Disk Winding Insulation with Diagonal Connecting Conductor
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Solution Overview
Problem
Existing methods for producing disk windings, particularly for high-voltage transformers, face challenges in ensuring proper insulation between disks without creating cavities, which can affect the electrical characteristics and compactness of the coil.
Innovation Solution
A method involving the simultaneous fitting of intermediate insulation between disks during the winding process, subdivided by a diagonal connecting conductor into triangular and opposite triangular cross-section sub-areas, ensures effective insulation without cavities, using glass rovings or pre-impregnated materials to fill spaces between conductor ribbons and turn insulators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If intermediate insulation is fitted between disks during the winding process, then insulation effectiveness is improved and cavities are prevented, but the complexity of the winding process increases due to simultaneous fitting requirements
Solution Approach 1:
The intermediate insulation is prepared and positioned in advance before the winding process begins. The insulation pieces are pre-cut to specific dimensions and shapes, and the connecting conductors are pre-positioned along diagonal paths. This preliminary preparation allows the insulation to be fitted smoothly during winding without requiring complex real-time adjustments, thus improving insulation effectiveness while controlling process complexity.
Solution Approach 2:
The connecting conductor serves as an intermediary element that runs diagonally between disks and divides the intermediate insulation into two sub-areas. This intermediary structure facilitates the fitting of insulation by providing a reference path and structural support, enabling simultaneous fitting of insulation in both triangular sub-areas during the winding process, thereby improving overall insulation effectiveness.
2Stability of the object's composition
If the intermediate insulation is subdivided into two triangular sub-areas by a diagonal connecting conductor, then insulation consistency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The intermediate insulation is segmented into two distinct triangular sub-areas by the diagonal connecting conductor. Each sub-area can be fitted independently with insulation pieces cut to specific dimensions. This segmentation allows for standardized manufacturing of insulation components and simplifies the fitting process, as each triangular area has well-defined boundaries and geometry, thereby improving insulation consistency while managing manufacturing precision requirements.
3Productivity
If insulation is fitted simultaneously with the winding process, then productivity is improved, but the difficulty of ensuring proper insulation placement increases
Solution Approach 1:
The intermediate insulation pieces are pre-cut to exact dimensions and pre-positioned along the winding path before the actual winding begins. The connecting conductors are also pre-positioned along diagonal paths between disks. This preliminary preparation ensures that when the winding process occurs, the insulation is already in the correct positions and orientations, allowing simultaneous fitting without compromising placement accuracy, thus improving productivity while maintaining ease of manufacture.
Data Source
AI summary
An method for producing a disk winding having disks arranged alongside one another, includes winding the disk winding and fitting intermediate insulation between adjacent disks simultaneously, and subdividing the insulation into two sub-areas with a connecting conductor that runs from an end of one disk to a start of an adjacent disk along a diagonal within the intermediate insulation. The sub-areas can include a first intermediate area with a triangular cross-section formed below this diagonal and a second intermediate area which has an opposite triangular cross-section and formed above this diagonal.