EP2102876B1 - Method for producing a transformer coil, and a transformer coil produced using this method - Google Patents

Method for producing a transformer coil, and a transformer coil produced using this method Download PDF

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Publication number
EP2102876B1
EP2102876B1 EP07856455.6A EP07856455A EP2102876B1 EP 2102876 B1 EP2102876 B1 EP 2102876B1 EP 07856455 A EP07856455 A EP 07856455A EP 2102876 B1 EP2102876 B1 EP 2102876B1
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EP
European Patent Office
Prior art keywords
winding
end wall
layer
sections
wall sections
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
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EP07856455.6A
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German (de)
French (fr)
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EP2102876A1 (en
Inventor
Karl Zillmann
Wolfgang MÖNIG
Benjamin Weber
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ABB AG Germany
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ABB AG Germany
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Priority to PL07856455T priority Critical patent/PL2102876T3/en
Publication of EP2102876A1 publication Critical patent/EP2102876A1/en
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/30Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/32Insulating of coils, windings, or parts thereof
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/32Insulating of coils, windings, or parts thereof
    • H01F27/323Insulation between winding turns, between winding layers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • H01F41/04Apparatus 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
    • H01F41/12Insulating of windings
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • H01F41/04Apparatus 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
    • H01F41/12Insulating of windings
    • H01F41/122Insulating between turns or between winding layers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2823Wires
    • H01F27/2828Construction of conductive connections, of leads
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/32Insulating of coils, windings, or parts thereof
    • H01F27/324Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H01F27/325Coil bobbins
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/32Insulating of coils, windings, or parts thereof
    • H01F27/327Encapsulating or impregnating
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • H01F41/04Apparatus 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
    • H01F41/12Insulating of windings
    • H01F41/127Encapsulating or impregnating
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/4902Electromagnet, transformer or inductor
    • Y10T29/49071Electromagnet, transformer or inductor by winding or coiling

