction but also effectively saves on wire usage and reduces costs.

[0065] In another embodiment, all four coil segments are foil-wound structures, meaning that each coil segment is formed by overlapping and winding conductive foil and interlayer insulating material. In this case, the width of the conductive foil and interlayer insulating material in each coil segment along the axial direction of the winding body 1310 is the width of that coil segment.

[0066] During winding, the first segment of coil 1321 is wound first. Within the marked area of ​​the first segment of coil 1321 on the winding body 1310, the overlapping conductive foil and interlayer insulation material are wound to a set number of layers, thus completing the winding of the first segment of coil 1321. The first end of the conductive foil at the first end of the first segment of coil 1321 on the winding body 1310 forms the first lead-out terminal D exposed outside the high-voltage insulation layer 1330. For ease of description, the end where the conductive foil of each segment of coil begins to be wound is defined as the conductive foil start end, and the end where the conductive foil of each segment of coil is finished is defined as the conductive foil end.

[0067] Then, following the above method, the second section of coil 1322, the third section of coil 1323, and the fourth section of coil 1324 are wound sequentially. The difference lies in that, during the winding of the second section of coil 1322, three taps are added to the conductive foil, namely taps 6, 4, and 2 as shown in Figure 6. Similarly, during the winding of the third section of coil 1323, three taps are added to the conductive foil, namely taps 3, 5, and 7 as shown in Figure 6. The end of the conductive foil at the second end of the winding body 1310 of the fourth section of coil 1324 forms a second lead-out terminal X exposed outside the high-voltage insulation layer 1330. The method of tapping and the connection method of each section of coil can be implemented using existing technology and are not specifically limited here. At this point, the high-voltage coil 1320 is wound. This winding method is simple to operate, highly efficient, and each section of coil is perpendicular to the axis of the winding body 1310, making winding convenient, the wire arrangement neat, and the mechanical strength good.

[0068] In another application scenario, referring to Figure 5, the high-voltage coil 1320 adopts a wire-wound layer structure. Each coil segment includes an equal-width section 1340 and a decreasing section 1350. The equal-width section 1340 includes a first-layer conductor and several layers of conductors with the same number of turns as the first-layer conductor around its outer periphery. That is, the winding width of the several layers of conductors in the equal-width section 1340 is equal, and is the winding width of the first-layer conductor. The decreasing section 1350 includes several layers of conductors wound around the outer periphery of the equal-width section 1340 with fewer turns than the first-layer conductor. The decreasing section 1350 includes several layers of wire with different widths. The width of the coil of the decreasing section 1350 gradually decreases from the inside to the outside along the radial direction of the winding body 1310. Each decreasing group of coils in the decreasing section 1350 is wound with a preset number of layers to have a preset thickness. In this embodiment, the decreasing section 1350 includes a first decreasing group 1351, a second decreasing group 1352, a third decreasing group 1353 and a fourth decreasing group 1354. The coils are arranged in the same width section 1340, the first decreasing group 1351, the second decreasing group 1352, the third decreasing group 1353 and the fourth decreasing group 1354 in sequence from the inside to the outside along the radial direction of the winding body 1310. In each coil segment, the winding width of several layers of wires remains constant from the inside to the outside along the radial direction of the winding body 1310 to form an equal width section 1340, and then gradually decreases to form a decreasing section 1350. That is, the innermost layer has the most wires and the outermost layer has the fewest wires. In this way, as the outermost layer of wires decreases, the insulation distance between coils can be increased, thereby enhancing the insulation reliability of the high voltage winding 130.

[0069] When winding the conductor of the equal width section 1340, after the first layer of conductor is wound according to the width of the marked area, the number of turns of the conductor is the full number of turns N0. Then, several layers of conductor are wound around the outer periphery of the first layer of conductor according to the full number of turns N0 until the equal width section 1340 is completed.

[0070] When winding the conductor in the decreasing section 1350, the first decreasing group 1351, the second decreasing group 1352, the third decreasing group 1353, and the fourth decreasing group 1354 are wound sequentially around the outermost conductor in the equal-width section 1340. Specifically, the first decreasing group 1351 comprises several layers of conductors of equal width, each with N1 turns, where N1 = N0 - M, and M is a positive integer, and N0 > 4M; the second decreasing group 1352 comprises several layers of conductors of equal width, each with N2 turns, where N2 = N0 - 2M; the third decreasing group 1353 comprises several layers of conductors of equal width, each with N3 turns, where N3 = N0 - 3M; and the fourth decreasing group 1354 comprises several layers of conductors of equal width, each with N4 turns, where N4 = N0 - 4M. In other embodiments, the decreasing section may include two, three, five or more decreasing groups, and the number of full turns N0 may be adjusted according to the size of M and the number of decreasing groups, without specific limitations.

