CN1008413B - Method for producing moulded coil - Google Patents

Abstract

To eliminate a mold for forming a winding and outer layer insulator, by winding and fixing a thin plate around the periphery of a winding drum, by forming in turn an inner insulating layer, conductor winding layer and outer insulating layer, by heating and hardening resin impregnated preliminarily in the inner and outer insulating layers, and by removing the winding drum and the thin plate. Since the sleeve 12 of a winding drum is displaced relatively to the center axis 9 by rotating a handle 11, links 14, 15, 16 are displaced radially just as an umbrella is opened and closed. A thin plate 18 which is later removed is wound and fixed around the outer periphery of the winding drum pieces. A conductor wound layer 21a of conductor 21 and an outer insulating layer 22 are formed in turn through an inner insulating layer 19 and inter-layer insulating layers 20 on the bobbin which is constituted through the thin plate 18 by the winding drum 8, thus constituting a winding 17. Thereafter, resin which is preliminarily being impregnated in the inner and outer insulating layers 19, 22 is heated and hardened, and then the winding drum 8 and thin plate 18 are removed.

Description

Method for producing moulded coil

The present invention relates to a kind of method of making molded winding, this molded winding is used for electric induction equipment such as transformer, reactor, static.

Up to this point, in method known, that be used for making resin moulded moulding winding, lead such as aluminum steel and copper cash and insulating material be alternately be wrapped in as on the cylindrical barrel of winding fuse so that make winding assembly, then thermosetting resin is poured in the Manufactured winding assembly.Then, the heating winding assembly is made resin moulded moulding winding so that make hardening of resin.This known method uses the cylindrical metal mould as above-mentioned coiling cylinder.This metal die is to be made of the die blade of making according to the fixed dimension of internal diameter that will seek out and length, and fits together by seal member.Then one pair of wooden model is inserted in the chamber of metal die.This wooden mold has the outer peripheral face of taper, thereby they can be separated with metal die easily.This metal die is pulled on the driving shaft of coil winding machine by its wooden model.

Yet this known method involves a problem, promptly makes the molded winding of different size and need prepare the metal die of different size and wooden model.So not only can increase the mould of making different size and the cost of model, but also need do the management work such as a lot of moulds and model are preserved and taken care of.In addition, when the size of the winding that will make changes, just need spend a large amount of labours and time assembly jig and model.Thereby, before the actual making of setting about winding, need a very long time.

In publication number is 5848/1970 Japan Patent, a kind of method has been proposed, in this method,, the mould of the external insulation part of winding as casting resin used in order to reduce the quantity of making the required mould of molded winding.Yet this known method is not to the in addition any consideration of the quantity that reduces the mould that constitutes the coiling cylinder.

In the open 57-157510 of Japan Patent, a kind of winding fuse that is made of elastic roll shape metallic plate is proposed, prepare prefabricated component by the mode more bigger than preliminary dimension, when coiling, it is constrained to preliminary dimension, so that when impregnation process, resist convergent force effectively and propelling coil expands outwardly, can under the effect of interior crowded external pressure, obtain winding closely thus by the resilience under the no restrained condition.But this method still needs the prefabricated component to the different sizes of different size winding preparation.

Therefore, the purpose of this invention is to provide a kind of method of making molded winding, in this method, reduced and prepared the coiling cylinder and make needed labour of winding and time, thereby improved the production efficiency of molded winding.

For this purpose, the invention provides a kind of method of making molded winding, in this method, lead and at least one insulator are wrapped on the columniform coiling cylinder with the predetermined number of plies, then thermosetting resin is poured in conductor layer and the insulating barrier, by heating it is solidified again, thereby make the molded winding of hard, feature of the present invention comprises the steps:

Prepare a general coiling cylinder with a plurality of bars, this tube bar is disposed in a kind of mode that makes the coiling drum have variable circumferential size, more this general cylinder is installed with predetermined circumferential size;

Then, an elastic sheet looping on general coiling cylinder, removably is fixed on this thin slice on the coiling cylinder again;

Outer surface at the thin slice of looping on general coiling cylinder carries out the die joint processing; Then;

Insulator and lead alternately are wrapped on the outer cylinder surface of thin slice from level to level, make molded winding in view of the above.