Definitions

  • the invention relates to a method according to the preamble of claim 1 and a transformer coil according to the preamble of claim 4.
  • a transformer coil has a coil tube which is surrounded by a secondary winding and a primary winding, the latter being embedded in a block of insulating material, wherein the windings are produced in the so-called filament winding method.
  • a first insulating layer is wound on the coil tube, which is separated from the secondary winding by means of spacers, on which a first layer of the winding wire is wound.
  • a layer of insulating material is applied, applied to this layer again a layer with Wicklüngsdraht, this layer has two ply sections which extend from the two ends of the inner layer of the winding wire to the inside, that is to each other and at a certain distance from each other end up.
  • the opposite ends of the inner layer are joined to the adjacent ends of the second ply sections. It should be ensured in known winding process that the opposite ends of the second layer sections do not slide over the inner first layer to the outside. This is achieved in that the opposite ends of the winding windings of the second layer portions at an axial distance from the turn ends of the inner layer, so that the connections of the adjacent turn ends each form an acute angle with the annular surface of the inner first layer; the two angles together form a V-shape whose open side is open to the inner first layer.
  • the opposite ends of the third ply portions terminate again at a distance from the adjacent ends of the second ply portions such that the connections of the inner, opposite ends of the second and third ply portions also form an acute angle with each other forming a V-shape whose tip points radially inwards.
  • These third storage sections are followed by e.g. two fourth and fifth layer sections whose lengths are shortened axially compared to the previously wound layers, so that form here the V-shapes.
  • the object of the invention is to provide a method for producing a transformer coil and a transformer coil of the type mentioned, in which the winding space is better utilized.
  • a further advantageous embodiment may be that to form the end wall sections L-shaped angle pieces are provided of metal, one leg of which form the end wall sections and the other leg are arranged parallel to the coil tube and are wrapped in the individual insulating layers. These L-shaped elbows can then be easily removed after curing. The resulting slot-like openings can be closed easily with insulating material, or simply remain open.
  • the angle pieces in such a way that the legs which form the end wall sections extend over the entire end face of the coil;
  • a plurality of L-shaped angle pieces radially spaced, with inner L-shaped angle pieces are wrapped by an inner insulating layer and outer L-shaped brackets of the corresponding outer insulating layer.
  • the angle pieces are formed by providing arcuate tubes which are provided at one end with slots which are bent perpendicular to the arcuate portions, so that the Endwandabitese are formed by the vertically bent leg.
  • wire winding sections are provided in the bobbin, whose interconnected winding ends lie in a respective radial plane, so that all winding sections lie between two radial planes in which simultaneously the mutually associated and interconnected winding ends, wherein connecting pieces are provided, which extend radially
  • the end wall portions may be formed on an insulating tube or coil tube surrounded by the bobbin; it is also possible that L-shaped angle element are provided, the legs of which are perpendicular to each other, wherein one of the legs is held parallel to the winding sections of the insulating layers, whereas the other leg projects radially outward and serves to form the end wall sections.
  • angle elements as arc-shaped angle elements, wherein one of the legs forms an arcuate shape and the other legs are bent as a flap perpendicular to it.
  • the legs for forming the Endwandabitese can cover the entire face; There is also the possibility that a plurality of angle elements are arranged in different radii, so that the legs forming the end wall sections only cover part of the end faces of the coil body.
  • a bobbin 10 which is produced by the process according to the invention, surrounds a coil tube 11, at the ends of which radially adjoining flange-like end wall sections 12, 13, here in the first exemplary embodiment, are integrally formed.
  • a first insulating layer 14 is applied, preferably wound.
  • This insulating layer 14 like all other insulating layers (see below), may contain a fibrous web impregnated with thermosetting plastic.
  • the insulating layer 14 extends to the end wall portions 12,13.
  • a first winding layer 15 is wound, which in the Fig. 1 (as well as in the Fig. 2 ) is drawn as a line.
  • a rectangular winding wire can be used.
  • a winding wire with a rectangular shape could also be used with a circular cross-section.
  • the cross-sectional shape is so far for the invention is not important.
  • the winding wire layer 15 terminates at a certain distance D from the end wall portions 12,13.
  • a second insulating layer 16 is applied, that is wound, again up to the end wall sections 12,13.
  • two winding layer sections 17,18 are wound, the opposite ends lie in the radial plane in which the ends of the first winding layer 15 lie and their opposite ends 19,20 are arranged at a distance D1 from each other.
  • the winding layers 15,17 and 18 are connected to each other with radially extending connecting elements 21, 22, wherein these connecting elements 21,22 lie in the planes in which the ends of the first winding layer 15 lie.
  • a third insulating layer 23 is wound, thereon two third winding sections 24,25 whose lengths are similar to those of the second winding sections 17,18 and with these at their opposite ends by means of radial links similar to those with the reference numerals 21st 22, thereafter a fourth insulating layer (not numbered) and thereon two fourth winding sections 26, 27, another insulating layer and thereon two fifth winding sections 26, 27, and thereon the outer insulating layer.
  • the third winding sections 24, 25 are connected to the fourth winding sections 26, 27 with connecting elements in the radial plane of the ends of the first winding layer 15 and the fourth to the fifth winding sections at the mutually facing ends, the length of the fourth and fifth winding sections is less than the length of the second and third winding sections 17,24; 18.25.
  • a plurality of circumferentially uniformly spaced spacer 30 Within the coil tube 11 are a plurality of circumferentially uniformly spaced spacer 30. Within the spacer 30 are secondary windings 31, which are indicated here only schematically. The space between the Anstandshaltern 30, which are radially aligned and extend over the entire length of the coil tube 11, is flowed through axially by a cooling fluid. The assignment of the secondary windings 31 and the spacers to the Spulerohr 11 are not relevant to the invention.
  • the end wall portions are formed by angle pieces, which in the Fig. 3 are shown in perspective.
  • adapted elbow 35 slots 36,37 are introduced.
  • the tabs 40, 41 and 42 formed between the peripheral ends 38, 39 and the slots 36, 37 are bent radially outward so that the slots 36, 37 become V-shaped.
  • the elbow 35 forms the leg 43 of the elbow, which in the Fig. 4 a total of the reference number 44 has received.
  • the axially extending leg 43 is wrapped with the first insulating layer 16 in the bobbin.
  • the elbows after Fig. 3 cover the entire circumference of the coil tube.
  • the elbows can be removed. Which thereby resulting openings can remain free or sealed with insulating material.
  • Angle pieces cover the radially oriented legs of the entire end faces of the bobbin.
  • the lobes have a radial length which is adapted to the installation point on the bobbin, wherein the lobes of all the angle pieces are each in a radial plane, which here correspond to the Stirnebenen the bobbin.
  • the legs 43 of the outer angle pieces are then enveloped by the corresponding insulating layers.
  • transformer cores 50 are shown in dashed lines, which engage with a leg 51 in the region within the secondary winding 31.
  • this has nothing to do with the invention described here, but merely serves for better understanding.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Of Transformers For General Uses (AREA)