[0071] Furthermore, during coil winding, each coil segment has a flush side on one side and a stepped side on the other. The wires on the flush side are wound against the support member 140. Since the decreasing section 1350 includes several layers of wires with different widths, the other side of the coil forms a stepped side. Any two adjacent coil segments are arranged with their flush sides or stepped sides facing each other. Thus, on the stepped side where adjacent coils are arranged opposite each other, as the outer layer of wires in the two coil segments decreases, the insulation distance between the two adjacent coil segments increases significantly, thereby greatly enhancing the insulation reliability of the high-voltage winding 130. In this embodiment, the first coil segment 1321 and the second coil segment 1322 are arranged with their flush sides facing each other and their stepped sides facing each other; the third coil segment 1323 and the fourth coil segment 1324 are arranged with their flush sides facing each other and their stepped sides facing each other. Specifically, the first coil segment 1321 is wound with its side near the first end of the winding body 1310 as a flush side and the other side as a stepped side; the second coil segment 1322 is wound with its side near the first coil segment 1321 as a stepped side and the other side as a flush side; the third coil segment 1323 is wound with its side near the second coil segment 1322 as a flush side and the other side as a stepped side; the fourth coil segment 1324 is wound with its side near the third coil segment 1323 as a stepped side and the other side as a flush side.

[0072] In this embodiment, the height of the n-type support block 1410 is equal to or slightly less than the ring width of the fixing ring 1420, and the height of the H-type support block 1410 is greater than the ring width of the fixing ring 1420. That is, the H-type support block 1420 provides stronger support for the coil. Therefore, the choice between n-type and H-type support blocks 1410 can be determined according to the specific structure of the coil winding, making the application of the support member 140 more flexible and its application range wider. Specifically, when the stepped sides of two adjacent coil segments are opposite each other, since the winding width of several layers of wires in the two coil segments decreases from the inside to the outside along the radial direction of the high-voltage winding 130, the stepped side wires of the two coil segments gradually move away from the support member 140 from the inside to the outside. That is, the support member 140 only needs to support the wires of the equal width portion 1340. At this time, selecting the n-type support block 1410 and the fixing ring 1420 to assemble the support member 140 can meet the support requirements. When the flush sides of two adjacent coil segments face each other, each layer of conductor in both coil segments requires support from the support member 140. That is, the support member 140 needs to support both the conductors of the equal-width section 1340 and the decreasing-width section 1350 simultaneously. In this case, assembling the support member 140 with a taller H-shaped support block 1410 and a fixing ring 1420 can meet the support requirements. The specific structure and quantity of the support block 1410 can be flexibly selected according to the structure of the high-voltage coil 1320, making it widely applicable.

[0073] In this embodiment, the support 140 between the first coil segment 1321 and the second coil segment 1322 is an n-type support block, the support 140 between the second coil segment and the third coil segment 1323 is an H-type support block, and the support 140 between the third coil segment 1323 and the fourth coil segment 1324 is an n-type support block. The n-type support block 1410 and the H-type support block 1410 work together to fix the coils, prevent wire displacement, and reduce the amount of raw materials used, thereby lowering costs. In other embodiments, either the n-type support block or the H-type support block can be randomly selected, as long as it can fix the coils; there is no limitation here.

[0074] In other embodiments, each coil segment may not have a flush side; that is, after the wire of the equal-width section is wound, the wire of the decreasing section is wound centered on the upper layer of the equal-width section, meaning that both sides of the decreasing section are stepped sides. In this case, the support blocks of each support member can be n-type support blocks.

[0075] The high-voltage insulation layer 1330 wraps around the high-voltage coil 1320 and the winding body 1310 to form the high-voltage winding 130.

[0076] In one embodiment, the high-voltage insulation layer 1330 is made of high-temperature vulcanized silicone rubber and is formed by injection molding. First, a support member 140 is installed on the winding body 1310, and then the conductor is wound around the winding body 1310 to form a high-voltage coil 1320. The support member 140 prevents displacement of the high-voltage coil 1320 during injection. The support member 140, the winding body 1310, and the high-voltage coil 1320 are used as the injection mold. The injection mold is placed into the mold of the injection molding machine, and high-temperature vulcanized silicone rubber is integrally injection molded around the outer periphery of the injection mold by adding silicone rubber raw material, thus obtaining the high-voltage winding 130. The use of high-temperature vulcanized silicone rubber in the high-voltage insulation layer 1330 improves the overall insulation and mechanical properties of the high-voltage winding 130.

[0077] The high-temperature vulcanized silicone rubber of this application adopts a high-temperature vulcanized silicone rubber material system, which specifically includes raw rubber, reinforcing agent, flame retardant, heat resistant agent and other auxiliary materials.

[0078] In another embodiment, the high-voltage insulation layer 1330 is made of liquid silicone rubber and is formed by casting or injection molding. When casting is used, the support 140 is first installed on the winding body 1310, and then the wire is wound around the winding body 1310 to form the high-voltage coil 1320. The support 140 can prevent the high-voltage coil 1320 from shifting during casting. The support 140, the winding body 1310, and the high-voltage coil 1320 are used as the casting body. The casting body is placed in the casting mold, and liquid silicone rubber is poured into the outer periphery of the casting body by adding silicone rubber raw material. After curing, the high-voltage winding 130 is obtained. When injection molding is used, the specific molding process is similar to the aforementioned injection process and will not be described again.

