CN111863388A

CN111863388A - Three-dimensional wound core resin-cast dry-type transformer and manufacturing method thereof

Info

Publication number: CN111863388A
Application number: CN202010861204.XA
Authority: CN
Inventors: 丁友源; 舒建华
Original assignee: Jiangxi Han's Power Technology Co ltd
Current assignee: Jiangxi Han's Power Technology Co ltd
Priority date: 2020-08-25
Filing date: 2020-08-25
Publication date: 2020-10-30

Abstract

The invention discloses a three-dimensional wound core resin-cast dry-type transformer and a manufacturing method thereof. The dry-type transformer comprises a three-dimensional roll iron core body mainly composed of three iron core columns arranged in a delta shape, wherein each iron core column of the iron core body is provided with a low-voltage coil positioned on the inner side and a high-voltage coil positioned on the outer side, the low-voltage coil and the high-voltage coil on each iron core column are cast into an inseparable integral structure by epoxy resin, and a plurality of air passages with an inner-outer double-layer structure are annularly arranged between the low-voltage coil and the high-voltage coil, so that the main insulation function and the heat dissipation function can be considered. The invention aims at the three-dimensional wound core, has the characteristics of compact structure (small volume and attractive appearance), excellent electrical strength (high insulating strength and strong short-circuit resistance), excellent moisture-proof (anti-corrosion) performance, excellent heat dissipation performance, high mechanical strength and the like, and is favorable for popularization and application of the three-dimensional wound core resin-cast dry-type transformer in the market.

Description

Three-dimensional wound core resin-cast dry-type transformer and manufacturing method thereof

Technical Field

The invention relates to a transformer, in particular to a three-dimensional wound core resin-cast dry-type transformer and a manufacturing method thereof.

Background

The transformer mainly comprises three-phase iron core columns, and a low-voltage coil and a high-voltage coil which are wound on each corresponding iron core column, wherein the iron core columns are used as a magnetic circuit of the transformer, and the low-voltage coil and the high-voltage coil are used as windings of the transformer. The three-dimensional wound core is a three-phase core column which is formed by three closed loops and arranged in a delta shape, and the three-dimensional wound core dry-type transformer is favored by users due to the characteristics of high efficiency, energy conservation, low noise and the like.

Generally, the winding of the resin-cast dry-type transformer is integrally cast with epoxy resin, which brings about the characteristics of compact structure, good electrical strength, excellent moisture resistance, high mechanical strength, and the like, and is most common in the resin-cast dry-type transformer of a planar laminated core, for example, a "high-low voltage integrated coil dry-type transformer" (publication No. CN 101083168, published 2007, 12/5). However, due to the characteristic that the core column of the three-dimensional wound core is formed by a closed-loop structure, if the winding is integrally cast by epoxy resin, the technical operation difficulty of the process links such as casting, die-filling, demolding, sealing and the like is very high, and the process is difficult to realize easily and economically, so that the low-voltage coil of the common three-dimensional wound core resin cast dry-type transformer is not cast by resin, and only the high-voltage coil is cast by resin, so that the electrical strength, the moisture resistance and the mechanical strength of the three-dimensional wound core resin cast dry-type transformer are greatly reduced.

In addition, the main insulation between high voltage and low voltage of the winding of the common three-dimensional wound core resin-cast dry-type transformer is realized by a half-and-half combined structure insulation cylinder arranged between a high-voltage coil and a low-voltage coil. This is because the closed-loop structure of the three-dimensional wound core makes the insulating cylinder of the full-circle structure unable to be sleeved, and only the insulating cylinder can be designed to be a split structure capable of being assembled in half for combination and sleeving, and this kind of process measure has the technical difficulties and high manufacturing cost, and has the technical problems of low insulating strength, unattractive appearance, etc.

In summary, these technical problems all limit the popularization and application of the three-dimensional wound core resin-cast dry-type transformer in the market to a great extent.

Disclosure of Invention

The technical purpose of the invention is as follows: aiming at the particularity of the three-dimensional wound core and the defects of the prior art, the three-dimensional wound core resin-cast dry-type transformer has the advantages of compact structure, good electrical strength, excellent moisture resistance and heat dissipation performance and high mechanical strength, and the low-cost manufacturing method of the transformer.

The technical object of the present invention can be achieved by various technical means described below.

The first technical scheme, a three-dimensional iron core resin pouring dry-type transformer of rolling up, include that the three-dimensional iron core body that rolls up that mainly comprises three iron core posts that are the article font and arrange, be provided with the high-voltage coil who is in inboard low-voltage coil and is in the outside on each iron core post of iron core body, low-voltage coil is the wire-wound structure, on each iron core post low-voltage coil with high-voltage coil is the inseparable overall structure by the epoxy pouring, just low-voltage coil with the air flue that can compromise main insulating function and heat dissipation function with inside and outside bilayer structure hoop has arranged a plurality of between the high-voltage coil.

A manufacturing method of the three-dimensional wound core resin-cast dry-type transformer comprises the following process steps:

step 1, clamping an iron core body, and assembling a winding former on a corresponding iron core column;

the winding die mainly comprises an inner die, a first radial plate, a second radial plate and an outer die, wherein the inner die is formed by a plurality of arc-shaped plates and can be matched with a corresponding iron core column, the first radial plate is connected with one end of the inner die and extends radially outwards, the second radial plate is connected with the other end of the inner die and extends radially outwards, the outer die is matched with the outer edge of the first radial plate and the outer edge of the second radial plate and is used in the winding process, and a plurality of air channel rod through holes are formed in the second radial plate corresponding to a main insulation region between a low-voltage coil winding region and a high-;

step 2, sequentially winding an insulating layer I, a low-voltage electromagnetic wire, an interlayer insulating layer and an insulating layer IV on the inner die;

the low-voltage incoming wire and the low-voltage outgoing wire of the low-voltage coil are made of electromagnetic wires of a primary coil;

step 3, penetrating inner side air passage rods into the inner side air passage rod through holes on the web plate II, wherein the insertion ends of the inner side air passage rods tightly abut against the web plate I;

step 4, winding an insulating layer five on the inner side air passage rod;

step 5, penetrating outer air passage rods into the outer air passage rod through holes in the web plate II, wherein the insertion ends of the outer air passage rods tightly abut against the web plate I;

step 6, sequentially winding an insulating layer six, a high-voltage electromagnetic wire, an interlayer insulating layer and an insulating layer nine on the outer air passage rod;

step 7, assembling an outer die on the winding die;

the inner die, the spoke plate I, the spoke plate II and the outer die of the winding die form a pouring space capable of pouring epoxy resin;

step 8, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum-casting epoxy resin in the die cavity of the winding die;

step 9, adopting a curing furnace to perform curing treatment;

step 10, removing the winding former;

the low-voltage coil and the high-voltage coil on the corresponding iron core column are poured into an inseparable integral structure by epoxy resin;

step 11, repeating the steps, and manufacturing a low-voltage coil and a high-voltage coil of an integral structure on the next iron core column on the iron core body;

and respectively manufacturing and molding the low-voltage coil and the high-voltage coil of each integral structure on the three-phase iron core column of the iron core body.