Description

Die Erfindung betrifft ein Verfahren nach dem Oberbegriff des Anspruches 1 und eine Transformatorspule nach dem Oberbegriff des Anspruches 4.The invention relates to a method according to the preamble of claim 1 and a transformer coil according to the preamble of claim 4.

Eine Transformatorspule besitzt ein Spulenrohr, das von einer Sekundärwicklung und von einer Primärwicklung umgeben ist, welche letztere in einen Block aus isolierendem Material eingebettet ist, wobei die Wicklungen im sog. Filament-Wickelverfahren hergestellt werden. Hierzu wird auf das Spulenrohr, das von der Sekundärwicklung mittels Abstandshalter getrennt ist, eine erste Isolierschicht aufgewickelt, auf die eine erste Lage des Wicklungsdraht aufgewickelt wird. Auf diese erste Lage wird eine Schicht Isoliermaterial aufgebracht, auf diese Lage wieder eine Lage mit Wicklüngsdraht aufgebracht, wobei diese Lage zwei Lagenabschnitte aufweist, die von den beiden Enden der inneren Lage des Wickeldrahtes nach Innen, d.h. aufeinander zu verlaufen und in einem bestimmten Abstand voneinander enden. Die entgegengesetzten Enden der inneren Lage werden mit den benachbarten Enden der zweiten Lagenabschnitte verbunden. Dabei ist bei bekannten Wickelverfahren darauf zu achten, dass die entgegengesetzt liegenden Enden der zweiten Lagenabschnitte nicht über die innere erste Lage nach außen abgleiten. Dies wird dadurch erreicht, dass sich die entgegengesetzt liegenden Windungsenden der zweiten Lagenabschnitte in einem axialen Abstand von den Windungsenden der inneren Lage befinden, so dass die Verbindungen der benachbarten Windungenden je einen spitzen Winkel mit der Ringfläche der inneren erste Lage bilden; die beiden Winkel bilden miteinander eine V-Form, deren offene Seite zur inneren ersten Lage geöffnet ist.A transformer coil has a coil tube which is surrounded by a secondary winding and a primary winding, the latter being embedded in a block of insulating material, wherein the windings are produced in the so-called filament winding method. For this purpose, a first insulating layer is wound on the coil tube, which is separated from the secondary winding by means of spacers, on which a first layer of the winding wire is wound. In this first layer, a layer of insulating material is applied, applied to this layer again a layer with Wicklüngsdraht, this layer has two ply sections which extend from the two ends of the inner layer of the winding wire to the inside, that is to each other and at a certain distance from each other end up. The opposite ends of the inner layer are joined to the adjacent ends of the second ply sections. It should be ensured in known winding process that the opposite ends of the second layer sections do not slide over the inner first layer to the outside. This is achieved in that the opposite ends of the winding windings of the second layer portions at an axial distance from the turn ends of the inner layer, so that the connections of the adjacent turn ends each form an acute angle with the annular surface of the inner first layer; the two angles together form a V-shape whose open side is open to the inner first layer.

