Stationary Transformer Core Winding Apparatus

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Solution Overview

Problem

Existing methods for applying band-like windings to large transformer cores are inefficient and require manual handling or complex machinery, especially for large transformers, where the core limbs are heavy and unwieldy, making automation challenging.

Innovation Solution

A winding apparatus with a guide member and rotary member that allows for the automatic application of band-like materials to stationary core limbs, featuring a carriage and servomotors for precise control, enabling simultaneous use of multiple materials and adjustable tension, and accommodating core limbs between yokes without axial movement of the core.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If the core limb is rotated during winding to apply band-like material, then automation is achieved, but the core limb becomes difficult to handle due to its heavy weight and large size

Engineering Contradiction:

Improveautomation of winding processVSAvoidhandling of core limb

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

Instead of rotating the core limb during winding as in prior art, this invention inverts the approach by keeping the core limb stationary and rotating the winding head assembly. The winding head rotates about an axis coextensive with the predetermined line of advancement, allowing the band-like material to be wrapped around the stationary core limb. This inversion eliminates the need to rotate heavy core limbs while achieving full automation of the winding process.

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If the core limb is rotated for winding, then automated winding is possible, but the axial length and diameter of large core limbs make rotation impractical

Engineering Contradiction:

Improvewinding application speedVSAvoidcomplexity of winding machinery

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention inverts the traditional winding approach by keeping the core limb stationary and rotating the winding head instead. This simplifies the mechanical requirements for handling large core limbs with significant axial length and diameter, as no rotation or complex positioning of the heavy core is needed. The winding head rotation about an axis coextensive with the advancement line enables efficient material application without the mechanical complexity of rotating large core structures.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The winding head assembly serves multiple functions: it guides the band-like material, rotates to wrap the material around the core limb, and advances linearly to cover the entire axial length. This multi-functional design consolidates what would otherwise require separate mechanisms into a single integrated assembly, reducing overall device complexity while maintaining high productivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If manual handling is used for large transformer cores, then equipment complexity is reduced, but winding application time increases significantly

Engineering Contradiction:

Improvesimplicity of winding apparatusVSAvoidwinding application time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The winding head assembly is self-propelled along the predetermined line through the opening in the base, eliminating the need for complex external feeding mechanisms. The drive means rotates the winding head, and the linear advancement is achieved through the interaction of the winding head with the base structure. This self-service mechanism reduces apparatus complexity while maintaining automated winding speed, significantly reducing application time compared to manual handling.

Inventive Principle:

Principle #25Self-service

4Productivity

If the core limb is moved axially through the winding apparatus, then continuous winding is achieved, but the core limb requires rotation or movement that complicates the process

Engineering Contradiction:

Improvecontinuous winding capabilityVSAvoidstationary position of core limb

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

Instead of moving the core limb axially through the winding apparatus, this invention inverts the approach by keeping the core limb stationary and moving the winding head. The winding head rotates and advances linearly through the opening in the base, allowing continuous winding to be applied along the entire axial length of the stationary core limb. This eliminates the need to rotate or axially move the heavy core limb while achieving continuous winding coverage.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP2062274B1A winding apparatus and a method of winding

Publication Date: 2015.09.30 ABB TECHNOLOGY LTD

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Figure 2

AI summary

A winding apparatus for and a method of applying a winding of a band-like material to a limb of a transformer core. The winding apparatus comprises a guide member (1) arranged to be fixed in relation to the core limb (30) and a rotary member (10) carrying a supply of a band-like material.