According to this method, the circumferential size of coiling cylinder can freely be adjusted, and thin slice is dismountable with being connected of cylinder that wind the line, thereby can make the winding fuse that has molded required continuous outer cylinder surface like a dream.In addition, can unload and make winding and thin slice to separate with thin slice from the coiling cylinder winding easily.

After in conjunction with the accompanying drawings most preferred embodiment being carried out following description, above-mentioned and other purposes, feature and advantage of the present invention will become more obvious.

Fig. 1 and Fig. 2 are respectively the front view and the end views of coiling cylinder, and the winding on the coiling cylinder is made according to method of the present invention;

Fig. 3 is the end view of the general coiling cylinder that adopted among the embodiment represented among Fig. 1;

Fig. 4 and Fig. 5 are the partial side view and the front views of the winding made of another embodiment according to method of the present invention;

Fig. 6 is the end view according to a part section of the molded winding of embodiment represented among Fig. 4 and Fig. 5;

Fig. 7 and Fig. 8 are the profiles of the different winding that can make according to method of the present invention;

Fig. 9 is the perspective view that is used for the lead of the represented winding of Fig. 8.

Fig. 1 and Fig. 2 represent according to embody the winding that method of the present invention is made on the coiling cylinder.In the step of manufacturing of illustrated this winding, on the face of cylinder of general coiling cylinder [1], make an inner insulating layer [21] earlier, then a winding [22] is become to be wrapped on this layer inner insulating layer [21] spiral yarn shapedly.As will be appreciated that by following description, general coiling cylinder is to constitute in the mode that a kind of permission is adjusted the circumferential size of coiling cylinder, thin slice [2] looping goes up and fixes with it at coiling cylinder [1], thereby can make the coiling cylinder have continuous external peripheral surface.

This general coiling cylinder [1] has and is suitable for the central shaft [10] that the driving shaft (not shown) with coil winding machine couples, and has radially a plurality of and be configured in central shaft [10] tube bar [12] on every side coaxially.Size according to the diameter of the winding that will make is done suitably to select to the quantity of these bars [12], and these bars are disposed so that forms the external cylindrical surface of the cylinder [1] that winds the line.As will be appreciated that by the Fig. 3 that represents coiling cylinder formation details, this central shaft [10] has threaded portion [11] on certain axial length, have a slide block [14] to slide in the above, the handle [13] that engages with threaded portion [11] can move along the axle of central shaft [10] when rotating.Slide block [14] is connected with handle [13] so that slide block can be slidably reciprocated along central shaft along with the rotation of handle [13].Each root tube bar is by connecting rod [15], and [16] and [17] are connected on the central shaft [10].These connecting rods [15], [16] be connected with support component on being fixed on central shaft [10] with the support component at the two ends of slide block [14] respectively on separately end pivoting formula ground with [17], and be connected with the two ends of each bar [12] pivotally at the other end separately.Assembling to connecting rod is such, and promptly when handle [13] rotated, slide bar [14] moved relative to central shaft [10], thereby makes a bar [12] by connecting rod [15], and [16] and [17] move radially, and changes the circumferential size of coiling cylinder [1] in view of the above.The general coiling cylinder and the structure of coil winding machine can be with the patent No. be that the disclosed coiling cylinder of the specification of 4061,289 United States Patent (USP) is identical with coil winding machine, this patent has transferred the application's applicant.Therefore, in order to make description for simplicity, omitted in this article and related to further describing of coiling cylinder and coil winding machine.