An den sich gegenüberliegenden Enden der zweiten Lagenabschnitte schließen je ein dritter Lagenabschnitt an, wobei zwischen den zweiten und den dritten Lagenabschnitten wiederum eine Zwischenlage aus Isoliermaterial eingebracht ist. Die sich gegenüberliegenden Enden der dritten Lagenabschnitte enden wieder in einem Abstand zu den benachbarten Enden der zweiten Lagenabschnitte, so dass die Verbindungen der inneren, sich gegenüberliegenden Enden der zweiten und dritten Lagenabschnitte ebenfalls einen spitzen Winkel miteinander bilden, wobei beide Verbindungen eine V-Form bilden, deren Spitze radial nach innen weist. Diesen dritten Lageabschnitten folgen z.B. zwei vierte und fünfte Lagenabschnitte, deren Längen gegenüber den vorher gewickelten Lagen axial verkürzt sind, so dass sich auch hier die V-Formen ausbilden.At the opposite ends of the second layer sections each include a third layer portion, wherein between the second and the third layer portions in turn an intermediate layer of insulating material is introduced. The opposite ends of the third ply portions terminate again at a distance from the adjacent ends of the second ply portions such that the connections of the inner, opposite ends of the second and third ply portions also form an acute angle with each other forming a V-shape whose tip points radially inwards. These third storage sections are followed by e.g. two fourth and fifth layer sections whose lengths are shortened axially compared to the previously wound layers, so that form here the V-shapes.

Diese Wicklungsformen, d.h. der Rückversatz, führen dazu, dass der zur Verfügung stehende Wicklungsraum nicht optimal und vollständig ausgenutzt wird.These winding forms, i. The offset, lead to the fact that the available winding space is not optimally and fully utilized.

Aufgabe der Erfindung ist es, ein Verfahren zur Herstellung einer Transformatorspule und eine damit hergestellte Transformatorspule der eingangs genannten Art zu schaffen, bei der der Wickelraum besser ausgenutzt wird.The object of the invention is to provide a method for producing a transformer coil and a transformer coil of the type mentioned, in which the winding space is better utilized.

Diese Aufgabe wird erfindungsgemäß durch die Merkmale des Anspruches 1 gelöst.This object is achieved by the features of claim 1.

Die Erfindung besteht also in einem Verfahren, das gekennzeichnet ist durch folgende Schritte:

  • Aufwickeln einer inneren ersten Isolierschicht auf einen zylinderförmigen Körper aus isolierendem Material, an dessen Enden radial nach außen vorspringenden Endwandabschnitte vorgesehen sind, wobei die Isolierschicht bis an die Endwandabschnitte gewickelt wird,
The invention thus consists in a method which is characterized by the following steps:
  • Winding an inner first insulating layer on a cylindrical body of insulating material, at the ends of which radially outwardly projecting end wall sections are provided, wherein the insulating layer is wound up to the end wall sections,

Aufwickeln einer inneren ersten Wicklungsdrahtlage, deren Endwindungen sich in einem Abstand zu den Endwandabschnitten befinden,Winding an inner first winding wire layer whose end turns are at a distance from the end wall sections,

Aufwickeln einer zweiten Isolierschicht auf die innere erste Wicklungsdrahtlage bis zu den Endwandabschnitten,Winding a second insulating layer on the inner first winding wire layer to the end wall portions,

Aufwickeln einer zweiten Wicklungsdrahtlage, die in einem oder zwei Lagenabschnitten gewickelt werden kann, wobei die entgegengesetzt liegenden Endwindungen der zweiten Wicklungsdrahtlage oder der Lagenabschnitte in der radialen Ebene der Endwindungen der inneren ersten Wicklungsdrahtlage liegen,Winding a second winding wire layer that can be wound in one or two layer sections, wherein the opposite end turns of the second winding wire layer or the layer sections lie in the radial plane of the end turns of the inner first winding wire layer,

Verbinden der benachbarten Enden der ersten und zweiten Wicklungsdrahtlagen mittels radialer Verbindungselemente,Connecting the adjacent ends of the first and second winding wire layers by means of radial connecting elements,

Aufwickeln einer dritten Isolierschicht bis hin zu den Endwandabschnitten,Winding a third insulating layer up to the end wall sections,

Aufwickeln einer dritten Wicklungsdrahtlage oder zweier dritter Lagenabschnitte, deren Endwindungen radial in der Ebene der Endwindungen der zweiten Lagenabschnitte liegen,Winding a third winding wire layer or two third layer sections whose end turns are located radially in the plane of the end turns of the second layer sections,

Verbinden der in je einer radialen Ebene liegenden Endwindungen der dritten Lagenabschnitte mit den Enden der zweiten Lagenabschnitte,Connecting the end turns of the third layer sections lying in a respective radial plane to the ends of the second layer sections,

Aufwickeln einer vierten Isolierschicht bis hin zu den Endwandabschnitten,
u.s.w., und
ggfls. Entfernen der Endwandabschnitte nach dem Aushärten des Isoliermaterials.
Winding a fourth insulating layer up to the end wall sections,
etc, and
sometimes. Removing the end wall portions after curing of the insulating material.

