CA2578758A1 - Method and device for producing a coil winding - Google Patents
Method and device for producing a coil winding Download PDFInfo
- Publication number
- CA2578758A1 CA2578758A1 CA002578758A CA2578758A CA2578758A1 CA 2578758 A1 CA2578758 A1 CA 2578758A1 CA 002578758 A CA002578758 A CA 002578758A CA 2578758 A CA2578758 A CA 2578758A CA 2578758 A1 CA2578758 A1 CA 2578758A1
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- Prior art keywords
- winding
- conductors
- coil
- conductor
- conductor bundles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/077—Deforming the cross section or shape of the winding material while winding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/082—Devices for guiding or positioning the winding material on the former
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Coil Winding Methods And Apparatuses (AREA)
- Coils Of Transformers For General Uses (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
The invention relates to a method for producing a coil winding which consists of one or more coil layers. If a coil winding has a plurality of coil layers, the individual coil layers have different numbers of turns, which mainly decrease from the inside to the outside. In order to guarantee identical coil layer heights, the cross-profile of the conductors or the conductor bundles is adapted by deforming the same. The aim of the invention is to make sure that the individual turns of the coil layers are wound neither at too high a pressure nor to loosely. For this purpose, the conductors or conductor bundles are deformed by means of a deformation device in a single process step at the same time as the deformed conductors or conductor bundles are insulated and the conductors and conductor bundles are wound. The height of the already wound part of the coil winding is continuously compared as the actual value with the theoretical value for the already wound part, a theoretical lead for the part of the coil layer to be wound is determined and the deformation device is adjusted in such a manner that the final axial length or height of the coil layer corresponds to a desired value or to the theoretical value. The invention also relates to a corresponding winding device.
Description
i x .
Method and device for producing a coil winding The invention relates to a method of producing a coil winding comprising one or more winding layers of essentially rectangular shaped conductors or conductor bundles and a winding device for producing a coil winding comprising one or more winding layers of essentially rectangular shaped conductors or conductor bundles.
With coils, in particular inductor coils provided with dry insulation with no iron core com-prising two or more cylindrical winding layers disposed concentrically one inside the other, electrically connected in parallel, with gaps left free in between, a known approach is to wind the winding layers from rectangular shaped conductors or conductor bundles so that the winding layers have different numbers of turns, primarily decreasing from the in-side towards the outside.
The basic structure of winding layers disposed concentrically one inside the other and elec-trically connected in parallel is known from the prior art, for example from European pat-ent EP 0 092 018 B1. Figures 1 and 2 illustrate the basic structural design of such winding layers 1 and coil windings made from them. The winding layers 1, which are made from largely rectangular shaped conductors or conductor bundles 6 and disposed concentrically one inside the other about a common coil mid-axis 7, are held together by means of retain-ing elements 2 at the coil ends, for example so-called coil stars of metal or plastic. As a rule, the retaining elements 2 disposed in the two distal end portions of the coil are held together by means of a clamping construction, e.g. by several tension elements 3 made from impregnated glass fibres, which are applied along the winding. Insulating elements 4 are usually fitted between the retaining elements 2 and the coil or winding ends, especially if the retaining elements 2 are electrically conductive. The winding layers 1 disposed con-centrically one inside the other are spaced apart from one another in the radial direction, preferably by other insulating elements 5, for example electrically insulating gap strips, in order to create vertical gaps to permit natural air cooling of the entire inductor coil. The extent to which the conductors or conductor bundles 6 comprising several insulated indi-vidual conductors are used depends on the anticipated eddy current losses, which must be kept within economically viable limits.
Method and device for producing a coil winding The invention relates to a method of producing a coil winding comprising one or more winding layers of essentially rectangular shaped conductors or conductor bundles and a winding device for producing a coil winding comprising one or more winding layers of essentially rectangular shaped conductors or conductor bundles.
With coils, in particular inductor coils provided with dry insulation with no iron core com-prising two or more cylindrical winding layers disposed concentrically one inside the other, electrically connected in parallel, with gaps left free in between, a known approach is to wind the winding layers from rectangular shaped conductors or conductor bundles so that the winding layers have different numbers of turns, primarily decreasing from the in-side towards the outside.
The basic structure of winding layers disposed concentrically one inside the other and elec-trically connected in parallel is known from the prior art, for example from European pat-ent EP 0 092 018 B1. Figures 1 and 2 illustrate the basic structural design of such winding layers 1 and coil windings made from them. The winding layers 1, which are made from largely rectangular shaped conductors or conductor bundles 6 and disposed concentrically one inside the other about a common coil mid-axis 7, are held together by means of retain-ing elements 2 at the coil ends, for example so-called coil stars of metal or plastic. As a rule, the retaining elements 2 disposed in the two distal end portions of the coil are held together by means of a clamping construction, e.g. by several tension elements 3 made from impregnated glass fibres, which are applied along the winding. Insulating elements 4 are usually fitted between the retaining elements 2 and the coil or winding ends, especially if the retaining elements 2 are electrically conductive. The winding layers 1 disposed con-centrically one inside the other are spaced apart from one another in the radial direction, preferably by other insulating elements 5, for example electrically insulating gap strips, in order to create vertical gaps to permit natural air cooling of the entire inductor coil. The extent to which the conductors or conductor bundles 6 comprising several insulated indi-vidual conductors are used depends on the anticipated eddy current losses, which must be kept within economically viable limits.