The second technical scheme is that the three-dimensional wound iron core resin-cast dry-type transformer comprises a three-dimensional wound iron core body which is mainly composed of three iron core columns which are arranged in a delta shape, wherein each iron core column of the iron core body is provided with a low-voltage coil at the inner side and a high-voltage coil at the outer side, the low-voltage coil is of a foil winding structure, a low-voltage incoming wire and a low-voltage outgoing wire of the low-voltage coil are respectively formed by overlapping and combining a plurality of arc-shaped thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm, and the low-voltage incoming wire and the low-voltage outgoing wire are tightly attached to copper foils/aluminum foils at the corresponding sides of the low-voltage; the low-voltage coil on each iron core post with high-voltage coil is the inseparable overall structure by the epoxy pouring, just low-voltage coil with a plurality of air flue that can compromise main insulating function and heat dissipation function is arranged to inside and outside bilayer structure hoop between the high-voltage coil.

step 2, winding an insulating layer I on the inner die;

pressing a plurality of thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm into an arc-shaped structure by taking an outer circle formed by the inner die as a reference, overlapping and combining the thin copper strips/thin aluminum strips together, welding and combining the thin copper strips/thin aluminum strips with a foil capable of forming a low-voltage coil, and forming a low-voltage incoming line on the foil of the low-voltage coil;

winding a low-voltage foil and interlayer insulation on the first insulation layer, wherein the low-voltage incoming wire is positioned on the inner side wall of the low-voltage coil in a tangent structure;

pressing a plurality of thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm into an arc-shaped structure by taking an excircle formed by a low-voltage coil as a reference, overlapping and combining the thin copper strips/thin aluminum strips together, welding and combining the thin copper strips/thin aluminum strips with a foil capable of forming the low-voltage coil, and forming a low-voltage outlet wire on the foil of the low-voltage coil;

winding an insulating layer IV on the low-voltage foil and the interlayer insulation;

step 4, winding an insulating layer five on the inner side air passage rod;

step 7, assembling an outer die on the winding die;

step 8, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum-casting epoxy resin in the die cavity of the winding die;

step 9, adopting a curing furnace to perform curing treatment;

step 10, removing the winding former;

According to the third technical scheme, the three-dimensional wound iron core resin casting dry-type transformer comprises an iron core body mainly composed of three iron core columns which are arranged in a delta shape, wherein each iron core column of the iron core body is provided with a low-voltage coil at the inner side and a high-voltage coil at the outer side, the low-voltage coil is of a foil winding structure, a low-voltage incoming wire and a low-voltage outgoing wire of the low-voltage coil are formed by respectively overlapping and combining a plurality of arc-shaped thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm, and the low-voltage incoming wire and the low-voltage outgoing wire are tightly attached to copper foils/aluminum foils at the corresponding sides of the welded low-voltage coils; on each iron core post the low voltage coil with high voltage coil is the inseparable overall structure by the epoxy pouring, just the low voltage coil with a plurality of air flue that can compromise main insulating function and heat dissipation function is arranged to inside and outside bilayer structure hoop between the high voltage coil, a plurality of low pressure side air flue is arranged to the inside hoop of low voltage coil.

the winding die mainly comprises an inner die, a first radial plate, a second radial plate and an outer die, wherein the inner die can be matched with the corresponding iron core column and consists of a plurality of arc-shaped plates, the first radial plate is connected at one end of the inner die and extends radially, the second radial plate is connected at the other end of the inner die and extends radially, the outer die is matched with the first outer edge of the radial plate and the second outer edge of the radial plate and is used for standby in the winding process, a plurality of air passage rod through holes are formed in the circumferential arrangement structure at the center of the second radial plate corresponding to the winding area of the low-voltage coil, and a plurality of air passage rod through holes are formed in the circumferential arrangement structure of an inner layer and an outer;

step 2, winding an insulating layer I on the inner die;

winding a second insulating layer on the low-voltage foil and the interlayer insulation;

step 3, penetrating low-pressure side air passage rods into the low-pressure side air passage rod through holes in the web plate II, wherein the insertion ends of the low-pressure side air passage rods tightly abut against the web plate I;

step 4, sequentially winding an insulating layer III, a low-voltage foil and interlayer insulation on the low-voltage side air passage rod;

the low-voltage coil foil on the inner side of the low-voltage side air passage rod and the low-voltage coil foil on the outer side of the low-voltage side air passage rod are continuous and uninterrupted;

step 5, penetrating inner side air passage rods into the inner side air passage rod through holes on the web plate II, wherein the insertion ends of the inner side air passage rods tightly abut against the web plate I;

step 6, winding an insulating layer five on the inner side air passage rod;

step 7, penetrating outer air passage rods into the outer air passage rod through holes in the web plate II, wherein the insertion ends of the outer air passage rods tightly abut against the web plate I;

step 8, sequentially winding an insulating layer six, a high-voltage electromagnetic wire, an interlayer insulating layer and an insulating layer nine on the outer air passage rod;

step 9, assembling an outer die on the winding die;

step 10, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum-casting epoxy resin in the die cavity of the winding die;

step 11, carrying out curing treatment by adopting a curing furnace;

step 12, removing the winding former;

step 13, repeating the steps, and manufacturing a low-voltage coil and a high-voltage coil of an integral structure on the next iron core column on the iron core body;

According to a fourth technical scheme, the three-dimensional wound iron core resin-cast dry-type transformer comprises a three-dimensional wound iron core body which is mainly composed of three iron core columns which are arranged in a delta shape, wherein each iron core column of the iron core body is provided with a low-voltage coil at the inner side and a high-voltage coil at the outer side, the low-voltage coil is of a foil winding structure, a low-voltage incoming wire and a low-voltage outgoing wire of the low-voltage coil are respectively formed by overlapping and combining a plurality of arc-shaped thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm, and the low-voltage incoming wire and the low-voltage outgoing wire are tightly attached to copper foils/aluminum foils at the corresponding sides of the low; on each iron core post low voltage coil with high voltage coil is the inseparable overall structure by the epoxy pouring, just low voltage coil with a plurality of having arranged between the high voltage coil with inside and outside bilayer structure hoop can compromise the air flue of main insulation function and heat dissipation function, a plurality of high-pressure side air flue has been arranged to high voltage coil's inside hoop.

the winding die mainly comprises an inner die, a first radial plate, a second radial plate and an outer die, wherein the inner die can be matched with the corresponding iron core column and consists of a plurality of arc-shaped plates, the first radial plate is connected at one end of the inner die and extends radially, the second radial plate is connected at the other end of the inner die and extends radially, the outer die is matched with the first outer edge of the radial plate and the second outer edge of the radial plate and is used for standby in the winding process, a plurality of air passage rod through holes are formed in the circumferential arrangement structure at the center of the second radial plate corresponding to the winding area of the high-voltage coil, and a plurality of air passage rod through holes are formed in the circumferential arrangement structure of an inner layer and an outer;

step 2, winding an insulating layer I on the inner die;

step 4, winding an insulating layer five on the inner side air passage rod;

step 6, sequentially winding an insulating layer six, a high-voltage electromagnetic wire, an interlayer insulating layer and an insulating layer seven on the outer air passage rod;

step 7, penetrating high-pressure side air passage rods into the high-pressure side air passage rod through holes in the web plate II, wherein the insertion ends of the high-pressure side air passage rods tightly abut against the web plate I;

step 8, sequentially winding an insulating layer eight, a high-voltage electromagnetic wire, an interlayer insulating layer and an insulating layer nine on the high-voltage side air passage rod; the high-voltage electromagnetic wire on the inner side of the high-voltage side air passage rod is communicated with the high-voltage electromagnetic wire on the outer side of the high-voltage side air passage rod;

step 9, assembling an outer die on the winding die;

step 10, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum-casting epoxy resin in the die cavity of the winding die;

step 11, carrying out curing treatment by adopting a curing furnace;

step 12, removing the winding former;

The beneficial technical effects of the invention are as follows:

1. aiming at the three-dimensional rolled iron core, the high-low voltage coil of the winding on the iron core column is poured into an inseparable integral structure by epoxy resin, a plurality of air passages which are arranged in a double-layer annular mode are formed in a main insulation area between the low-voltage coil and the high-voltage coil, and the air passage structure is used as the main insulation between the high-low voltage coil and the low-voltage coil, so that compared with the traditional insulation cylinder structure, more excellent electrical strength and mechanical strength can be obtained at low cost (including the aspects of process and materials), and therefore, the three-dimensional rolled iron core resin cast dry-type transformer has the characteristics of compact structure (small volume, attractive appearance), excellent electrical strength (high insulation strength and strong short-circuit resistance), excellent moisture-proof (anti-corrosion) performance, excellent heat dissipation performance, high mechanical;

2. the low-voltage coil of the invention adopts the molding of the foil coil which is helpful for increasing the capacity of the transformer; the inlet/outlet wire is convenient to fold and hide, the height of an iron core window and the column distance of the iron core do not need to be increased, higher current-carrying capacity can be obtained through the skin effect of current, namely, the low-voltage foil-wound coil which has more excellent performance and is beneficial to increasing the capacity of the transformer can be reliably formed by the compact structure of the iron core body, and the formed transformer has small volume and low cost;

3. the invention is beneficial to effectively enhancing the heat radiation performance of the transformer by forming the heat radiation air passage in the low-voltage coil or the high-voltage coil which is beneficial to increasing the capacity structure of the transformer, thereby ensuring that the transformer can stably and reliably operate;

4. the manufacturing method of the invention can make the transformer with the corresponding structure manufactured and molded by the characteristics of simplicity, feasibility, high efficiency and economy, has good economy and is beneficial to the popularization and application of the manufactured and molded three-dimensional wound core resin-cast dry-type transformer in the market.