Es besteht die Möglichkeit, die Endwandabschnitte an dem Innenrohr anzuformen.It is possible to form the end wall sections on the inner tube.

Eine weitere vorteilhafte Ausgestaltung kann dahin bestehen, dass zur Bildung der Endwandabschnitte L-förmige Winkelstücke aus Metall vorgesehen werden, deren eine Schenkel die Endwandabschnitte an sich bilden und deren andere Schenkel parallel zum Spulenrohr angeordnet sind und in die einzelnen Isolierschichten eingewickelt werden. Diese L-förmigen Winkelstücke können dann ohne weiteres nach dem Aushärten entfernt werden. Die dabei entstehenden schlitzartigen Öffnungen können ohne weiteres mit Isoliermaterial geschlossen werden, oder auch einfach offen bleiben.A further advantageous embodiment may be that to form the end wall sections L-shaped angle pieces are provided of metal, one leg of which form the end wall sections and the other leg are arranged parallel to the coil tube and are wrapped in the individual insulating layers. These L-shaped elbows can then be easily removed after curing. The resulting slot-like openings can be closed easily with insulating material, or simply remain open.

Dabei besteht die Möglichkeit, die Winkelstücke so auszubilden, dass die Schenkel, die die Endwandabschnitte bilden, über die gesamte Stirnfläche der Spule verlaufen; es besteht natürlich auch die Möglichkeit, mehrere L-förmige Winkelstücke radial in Abstand anzuordnen, wobei innere L-förmige Winkelstücke von einer inneren Isolierschicht und äußere L-förmige Winkelstücke von der entsprechenden äußeren Isolierschicht eingewickelt sind. In bevorzugter Weise werden die Winkelstücke dadurch gebildet, dass bogenförmige Rohre vorgesehen sind, die an einem Ende mit Schlitzen versehen sind, die senkrecht zu den bogenförmigen Bereichen aufgebogen sind, so dass durch die senkrecht aufgebogenen Schenkel die Endwandabschnitte gebildet sind.In this case, it is possible to design the angle pieces in such a way that the legs which form the end wall sections extend over the entire end face of the coil; Of course, it is also possible to arrange a plurality of L-shaped angle pieces radially spaced, with inner L-shaped angle pieces are wrapped by an inner insulating layer and outer L-shaped brackets of the corresponding outer insulating layer. Preferably, the angle pieces are formed by providing arcuate tubes which are provided at one end with slots which are bent perpendicular to the arcuate portions, so that the Endwandabschnitte are formed by the vertically bent leg.

Mit der erfindungsgemäßen Wicklungsmethode und insbesondere mit dem Vorsehen von Endwandabschnitten zur Führung und Formhaltung der Isolierwicklungen oder -schichten an den axialen Spulenden kann die Verbindung der übereinanderliegenden Wicklungsdrahtlagen mittels der radial verlaufenden Verbindungsstücke erfolgen, weil aufgrund der Endwandabschnitte ein Abgleiten der übereinanderliegenden Endwindungen der jeweils äußeren Wicklungsdrahtlage axial nach außen oder ggfls. nach Innen vermieden ist und demgemäß die zu verbindenden Windungen radial übereinander liegen. Die äußere Form der Transformatorspule besitzt damit radiale Stirnenden und im Inneren der Isolierung, die aus den verschiedenen Isolierschichten gebildet ist, ist der Wicklungsraum optimal ausgenutzt. Dies bewirkt eine kürzere Spulenlänge und die Menge des Isoliermaterials ist reduziert. Auch kann die Schenkellänge des dazu passenden Kerns verringert werden, wodurch sich auch das Kerngewicht reduziert.With the winding method according to the invention and in particular with the provision of Endwandabschnitten for guiding and shape retention of the insulating windings or layers on the axial coil ends, the connection of the superimposed winding wire layers by means of radially extending connectors, because due to the Endwandabschnitte slipping of the superimposed end turns of each outer winding wire layer axially outward or if necessary. is avoided to the inside and accordingly the turns to be connected are radially superimposed. The outer shape of the transformer coil thus has radial ends and in the interior of the insulation, which is formed from the various insulating layers, the winding space is optimally utilized. This causes a shorter coil length and the amount of insulating material is reduced. Also, the leg length of the matching core can be reduced, which also reduces the core weight.