The numbers of windings or coil layers I and the electric coils to be made are determined both with a view to achieving the desired inductivity and the desired current and operating temperature distribution across the winding layers 1 connected in parallel -see Fig. 1. As a result of these requirements, the numbers of turns for the winding layers 1 connected in parallel differ, primarily decreasing from the inside towards the outside.
In order to obtain an axial voltage gradient that is as uniform as possible in all the turn lay-ers I and thus avoid significant voltage differences between the oppositely lying windings of adjacent winding layers 1, the individual winding layers 1 are of identical heights or identical axial lengths, thereby ensuring that the winding heights H are kept as identical as possible. This is achieved by adapting the height GHI, GH2, GH3 of the conductor or con-ductor bundle 6 as measured in the axial direction of the winding layers I to the different numbers ofturns of the winding layers 1 electrically connected in parallel.
The height GH1, GH2, GH3 of the conductor or conductor bundle 6 in the individual winding layers 1 as measured in the axial direction of the winding layers I is also referred to as pitch height, which defines the dimension of the conductor or conductor bundle 6 in the direction of the winding or coil axis. Due to the decreasing numbers of turns, primarily from the inner wind-ing layers 1 to the outer winding layers 1, the conductors or conductor bundles 6 in the outer winding layers I are of bigger dimensions in the axial direction. In particular, the conduc-tors or conductor bundles 6 of the outer winding layers 1 in the direction parallel with the coil longitudinal or coil mid-axis 7 have bigger heights GH 2, GH3 than the heights GH1 of the conductors or conductor bundles 6 of the inner winding layer 1 of the coil.
The axial height GHI, GH2 or GH3 of the conductor or the conductor bundle 6 is adapted to the requisite conductor or conductor bundle 6 with an approximately or largely rectangular cross-sectional shape by pressing a round conductor or a cable-shaped conductor material.
The requisite dimensions of the conductor or conductor bundle 6, in particular the pitch heights GH1, GH2, GH3 mentioned above, are calculated beforehand depending on the numbers of turns needed for the concentrically disposed winding layers 1 during the course of determining the electrical or thermal rating of the inductor coil.
Allowance is also made for the extra dimension needed due to the electrical external insulation which has to be ap-plied to the conductor or conductor bundle 6 when determining the requisite dimensions.
In order to obtain an axial voltage gradient that is as uniform as possible in all the turn lay-ers I and thus avoid significant voltage differences between the oppositely lying windings of adjacent winding layers 1, the individual winding layers 1 are of identical heights or identical axial lengths, thereby ensuring that the winding heights H are kept as identical as possible. This is achieved by adapting the height GHI, GH2, GH3 of the conductor or con-ductor bundle 6 as measured in the axial direction of the winding layers I to the different numbers ofturns of the winding layers 1 electrically connected in parallel.
The height GH1, GH2, GH3 of the conductor or conductor bundle 6 in the individual winding layers 1 as measured in the axial direction of the winding layers I is also referred to as pitch height, which defines the dimension of the conductor or conductor bundle 6 in the direction of the winding or coil axis. Due to the decreasing numbers of turns, primarily from the inner wind-ing layers 1 to the outer winding layers 1, the conductors or conductor bundles 6 in the outer winding layers I are of bigger dimensions in the axial direction. In particular, the conduc-tors or conductor bundles 6 of the outer winding layers 1 in the direction parallel with the coil longitudinal or coil mid-axis 7 have bigger heights GH 2, GH3 than the heights GH1 of the conductors or conductor bundles 6 of the inner winding layer 1 of the coil.
The axial height GHI, GH2 or GH3 of the conductor or the conductor bundle 6 is adapted to the requisite conductor or conductor bundle 6 with an approximately or largely rectangular cross-sectional shape by pressing a round conductor or a cable-shaped conductor material.
The requisite dimensions of the conductor or conductor bundle 6, in particular the pitch heights GH1, GH2, GH3 mentioned above, are calculated beforehand depending on the numbers of turns needed for the concentrically disposed winding layers 1 during the course of determining the electrical or thermal rating of the inductor coil.
Allowance is also made for the extra dimension needed due to the electrical external insulation which has to be ap-plied to the conductor or conductor bundle 6 when determining the requisite dimensions.
Based on the prior art, the original conductors or conductor bundle strands to be processed are moulded or pressed to obtain a largely rectangular cross-sectional shape of the fixed, previously calculated dimensions. Based on the known sequences, the conductor or con-ductor bundle is pressed in a separate process which takes place before the actual winding process. The round conductor or the round, previously produced conductor bundle is fed through several pairs of pressing rollers of hardened steel. As a rule, application of the ex-ternal insulation for the conductor or the conductor bundle is integrated in this process.
This being the case, insulating foils which can withstand high temperatures and/or woven fabric tapes which can be impregnated are used for this purpose. The insulating material is therefore applied directly after shaping the conductor or conductor bundle, but in any case prior to winding the pre-shaped conductor or conductor bundle onto a winding material supply reel, where the conductor or conductor bundle is temporarily stored before being used - in a subsequent process - to wind electric coils.