Drawings

Fig. 1 is a schematic diagram of a structure of the present invention (low-voltage coil wire-wound structure).

Fig. 2 is a schematic view of a winding former for manufacturing the transformer shown in fig. 1 (the outer die is not shown).

Fig. 3 is a schematic diagram of a state of the transformer shown in fig. 1 during a manufacturing process.

Fig. 4 is another schematic diagram of the present invention (low-voltage coil foil-wound configuration).

Fig. 5 is a schematic view of a winding former for manufacturing the transformer shown in fig. 4 (the outer die is not shown).

Fig. 6 is a schematic diagram of a state of the transformer shown in fig. 4 during a manufacturing process.

The reference numbers in the figures mean: 1-an iron core body; 11-core limb a; 12-core limb B; 13-core limb C; 2-low voltage coil; 21-low voltage incoming; 22-low voltage outgoing line; 23, insulating layer one; 24-low voltage electromagnetic wire and interlayer insulation; 25-insulating layer two; 26-insulating layer three; 27-insulating layer four; 28-low pressure side gas channel; 29-low voltage foil and interlayer insulation; 3-the airway; 31 — medial airway; 32 — lateral airway; 33-insulating layer five; 4-high voltage coil; 41-insulating layer six; 42, high-voltage electromagnetic wire and interlayer insulation; 43 — insulating layer seven; 44-insulating layer eight; 45-nine insulating layers; 5, winding a wire mould; 51, an inner mold; 52-web one; 53-gear ring one; 54-spoke plate two; 55-gear ring two; 56-inner airway rod perforation; 57-perforation of the outer airway rod; 58-inner airway rod; 59-outer airway rod; 510-low pressure side air channel rod perforation; 511-high pressure side air channel rod perforation; 512-low pressure side air channel bar; 513 — high pressure side air channel rod.

Detailed Description

The present invention relates to a three-dimensional wound core resin-cast dry-type transformer and a method for manufacturing the transformer, and the main technical content of the present invention will be described in detail with reference to a plurality of embodiments. In the embodiment 1, the technical scheme content of the invention is clearly and specifically explained in conjunction with the attached drawings of the specification, namely, fig. 1, fig. 2 and fig. 3; embodiment 2, although not separately depicted, the main structure thereof can still refer to the drawings of embodiment 1; embodiment 3, the technical contents of the present invention are clearly and specifically explained in conjunction with the drawings of the specification, i.e. fig. 4, 5 and 6; embodiment 4 is combined with the drawings of the specification, namely fig. 4, fig. 5 and fig. 6 to clearly and specifically explain the technical contents of the present invention.

It is expressly noted here that the drawings of the present invention are schematic and have been simplified in unnecessary detail for the purpose of clarity and to avoid obscuring the technical solutions that the present invention contributes to the prior art.

Example 1

Referring to fig. 1, 2 and 3, the present invention includes an iron core body 1 with a three-dimensional wound iron core structure, that is, the iron core body 1 mainly includes an iron core column a11, an iron core column B12 and an iron core column C13, which are formed by three single-frame closed-loop iron cores in a butting manner and are arranged in a delta shape. Each iron core column is provided with a group of windings, and the windings consist of a low-voltage coil 2 positioned at the inner side and a high-voltage coil 4 positioned at the outer side; the low-voltage coil 2 is in a wire-wound structure, and the low-voltage incoming wire 21 and the low-voltage outgoing wire 22 are directly manufactured and molded by the electromagnetic wire of the low-voltage coil 2.

The low-voltage coil 2 and the high-voltage coil 4 on each core limb are cast by epoxy resin to form an inseparable integral structure, that is, the low-voltage coil 2 and the high-voltage coil 4 forming the winding on the core limb are cured by co-cast epoxy resin to form an inseparable integral structure. Meanwhile, a plurality of air passages 3 are annularly arranged in an inner-outer double-layer structure at a main insulation area between the low-voltage coil 2 and the high-voltage coil 4, and the air passages 3 are formed by integrally casting the high-voltage coil and the low-voltage coil; the adjacent inner air passages 31 or the adjacent outer air passages 32 are separated by epoxy resin respectively, the inner air passages 31 and the outer air passages 32 are separated by an insulating layer five 33 and epoxy resin attached to the insulating layer five 33, and the inner air passages 31 and the outer air passages 32 are in one-to-one corresponding matching relationship; the cross section of each air passage 3 is of a rectangular hole-shaped structure with round corners or a waist-shaped hole-shaped structure with two semicircular ends, so that the outer diameter of the whole winding can be effectively prevented from being overlarge; the double-layer structure air flue 3 between low voltage coil 2 and the high voltage coil 4 compromises main insulation function and heat dissipation function, can also effectively increase the heat radiating area between the high low voltage coil like this when forming main insulation, in order to reduce in operation to lead to the problem of coil burning out because of insulating thermal ageing because of the heat dissipation is not enough to take place.

The air duct 3 with a double-layer structure is adopted between the low-voltage coil 2 and the high-voltage coil 4, because the main insulation (i.e. the position bearing the highest voltage) between the high-voltage coil and the low-voltage coil is mainly ensured by the air in the gap (distance) between the high-voltage coil and the low-voltage coil, and the strength of the air insulation is far lower than that of epoxy resin, so the gap (distance) needs to be increased to achieve the same insulation strength. If set up 1 insulating cylinder between high low voltage coil, then can reduce clearance (distance), for reducing product volume, reduce cost, generally all can set up an insulating cylinder and come the support with a plurality of stay to fix on the low voltage coil surface, however, this structure is than bilayer structure air flue 3, and its electrical strength, mechanical strength all show inadequately, and process cost and material cost all are higher than bilayer structure air flue 3. If the double-layer structure air passage 3 is replaced by other layers, the cost of the 10 kV-level transformer is far higher than that of the double-layer structure air passage 3.

The manufacturing method of the three-dimensional wound core resin-cast dry-type transformer comprises the following process steps (the manufacturing process is set as a core limb A11, a core limb B12 and a core limb C13):

step 1, clamping an iron core body 1, and assembling a winding former 5 on an iron core column A11;

the winding former 5 mainly comprises an inner die 51 which is composed of a plurality of arc-shaped plates (usually three or four arc-shaped plates with an equal division structure) and can be matched with the iron core column A11, a first radial plate 52 which is connected with one end of the inner die 51 and extends radially outwards, a second radial plate 54 which is connected with the other end of the inner die 51 and extends radially outwards, and an outer die which is matched with the outer edge of the first radial plate 52 and the outer edge of the second radial plate 54 and is used in the winding process; the first wheel disk 52 is mainly composed of two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the first wheel disk 52 is connected with a first gear ring 53 in a detachable structure through fastening screws and the like, and the first gear ring 53 is mainly composed of two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction; the radial plate II 54 mainly comprises two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the radial plate II 54 is connected with a gear ring II 55 through fastening screws and the like in a detachable structure, and the gear ring II 55 mainly comprises two split bodies which can be combined into the whole circle in the butt joint mode in the circumferential direction; the outer mold is mainly composed of two split bodies which can be butted and combined into a whole circle in the circumferential direction; a plurality of air channel rod through holes, namely an inner air channel rod through hole 56 and an outer air channel rod through hole 57, are formed in the inner and outer double-layer annular arrangement structure corresponding to the main insulation region between the low-voltage coil winding region and the high-voltage coil winding region on the radial plate II 54;