Weitere vorteilhafte Ausgestaltungen und Verbesserungen des erfindungsgemäßen Verfahrens sind den Unteransprüchen 2 und 3 zu entnehmen.Further advantageous embodiments and improvements of the method according to the invention can be found in the subclaims 2 and 3.

Eine Spule, die mittels des erfindungsgemäßen Verfahrens geschaffen wurde, ist den Unteransprüchen 4 bis 9 zu entnehmen.A coil, which was created by means of the method according to the invention, can be found in the dependent claims 4 to 9.

Erfindungsgemäß also sind im Spulenkörper Drahtwicklungsabschnitte vorgesehen, deren miteinander verbundene Windungsenden in je einer radialen Ebene liegen, so dass alle Wicklungsabschnitte zwischen zwei radialen Ebenen liegen, in denen gleichzeitig auch die einander zugehörigen und miteinander verbundenen Windungsenden liegen, wobei Verbindungsstücke vorgesehen sind, die radial verlaufen. Die Endwandabschnitte können an einem vom Spulenkörper umgebenen Isolierrohr oder Spulenrohr angeformt sein; es besteht auch die Möglichkeit, dass L-förmige Winkelelement vorgesehen sind, deren Schenkel senkrecht zueinander verlaufen, wobei einer der Schenkel parallel zu den Wicklungsabschnitten von den Isolierschichten festgehalten wird, wogegen der andere Schenkel radial nach außen vorspringt und zur Bildung der Endwandabschnitte dient.According to the invention, wire winding sections are provided in the bobbin, whose interconnected winding ends lie in a respective radial plane, so that all winding sections lie between two radial planes in which simultaneously the mutually associated and interconnected winding ends, wherein connecting pieces are provided, which extend radially , The end wall portions may be formed on an insulating tube or coil tube surrounded by the bobbin; it is also possible that L-shaped angle element are provided, the legs of which are perpendicular to each other, wherein one of the legs is held parallel to the winding sections of the insulating layers, whereas the other leg projects radially outward and serves to form the end wall sections.

Es besteht die Möglichkeit, die Winkelelemente als bogenförmige Winkelelemente auszubilden, wobei einer der Schenkel eine Bogenform bildet und die anderen Schenkel als Lappen senkrecht dazu ausgebogen sind.It is possible to form the angle elements as arc-shaped angle elements, wherein one of the legs forms an arcuate shape and the other legs are bent as a flap perpendicular to it.

Die Schenkel zur Bildung der Endwandabschnitte können dabei die gesamte Stirnfläche überdecken; es besteht auch die Möglichkeit, dass mehrere Winkelelemente in unterschiedlichen Radien angeordnet sind, so dass die die Endwandabschnitte bildenden Schenkel lediglich einen Teil der Stirnflächen des Spulenkörpers überdecken.The legs for forming the Endwandabschnitte can cover the entire face; There is also the possibility that a plurality of angle elements are arranged in different radii, so that the legs forming the end wall sections only cover part of the end faces of the coil body.

An Hand der Zeichnung, in der einige Ausführungsbeispiele der Erfindung dargestellt sind, sollen die Erfindung sowie weitere vorteilhafte Ausgestaltungen der Erfindung und weitere Vorteile näher erläutert und beschrieben werden.With reference to the drawing, in which some embodiments of the invention are shown, the invention and further advantageous embodiments of the invention and further advantages are explained and described in detail.