As with any other manufacturing process, the processes of pressing the conductor or con-ductor bundle and applying the external insulation are subject to manufacturing tolerances, which can lead to a discrepancy between the actual and the pre-calculated dimensions of the cross-sectional shape. Since the conductors or conductor bundles will be wound back onto a winding material storage drum again after pressing, slight cross-sectional deforma-tions or cross-sectional changes can also occur due to forces generated in the conductors or conductor bundles during reeling. Finally, for the same reason, the cross-sectional dimen-sions of the conductor or conductor bundle 6 may vary during the actual winding process, in other words when winding the winding layers 1. The result of all of these factors and effects which can alter the cross-sectional dimensions after pressing the conductor or con-ductor bundle 6, amongst other things, is that the axial winding dimensions or the axial winding heights H of the concentric turn layers are not exactly identical.
This means that there will be electric voltage differences between oppositely lying windings of adjacent winding layers I during operation of the inductor coils. Deviations from the previously calculated winding layer height H also lead to deviations from the desired current and tem-perature distribution across the winding layers I connected in parallel.
In the past, it has been standard practice either to accept these dimensional tolerances in spite of the disadvantages outlined above, or to compensate for these tolerances as far as possible by applying a differing contact pressure to the turns during the winding process.
By contact pressure is meant the surface pressure by means of which the individual turns of the winding layer I are pressed together in the direction of the coil mid-axis 7 during the winding process by means of a pressing device or by means of manually operated pressing tools. For example, if the conductor or conductor bundle 6 has too big an axial height GH 1, GH2, GH3, the contact pressure is increased. If the axial height GHI, GH2, GH3 is short of the required dimension, the contact pressure is reduced, i.e. the winding operation is "looser". In the latter case, thermal stress affecting the winding layers I or the single-layered or multi-layered winding during subsequent operation of the inductor coil can lead to settlement in the affected winding layers 1. This specifically leads to shortening of the winding layer height H of those winding layers I that were wound at a reduced contact pressure.
Against the background of this prior art, the objective of the invention is to propose a method and a winding device, by means of which coils of the type outlined above can be produced more rationally than in the past, and the winding layers are wound with neither too high a contact pressure nor too loosely.
This objective is achieved by the invention due to the fact that the processes of forming the conductors or conductor bundles with a forming device to obtain the essentially rectangular cross-section, insulating the formed conductors or conductor bundles and winding the con-ductors or conductor bundles to produce the desired winding layer all take place in a single work operation, and an axial length of an already wound part of the winding layer is used as an actual value and compared with a desired value for the already wound part on a con-tinuous or periodic basis, a desired pitch height is determined for the part of the coil layer still to be wound and the forming device is set so that the final axial length or winding layer height of the winding layer corresponds to a desired value or specified value.
One advantage gained as a result of the features defined in the characterising part of claim 1 resides in the fact that combining the part-processes of forming, insulating and winding the conductors or conductor bundles into a closed, integrated process enables costs and processing time involved in producing electric windings to be reduced, in particular induc-tor coils with no iron core provided with dry insulation.
In addition to reducing process costs and processing times, another advantage is the fact that the insulating materials are subjected to less mechanical stress and can therefore be better protected from damage. Another advantage in terms of increasing product quality achieved as a result of the method proposed by the invention is the fact that the continuous control and regulation of the dimensions of the conductor or conductor bundle whilst lay-ing the turns during the winding operation means that a largely constant contact pressure can be used. This rules out the risk of winding settlement due to thermal stress during sub-sequent service of the inductor coils. This also minimises or reduces the risk of damage or breakage of the external insulation for the conductor or conductor bundle which previously existed due to too high a contact pressure.
In one embodiment of the invention, a winding layer has at least two winding portions with different pitch heights. This enables winding layers to be made whereby parts of the wind-ing subjected to different amounts of stress can be provided with a different insulation or a different insulation thickness.
The objective of the invention is also achieved by means of a winding device, which is characterised by the fact that it comprises at least one forming device, at least one device for applying insulation and at least one automatically or manually operated control unit, which sets the forming unit or by means of which the forming unit can be set so that the final axial length or winding layer height of the winding layer corresponds to a predefined value or desired value.
In one advantageous embodiment of the invention, the control unit is designed to change the setting values of the forming unit on an automated or user-assisted basis whilst a wind-ing process is running. This enables constant intervention or a continuous or quasi-continuous control of the forming values so that the desired values of the final winding layer can be achieved as best possible. Production can also be run with short cycle times.
This being the case, insulating foils which can withstand high temperatures and/or woven fabric tapes which can be impregnated are used for this purpose. The insulating material is therefore applied directly after shaping the conductor or conductor bundle, but in any case prior to winding the pre-shaped conductor or conductor bundle onto a winding material supply reel, where the conductor or conductor bundle is temporarily stored before being used - in a subsequent process - to wind electric coils.
As with any other manufacturing process, the processes of pressing the conductor or con-ductor bundle and applying the external insulation are subject to manufacturing tolerances, which can lead to a discrepancy between the actual and the pre-calculated dimensions of the cross-sectional shape. Since the conductors or conductor bundles will be wound back onto a winding material storage drum again after pressing, slight cross-sectional deforma-tions or cross-sectional changes can also occur due to forces generated in the conductors or conductor bundles during reeling. Finally, for the same reason, the cross-sectional dimen-sions of the conductor or conductor bundle 6 may vary during the actual winding process, in other words when winding the winding layers 1. The result of all of these factors and effects which can alter the cross-sectional dimensions after pressing the conductor or con-ductor bundle 6, amongst other things, is that the axial winding dimensions or the axial winding heights H of the concentric turn layers are not exactly identical.