step 2, sequentially winding an insulating layer I23, a low-voltage electromagnetic wire, an interlayer insulating layer 24 and an insulating layer IV 27 on the inner die 51;

the first insulating layer 23 is usually a 0.5mm thick glass cloth plate or 0.5-1 mm (e.g., 0.5mm, 0.8mm, or 1 mm) thick PET; when the first insulating layer 23 is wound, a tight interface needs to be bonded, and a gap between the first insulating layer 23 and the first and second spoke plates 52 and 54 is sealed by using a sealant;

in the process of winding the low-voltage electromagnetic wire and the interlayer insulation 24, a low-voltage incoming wire 21 and a low-voltage outgoing wire 22 are manufactured by using a primary coil electromagnetic wire of the low-voltage coil 2, wherein the low-voltage incoming wire 21 is positioned on the inner side of the low-voltage coil 2, and the low-voltage outgoing wire 22 is positioned on the outer side of the low-voltage coil 2;

the number of turns of the low-voltage coil 2 is determined according to design requirements;

the fourth insulating layer 27 is of an insulating grid cloth structure;

step 3, penetrating inner air passage rods 58 into the inner air passage rod through holes 56 in the web plate II 54, wherein the inserted ends of the inner air passage rods 58 are tightly abutted against the web plate I52 in a vertical fit mode, and the non-inserted ends of the inner air passage rods 58 extend out of the web plate II 54;

the cross section of each inner air flue rod 58 is in a rectangular structure with round corners (or a 'runway' -shaped structure with two semicircular ends is adopted for replacement);

step 4, winding an insulating layer five 33 on the inner air passage rod 58;

the insulating layer five 33 is of an insulating grid cloth structure;

step 5, penetrating outer air passage rods 59 into the outer air passage rod through holes 57 on the web plate II 54, wherein the inserted ends of the outer air passage rods 59 tightly abut against the web plate I52 in a vertical fit mode, and the non-inserted ends of the outer air passage rods 59 extend out of the web plate II 54;

the cross section of each outer air flue rod 59 is in a rectangular structure with round corners (or a 'runway' -shaped structure with two semicircular ends is adopted for replacement);

step 6, sequentially winding an insulating layer six 41, a high-voltage electromagnetic wire, an interlayer insulating layer 42 and an insulating layer nine 45 on the outer air passage rod 59, and welding a wire holder;

the insulation layer six 41 and the insulation layer nine 45 are respectively of an insulation grid cloth structure;

the number of turns of the high-voltage coil 4 is determined according to design requirements;

step 7, assembling an external mold on the winding mold 5 through fastening screws and the like;

the inner die 51, the first spoke plate 52, the second spoke plate 54 and the outer die of the winding die 5 form a pouring space for pouring epoxy resin;

step 8, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum casting epoxy resin in the mold cavity of the winding mold 5;

step 9, adopting a curing furnace to perform curing treatment;

step 10, removing the winding former 5, including removing the external mold, removing the internal and external air channel rods, removing the first web plate 52, removing the second web plate 55, removing the internal mold 51 and the like;

the low-voltage coil 2 and the high-voltage coil 4 on the core limb A11 are cast into the inseparable integral structure by epoxy resin;

step 11, repeating the steps, and manufacturing a low-voltage coil 2 and a high-voltage coil 4 which are of an integral structure on the iron core column B12 of the iron core body 1;

step 12, repeating the steps 1 to 10, and manufacturing a low-voltage coil 2 and a high-voltage coil 4 which are of an integral structure on the iron core column C12 of the iron core body 1;

to this end, the low-voltage coil 2 and the high-voltage coil 4 of the overall structure on the three-phase core limb of the iron core body 1 are respectively manufactured and molded.

According to the manufacturing method, the high-low voltage coil of each phase winding on the iron core body shares the same set of die for winding and casting, and the low-voltage coil, the main insulation and the high-voltage coil can be integrally molded with high strength finally, so that the economical efficiency is good.

Example 2

The three-dimensional iron core comprises an iron core body with a three-dimensional rolling structure, namely the iron core body mainly comprises an iron core column A, an iron core column B and an iron core column C which are formed by butting three single-frame closed-loop iron cores and are arranged in a delta shape. Each iron core column is provided with a group of windings, and each winding consists of a low-voltage coil positioned at the inner side and a high-voltage coil positioned at the outer side; the low-voltage coil is a foil winding structure of a copper foil (or an aluminum foil), a low-voltage incoming wire and a low-voltage outgoing wire of the low-voltage coil are respectively formed by overlapping and combining a plurality of arc-shaped (arc-shaped with a certain width) thin copper strips (thin aluminum strips) with the thickness of 0.1-1 mm (such as 0.1mm, 0.3mm, 0.5mm, 0.8mm or 1mm and the like), the low-voltage incoming wire and the low-voltage outgoing wire are welded on the copper foil (aluminum foil) on the corresponding side of the low-voltage coil in a clinging manner, and usually, the low-voltage incoming wire is positioned on the inner side of the low-voltage coil, and the low;

the low-voltage coil and the high-voltage coil on each iron core column are cast by epoxy resin to form an inseparable integral structure, that is, the low-voltage coil and the high-voltage coil which form the winding on the iron core column are solidified by co-cast epoxy resin to form the inseparable integral structure. Meanwhile, a plurality of air passages are annularly distributed in an inner-outer double-layer structure at a main insulation area between the low-voltage coil and the high-voltage coil, and the air passages are formed by integral casting of the high-voltage coil and the low-voltage coil; the adjacent inner air passages or the adjacent outer air passages are separated by epoxy resin respectively, the inner air passages and the outer air passages are separated by an insulating layer five and epoxy resin attached to the insulating layer five, and the inner air passages and the outer air passages are in one-to-one corresponding matching relation; the cross section of each air passage is of a rectangular hole-shaped structure with round corners or a waist-shaped hole-shaped structure with two semicircular ends, so that the outer diameter of the whole winding can be effectively prevented from being overlarge; the double-layer structure air flue between low voltage coil and the high voltage coil compromises main insulation function and heat dissipation function, can also effectively increase the heat radiating area between the high low voltage coil when forming main insulation like this, in order to reduce in operation to lead to the problem of coil burning out because of insulating thermal ageing because of the heat dissipation is not enough to take place.

The air channel with the double-layer structure is adopted between the low-voltage coil and the high-voltage coil, because the main insulation (namely, the position bearing the highest voltage) between the high-voltage coil and the low-voltage coil is mainly ensured by the air in the gap (distance) between the high-voltage coil and the low-voltage coil, and the strength of the air insulation is far lower than that of epoxy resin, so the gap (distance) needs to be increased to achieve the same insulation strength. If set up a insulating cylinder between high low voltage coil, then can reduce clearance (distance), for reducing product volume, reduce cost, generally all can set up an insulating cylinder and come the support with a plurality of stay to fix on low voltage coil surface, however, this structure is than bilayer structure air flue, and its electrical strength, mechanical strength all show inadequately, and processing cost and material cost all are higher than bilayer structure air flue. If the double-layer structure air passage is replaced by other layers, the cost of the 10 kV-level transformer is far higher than that of the double-layer structure air passage.