Es zeigen:

Fig. 1
eine Längsschnittansicht einer ersten Ausgestaltung einer erfindungsgemäßen Spule,
Fig. 2
eine Längsschnittansicht ähnlich derjenigen der Fig. 1 einer zweiten Ausgestaltung einer erfindungsgemäßen Spule,
Fig. 3
eine Ausgestaltung eines Winkelstückes für die zweite Ausführungsform, in perspektivischer Darstellung und
Fig. 4
einen vergrößerten Ausschnitt gemäß "A" der Fig. 3.
Show it:
Fig. 1
a longitudinal sectional view of a first embodiment of a coil according to the invention,
Fig. 2
a longitudinal sectional view similar to that of Fig. 1 one Second embodiment of a coil according to the invention,
Fig. 3
an embodiment of an angle piece for the second embodiment, in perspective view and
Fig. 4
an enlarged section according to "A" of Fig. 3 ,

Es sei nun Bezug genommen auf die Fig. 1.It is now referred to the Fig. 1 ,

Ein Spulenkörper 10, der nach dem erfindungsgemäßen Verfahren hergestellt ist, umgibt ein Spulenrohr 11, an dessen Enden radial nach außen anschließende, flanschartige Endwandabschnitte 12,13 angebracht, hier im ersten Ausführungsbeispiel, angeformt sind. Auf das Spulenrohr 11 zwischen den Endwandabschnitten 12,13 wird eine erste Isolierschicht 14 aufgebracht, vorzugsweise aufgewickelt. Diese Isolierschicht 14 kann, wie alle anderen Isolierschichten (s. unten), ein Fasergewebe enthalten, das mit aushärtbarem Kunststoff getränkt ist. Die Isolierschicht 14 erstreckt sich bis hin zu den Endwandabschnitten 12,13. Auf diese Isolierschicht wird eine erste Wicklungslage 15 aufgewickelt, die in der Fig. 1 (ebenso wie in der Fig. 2) als Linie gezeichnet ist. Wie aus der Fig. 4 hervorgeht, kann ein rechteckiger Wicklungsdraht verwendet werden. Anstatt eines Wicklungsdrahtes mit Rechteckform könnte auch einer mit einem kreisrunden Querschnitt eingesetzt werden. Die Querschnittsform ist insoweit für die Erfindung nicht von Bedeutung. Die Wicklungsdrahtlage 15 endet in einem bestimmten Abstand D von den Endwandabschnitten 12,13.A bobbin 10, which is produced by the process according to the invention, surrounds a coil tube 11, at the ends of which radially adjoining flange-like end wall sections 12, 13, here in the first exemplary embodiment, are integrally formed. On the coil tube 11 between the end wall portions 12,13 a first insulating layer 14 is applied, preferably wound. This insulating layer 14, like all other insulating layers (see below), may contain a fibrous web impregnated with thermosetting plastic. The insulating layer 14 extends to the end wall portions 12,13. On this insulating layer, a first winding layer 15 is wound, which in the Fig. 1 (as well as in the Fig. 2 ) is drawn as a line. Like from the Fig. 4 As can be seen, a rectangular winding wire can be used. Instead of a winding wire with a rectangular shape could also be used with a circular cross-section. The cross-sectional shape is so far for the invention is not important. The winding wire layer 15 terminates at a certain distance D from the end wall portions 12,13.

Auf die erste Wicklungs- oder -drahtlage 15 wird eine zweite Isolierschicht 16 aufgebracht, d.h. aufgewickelt, und zwar wieder bis hin an die Endwandabschnitte 12,13. Auf diese zweite Isolierschicht 16 werden zwei Wicklungslagenabschnitte 17,18 aufgewickelt, deren entgegengesetzten Enden in der Radialebene liegen, in denen die Enden der ersten Wicklungslage 15 liegen und deren sich gegenüberliegende Enden 19,20 in einem Abstand D1 voneinander angeordnet sind. Wie aus der Fig. 4 ersichtlich ist, werden die Wicklungslagen 15,17 und 18 mit radial verlaufenden Verbindungselementen 21, 22 miteinander verbunden, wobei diese Verbindungselemente 21,22 in den Ebenen liegen, in denen die Enden der ersten Wicklungslage 15 liegen.On the first winding or wire layer 15, a second insulating layer 16 is applied, that is wound, again up to the end wall sections 12,13. On this second insulating layer 16, two winding layer sections 17,18 are wound, the opposite ends lie in the radial plane in which the ends of the first winding layer 15 lie and their opposite ends 19,20 are arranged at a distance D1 from each other. Like from the Fig. 4 it can be seen, the winding layers 15,17 and 18 are connected to each other with radially extending connecting elements 21, 22, wherein these connecting elements 21,22 lie in the planes in which the ends of the first winding layer 15 lie.