This means that there will be electric voltage differences between oppositely lying windings of adjacent winding layers I during operation of the inductor coils. Deviations from the previously calculated winding layer height H also lead to deviations from the desired current and tem-perature distribution across the winding layers I connected in parallel.
In the past, it has been standard practice either to accept these dimensional tolerances in spite of the disadvantages outlined above, or to compensate for these tolerances as far as possible by applying a differing contact pressure to the turns during the winding process.
By contact pressure is meant the surface pressure by means of which the individual turns of the winding layer I are pressed together in the direction of the coil mid-axis 7 during the winding process by means of a pressing device or by means of manually operated pressing tools. For example, if the conductor or conductor bundle 6 has too big an axial height GH 1, GH2, GH3, the contact pressure is increased. If the axial height GHI, GH2, GH3 is short of the required dimension, the contact pressure is reduced, i.e. the winding operation is "looser". In the latter case, thermal stress affecting the winding layers I or the single-layered or multi-layered winding during subsequent operation of the inductor coil can lead to settlement in the affected winding layers 1. This specifically leads to shortening of the winding layer height H of those winding layers I that were wound at a reduced contact pressure.
Against the background of this prior art, the objective of the invention is to propose a method and a winding device, by means of which coils of the type outlined above can be produced more rationally than in the past, and the winding layers are wound with neither too high a contact pressure nor too loosely.
This objective is achieved by the invention due to the fact that the processes of forming the conductors or conductor bundles with a forming device to obtain the essentially rectangular cross-section, insulating the formed conductors or conductor bundles and winding the con-ductors or conductor bundles to produce the desired winding layer all take place in a single work operation, and an axial length of an already wound part of the winding layer is used as an actual value and compared with a desired value for the already wound part on a con-tinuous or periodic basis, a desired pitch height is determined for the part of the coil layer still to be wound and the forming device is set so that the final axial length or winding layer height of the winding layer corresponds to a desired value or specified value.
One advantage gained as a result of the features defined in the characterising part of claim 1 resides in the fact that combining the part-processes of forming, insulating and winding the conductors or conductor bundles into a closed, integrated process enables costs and processing time involved in producing electric windings to be reduced, in particular induc-tor coils with no iron core provided with dry insulation.
In addition to reducing process costs and processing times, another advantage is the fact that the insulating materials are subjected to less mechanical stress and can therefore be better protected from damage. Another advantage in terms of increasing product quality achieved as a result of the method proposed by the invention is the fact that the continuous control and regulation of the dimensions of the conductor or conductor bundle whilst lay-ing the turns during the winding operation means that a largely constant contact pressure can be used. This rules out the risk of winding settlement due to thermal stress during sub-sequent service of the inductor coils. This also minimises or reduces the risk of damage or breakage of the external insulation for the conductor or conductor bundle which previously existed due to too high a contact pressure.
In one embodiment of the invention, a winding layer has at least two winding portions with different pitch heights. This enables winding layers to be made whereby parts of the wind-ing subjected to different amounts of stress can be provided with a different insulation or a different insulation thickness.
The objective of the invention is also achieved by means of a winding device, which is characterised by the fact that it comprises at least one forming device, at least one device for applying insulation and at least one automatically or manually operated control unit, which sets the forming unit or by means of which the forming unit can be set so that the final axial length or winding layer height of the winding layer corresponds to a predefined value or desired value.
In one advantageous embodiment of the invention, the control unit is designed to change the setting values of the forming unit on an automated or user-assisted basis whilst a wind-ing process is running. This enables constant intervention or a continuous or quasi-continuous control of the forming values so that the desired values of the final winding layer can be achieved as best possible. Production can also be run with short cycle times.
In an alternative embodiment, the control unit is designed to vary the setting values of the device for applying insulation on an automated or user-assisted basis whilst a winding process is running. This enables sufficiently accurate dimensional desired values of the winding layer being made to be obtained, especially if the automatic interventions take place early or continuously or periodically. This also avoids excessive variations in the shape imparted to the conductors or conductor bundles.
A coil of the type known from the prior art and examples of embodiments of the invention will be described below with reference to the appended drawings.
Of these:
Fig. I is a simplified, schematic diagram showing a detail of a coil known from the prior art comprising three coaxially disposed cylindrical winding layers;
Fig. 2 shows a detail from Figure I on a larger scale;
Fig. 3 is a schematic diagram depicting one embodiment of the method proposed by the invention for producing winding layers of a coil winding;
Fig. 4 is a highly schematic view of a winding device for running the method pro-posed by the invention.
Firstly, it should be pointed out that positions chosen for the purposes of the description, such as top, bottom, side, etc,. relate to the drawing specifically being described and can be transposed in terms of meaning to a new position when another position is being described.
