CN110033932A - 一种变压器线圈的绕制结构及其绕制方法 - Google Patents
一种变压器线圈的绕制结构及其绕制方法 Download PDFInfo
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Abstract
本发明提供了一种变压器线圈的绕制结构,包括绕线模具和线体,线体从所述绕线模具的起绕端缠绕至末端,沿起绕端至末端方向线体为顺时针缠绕,第一匝的线体在起绕端揻成“S”弯,随后线体水平绕一圈,再向右下方揻一个斜线,斜线的上端和下端的竖直距离为线体的直径和每匝线圈之间的间距之和,随后线体重复水平绕圈和斜向下绕制,直到末端时,线体揻成“S”弯竖直向下伸出。本申请将端部第一匝导线揻一个导线高的“S”弯,减少一匝导线的螺旋角,每一段端部拉平,计算高度较传统结构减少一根线体直径的高度,从而线圈高度降低;绝缘结构与电气距离与传统结构一样的条件下,能够有效地降低铁芯窗口高,减少铁芯硅钢片的用量,降低空载损耗。
Description
技术领域
本发明涉及变压器制造技术领域,尤其涉及一种变压器线圈的绕制结构及其绕制方法。
背景技术
为了使绝缘材料在安全电压范围内可靠运行,通常将线圈设计成2段以上的多段多层圆筒式结构,以降低其层间电压和段间电压,并且采取在层间放置格外的绝缘材料和拉开段间距离的方法,以满足变压器电气强度的技术要求。电压越高,段数越多。但是,段数越多,段间累计间距也就越大,这就造成线圈的轴向高度越高。造成变压器的体积增大,还会因铁芯高度尺寸增加而增加硅钢片、绝缘材料、钢材及树脂重量,材料消耗增多,产品成本上升,价格竞争力下降。
传统的线圈绕制是斜线绕制,在线圈横截面存在绕制高度,在线圈横截面端部时存在一定的螺旋角,这样每匝线圈的轴向高度会拉的很高,铁芯窗口越高,因此,必须在满足变压器电气强度技术要求的前提下,改变线圈的绕制结构,尽量避免线圈结构内存在不必要的空间浪费,尽最大可能填充线圈内部的空间,把段间累计间距缩到最小程度。
发明内容
为克服现有技术中存在的线圈结构内存在不必要的空间浪费的问题,本发明提供了一种变压器线圈的绕制结构及其绕制方法。
一种变压器线圈的绕制结构,其特征在于:包括绕线模具和线体,所述线体从所述绕线模具的起绕端缠绕至末端,沿所述起绕端至末端方向所述线体为顺时针缠绕,第一匝的线体在起绕端揻成“S”弯,随后线体水平绕一圈,再向右下方揻一个斜线,斜线的上端和下端的竖直距离为线体的直径和每匝线圈之间的间距之和,随后线体继续水平绕一圈,再向右下方揻一个斜线,与上一个斜线平行,斜线的上端和下端的竖直距离也为线体的直径和每匝线圈之间的间距之和,所有斜线的上端和下端分别在一条竖直线上,随后线体重复水平绕圈和斜向下绕制,一直到绕线模具的末端时,线体揻成“S”弯竖直向下伸出。
在本发明一优选实施例中,所述“S”弯和斜线的上下端都包裹有三层绝缘纸。
在本发明一优选实施例中,相邻线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件。
在本发明一优选实施例中,所述起绕端与末端为所述绕线模具的同一端面。
在本发明一优选实施例中,所述绕线模具为圆柱体。
一种变压器线圈的绕制方法,包括如下步骤:
a.在绕线模具上从上至下从起绕端到末端顺时针顺序绕制线圈第一匝,将第一匝的线体在起绕端揻弯形成“S”弯,在“S”弯上包裹绝缘纸,随后将线体水平绕制一圈,形成从上到下顺序的第一匝;
b.在靠近第一匝起绕端的“S”弯的地方,向右下方揻一个斜线,斜线的上端和下端的竖直距离为线体的直径和每匝线圈之间的间距之和,在斜线的上端和下端包裹绝缘纸,在斜线的上端和下端的位置放置绝缘支撑件,随后线体继续水平绕制一圈,形成从上到下顺序的第二匝;
c.重复步骤b完成中间线圈的绕制,在斜线的上端和下端包裹绝缘纸,在相邻的线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件;
d.绕制到最后一匝时,线体(水平绕制到绕线模具的末端时,线体揻成“S”弯竖直向下伸出,完成线圈的绕制。