The manufacturing method of the three-dimensional wound iron core resin-cast dry-type transformer comprises the following process steps (the manufacturing process is set as an iron core column A, an iron core column B and a final iron core column C):

step 1, clamping an iron core body, and assembling a winding former on an iron core column A;

the winding mold mainly comprises an inner mold, a first radial plate, a second radial plate and an outer mold, wherein the inner mold is composed of a plurality of arc-shaped plates (usually three or four arc-shaped plates with an equal division structure) and can be matched with an iron core column A, the first radial plate is connected at one end of the inner mold and extends radially outwards, the second radial plate is connected at the other end of the inner mold and extends radially outwards, and the outer mold is matched with the outer edge of the first radial plate and the outer edge of the second radial plate; the first wheel disk mainly comprises two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the first wheel disk is connected with a first gear ring in a detachable structure through fastening screws and the like, and the first gear ring mainly comprises two split bodies which can be combined into the whole circle in the butt joint mode in the circumferential direction; the wheel disk II is mainly composed of two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the wheel disk II is connected with a gear ring II through fastening screws and the like in a detachable structure, and the gear ring II is mainly composed of two split bodies which can be combined into the whole circle in the butt joint mode in the circumferential direction; the outer mold is mainly composed of two split bodies which can be butted and combined into a whole circle in the circumferential direction; a plurality of air flue rod through holes, namely an inner air flue rod through hole and an outer air flue rod through hole, are formed in the inner and outer double-layer annular arrangement structure corresponding to the main insulation region between the low-voltage coil winding region and the high-voltage coil winding region on the web plate II;

step 2, winding an insulating layer I on the inner die; the insulation layer is usually a 0.5mm thick glass cloth plate or 0.5-1 mm (e.g. 0.5mm, 0.8mm or 1 mm) thick PET; when the first insulating layer is wound, a tight interface needs to be bonded, and a gap between the first insulating layer and the first and second radials is sealed by using a sealant;

pressing a plurality of thin copper strips (or thin aluminum strips) with certain widths and thicknesses of 0.1-1 mm (such as 0.1mm, 0.3mm, 0.5mm, 0.8mm or 1mm and the like) into an arc-shaped structure by taking an outer circle formed by the inner die as a reference, overlapping and combining the thin copper strips (or the thin aluminum strips) together, welding and combining the thin copper strips (or the thin aluminum strips) with foil materials-copper foils (or aluminum foils) capable of forming a low-voltage coil, and forming a low-voltage incoming line on the foil material of the low-voltage coil;

winding a low-voltage foil and interlayer insulation on the first insulation layer, wherein a low-voltage incoming wire is positioned on the inner side wall of the low-voltage coil in a tangent structure;

pressing a plurality of thin copper strips (or thin aluminum strips) with certain widths and thicknesses of 0.1-1 mm (such as 0.1mm, 0.3mm, 0.5mm, 0.8mm or 1mm and the like) into an arc-shaped structure by taking an excircle formed by a low-voltage coil as a reference, overlapping and combining the thin copper strips (or the thin aluminum strips) together, and closely welding and combining the thin copper strips (or the thin aluminum strips) with foil-copper foil (or aluminum foil) capable of forming the low-voltage coil to form a low-voltage outlet wire on the foil of the low-voltage coil;

the number of turns of the low-voltage coil is determined according to design requirements;

winding an insulating layer IV on the low-voltage foil and the interlayer insulation; the fourth insulating layer is an insulating grid cloth structure;

step 3, penetrating inner side air passage rods into the inner side air passage rod through holes on the web plate II, wherein the insertion ends of the inner side air passage rods tightly abut against the web plate I in a vertical matching manner, and the non-insertion ends of the inner side air passage rods extend out of the web plate II;

the cross section of each inner air flue rod is in a rectangular structure with round corners (or a 'runway' -shaped structure with two semicircular ends is adopted for replacement);

step 4, winding an insulating layer five on the inner side air passage rod; the insulation layer five is in an insulation grid cloth structure;

step 5, penetrating outer side air passage rods into the outer side air passage rod through holes on the web plate II, wherein the insertion ends of the outer side air passage rods tightly abut against the web plate I in a vertical matching manner, and the non-insertion ends of the outer side air passage rods extend out of the web plate II;

the cross section of each outer air flue rod is in a rectangular structure with round corners (or a 'runway' -shaped structure with two semicircular ends is adopted for replacement);

step 6, sequentially winding an insulating layer six, a high-voltage electromagnetic wire, an interlayer insulating layer and an insulating layer nine on the outer air passage rod, and welding a wire holder;

the insulation layer six and the insulation layer nine are respectively of an insulation grid cloth structure;

the number of turns of the high-voltage coil is determined according to design requirements;

step 7, assembling an external mold on the winding mold through fastening screws and the like;

step 8, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum casting epoxy resin in the mold cavity of the winding mold;

step 9, adopting a curing furnace to perform curing treatment;

step 10, removing the winding former, including removing the external mold, pulling out the internal and external air flue rods, removing the first radial plate, removing the second radial plate, removing the internal mold and the like;

the low-voltage coil and the high-voltage coil on the iron core column A are poured into the inseparable integral structure by epoxy resin;

step 11, repeating the steps, and manufacturing a low-voltage coil and a high-voltage coil of an integral structure on the iron core column B of the iron core body;

step 12, repeating the steps 1 to 10, and manufacturing a low-voltage coil and a high-voltage coil of an integral structure on the iron core column C of the iron core body;

and at this moment, the low-voltage coil and the high-voltage coil of each integral structure on the three-phase iron core column of the iron core body are respectively manufactured and molded.

In the manufacturing method, the part of the low-voltage incoming wire, which exceeds the low-voltage coil, can be folded and hidden in a gap at one side of the corresponding web plate of the low-voltage coil and the winding former.

Example 3

Referring to fig. 4, 5 and 6, the present invention includes an iron core body 1 with a three-dimensional roll structure, that is, the iron core body 1 mainly includes an iron core column a11, an iron core column B12 and an iron core column C13, which are formed by three single-frame closed-loop iron cores in a butting manner and are arranged in a delta shape. Each iron core column is provided with a group of windings, and the windings consist of a low-voltage coil 2 positioned at the inner side and a high-voltage coil 4 positioned at the outer side; the low-voltage coil 2 is a foil winding structure of a copper foil (or an aluminum foil), a low-voltage incoming wire 21 and a low-voltage outgoing wire 22 of the low-voltage coil are respectively formed by overlapping and combining a plurality of arc-shaped (arc-shaped with a certain width) thin copper strips (thin aluminum strips) with the thickness of 0.1-1 mm (such as 0.1mm, 0.3mm, 0.5mm, 0.8mm or 1mm and the like), the low-voltage incoming wire 21 and the low-voltage outgoing wire 22 are welded on the copper foil (aluminum foil) on the corresponding side of the low-voltage coil 2 in a clinging mode, and usually, the low-voltage incoming wire 21 is positioned on the inner side of the low-voltage coil 2, and the low-voltage;

the low-voltage coil 2 and the high-voltage coil 4 on each core limb are cast by epoxy resin to form an inseparable integral structure, that is, the low-voltage coil 2 and the high-voltage coil 4 forming the winding on the core limb are cured by co-cast epoxy resin to form an inseparable integral structure. Meanwhile, a plurality of air passages 3 are annularly arranged in an inner-outer double-layer structure at a main insulation area between the low-voltage coil 2 and the high-voltage coil 4, and the air passages 3 are formed by integrally casting the high-voltage coil and the low-voltage coil; the adjacent inner air passages 31 or the adjacent outer air passages 32 are separated by epoxy resin respectively, the inner air passages 31 and the outer air passages 32 are separated by an insulating layer five 33 and epoxy resin attached to the insulating layer five 33, and the inner air passages 31 and the outer air passages 32 are in one-to-one corresponding matching relationship; the cross section of each air passage 3 is of a rectangular hole-shaped structure with round corners or a waist-shaped hole-shaped structure with two semicircular ends, so that the outer diameter of the whole winding can be effectively prevented from being overlarge; the double-layer structure air flue 3 between low voltage coil 2 and the high voltage coil 4 compromises main insulation function and heat dissipation function, can also effectively increase the heat radiating area between the high low voltage coil like this when forming main insulation, in order to reduce the problem that leads to the coil to burn out because of the heat dissipation is not enough in service and take place.