Individual features or combinations of features from the different embodiments illustrated and described may be construed as independent inventive solutions or solutions proposed by the invention in their own right. The embodiments shown as examples represent possi-ble embodiments of the invention and it should be pointed out at this stage that the inven-tion is not restricted to the examples of embodiments specifically illustrated.
A coil of the type known from the prior art and examples of embodiments of the invention will be described below with reference to the appended drawings.
Of these:
Fig. I is a simplified, schematic diagram showing a detail of a coil known from the prior art comprising three coaxially disposed cylindrical winding layers;
Fig. 2 shows a detail from Figure I on a larger scale;
Fig. 3 is a schematic diagram depicting one embodiment of the method proposed by the invention for producing winding layers of a coil winding;
Fig. 4 is a highly schematic view of a winding device for running the method pro-posed by the invention.
Firstly, it should be pointed out that positions chosen for the purposes of the description, such as top, bottom, side, etc,. relate to the drawing specifically being described and can be transposed in terms of meaning to a new position when another position is being described.
Individual features or combinations of features from the different embodiments illustrated and described may be construed as independent inventive solutions or solutions proposed by the invention in their own right. The embodiments shown as examples represent possi-ble embodiments of the invention and it should be pointed out at this stage that the inven-tion is not restricted to the examples of embodiments specifically illustrated.
The structure of the coil illustrated in Figures 1 and 2 is known from the prior art and has already been described above.
Figure 3 is a schematic illustration of one embodiment of the method proposed by the in-vention. The process of producing the coils and processing the conductor or conductor bundle 6 is indicated in a box framed by broken lines in the drawing and denoted by refer-ence 13. It comprises the steps of forming 12 the conductor or conductor bundle 6, insulat-ing 14 and winding 15 to obtain the required winding layer 1 or coil winding.
The axial length or height of the wound winding layer I or coil is measured continuously or periodi-cally by a measuring element 17 and the number of turns already wound is simultaneously detected by means of a detection and counting element, although this is not illustrated. On the basis of these values, a computer element 18 determines an anticipated actual value 9 of the coil height or axial winding layer height H. This is compared with the desired value 8 of the coil height or winding layer height H and on this basis, a control unit 10 calculates a positioning variable for a positioning element 11 of the forming unit 12.
As an alternative to using an automated control unit 10, it is also possible to provide a manually operated control unit 10. For example, an adjusting device which has to be changed manually, especially for the forming elements, in particular the pressing rollers of the forming unit 12, may be used to vary the operating values and adapt or as far as possi-ble approximate exactly to the desired value 8 of the final winding layer height H. Natu-rally, the actual values for the winding layer height H at any one time or for the pitch height GH1, GH2, GH3 at any one time may also be detected manually, semi-automati-cally or automatically by means of appropriate sensors. Instead of measuring the coil or winding layer height H continuously or periodically, it would also be possible to determine the actual value of the current winding layer height H on the basis of the respective pitch height GH1, GH2, GH3 on the winding layer 1 being made and on the number of turns achieved, predetermine the anticipated actual value 9 of the winding layer height H and intervene in the winding process at an early stage as it is running on the basis of an adjust-ment or control of the forming unit 12 by means of a manually operated or automated, for example motor-driven, positioning element 11, so that the desired value 8 for the winding layer height H of the finished winding layer 1 is obtained as exactly as possible.
The variables which detrimentally affect the entire process and hence the pitch height of the conductors or conductor bundles 6 are denoted by reference 16 in Figure 3.
These are toler-ances in the setting of the forming elements in particular, especially the pressing rollers, in order to vary the dimensions due to the pressure release downstream of the pressing rollers, in particular when pressing conductor bundles, tolerances in applying the external insulation and shape-changing forces which occur in the conductor or conductor bundle 6 when wind-ing the winding layer 1 or coil. The latter are dependent on the geometric dimensions of the conductor or conductor bundle 6 and the winding diameter, amongst other things.
The method proposed by the invention also offers the possibility of pre-setting desired heights for specific winding portions within a winding layer 1 to obtain different pitch heights GH1, GH2, GH3 for these portions of the winding layer 1. This is particularly ex-pedient when making allowance for different external insulation materials of the conductor or conductor bundle 6 for winding portions that are exposed to a high amount of stress, in particular. For example, it makes it much easier to provide the conductors or conductor bundles 6 in the distal terminal end portions of the winding layers I with different, in par-ticular stronger or thicker insulation than the conductors or conductor bundles 6 in the middle portion of a winding layer 1. Allowance for the change in thickness of the insula-tion of the conductor or conductor bundle 6 is made by the method proposed by the inven-tion due to the detection of the desired value 8, which means that the final or ultimate winding layer height H can be kept as accurate as possible even if there is a different insu-lating structure within a winding layer 1.
Fig. 4 is a schematic diagram illustrating a winding device 20 proposed by the invention.
From a supply reel 21 with the conductor material to be processed, these conductors or conductor bundles are fed one after the other to a shaping unit 12 and a unit 14 for insulat-ing the conductors or conductor bundles 6, before they are processed to form coils at point 15 and wound onto a winding body and are thus processed "online" as it were or continu-ously, i.e. essentially without any interruptions or intermediate storage, to produce the ap-propriate winding layers 1 for electric inductor coils. The conductors or conductor bundles 6 processed by means of the winding device 20 can therefore be pressed against one an-other by a pressing device 19 with a specific, largely constant pressure.
