Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
  • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
  • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
  • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
  • H01F41/06—Coil winding
  • H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores

Definitions

• the invention relates to a method and an apparatus for winding a closed toroidal core for transformers and chokes of high power.
• toroidal cores are used only in special cases, and in particular mostly toroidal cores with separation points, which are wound by hand.
• the necessary conductor cross-sections require so much effort when winding that transformers of even greater power cannot be realized with toroidal cores.
• toroidal cores would be desirable at high outputs, for example in the MVA area, particularly for energy distribution networks, since the significantly lower losses and the other known advantages would have a particularly advantageous effect when using toroidal transformers, and would therefore be more economical Benefit would exist.
• the windings In the case of transformers of very high power, the windings generally consist of tapes which are very wide for the necessary conductor cross sections, so that the thickness of the conductors can be reduced to such an extent that the band-shaped conductor can still be wound around the core and thereby bent.
• the object of the present invention is to provide a method and a winding device for closed toroidal cores, with which also very high power transformers for example for distribution networks.
• the effort for this should be comparatively low.
• the conductor provided for a winding or a partial winding is applied to a winding roller that passes through the ring core opening together with the winding material, and this winding roller then leads around the ring core and through the inner opening and thereby winds the winding from the winding winding is wound onto the toroidal core -
• a first winding segment is applied to a ring core radial section, with several layers of a conductor and an intermediate insulation being applied to the ring core radial section in the creation of this winding segment by means of several revolving winding rollers.
• the ring core and the winding device are then rotated relative to one another in order to apply a further winding segment to another ring core radial section, and the ring core is then wrapped with a further winding.
• this process can either be used to wind the respective winding in one operation or it is also possible to distribute the conductor cross-section over several windings and to apply these windings one after the other.
• the winding or partial winding to be applied in one winding operation is first applied to the winding roller and this is then passed around the ring and through the ring opening while the electrical conductor is being unwound.
• the size of the winding roll with the material to be wound is based on the clear internal cross-section of the ring core used.
• toroidal core transformers and chokes can also be built for the highest performance with reasonable effort. If required, toroidal core transformers can also be implemented in a modular manner from a plurality of smaller basic units for very high outputs, which results in advantages in particular for transport and assembly on site.
• a further development of the method according to the invention provides that windings are wound around the ring core, that a further ring core provided with air gaps is then preferably arranged concentrically in the first ring core and that both ring cores are then wound with common windings. In this way, a transformer can be wound simultaneously with an integrated choke.
• the device according to the invention for carrying out the method provides that it has a guide encompassing the ring leg to be wound and a plurality of rollable winding rolls with winding material, i.e. with a conductor or with intermediate insulation, which can be transported along this guide through the ring core, and that the guide leads to Gripping the ring leg has a separation point and can therefore be opened and closed like a pincer.
• the guide of the winding machine is first opened like a pincer and then, after closing, engages around a ring core portion from one side. The winding rollers then run around this guide, the electrical conductor wound on the winding roll and the intermediate insulation being simultaneously unwound from the respective winding roll and wound onto the ring core.
• the conductor cross section used for a winding process and the conductor length depend in particular on the existing opening cross section of the toroidal core.
• a division according to the required total cross section of the high and low voltage windings into several partial windings is carried out next to one another or also one on top of the other.
• FIG. 1 is a side view of a winding machine when winding a ring core
• Fig. 3 is a plan view of a partially wound ring core
• Fig. 4 and 5 plan views of ring cores with an air gap
• FIGS. 7 and 8 different embodiments of end coupling layers located on the ring core 9 to 11 winding conductor ends in different shaping phases.
• a winding device 1 shown in FIG. 1 is used for winding closed toroidal cores 2 for transformers or chokes.
• this winding device is intended to wind ring cores 2 of high-performance transformers whose output is above 120 KVA, for example.
• the windings to be applied have considerable conductor cross sections that are difficult to handle during winding.
• the winding device 1 essentially has a guide 3 with revolving winding rolls 4.
• the guide 3 encompasses, as can be clearly seen in FIG. 1, the ring core leg 5, which in the exemplary embodiment consists of wound electrical sheet 6.
• the guide 3 is in the form of pliers and has a separating point 7 and a further separating point, not visible here, or a swivel joint opposite the Separation point 7. The guide 3 can thus be opened and placed around the ring core leg 5.
• the winding rollers 4,4a rotate in the direction of arrow Pf 1.
• the front winding roller 4 in the direction of rotation carries the electrical conductor 8 intended for the winding to be applied, while insulation material 26 for the layer insulation is wound on a subsequent winding roller 4a.