A plurality of low-pressure side air passages 28 are annularly arranged at the radial middle area of the low-pressure coil 2, and the low-pressure side air passages 28 are formed by integrally casting the high-pressure coil and the low-pressure coil; the low-voltage side gas passage 28 can effectively increase the heat radiation area of the low-voltage coil 2. The cross section of each low-voltage side air channel 28 is in a rectangular hole structure with round corners or a waist-shaped hole structure with two semicircular ends, so that the outer diameter of the whole winding can be effectively prevented from being overlarge.

The air duct 3 with a double-layer structure is adopted between the low-voltage coil 2 and the high-voltage coil 4, because the main insulation (i.e. the position bearing the highest voltage) between the high-voltage coil and the low-voltage coil is mainly ensured by the air in the gap (distance) between the high-voltage coil and the low-voltage coil, and the strength of the air insulation is far lower than that of epoxy resin, so the gap (distance) needs to be increased to achieve the same insulation strength. If set up a insulating cylinder between high low voltage coil, then can reduce clearance (distance), for reducing product volume, reduce cost, generally all can set up an insulating cylinder and come the support with a plurality of stay to fix on the low voltage coil surface, however, this structure is than bilayer structure air flue 3, and its electrical strength, mechanical strength all show inadequately, and process cost and material cost all are higher than bilayer structure air flue 3. If the double-layer structure air passage is replaced by other layers, the cost of the 10 kV-level transformer is far higher than that of the double-layer structure air passage 3.

the winding former 5 mainly comprises an inner die 51 which is composed of a plurality of arc-shaped plates (usually three or four arc-shaped plates with an equal division structure) and can be matched with the iron core column A11, a first radial plate 52 which is connected with one end of the inner die 51 and extends radially outwards, a second radial plate 54 which is connected with the other end of the inner die 51 and extends radially outwards, and an outer die which is matched with the outer edge of the first radial plate 52 and the outer edge of the second radial plate 54 and is used in the winding process; the first wheel disk 52 is mainly composed of two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the first wheel disk 52 is connected with a first gear ring 53 in a detachable structure through fastening screws and the like, and the first gear ring 53 is mainly composed of two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction; the radial plate II 54 mainly comprises two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the radial plate II 54 is connected with a gear ring II 55 through fastening screws and the like in a detachable structure, and the gear ring II 55 mainly comprises two split bodies which can be combined into the whole circle in the butt joint mode in the circumferential direction; the outer mold is mainly composed of two split bodies which can be butted and combined into a whole circle in the circumferential direction; a plurality of air flue rod through holes, namely an inner air flue rod through hole 56 and an outer air flue rod through hole 57, are formed in the inner and outer double-layer annular arrangement structure corresponding to the main insulation region between the low-voltage coil winding region and the high-voltage coil winding region on the radial plate II 55; a plurality of air channel rod through holes, namely low-voltage side air channel rod through holes 510, are formed in the radial center of the radial plate II 54 corresponding to the winding area of the low-voltage coil in an annular arrangement structure;

step 2, winding an insulating layer I23 on the inner die 51; the insulation layer is usually a 0.5mm thick glass cloth plate or 0.5-1 mm (e.g. 0.5mm, 0.8mm or 1 mm) thick PET; when the first insulating layer is wound, a tight interface needs to be bonded, and a gap between the first insulating layer and the first and second radials is sealed by using a sealant;

with an excircle formed by the inner die 51 as a reference, pressing a plurality of thin copper strips (or thin aluminum strips) with certain widths and thicknesses of 0.1-1 mm (such as 0.1mm, 0.3mm, 0.5mm, 0.8mm or 1 mm) into an arc-shaped structure, overlapping and combining the thin copper strips (or thin aluminum strips) together, and closely welding and combining the thin copper strips (or thin aluminum strips) with foil-copper foil (or aluminum foil) capable of forming a low-voltage coil to form a low-voltage incoming line 21 on the low-voltage coil foil;

winding a low-voltage foil and an interlayer insulation 29 on an insulation layer I23, wherein a low-voltage incoming wire 21 is positioned on the inner side wall of the low-voltage coil in a tangent structure;

winding a second insulating layer 25 on the low-voltage foil and the interlayer insulating layer 29; the second insulating layer 25 is an insulating grid cloth structure;

step 3, penetrating low-pressure side air channel rods 512 into the low-pressure side air channel rod through holes 510 in the web plate II 54, wherein the insertion ends of the low-pressure side air channel rods 512 tightly abut against the web plate I52 in a vertical matching manner, and the non-insertion ends of the low-pressure side air channel rods 512 extend out of the web plate II 54;

the cross section of each low-pressure side air channel rod 512 is in a rectangular structure with round corners (or a 'runway' -shaped structure with two semicircular ends is adopted for replacement);

step 4, sequentially winding an insulating layer III 26, a low-voltage foil and an interlayer insulating layer 29 on the low-voltage side air channel rod 512;

the third insulating layer 26 is an insulating grid cloth structure;

the low-voltage coil foil on the inner side and the low-voltage coil foil on the outer side of the low-voltage side air channel rod 512 are continuous and uninterrupted;

pressing a plurality of thin copper strips (or thin aluminum strips) with certain widths and thicknesses of 0.1-1 mm (such as 0.1mm, 0.3mm, 0.5mm, 0.8mm or 1mm and the like) into an arc-shaped structure by taking an outer circle formed by the low-voltage coil 2 as a reference, overlapping and combining the thin copper strips (or the thin aluminum strips) together, and closely welding and combining the thin copper strips (or the thin aluminum strips) with a foil material-copper foil (or aluminum foil) capable of forming the low-voltage coil to form a low-voltage outlet wire 22 on the foil material of the low-voltage coil;

winding an insulating layer IV 27 on the low-voltage foil and the interlayer insulation 29; the fourth insulating layer 27 is an insulating grid cloth structure;

step 5, penetrating inner air passage rods 58 into the inner air passage rod through holes 56 on the web plate II 54, wherein the inserted ends of the inner air passage rods 58 are tightly abutted against the web plate I52 in a vertical fit mode, and the non-inserted ends of the inner air passage rods 58 extend out of the web plate II 54;

step 6, winding an insulating layer five 33 on the inner air passage rod 58; the insulating layer five 33 is an insulating grid cloth structure;

step 7, penetrating outer air passage rods 59 into the outer air passage rod through holes 57 on the web plate II 54, wherein the inserted ends of the outer air passage rods 59 tightly abut against the web plate I52 in a vertical fit mode, and the non-inserted ends of the outer air passage rods 59 extend out of the web plate II 54;

step 8, sequentially winding an insulating layer six 41, a high-voltage electromagnetic wire, an interlayer insulating layer 42 and an insulating layer nine 45 on the outer air passage rod 59, and welding a wire holder;

step 9, assembling an external mold on the winding mold 5 through fastening screws and the like;

step 10, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum casting epoxy resin in the mold cavity of the winding mold 5;

step 11, carrying out curing treatment by adopting a curing furnace;

step 12, removing the winding former 5, including removing the external mold, removing the internal and external air passage rods, removing the low-pressure side air passage rods 512, removing the first web plate 52, removing the second web plate 54, removing the internal mold 51 and the like;

step 13, repeating the steps, and manufacturing a low-voltage coil 2 and a high-voltage coil 4 which are of an integral structure on the iron core column B12 of the iron core body 1;

step 14, repeating the steps 1 to 12, and manufacturing the low-voltage coil 2 and the high-voltage coil 4 which are of an integral structure on the iron core column C13 of the iron core body 1;

Example 4

A plurality of high-pressure side air passages 46 are annularly arranged at the radial middle area of the high-pressure coil 4, and the high-pressure side air passages 46 are formed by integrally casting the high-pressure coil and the low-pressure coil; the high-pressure side air passage 46 can effectively increase the heat radiation area of the high-pressure coil 4. The cross section of each high-pressure side air passage 46 is in a rectangular hole structure with round corners or a waist-shaped hole structure with two semicircular ends, so that the outer diameter of the whole winding can be effectively prevented from being overlarge.