State that as top the external cylindrical surface of general coiling cylinder [1] is limited by a plurality of tube bars [12] of separately being settled in a circumferential direction.Therefore, except the situation that the tube bar is arranged to minimum barrel dliameter, between adjacent cartridges bar [12], all leave certain circumference space, this can cause that in molded process the resin by heating＜liquefaction flows to the coiling cylinder by the space, this is nonconforming, therefore, obviously just can not directly on the coiling cylinder, carry out molded operation.At the insulating material such as glass fibre that adopts the pre-soaked mistake of thermosetting resin during as pre impregnated material, the direct lead on general coiling cylinder and can make winding have polygon cross section through the insulating material of pre-preg.So also can make preimpregnation material hang down into space between the bar, and cause insulating with low quality.For this reason, a kind of thin slice looping with suitable hardness is constituted dismountable fixedlying connected on general reel and with reel, so just formed a kind of fuse that has continuous outer cylinder surface according to the present invention.

In the present embodiment, thin slice [2] is to make according to the size that is enough to topped coiling cylinder [1], thin slice [2] looping diameter according to the coiling cylinder [1] of the diameter of the winding that will make configuration around, then in end fixed mode thin slice removably is fixed up such as a kind of heat-resisting resin bonding band (referring to Fig. 1) by employing again with thin slice [2].After this, carry out suitable somatotype processing by applying a kind of parting compound such as outer cylinder surface and making winding have a kind of die joint film to thin slice [2].This thin slice [2] should have suitable hardness, because excessive hardness can make the end resilience of thin slice, thus the smooth surface of infringement cylindrical core, same, too little hardness can not provide core rod needed intensity.Therefore, this thin slice is preferably made with the stainless steel of 0.2 to 1.0 millimeter thickness or the thin slice that contains the polymerization insulating material of tetrafluoroethene compound film.For consideration economically, can suitably use heat-resisting insulation resin pressboard, are significantly equivalent other materials but also can adopt those professionals to the present technique field.

To carry out part to the method for making winding on the coiling core that mode was provided of foregoing description below describes.

As the first step, with a kind of preimpregnation material of partial coagulation, promptly a kind of by glass fibre or by the band looping of epoxy resin impregnated mistake on thin slice [2], meanwhile, power by the coil winding machine (not shown) makes the rotation of coiling cylinder, can be made into the inner insulating layer [21] of predetermined thickness thus.Secondly, on predetermined axial region and with the predetermined number of plies, lead [22] is twined to form a winding.Between the adjacent layer of lead [22] is inferior, lay the interlayer insulating film of one deck such as insulating paper at least, its objective is for isolation that the induced voltage between the adjacent conductor layer is insulated.Once more, make an external insulation layer according to the mode identical at the outer surface of coil with making inner insulating layer [21].

Then, top made winding is put in the drying oven together with coiling cylinder [1], and it is heated according to suitable method.As the result of heating, interlayer insulating film is dried, constitute internal layer and outer insulation originally the thermoset resin of part solidified fully substantially.Thereby the inside and outside circle cylinder of winding is fixed.The internal layer that solidifies, outer insulation are used as the mould of casting resin, and the thermosetting resin that will be sticking shape is inserted two axial port of winding.Then, make as a whole winding and be put in the drying oven heating once more so that carry out solidifying of second stage, in this course, resin and internal layer, outer insulation and interlayer insulating film in two axial port of winding are bonding, thereby have made a complete molded winding.After the solidifying of second stage, general coiling cylinder [1] is made radial contraction, and from by deviating from the made cylinder of thin slice [2].Then, throw off the end [3] of thin slice [2], and thin slice [2] is made radial contraction, thereby it is separated with molded winding.Can carry out this separation easily by means of handling at the die joint on the surface of thin slice [2].

In described embodiment, when winding also is fixed on the coiling cylinder [1], carry out first and second stages to hardening of resin.Yet this way is not unique, and solidifying also of second stage can be carried out after winding is unloaded from the coiling cylinder again.In the later case, after the outside that makes winding by solidifying of phase I and inner circular cylinder are fixing, with a kind of with the similar mode of top described mode winding disengagement from coiling cylinder [1] and thin slice [2].The thermosetting resin that then will be sticking shape is filled into two axial ends of the winding that has disassembled, winding is heated so that thermosetting resin is solidified again.This improved method is compared with the embodiment that has described, can the more convenient two ends that the thermosetting sticky matter are filled into winding.