在本发明一优选实施例中,所述步骤b中在“S”弯上包裹三层绝缘纸。
在本发明一优选实施例中,所述步骤b和c中在斜线的上端和下端包裹三层绝缘纸。
在本发明一优选实施例中,所述步骤b和c中相邻的线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件。
在本发明一优选实施例中,所述放置绝缘支撑件的具体内容为,将厚度为0.4mm的绝缘网格卷绕6~8层制成直径与各匝线圈辐向尺寸相同的绝缘支撑件,在相邻两匝线圈之间的位置放置3件以上绝缘支撑件。
与现有技术相比,本发明的有益效果是:
(1)本申请将每段线圈的端部第一匝导线揻一个导线高的“S”弯,从而减少一匝线体的螺旋角,使每一段端部拉平,计算高度较传统结构减少一根线体直径的高度,每匝线圈至少降低4根线体的直径高度,从而使得线圈高度降低;
(2)本申请的绝缘结构、电气距离与传统结构一样的条件下,能够有效地降低线圈结构内空间的浪费,降低铁芯窗口高,减少铁芯硅钢片的用量,降低空载损耗,节能效果显著提升;
(3)增加了线圈内部的段间距离,降低段间场强,为变压器的安全稳定运行提供可靠保障。
附图说明
图1是本发明一种变压器线圈的绕制结构一优选实施例的结构示意图;
图中:1-绕线模具;2-线体;3-起绕端;4-末端。
具体实施方式
以下结合附图和实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。
实施例1:
请参看图1,是本发明一种变压器线圈的绕制结构一优选实施例的结构示意图,一种变压器线圈的绕制结构,包括绕线模具和线体,所述线体从所述绕线模具的起绕端缠绕至末端,沿所述起绕端至末端方向所述线体为顺时针缠绕,第一匝的线体在起绕端揻成“S”弯,随后线体水平绕一圈,再向右下方揻一个斜线,斜线的上端和下端的竖直距离为线体的直径和每匝线圈之间的间距之和,随后线体继续水平绕一圈,再向右下方揻一个斜线,与上一个斜线平行,斜线的上端和下端的竖直距离也为线体的直径和每匝线圈之间的间距之和,所有斜线的上端和下端分别在一条竖直线上,随后线体重复水平绕圈和斜向下绕制,一直到绕线模具的末端时,线体揻成“S”弯竖直向下伸出。
在本实施例中,所述“S”弯和斜线的上下端都包裹有三层绝缘纸。
在本实施例中,相邻线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件。
在本实施例中,所述起绕端与末端为所述绕线模具的同一端面。
在本实施例中,所述绕线模具为圆柱体。
实施例2:
一种变压器线圈的绕制方法,包括如下步骤:
a.在绕线模具上从上至下从起绕端到末端顺时针顺序绕制线圈第一匝,将第一匝的线体在起绕端揻弯形成“S”弯,在“S”弯上包裹绝缘纸,随后将线体水平绕制一圈,形成从上到下顺序的第一匝;
b.在靠近第一匝起绕端的“S”弯的地方,向右下方揻一个斜线,斜线的上端和下端的竖直距离为线体的直径和每匝线圈之间的间距之和,在斜线的上端和下端包裹绝缘纸,在斜线的上端和下端的位置放置绝缘支撑件,随后线体继续水平绕制一圈,形成从上到下顺序的第二匝;
c.重复步骤b完成中间线圈的绕制,在斜线的上端和下端包裹绝缘纸,在相邻的线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件;
d.绕制到最后一匝时,线体(水平绕制到绕线模具的末端时,线体揻成“S”弯竖直向下伸出,完成线圈的绕制。
在本实施例中,所述步骤b中在“S”弯上包裹三层绝缘纸。
在本实施例中,所述步骤b和c中在斜线的上端和下端包裹三层绝缘纸。
在本实施例中,所述步骤b和c中相邻的线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件。
在本实施例中,所述放置绝缘支撑件的具体内容为,将厚度为0.4mm的绝缘网格卷绕6~8层制成直径与各匝线圈辐向尺寸相同的绝缘支撑件,在相邻两匝线圈之间的位置放置3件以上绝缘支撑件。