the winding former 5 mainly comprises an inner die 51 which is composed of a plurality of arc-shaped plates (usually three or four arc-shaped plates with an equal division structure) and can be matched with the iron core column A11, a first radial plate 52 which is connected with one end of the inner die 51 and extends radially outwards, a second radial plate 54 which is connected with the other end of the inner die 51 and extends radially outwards, and an outer die which is matched with the outer edge of the first radial plate 52 and the outer edge of the second radial plate 54 and is used in the winding process; the first wheel disk 52 is mainly composed of two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the first wheel disk 52 is connected with a first gear ring 53 in a detachable structure through fastening screws and the like, and the first gear ring 53 is mainly composed of two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction; the radial plate II 54 mainly comprises two split bodies which can be combined into a whole circle in a butt joint mode in the circumferential direction, the outer edge of the radial plate II 54 is connected with a gear ring II 55 through fastening screws and the like in a detachable structure, and the gear ring II 55 mainly comprises two split bodies which can be combined into the whole circle in the butt joint mode in the circumferential direction; the outer mold is mainly composed of two split bodies which can be butted and combined into a whole circle in the circumferential direction; a plurality of air channel rod through holes, namely an inner air channel rod through hole 56 and an outer air channel rod through hole 57, are formed in the inner and outer double-layer annular arrangement structure corresponding to the main insulation region between the low-voltage coil winding region and the high-voltage coil winding region on the radial plate II 54; a plurality of air passage rod through holes, namely high-pressure side air passage rod through holes 511, are formed in the radial center of the radial second plate 54 corresponding to the winding area of the high-voltage coil in an annular arrangement structure;

step 4, winding an insulating layer five 33 on the inner air passage rod 58; the insulating layer five 33 is an insulating grid cloth structure;

step 6, sequentially winding an insulating layer six 41, a high-voltage electromagnetic wire, an interlayer insulating layer 42 and an insulating layer seven 43 on the outer air passage rod 59;

the insulation layer six 41 and the insulation layer seven 43 are respectively of an insulation grid cloth structure;

step 7, penetrating high-pressure side air passage rods 513 into the high-pressure side air passage rod through holes 511 in the web plates 54, wherein the insertion ends of the high-pressure side air passage rods 513 tightly abut against the web plates 52 in a vertical matching manner, and the non-insertion ends of the high-pressure side air passage rods 513 extend out of the web plates 54;

the cross section of each high-pressure side air channel rod 513 is of a rectangular structure with round corners (or is replaced by a track-shaped structure with two semicircular ends);

step 8, winding an insulating layer eight 44, a high-voltage electromagnetic wire, an interlayer insulating layer 42 and an insulating layer nine 45 on the high-voltage side air passage rod 513 in sequence, and welding a wire holder;

the insulating layer eight 44 and the insulating layer nine 45 are respectively of an insulating grid cloth structure;

the high-voltage magnet wire on the inner side of the high-voltage side air passage rod 513 is connected with the high-voltage magnet wire on the outer side;

step 10, carrying out vacuum drying treatment in vacuum pouring equipment;

vacuum casting epoxy resin in the mold cavity of the winding mold 5;

step 11, carrying out curing treatment by adopting a curing furnace;

step 12, removing the winding former 5, including removing the external mold, removing the internal and external air passage rods, removing the high-pressure side air passage rods 513, removing the first web plate 52, removing the second web plate 54, removing the internal mold 51 and the like;

The above examples are intended to illustrate the invention, but not to limit it. Although the present invention has been described in detail with reference to the above embodiments, it should be understood by those skilled in the art that: the above embodiments may still be modified, or some technical features may be equivalently replaced, for example, air passages arranged in a ring shape are respectively arranged inside the low-voltage coil and the high-voltage coil; and such modifications or substitutions do not depart from the spirit and scope of the present invention in its essence.

Claims

1. The utility model provides a three-dimensional iron core resin pouring dry-type transformer that rolls up, includes that the three-dimensional iron core body (1) of rolling up that mainly constitutes by three iron core posts that are the article font and arrange, be provided with on each iron core post of iron core body (1) and be in inboard low voltage coil (2) and be in high voltage coil (4) in the outside, low voltage coil (2) are the wire-wound structure, its characterized in that, on each iron core post low voltage coil (2) with high voltage coil (4) are inseparable overall structure by the epoxy pouring, just low voltage coil (2) with air flue (3) that main insulating function and heat dissipation function can be compromise with a plurality of annular the arranging of inside and outside bilayer structure between high voltage coil (4).

2. A three-dimensional wound iron core resin casting dry-type transformer comprises a three-dimensional wound iron core body (1) mainly composed of three iron core columns which are arranged in a delta shape, wherein each iron core column of the iron core body (1) is provided with a low-voltage coil (2) at the inner side and a high-voltage coil (4) at the outer side, and the low-voltage coil (2) is of a foil winding structure, and is characterized in that a low-voltage incoming wire (21) and a low-voltage outgoing wire (22) of the low-voltage coil (2) are formed by overlapping and combining a plurality of arc-shaped thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm respectively, and the low-voltage incoming wire (21) and the low-voltage outgoing wire (22) are tightly attached to copper foils/aluminum foils at the corresponding sides of the low-voltage coil (; on each iron core post low pressure coil (2) with high voltage coil (4) are by the epoxy pouring integral structure that inseparable, just low pressure coil (2) with air flue (3) that can compromise main insulating function and heat dissipation function of a plurality of is arranged to inside and outside bilayer structure hoop between high voltage coil (4).

3. A three-dimensional wound iron core resin casting dry-type transformer comprises a three-dimensional wound iron core body (1) mainly composed of three iron core columns which are arranged in a delta shape, wherein each iron core column of the iron core body (1) is provided with a low-voltage coil (2) at the inner side and a high-voltage coil (4) at the outer side, and the low-voltage coil (2) is of a foil winding structure, and is characterized in that a low-voltage incoming wire (21) and a low-voltage outgoing wire (22) of the low-voltage coil (2) are formed by overlapping and combining a plurality of arc-shaped thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm respectively, and the low-voltage incoming wire (21) and the low-voltage outgoing wire (22) are tightly attached to copper foils/aluminum foils at the corresponding sides of the low-voltage coil (; on each iron core post low pressure coil (2) with high voltage coil (4) are the inseparable overall structure by the epoxy pouring, just low pressure coil (2) with air flue (3) that main insulation function and heat dissipation function can be compromise to a plurality of that have arranged with inside and outside bilayer structure hoop between high voltage coil (4), a plurality of low pressure side air flue (28) have been arranged to the inside hoop of low pressure coil (2).

4. A three-dimensional wound iron core resin casting dry-type transformer comprises a three-dimensional wound iron core body (1) mainly composed of three iron core columns which are arranged in a delta shape, wherein each iron core column of the iron core body (1) is provided with a low-voltage coil (2) at the inner side and a high-voltage coil (4) at the outer side, and the low-voltage coil (2) is of a foil winding structure, and is characterized in that a low-voltage incoming wire (21) and a low-voltage outgoing wire (22) of the low-voltage coil (2) are formed by overlapping and combining a plurality of arc-shaped thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm respectively, and the low-voltage incoming wire (21) and the low-voltage outgoing wire (22) are tightly attached to copper foils/aluminum foils at the corresponding sides of the low-voltage coil (; on each iron core post low pressure coil (2) with high voltage coil (4) are the inseparable overall structure by the epoxy pouring, just low pressure coil (2) with air flue (3) that main insulation function and heat dissipation function can be compromise to a plurality of that have arranged with inside and outside bilayer structure hoop between high voltage coil (4), a plurality of high pressure side air flue (46) have been arranged to the inside hoop of high voltage coil (4).