Figure 3 is a schematic illustration of one embodiment of the method proposed by the in-vention. The process of producing the coils and processing the conductor or conductor bundle 6 is indicated in a box framed by broken lines in the drawing and denoted by refer-ence 13. It comprises the steps of forming 12 the conductor or conductor bundle 6, insulat-ing 14 and winding 15 to obtain the required winding layer 1 or coil winding.
The axial length or height of the wound winding layer I or coil is measured continuously or periodi-cally by a measuring element 17 and the number of turns already wound is simultaneously detected by means of a detection and counting element, although this is not illustrated. On the basis of these values, a computer element 18 determines an anticipated actual value 9 of the coil height or axial winding layer height H. This is compared with the desired value 8 of the coil height or winding layer height H and on this basis, a control unit 10 calculates a positioning variable for a positioning element 11 of the forming unit 12.
As an alternative to using an automated control unit 10, it is also possible to provide a manually operated control unit 10. For example, an adjusting device which has to be changed manually, especially for the forming elements, in particular the pressing rollers of the forming unit 12, may be used to vary the operating values and adapt or as far as possi-ble approximate exactly to the desired value 8 of the final winding layer height H. Natu-rally, the actual values for the winding layer height H at any one time or for the pitch height GH1, GH2, GH3 at any one time may also be detected manually, semi-automati-cally or automatically by means of appropriate sensors. Instead of measuring the coil or winding layer height H continuously or periodically, it would also be possible to determine the actual value of the current winding layer height H on the basis of the respective pitch height GH1, GH2, GH3 on the winding layer 1 being made and on the number of turns achieved, predetermine the anticipated actual value 9 of the winding layer height H and intervene in the winding process at an early stage as it is running on the basis of an adjust-ment or control of the forming unit 12 by means of a manually operated or automated, for example motor-driven, positioning element 11, so that the desired value 8 for the winding layer height H of the finished winding layer 1 is obtained as exactly as possible.
The variables which detrimentally affect the entire process and hence the pitch height of the conductors or conductor bundles 6 are denoted by reference 16 in Figure 3.
These are toler-ances in the setting of the forming elements in particular, especially the pressing rollers, in order to vary the dimensions due to the pressure release downstream of the pressing rollers, in particular when pressing conductor bundles, tolerances in applying the external insulation and shape-changing forces which occur in the conductor or conductor bundle 6 when wind-ing the winding layer 1 or coil. The latter are dependent on the geometric dimensions of the conductor or conductor bundle 6 and the winding diameter, amongst other things.
The method proposed by the invention also offers the possibility of pre-setting desired heights for specific winding portions within a winding layer 1 to obtain different pitch heights GH1, GH2, GH3 for these portions of the winding layer 1. This is particularly ex-pedient when making allowance for different external insulation materials of the conductor or conductor bundle 6 for winding portions that are exposed to a high amount of stress, in particular. For example, it makes it much easier to provide the conductors or conductor bundles 6 in the distal terminal end portions of the winding layers I with different, in par-ticular stronger or thicker insulation than the conductors or conductor bundles 6 in the middle portion of a winding layer 1. Allowance for the change in thickness of the insula-tion of the conductor or conductor bundle 6 is made by the method proposed by the inven-tion due to the detection of the desired value 8, which means that the final or ultimate winding layer height H can be kept as accurate as possible even if there is a different insu-lating structure within a winding layer 1.
Fig. 4 is a schematic diagram illustrating a winding device 20 proposed by the invention.
From a supply reel 21 with the conductor material to be processed, these conductors or conductor bundles are fed one after the other to a shaping unit 12 and a unit 14 for insulat-ing the conductors or conductor bundles 6, before they are processed to form coils at point 15 and wound onto a winding body and are thus processed "online" as it were or continu-ously, i.e. essentially without any interruptions or intermediate storage, to produce the ap-propriate winding layers 1 for electric inductor coils. The conductors or conductor bundles 6 processed by means of the winding device 20 can therefore be pressed against one an-other by a pressing device 19 with a specific, largely constant pressure.
Via the control unit 10, the winding device 20 permits automatically, semi-automatically or manually controlled shaping of the conductors or conductor bundles 6 which have to be wound, depending on the winding layer height H to be achieved, without intermediate stor-age or without reeling the conductor or conductor bundle 6 of the produced winding layer I in between, and the adaptation or change to the forming results of the forming unit 12 takes place whilst the winding process is running, so that the process of forming the con-ductor or conductor bundle 6 to be processed is integrated in the process whereby the elec-tric coil or winding layer I is produced.
As indicated by broken lines in Fig. 4, it is also possible to provide the insulating unit 14 with a control unit 10 or a positioning element for influencing the dimensions, in particular the height GH1, GH2, GH3, of the conductor or conductor bundle 6, making it possible to intervene on an automated, semi-automatic or manual basis for control purposes whilst the winding process is running on the winding device 20, so that a final axial length or a fin-ished winding layer height (H) of the finished winding layer 1 corresponds to the desired value 8 as exactly as possible.
The control unit 10 may also require a person for at least some intervention or control op-erations and may be automated to a greater or lesser degree depending on the number of different sensors and/or actuators integrated in the system.