本申请将每段线圈的端部第一匝导线揻一个导线高的“S”弯,从而减少一匝导线的螺旋角,使每一段端部拉平,计算高度较传统结构减少一根线体直径的高度,每匝线圈至少降低4根线体的直径高度,从而使得线圈高度降低;本申请的绝缘结构与电气距离与传统结构一样的条件下,能够有效地降低线圈结构内空间的浪费,降低铁芯窗口高,减少铁芯硅钢片的用量,降低空载损耗,节能效果显著提升;增加了线圈内部的段间距离,降低段间场强,为变压器的安全稳定运行提供可靠保障。
上述说明示出并描述了本发明的优选实施例,如前所述,应当理解本发明并非局限于本文所披露的形式,不应看作是对其他实施例的排除,而可用于各种其他组合、修改和环境,并能够在本文所述发明构想范围内,通过上述教导或相关领域的技术或知识进行改动。而本领域人员所进行的改动和变化不脱离本发明的精神和范围,则都应在本发明所附权利要求的保护范围内。
Claims (10)
1.一种变压器线圈的绕制结构,其特征在于:包括绕线模具(1)和线体(2),所述线体(2)从所述绕线模具(1)的起绕端(3)缠绕至末端(4),沿所述起绕端(3)至末端(4)方向所述线体(2)为顺时针缠绕,第一匝的线体(2)在起绕端(3)揻成“S”弯,随后线体(2)水平绕一圈,再向右下方揻一个斜线,斜线的上端和下端的竖直距离为线体(2)的直径和每匝线圈之间的间距之和,随后线体(2)继续水平绕一圈,再向右下方揻一个斜线,与上一个斜线平行,斜线的上端和下端的竖直距离也为线体(2)的直径和每匝线圈之间的间距之和,所有斜线的上端和下端分别在一条竖直线上,随后线体(2)重复水平绕圈和斜向下绕制,一直到绕线模具(1)的末端(4)时,线体(2)揻成“S”弯竖直向下伸出。
2.根据权利要求1所述的一种变压器线圈的绕制结构,其特征在于:所述“S”弯和斜线的上下端都包裹有三层绝缘纸。
3.根据权利要求1所述的一种变压器线圈的绕制结构,其特征在于:相邻线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件。
4.根据权利要求1所述的一种变压器线圈的绕制结构,其特征在于:所述起绕端(3)与末端(4)为所述绕线模具(1)的同一端面。
5.根据权利要求1所述的一种变压器线圈的绕制结构,其特征在于:所述绕线模具(1)为圆柱体。
6.一种如权利要求1所述的一种变压器线圈的绕制方法,其特征在于,包括如下步骤:
a.在绕线模具(1)上从上至下从起绕端(3)到末端(4)顺时针顺序绕制线圈第一匝,将第一匝的线体在起绕端(3)揻弯形成“S”弯,在“S”弯上包裹绝缘纸,随后将线体水平绕制一圈,形成从上到下顺序的第一匝;
b.在靠近第一匝起绕端(3)的“S”弯的地方,向右下方揻一个斜线,斜线的上端和下端的竖直距离为线体(2)的直径和每匝线圈之间的间距之和,在斜线的上端和下端包裹绝缘纸,在斜线的上端和下端的位置放置绝缘支撑件,随后线体(2)继续水平绕制一圈,形成从上到下顺序的第二匝;
c.重复步骤b完成中间线圈的绕制,在斜线的上端和下端包裹绝缘纸,在相邻的线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件;
d.绕制到最后一匝时,线体(2)水平绕制到绕线模具(1)的末端(4)时,线体(2)揻成“S”弯竖直向下伸出,完成线圈的绕制。
7.根据权利要求6所述的一种变压器线圈的绕制方法,其特征在于:所述步骤b中在”S”弯上包裹三层绝缘纸。
8.根据权利要求6所述的一种变压器线圈的绕制方法,其特征在于:所述步骤b和c中在斜线的上端和下端包裹三层绝缘纸。
9.根据权利要求6所述的一种变压器线圈的绕制方法,其特征在于:所述步骤b和c中相邻的线圈之间和每个斜线的上端下端的位置都放置绝缘支撑件。
10.根据权利要求9所述的一种变压器线圈的绕制方法,其特征在于:所述放置绝缘支撑件的具体内容为,将厚度为0.4mm的绝缘网格卷绕6~8层制成直径与各匝线圈辐向尺寸相同的绝缘支撑件,在相邻两匝线圈之间的位置放置3件以上绝缘支撑件。
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