5. A method for manufacturing a three-dimensional wound core resin-cast dry-type transformer according to claim 1, wherein the method comprises the following steps:

step 1, clamping an iron core body (1), and assembling a winding former (5) on a corresponding iron core column;

the winding former (5) mainly comprises an inner die (51) which is formed by a plurality of arc-shaped plates and can be matched with a corresponding iron core column, a first radial plate (52) which is connected at one end of the inner die (51) and extends radially, a second radial plate (54) which is connected at the other end of the inner die (51) and extends radially, and an outer die which is matched with the outer edge of the first radial plate (52) and the outer edge of the second radial plate (54) and used in the winding process, wherein the second radial plate (54) is provided with a plurality of air channel rod through holes corresponding to a main insulation region between a low-voltage coil winding region and a high-voltage coil winding region and is provided with an inner-outer double-layer;

step 2, sequentially winding a first insulating layer (23), a low-voltage electromagnetic wire, an interlayer insulating layer (24) and a fourth insulating layer (27) on the inner die (51);

the low-voltage incoming wire (21) and the low-voltage outgoing wire (22) of the low-voltage coil (2) are made of electromagnetic wires of a primary coil;

step 3, penetrating inner air passage rods (58) into the inner air passage rod through holes (56) in the web plate II (54), wherein the insertion ends of the inner air passage rods (58) are abutted against the web plate I (52);

step 4, winding an insulating layer five (33) on the inner side air channel rod (58);

step 5, penetrating outer air channel rods (59) into the outer air channel rod through holes (57) in the web plate II (54), wherein the inserting ends of the outer air channel rods (59) are abutted against the web plate I (52);

step 6, winding an insulating layer six (41), a high-voltage electromagnetic wire, an interlayer insulating layer 42 and an insulating layer nine (45) on the outer air passage rod (59) in sequence;

step 7, assembling an outer die on the winding die (5);

the inner die (51), the spoke plate I (52), the spoke plate II (54) and the outer die of the winding die (5) form a pouring space in which epoxy resin can be poured;

step 8, carrying out vacuum drying treatment in vacuum pouring equipment;

epoxy resin is poured into a die cavity of the winding die (5) in a vacuum mode;

step 9, adopting a curing furnace to perform curing treatment;

step 10, removing the winding former (5);

the low-voltage coil (2) and the high-voltage coil (4) on the corresponding iron core column are poured into an inseparable integral structure by epoxy resin;

step 11, repeating the steps, and manufacturing a low-voltage coil (2) and a high-voltage coil (4) of an integral structure on the next iron core column on the iron core body (1);

until the low-voltage coil (2) and the high-voltage coil (4) of the overall structure on the three-phase iron core column of the iron core body (1) are respectively manufactured and molded.

6. A method for manufacturing a three-dimensional wound core resin-cast dry-type transformer according to claim 2, wherein the method comprises the following steps:

step 2, winding a first insulating layer (23) on the inner die (51);

pressing a plurality of thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm into an arc-shaped structure by taking the outer circle formed by the inner die (51) as a reference, overlapping and combining the thin copper strips/thin aluminum strips together, welding and combining the thin copper strips/thin aluminum strips with a foil capable of forming a low-voltage coil, and forming a low-voltage incoming line (21) on the low-voltage coil foil;

winding a low-voltage foil and an interlayer insulation (29) on the first insulation layer (23), wherein the low-voltage incoming wire (21) is positioned on the inner side wall of the low-voltage coil in a tangent structure;

pressing a plurality of thin copper strips/thin aluminum strips with the thickness of 0.1-1 mm into an arc-shaped structure by taking the excircle formed by the low-voltage coil (2) as a reference, overlapping and combining the thin copper strips/thin aluminum strips together, welding and combining the thin copper strips/thin aluminum strips with a foil capable of forming the low-voltage coil, and forming a low-voltage outlet wire (22) on the foil of the low-voltage coil;

winding an insulating layer IV (27) on the low-voltage foil and the interlayer insulation (29);

step 7, assembling an outer die on the winding die (5);

step 8, carrying out vacuum drying treatment in vacuum pouring equipment;

step 9, adopting a curing furnace to perform curing treatment;

step 10, removing the winding former (5);

7. A method for manufacturing a three-dimensional wound core resin-cast dry-type transformer according to claim 3, wherein the method comprises the following steps:

the winding die (5) mainly comprises an inner die (51) which is composed of a plurality of arc-shaped plates and can be matched with a corresponding iron core column, a first radial plate (52) which is connected at one end of the inner die (51) and extends radially, a second radial plate (54) which is connected at the other end of the inner die (51) and extends radially, and an outer die which is matched with the outer edge of the first radial plate (52) and the outer edge of the second radial plate (54) and is used in the winding process, wherein a plurality of air passage rod through holes are formed in the radial plate (54) in a circumferential arrangement structure corresponding to the center of a low-voltage coil winding area, and a plurality of air passage rod through holes are formed in the radial plate (54) in a circumferential arrangement structure corresponding to an inner layer and an outer layer of a main insulation area between a low;

step 2, winding a first insulating layer (23) on the inner die (51);

winding a second insulating layer (25) on the low-voltage foil and the interlayer insulating layer (29);

step 3, penetrating low-pressure side air channel rods (512) into the low-pressure side air channel rod through holes (510) in the web plate II (54), wherein the inserting ends of the low-pressure side air channel rods (512) are abutted against the web plate I (52);

step 4, sequentially winding an insulating layer III (26), a low-voltage foil and an interlayer insulating layer (29) on the low-voltage side air channel rod (512);

the low-voltage coil foil on the inner side and the low-voltage coil foil on the outer side of the low-voltage side air channel rod (512) are continuous and uninterrupted;

step 5, penetrating inner air channel rods (58) into the inner air channel rod through holes (56) in the web plate II (54), wherein the inserting ends of the inner air channel rods (58) are abutted against the web plate I (52);

step 6, winding an insulating layer five (33) on the inner side air channel rod (58);

step 7, penetrating outer air channel rods (59) into the outer air channel rod through holes (57) in the web plate II (54), wherein the inserting ends of the outer air channel rods (59) are abutted against the web plate I (52);

step 8, sequentially winding an insulating layer six (41), a high-voltage electromagnetic wire, an interlayer insulating layer 42 and an insulating layer nine (45) on the outer air passage rod (59);

step 9, assembling an outer die on the winding die (5);

step 10, carrying out vacuum drying treatment in vacuum pouring equipment;

step 11, carrying out curing treatment by adopting a curing furnace;

12, removing the winding former (5);

step 13, repeating the steps, and manufacturing a low-voltage coil (2) and a high-voltage coil (4) of an integral structure on the next iron core column on the iron core body (1);

8. A method for manufacturing the three-dimensional wound core resin-cast dry-type transformer according to claim 4, wherein the method comprises the following steps:

the winding die (5) mainly comprises an inner die (51) which is composed of a plurality of arc-shaped plates and can be matched with a corresponding iron core column, a first radial plate (52) which is connected at one end of the inner die (51) and extends radially, a second radial plate (54) which is connected at the other end of the inner die (51) and extends radially, and an outer die which is matched with the outer edge of the first radial plate (52) and the outer edge of the second radial plate (54) and is used in the winding process, wherein a plurality of air passage rod through holes are formed in the annular arrangement structure corresponding to the center of a high-voltage coil winding area on the second radial plate (54), and a plurality of air passage rod through holes are formed in the annular arrangement structure of an inner layer and an outer layer corresponding to a main insulation area between a low-voltage coil winding area and a;

step 2, winding a first insulating layer (23) on the inner die (51);

step 6, winding an insulating layer six (41), a high-voltage electromagnetic wire, an interlayer insulating layer (42) and an insulating layer seven (43) on the outer air passage rod (59) in sequence;

step 7, penetrating high-pressure side air passage rods (513) into the high-pressure side air passage rod through holes (511) in the web plate II (54), wherein the insertion ends of the high-pressure side air passage rods (513) are abutted against the web plate I (52);

8, winding an insulating layer eight (44), a high-voltage electromagnetic wire, an interlayer insulating layer 42 and an insulating layer nine (45) on the high-voltage side air passage rod (513) in sequence; the high-voltage magnet wire on the inner side of the high-voltage side air passage rod (513) is connected with the high-voltage magnet wire on the outer side;

step 9, assembling an outer die on the winding die (5);

step 10, carrying out vacuum drying treatment in vacuum pouring equipment;

step 11, carrying out curing treatment by adopting a curing furnace;

12, removing the winding former (5);