[0079] The liquid silicone rubber in this application adopts a liquid silicone rubber material system, specifically including base rubber, reinforcing agent, flame retardant, heat resistant agent and other auxiliary materials.

[0080] Under vacuum conditions, after the support 140, high-voltage coil 1320 and winding body 1310 are covered with high-temperature vulcanized silicone rubber or liquid silicone rubber, the high-temperature vulcanized silicone rubber or liquid silicone rubber fills the gap between the support 140, high-voltage coil 1320 and winding body 1310 and wraps both ends of the winding body 1310, but does not cover the inner wall of the winding body 1310, so that the high-voltage winding 130 is hollow columnar in shape. It can be a hollow cylinder, a hollow elliptical cylinder or other hollow columnar shape.

[0081] Compared to existing epoxy resin high-voltage insulation layers, silicone rubber offers the following advantages: 1) It possesses better fire resistance, low-temperature resistance, aging resistance, and short-circuit resistance, extending the service life of the dry-type transformer 10; 2) The copper coil is easily peeled off from the silicone rubber, and the material has a recyclability rate of over 99%, making it more environmentally friendly; 3) The silicone rubber elastomer can reduce partial discharge caused by mechanical vibration, suppressing equipment discharge. Furthermore, the product of silicone rubber under discharge is non-conductive silicon dioxide, effectively inhibiting further insulation degradation; 4) It can reduce the operating losses of the dry-type transformer 10, resulting in greater energy savings; 5) It has better resistance to harsh environments and can be installed both indoors and outdoors. Simultaneously, the high-voltage insulation layer 1330 is integrally molded using injection or casting processes, making it more stable, with higher mechanical properties, and exhibiting better adhesion to the high-voltage coil 1320 and winding body 1310, effectively extending the service life of the high-voltage insulation layer 1330.

[0082] The beneficial effects of this application are: the high voltage winding of this application can effectively prevent the high voltage coil from shifting during transfer, transportation, mold assembly and forming by setting support members to abut and fix the high voltage coil, thus ensuring the quality of the high voltage winding.

[0083] Meanwhile, the support component of this application is formed by the snap-fit ​​of the support block and the fixing ring, which has a simple and reliable structure, is easy to process, and is flexible in installation. Furthermore, there is no need to tie the support block and the fixing ring separately, resulting in high work efficiency. Moreover, the structure and quantity of the support component can be flexibly selected according to the structure of the high-voltage coil, making it widely applicable.

[0084] The technical content and features of this application have been disclosed above. However, it is understood that, based on the inventive concept of this application, those skilled in the art can make various changes and improvements to the above-described structure and materials, including combinations of the technical features disclosed or claimed herein, and explicitly including other combinations of these features. All such modifications and / or combinations fall within the technical field to which this application pertains and are within the scope of protection of the claims of this application.

Claims

1. A high voltage winding, characterized by The high-voltage winding comprises a winding body, a high-voltage coil and a high-voltage insulation layer, the high-voltage coil is formed by winding a wire on the winding body, the high-voltage coil comprises a plurality of coil segments, and the high-voltage insulation layer wraps the high-voltage coil and the winding body; Any two adjacent coil segments are provided with a support, the support comprises a plurality of support blocks and a fixing ring, the fixing ring is provided with a plurality of first clamping grooves, and the support blocks are fixed on the fixing ring through the first clamping grooves.

2. The high voltage winding of claim 1, wherein, The support block comprises at least one hollow part, and the support block is clamped and connected with the first clamping groove through the hollow part.

3. The high voltage winding of claim 2, wherein, The sum of the groove depth of the first clamping groove and the depth of the hollow part is equal to the ring width of the fixing ring.

4. The high voltage winding of claim 2, wherein, The support block abuts against the outer circumferential surface of the winding body, and the top of the hollow part abuts against the groove bottom of the first clamping groove.

5. The high voltage winding of claim 2, wherein, The support block is in the shape of n, and the support block comprises one hollow part.

6. The high voltage winding of claim 2, wherein, The support block is in the shape of H, and the support block comprises two hollow parts.

7. The high voltage winding of claim 1, wherein, The width of the support block matches the groove width of the first clamping groove.

8. The high voltage winding of claim 1, wherein, The plurality of first clamping grooves are arranged on the outer circumferential surface of the fixing ring and uniformly distributed along the circumferential direction of the fixing ring.

9. The high voltage winding of claim 1, wherein, The fixing ring is also provided with a plurality of second clamping grooves, and the plurality of second clamping grooves are arranged on the inner circumferential surface of the fixing ring and uniformly distributed along the circumferential direction of the fixing ring.

10. The high voltage winding of claim 1, wherein, The width of the support is greater than or equal to the ring width of the coil.

11. The high voltage winding of claim 1, wherein The high-voltage insulation layer is made of high-temperature vulcanized silicone rubber or liquid silicone rubber.

12. Dry-type transformer, characterized in that The transformer comprises an iron core, a low-voltage winding and a high-voltage winding, the low-voltage winding is sleeved outside the iron core, and the high-voltage winding is sleeved outside the low-voltage winding.

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