• the winding rollers 4, 4a run along the guide 3, the material located on the winding rollers is unwound and in layers wound on the ring core leg 5 in the segment provided for this purpose
• the entire length of the electrical conductor required for a winding usually does not fit on a winding roller 4, or the winding roller 4 wound therewith does not fit through the inner opening 9 of the ring core 2, as is well shown in FIG 3 recognizable, several winding segments 10 distributed over the circumference of the ring core 2.
• a sufficient amount of winding material can be applied to the winding roll 4 for each of these partial windings.
• the partial windings or winding segments 10 are then connected to one another, so that the undervoltage winding and possibly also the high-voltage winding are formed from a plurality of partial windings.
• the division of the high-voltage and low-voltage windings with respect to the arrangement of the individual winding segments 10 can be provided practically as desired. For example, it is possible to assign high-voltage and low-voltage windings alternately next to one another or in groups to one another. As a result, the degree of coupling can be varied within wide limits.
• both the high-voltage and the low-voltage winding could be in circulation, the first winding roller being provided, for example, for the undervoltage winding, the second winding roller for the insulation and the third winding roller for the high-voltage winding.
• the annular guide 3 here has two guide rails 11, 11a arranged concentrically at a distance from one another, between which a circumferential transport means 12 connected to a drive is guided (FIG. 2).
• a circulating chain or a belt or the like can be used as the transport means 12, on which the coupling points 13 for winding rolls are located.
• the winding rolls have winding bodies 14 which are rotatably mounted on an axis 15.
• the axis is designed as a coupling part and can therefore preferably engage in a rotationally fixed manner at the coupling points 13 of the means of transport 12.
• a fastening screw 16 is provided to secure the plug connection.
• the winding body 14 is rotatably mounted on the axis 15 and a preferably adjustable braking device 17 is provided, with which the winding body can be braked when the electrical conductor is unwound. With the brake device 17, the winding tension and thus the strength of the winding to be applied can be controlled.
• a roller bearing 18 which engages between the guide rails 11, 11a is also provided thereon.
• an elastic decoupling layer 19 is applied to the ring core 2, which consists, for example, of wound electrical sheet 6. This is used to compensate for thermal expansion, especially when the transformer is cast in casting resin after winding.
• 1 also shows a holding device 20 for the ring core 2 to be wound, by means of which the ring core 2 can be held and possibly also rotated.
• the ring core 2 can be rotated in the circumferential direction and then another winding can be applied.
• the relative rotary movement between the ring core and the winding device 1 is carried out by the winding device itself by being able to be positioned in the circumferential direction of the ring core 2.
• the end of the band-shaped electrical conductor 8 is folded around an oblique fold line 21 lying in the band plane, so that the end then runs at an angle to the rest of the conductor 8, preferably at right angles.
• This angled, folded end can then, as shown in FIG. be halved in width by repositioning. This can be repeated until a compact connection end 22 is created which is mechanically stable and can be connected to the connection ends of adjacent windings, which are also formed in this way, by means of press, welding or soldering technology. This therefore considerably simplifies the interconnection of the individual part windings.
• the transformer produced by the method according to the invention can also be equipped with an integrated choke.
• a part of the windings or the winding segments 10 is first applied to the ring core 2.
• a further ring core 2a or 2b (compare FIGS. 4 and 5), which are provided with air gaps 23, is then assigned to the partially wound ring core 2 and both ring cores are then wrapped together with further windings
• Fig. 6 shows a step ring core 2c shown in section, by means of which undesired winding spaces between the ring core and the winding can be avoided.
• the course of the provided decoupling layers 19 can also be clearly seen here.
• FIG. 7 and 8 show intermediate layers 24 located between the ring core 2 and a winding to be applied (not shown here), the cooling channels 25 Has cooling of the windings and the core. From the outside, these cooling channels 25 can be supplied with a cooling medium.
• FIG. 7 shows an embodiment in which the intermediate layer 24 is made of elastic material and thus simultaneously forms the decoupling layer 19.
• FIG. 8 shows another embodiment where the cooling channels 25 are accommodated in an intermediate layer 24 separated from the decoupling layer 19.
• the decoupling layer on the radial and the axial sides of the ring core can be designed differently in order to influence the magnetic properties of the core through different pressurization.

Landscapes

• Engineering & Computer Science (AREA)
• Power Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Coils Or Transformers For Communication (AREA)
• Coils Of Transformers For General Uses (AREA)
• Insulating Of Coils (AREA)
• Transformers For Measuring Instruments (AREA)
• Insulation, Fastening Of Motor, Generator Windings (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=6501650

Family Applications (1)

Country Status (6)

Families Citing this family (6)

Citations (1)

Family Cites Families (4)

• 1994
  • 1994-10-20 AU AU79387/94A patent/AU7938794A/en not_active Abandoned
  • 1994-10-20 EP EP94930197A patent/EP0761009B1/fr not_active Expired - Lifetime
  • 1994-10-20 WO PCT/EP1994/003447 patent/WO1995012887A1/fr active IP Right Grant
  • 1994-10-20 ES ES94930197T patent/ES2116622T3/es not_active Expired - Lifetime
  • 1994-10-20 DE DE59405966T patent/DE59405966D1/de not_active Expired - Fee Related
  • 1994-10-20 AT AT94930197T patent/ATE166180T1/de not_active IP Right Cessation

Patent Citations (1)

Non-Patent Citations (1)

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