Naturally, it would also be possible to wind two or more conductors or conductor bundles 6 in parallel within a winding layer 1. With the winding device 20 proposed by the inven-tion, it is also possible in particular to wind two parallel conductors or conductor bundles 6 simultaneously or to provide the winding device 20 and its components in a multiple con-figuration. The diagram of three winding layers 1 shown in Fig.1 and. Fig. 2 should like-wise be regarded as an example. In particular, the system may be configured to wind only one winding layer I or a plurality of winding layers 1.
For the sake of good order, it should be pointed out that in order to provide a clearer under-standing of the structure of the coil , it and its constituent parts are illustrated to a certain extent out of scale and./or on an enlarged scale and/or on a reduced scale.
As indicated by broken lines in Fig. 4, it is also possible to provide the insulating unit 14 with a control unit 10 or a positioning element for influencing the dimensions, in particular the height GH1, GH2, GH3, of the conductor or conductor bundle 6, making it possible to intervene on an automated, semi-automatic or manual basis for control purposes whilst the winding process is running on the winding device 20, so that a final axial length or a fin-ished winding layer height (H) of the finished winding layer 1 corresponds to the desired value 8 as exactly as possible.
The control unit 10 may also require a person for at least some intervention or control op-erations and may be automated to a greater or lesser degree depending on the number of different sensors and/or actuators integrated in the system.
Naturally, it would also be possible to wind two or more conductors or conductor bundles 6 in parallel within a winding layer 1. With the winding device 20 proposed by the inven-tion, it is also possible in particular to wind two parallel conductors or conductor bundles 6 simultaneously or to provide the winding device 20 and its components in a multiple con-figuration. The diagram of three winding layers 1 shown in Fig.1 and. Fig. 2 should like-wise be regarded as an example. In particular, the system may be configured to wind only one winding layer I or a plurality of winding layers 1.
For the sake of good order, it should be pointed out that in order to provide a clearer under-standing of the structure of the coil , it and its constituent parts are illustrated to a certain extent out of scale and./or on an enlarged scale and/or on a reduced scale.
List of reference numbers I winding layer H Winding layer height 2 Retaining element GH1 Height of conductor/ conductor 3 Tension element bundle 4 Insulating element GH2 Height of conductor/ conductor Insulating element bundle GH3 Height of conductor/ conductor 6 Conductor bundle bundle 7 Coil mid-axis 8 Desired value coil height/winding layer 9 Anticipated actual value coil height/
winding layer Control unit 11 Positioning element 12 Forming 13 Processing 14 Insulation Winding 16 Detrimental variable 17 Measuring element 18 Computer element 19 Pressing device Winding device 21 Supply reel
winding layer Control unit 11 Positioning element 12 Forming 13 Processing 14 Insulation Winding 16 Detrimental variable 17 Measuring element 18 Computer element 19 Pressing device Winding device 21 Supply reel
Claims (5)
1. Method of producing a coil winding, comprising one or more winding layers (1) of essentially rectangular shaped conductors or conductor bundles (6), characterised in that the processes of forming the conductors or conductor bundles (6) with a forming unit (12) into the essentially rectangular shaped cross-section, insulating the formed conductors or conductor bundles (6) and winding the conductors or conductor bundles (6) to obtain the desired winding layer (1) are operated in a single work operation, an axial length of an already wound part of the winding layer (1) is used as an actual value and compared with a desired value for the already wound part on a continuous or periodic basis, a desired pitch height for the part of the winding layer (1) still to be wound is determined and the forming unit is set so that the final axial length or winding layer height (H) of the winding layer (1) corresponds to a desired value or specified value.
2. Method as claimed in claim 1, characterised in that a winding layer comprises at least two winding portions with differing pitch heights.
3. Winding device for producing a coil winding comprising one or more winding layers (1) of essentially rectangular shaped conductors or conductor bundles (6), character-ised in that it comprises at least one forming unit (12), at least one device (14) for applying insulation and at least one automatically or manually operated control unit (10), which sets the forming unit (12) or enables the forming unit (12) to be set so that the final axial length or winding layer height (H) of the winding layer (1) corresponds to a predefined value or desired value.
4. Winding device as claimed in claim 3, characterised in that the control unit (10) is designed to vary the settings values of the forming unit (12) on an automated or user-assisted basis whilst a winding process is running.
5. Winding device as claimed in claim 3 or 4, characterised in that the control unit (10) is designed to vary the settings values of the device (14) for applying insulation on an automated or user-assisted basis whilst a winding process is running.
The invention describes a method of producing a coil winding comprising one or more winding layers, and if there are several winding layers of a coil winding, the individual winding layers have different numbers of turns, primarily decreasing from the inside towards the outside. In order to ensure identical winding layer heights, the cross-sectional shape of the conductors or conductor bundles is adapted by a forming process.
To ensure that the individual turns of the winding layers are wound with neither too high a contact pressure or too loosely, the invention proposes operating the processes of forming the con-ductors or conductor bundles with a forming unit, insulating the formed conductors or conductor bundles and winding the conductors or conductor bundles in a single work opera-tion. This being the case, the height of an already wound part of the coil winding is used as an actual value and compared with a desired value for the already wound part on a con-tinuous basis, a desired pitch height for the part of the winding layer still to be wound is determined and the forming unit is set so that the final axial length or height of the winding layer corresponds to a specified value or the desired value. Also specified is an appropriate winding device.
