Foil Coil Winding for Stereoscopic Iron Core Gap Reduction
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Solution Overview
Problem
The existing method for winding a foil coil on a stereoscopic wound iron core transformer is inefficient, requiring high investment in tooling, long production cycles, and potential air gaps between the coil and the core, affecting heat dissipation and anti-short circuit capabilities.
Innovation Solution
A method and device that involve a rotating assembly and cylinders to wind the foil conductor, interlayer insulator, and end insulator on the iron core post, reducing the gap between the coil and the core, and improving automation, efficiency, and quality of the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a common method for winding a foil winding of the stereoscopic wound iron core is to customize the winding devices according to iron cores and winding sizes of different products, then the winding can be completed, but a high investment in tooling equipment is required
Solution Approach 1:
The patent applies universality by designing a winding device that can accommodate different iron core sizes and winding specifications through adjustable components. The device includes adjustable winding heads and positioning mechanisms that can be reconfigured for different product requirements, eliminating the need for completely custom tooling for each product variant.
Solution Approach 2:
The patent implements dynamics through adjustable and reconfigurable winding device components. The winding device includes movable positioning mechanisms and adjustable parameters that can be dynamically changed to suit different iron core sizes and winding requirements, allowing a single device to perform multiple functions.
2Ease of manufacture
If a common method for winding a foil winding of the stereoscopic wound iron core is to customize the winding devices according to iron cores and winding sizes of different products, then the winding can be completed, but a long production cycle is required
Solution Approach 1:
The patent applies preliminary action by pre-configuring the winding device with adjustable components and standardization features that allow quick setup for different product types. The device includes pre-positioned tooling elements and standardized interfaces that reduce setup time when transitioning between different iron core sizes and winding specifications.
3Ease of manufacture
If a common method for winding a foil winding of the stereoscopic wound iron core is to customize the winding devices according to iron cores and winding sizes of different products, then the winding can be completed, but a reduced production efficiency is achieved
Solution Approach 1:
The patent applies universality by designing a winding device that can accommodate different iron core sizes and winding specifications through adjustable components. The device includes adjustable winding heads and positioning mechanisms that can be reconfigured for different product requirements, eliminating the need for completely custom tooling for each product variant.
Solution Approach 2:
The patent implements dynamics through adjustable and reconfigurable winding device components. The winding device includes movable positioning mechanisms and adjustable parameters that can be dynamically changed to suit different iron core sizes and winding requirements, allowing a single device to perform multiple functions.
4Ease of manufacture
If the foil winding is wound on the iron core through customized winding devices, then the winding can be completed, but an air gap between the foil winding and the iron core is caused
Solution Approach 1:
The patent applies local quality by implementing precise positioning mechanisms and adjustable tooling elements that ensure the foil winding is placed in optimal contact with the iron core surface. The winding device includes localized adjustment capabilities that allow precise control of winding position and pressure at different locations to eliminate air gaps.
Data Source
AI summary
Disclosed are a method and device for winding a foil coil of a stereoscopic wound iron core transformer. The device includes a rotating assembly, a driving device and a plurality of loading assemblies; the rotating assembly is provided with a through hole matched with an iron core post, the rotating assembly is provided with a gear plate and a track ring around the through hole, and the gear plate and the track ring are fixedly connected by a fixing block; the loading assembly includes a cylinder and a tension device, and the cylinder is movably connected with the rotating assembly; and a driving end of the driving device is connected with the gear plate.