Foil Coil Winding with Pre-Marking for Compact Transformer Layers
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Solution Overview
Problem
Foil coils in transformers face challenges in controlling material length and width, leading to loose winding, interlayer gaps, and reduced anti-short circuit capability due to their long, thin nature, which can result in deformation and displacement during short circuits.
Innovation Solution
A winding method for foil coils involving a hollow winding die with a core post, precise measurement and marking of foil and insulating materials, and continuous adjustment during winding to ensure accurate layer circumference, maintaining compactness and meeting preset standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foil is used for coil winding to reduce material cost and improve anti-short circuit performance, then material cost and anti-short circuit performance are improved, but controlling material length and width becomes difficult leading to loose winding and interlayer gaps
Solution Approach 1:
The patent applies preliminary action by pre-marking the foil at regular intervals (e.g., every 50-100mm) before winding, and pre-calculating the required foil length for each layer based on measured dimensions of the iron core and winding die. This allows operators to monitor and adjust winding tightness in real-time, preventing loose winding and interlayer gaps before they occur.
Solution Approach 2:
The patent implements feedback control by continuously measuring the actual foil length used during winding, comparing it with the pre-calculated required length, and making real-time adjustments to maintain proper winding compactness. This closed-loop control ensures consistent winding quality despite variations in foil dimensions.
2Ease of manufacture
If foil width is made large to reduce number of layers, then material usage is simplified, but interlayer gaps become more prone to appear during winding
Solution Approach 1:
The patent applies preliminary action by pre-calculating the exact foil length required for each layer based on measured dimensions, and pre-marking the foil at regular intervals. This allows operators to maintain proper tension and alignment during winding, preventing interlayer gaps even with large foil widths.
3Loss of substance
If foil is made thin to reduce material consumption, then material cost is reduced, but short-circuit force easily causes deformation and displacement of the foil
Solution Approach 1:
The patent applies preliminary action by pre-calculating and marking the exact foil length required for each layer, ensuring proper winding tension is maintained throughout the process. This prevents excessive loose winding that would create interlayer gaps and reduce the effectiveness of thin foil in resisting short-circuit forces.
4Productivity
If regular winding process is used without measurement and adjustment, then production efficiency is maintained, but material consumption cannot be accurately controlled and winding quality varies
Solution Approach 1:
The patent applies preliminary action by pre-measuring and marking the foil at regular intervals before winding, and pre-calculating the required length for each layer. This allows operators to quickly reference markings during winding without stopping for measurements, maintaining high productivity while ensuring accurate material consumption control through real-time comparison with calculated values.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the actual foil length used during winding against the pre-calculated required length, and making real-time adjustments to maintain consistent winding quality and accurate material consumption control throughout production.
Data Source
AI summary
A winding method for a foil coil includes the following process steps of, step S1: fixing an iron core, and preparing a winding die; step S2: calculating a circumference of a foil needed by each layer of coil; step S3: making one size mark on the foil at every regular interval; step S4: arranging the foil on a winding device; step S5: fixing a start end of the coil, and arranging a reference point on a transformer; step S6: starting to wind the coil; step S7: checking whether the winding meets a preset standard requirement; and step S8: fixing a tail end of the coil.