The invention describes a method of producing a coil winding comprising one or more winding layers, and if there are several winding layers of a coil winding, the individual winding layers have different numbers of turns, primarily decreasing from the inside towards the outside. In order to ensure identical winding layer heights, the cross-sectional shape of the conductors or conductor bundles is adapted by a forming process.
To ensure that the individual turns of the winding layers are wound with neither too high a contact pressure or too loosely, the invention proposes operating the processes of forming the con-ductors or conductor bundles with a forming unit, insulating the formed conductors or conductor bundles and winding the conductors or conductor bundles in a single work opera-tion. This being the case, the height of an already wound part of the coil winding is used as an actual value and compared with a desired value for the already wound part on a con-tinuous basis, a desired pitch height for the part of the winding layer still to be wound is determined and the forming unit is set so that the final axial length or height of the winding layer corresponds to a specified value or the desired value. Also specified is an appropriate winding device.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AT0147704A AT501074B8 (en) | 2004-09-03 | 2004-09-03 | METHOD AND DEVICE FOR PRODUCING A COIL DEVELOPMENT |
| ATA1477/2004 | 2004-09-03 | ||
| PCT/AT2005/000334 WO2006024057A1 (en) | 2004-09-03 | 2005-08-24 | Method and device for producing a coil winding |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2578758A1 true CA2578758A1 (en) | 2006-03-09 |
| CA2578758C CA2578758C (en) | 2014-02-25 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2578758A Active CA2578758C (en) | 2004-09-03 | 2005-08-24 | Method and device for producing a coil winding |
Country Status (7)
| Country | Link |
|---|---|
| EP (1) | EP1789978B1 (en) |
| CN (1) | CN101044582B (en) |
| AT (1) | AT501074B8 (en) |
| BR (1) | BRPI0514840B1 (en) |
| CA (1) | CA2578758C (en) |
| ES (1) | ES2443215T3 (en) |
| WO (1) | WO2006024057A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT507928B1 (en) | 2008-06-30 | 2015-09-15 | Coil Holding Gmbh | THROTTLE COIL FOR ELECTRIC POWER SUPPLY NETWORKS WITH REDUCED BARE MISSIONS |
| AT523998B1 (en) | 2020-07-07 | 2023-11-15 | Coil Holding Gmbh | HVDC air choke coil |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS55163826A (en) | 1979-06-07 | 1980-12-20 | Toko Inc | Manufacture of coil for switching power transformer |
| ATE17287T1 (en) * | 1982-04-21 | 1986-01-15 | Esslinger Spezielektra | CHOKE COIL, ESPECIALLY DRY INSULATED CHOKE COIL WITHOUT IRON CORE. |
| EP0120154A1 (en) * | 1983-03-25 | 1984-10-03 | TRENCH ELECTRIC, a Division of Guthrie Canadian Investments Limited | Continuously transposed conductor |
| US5174013A (en) * | 1988-06-16 | 1992-12-29 | Nippondenso Co., Ltd. | Winding apparatus and method which deforms the wire during winding |
| JP2637357B2 (en) * | 1993-07-30 | 1997-08-06 | 日特エンジニアリング株式会社 | Litz wire twisting method and litz wire twisting device |
| JP3613994B2 (en) * | 1998-02-12 | 2005-01-26 | トヨタ自動車株式会社 | Flat wire coil manufacturing apparatus and flat wire coil manufacturing method |
| DE19963365A1 (en) * | 1999-12-27 | 2001-06-28 | Uwe Friebe | Traffic control system involves recognizing and analyzing noise patterns captured as data picked up from self-illuminating traffic signs or lighting units |
| DE19963363C2 (en) * | 1999-12-27 | 2003-09-18 | Heinz-Guenther Franz | Magnetic material measure and method and device for producing such |
-
2004
- 2004-09-03 AT AT0147704A patent/AT501074B8/en active
-
2005
- 2005-08-24 ES ES05773971.6T patent/ES2443215T3/en active Active
- 2005-08-24 EP EP05773971.6A patent/EP1789978B1/en active Active
- 2005-08-24 CN CN2005800347463A patent/CN101044582B/en active Active
- 2005-08-24 CA CA2578758A patent/CA2578758C/en active Active
- 2005-08-24 WO PCT/AT2005/000334 patent/WO2006024057A1/en active Application Filing
- 2005-08-24 BR BRPI0514840-5A patent/BRPI0514840B1/en active IP Right Grant
Also Published As
| Publication number | Publication date |
|---|---|
| AT501074B1 (en) | 2007-05-15 |
| EP1789978B1 (en) | 2013-10-23 |
| WO2006024057A1 (en) | 2006-03-09 |
| ES2443215T3 (en) | 2014-02-18 |
| CA2578758C (en) | 2014-02-25 |
| BRPI0514840B1 (en) | 2018-03-06 |
| CN101044582B (en) | 2011-06-08 |
| AT501074A1 (en) | 2006-06-15 |
| EP1789978A1 (en) | 2007-05-30 |
| CN101044582A (en) | 2007-09-26 |
| AT501074B8 (en) | 2007-07-15 |
| BRPI0514840A (en) | 2008-06-24 |
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