In the foregoing embodiments, inside and outside insulating barrier is made by preimpregnation material.Yet this way is not unique, and for the mode of again thermosetting resin being inserted after making at winding, the present invention is suitable for too.Indicated as Fig. 4, in this mode, winding [30] is fabricated on the coiling cylinder according to the mode of aforesaid embodiment, and this winding has an inner insulation layer [31], conductor layer [32]) interlayer insulating film [35] and outer insulation [34].The insulator of the insulating effect that one of reference number [35] expression guarantees to reach satisfied between each layer of lead at two axial end places of lead.Therefore, each overhang insulation layer has filled up the space between the end of insulating barrier between adjacent two layers, and this interlayer insulating film is designed to slightly exceed the axial end of conductor layer [32].After winding [30] was made, the coiling cylinder was made radial contraction, then deviate from from the cylindrical inner chamber that is made of thin slice [2], but thin slice [2] is because of having rebound performance, so still keep in touch with winding.Secondly, support component [5] and [6] are put in the chamber of thin slice [2] so that it is propped up thin slice [2].Again secondly,, press among Fig. 6 representedly, end formed plate [7] is placed on and two axial end touching positions of winding [30], and they fixed with connecting rod [8].Then, thermosetting resin [9] is inserted in the winding [30] between the end formed plate [7], simultaneously, thin slice [2] is used as molded fuse.Make hardening of resin by heating again.Thereby,, also can utilize method of the present invention to make molded winding by inserting the mode of thermosetting resin after making at winding [30].

Although as long as the winding size is smaller, do not use end forming board [7] can make yet and reach gratifying degree with resin bonding, but had better aforesaid, utilize preimpregnation material also to adopt this end formed parts [7] in as the embodiment of inside and outside insulating barrier.

Fig. 7 and Fig. 8 represent the molded structure that can make with method provided by the present invention.The structure that represented molded winding [40] has among Fig. 7 structure with the winding of being described in conjunction with Fig. 4 [30] basically is identical, that is to say, this structure is by inner insulation layer [41], conductor layer [42], interlayer insulating film [43], outer insulation [44] and overhang insulation layer [45] constitute.Yet winding [40] and winding [30] are distinguishing, and in winding [40], conductor layer [42] is to be made by the lead of the cross section with flat pattern.

On the other hand, the structure that represented lead has among Fig. 8 is: it is by inner insulation layer [51], conductor layer [52], and insulator [53] and [54] and outer insulator [55] constituted between layer was interior.In this mode, conductor layer [52] also is to be made by the lead of the cross section with flat pattern.Yet the structure of represented winding [40] is distinguishing on the arrangement of interlayer insulating film [53], [54] and overhang insulation layer [56] among winding [50] and Fig. 7.In other words, in winding [50], each overhang insulation layer is made of one-sided insulation adhesive band, and is bonding with a side of conductor layer [52] again after this adhesive tape is folded continuously.This insulation adhesive band is to add that by the one side to insulating paper suitable binding agent makes.Interlayer insulating film [53] and [54] are made of insulating paper, and this insulating paper has enough big width separately and covers this part conductor layer [52] between the end insulating barrier [56], and has and the conductor layer equal widths.This structure of winding [50] makes that the overhang insulation layer of conductor layer is simple for production, and can reduce the processing step of making winding.In addition, can between resin and overhang insulation layer, reach higher dielectric strength, thereby make molded winding more sturdy and durable.

As will be appreciated that by foregoing description, according to method of the present invention, molded winding is by adopting a kind of laminar coiling fuse of being handled by the coiling cylinder that can change circumferential size and a kind of disconnectable process die joint to be made.Therefore, this method has following advantage:

(1). the reel of being regulated by the internal diameter that adopts the winding that a barrel dliameter can be as required and looping on the coiling cylinder, with the thin slice that the size of coiling cylinder is complementary, make the molded winding that might make various sizes.And, can reduce the manufacturing cost of making molded winding significantly.

(2) even if. need to produce the winding of different size, also can shorten needed time before the processing winding.And, can also like a dream winding be disassembled from the coiling cylinder, thereby also just greatly reduce the processing step of making winding.

(3). because can freely dispose the diameter of coiling core, also just obviously enlarged the molded Winding Design degree of freedom.

(4) fixed in the mode that winding closely contacts because of thin slice, so that can be used as the mould fuse, uses thin slice, even so winding is carried out the molded this method after disassembling from the coiling cylinder again, also can obtain a kind of not only closely but also firm winding.

Although the present invention is described by special term, but what should emphasize herein is, described embodiment is a kind of schematic explanation, might make various changes and modifications under the condition that does not break away from the scope of the invention, scope of the present invention is only limited by following claim.

Claims (7)

1, a kind of method of making molded winding, in this method, one lead and at least one insulator are pressed predetermined number of plies looping on columniform coiling cylinder, then thermosetting resin is poured in conductor layer and the insulating barrier, by heating thermosetting resin is solidified again, the invention is characterized in that the step that said method comprises is:

(a) prepare a kind of general coiling cylinder, it has a plurality of bars, and this tube bar is disposed with a kind of method that makes above-mentioned coiling cylinder possess variable circumferential size, and above-mentioned general cylinder can be formed predetermined circumferential size,

(b) resilient thin slice is wrapped in the top of above-mentioned general cylinder and above-mentioned thin slice removably is fixed on the above-mentioned coiling cylinder, described thin slice is a kind of Thin Stainless Steel steel disc with thickness between 0.2 millimeter to 1.0 millimeters,

(c) on the outer surface of the above-mentioned thin slice of looping on above-mentioned general coiling cylinder, carry out die joint and handle, and

(d) above-mentioned insulator and above-mentioned lead alternately in layer are wrapped on the cylindrical outer surface of above-mentioned thin slice, thereby make molded winding.

2, according to the method described in the claim 1, it is characterized in that, comprise like this some steps: make inner insulating layer and external insulation layer by twining in advance the insulator of making impregnation process with thermosetting resin, then, after winding finishes, to the heating of the winding on above-mentioned coiling cylinder, thereby above-mentioned internal layer, outer insulation are done solidifying of phase I.

3, according to the method described in the claim 2, it is characterized in that, comprise like this some steps: after the solidifying of above-mentioned phase I, thermosetting resin is filled between the internal layer, outer insulation of above-mentioned winding, then heat, thereby above-mentioned winding is done solidifying of second stage making as a whole above-mentioned winding.

4, according to the method described in the claim 2, it is characterized in that, comprise some steps like this: after the above-mentioned phase I, make above-mentioned general cylinder make radial contraction, above-mentioned winding is disassembled from above-mentioned general cylinder, then disassemble from thin slice again, thermosetting resin is filled between above-mentioned internal layer in the winding, the outer insulation, to doing as a whole above-mentioned winding heating, above-mentioned winding is done solidifying of second stage again with this.

5, according to the method described in the claim 1, it is characterized in that comprising some steps like this: after the coiling step is finished, above-mentioned coiling cylinder is shunk, then winding is disassembled from above-mentioned general coiling cylinder together with above-mentioned thin slice, thermosetting resin is filled in the above-mentioned winding, again above-mentioned winding is done as a whole the heating, make a solid molded winding with this.

According to the method described in the claim 1, it is characterized in that 6, above-mentioned thin slice is a kind of profiled sheeting that contains the polymerization insulating material of tetrafluoroethene compound film.

According to the method described in the claim 1, it is characterized in that 7, above-mentioned thin slice is a kind of heat-resisting pressed sheet.

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