Auf die zweiten Wicklungsabschnitte 17,18 wird eine dritte Isolierschicht 23 aufgewickelt, hierauf zwei dritte Wicklungsabschnitte 24,25, deren Längen denen der zweiten Wicklungsabschnitte 17,18 gleichen und die mit diesen an ihren sich gegenüberliegenden Enden mittels radialer Verbindungsglieder ähnlich denen mit den Bezugsziffern 21,22 verbunden werden, danach eine vierte Isolierschicht (ohne Bezugsziffer) und darauf zwei vierte Wicklungsabschnitte 26,27, eine weitere Isolierschicht und darauf zwei fünfte Wicklungsabschnitte 26,27, und darauf die äußere Isolierschicht. Die dritten Wicklungsabschnitte 24,25 werden mit den vierten Wicklungsabschnitten 26,27 mit Verbindungselementen in der radialen Ebene der Enden der ersten Wicklungslage 15 und die vierten mit den fünften Wicklungsabschnitten an den sich aufeinander zu weisenden Enden verbunden, wobei die Länge der vierten und fünften Wicklungsabschnitte geringer ist als die Länge der zweiten und dritten Wicklungsabschnitte 17,24; 18,25.On the second winding sections 17,18 a third insulating layer 23 is wound, thereon two third winding sections 24,25 whose lengths are similar to those of the second winding sections 17,18 and with these at their opposite ends by means of radial links similar to those with the reference numerals 21st 22, thereafter a fourth insulating layer (not numbered) and thereon two fourth winding sections 26, 27, another insulating layer and thereon two fifth winding sections 26, 27, and thereon the outer insulating layer. The third winding sections 24, 25 are connected to the fourth winding sections 26, 27 with connecting elements in the radial plane of the ends of the first winding layer 15 and the fourth to the fifth winding sections at the mutually facing ends, the length of the fourth and fifth winding sections is less than the length of the second and third winding sections 17,24; 18.25.

Innerhalb des Spulenrohres 11 befinden sich mehrere am Umfang gleichmäßig verteilt angeordnete Abstandshalter 30. Innerhalb der Abstandshalter 30 liegen Sekundärwicklungen 31, die hier nur schematisch angedeutet sind. Der Raum zwischen den Anstandshaltern 30, die radial ausgerichtet sind und sich über die gesamte Länge des Spulenrohres 11 erstrecken, wird von einem Kühlfluid axial durchströmt. Die Zuordnung der sekundär Wicklungen 31 sowie der Abstandshalter zu dem Spulerohr 11 sind für die Erfindung nicht von Bedeutung.Within the coil tube 11 are a plurality of circumferentially uniformly spaced spacer 30. Within the spacer 30 are secondary windings 31, which are indicated here only schematically. The space between the Anstandshaltern 30, which are radially aligned and extend over the entire length of the coil tube 11, is flowed through axially by a cooling fluid. The assignment of the secondary windings 31 and the spacers to the Spulerohr 11 are not relevant to the invention.

Bei der zweiten Ausgestaltung sind die Endwandabschnitte durch Winkelstücke gebildet, die in der Fig. 3 perspektivisch dargestellt sind. An einem Ende eines dem Spulenrohr 11 angepassten Bogenstückes 35 sind Schlitze 36,37 eingebracht. Die zwischen den peripheren Enden 38,39 und den Schlitzen 36,37 sich bildenden Lappen 40,41 und 42 werden radial nach außen aufgebogen, so dass die Schlitze 36,37 V-förmig werden. Das Bogenstück 35 bildet den Schenkel 43 des Winkelstückes, das in der Fig. 4 insgesamt die Bezugsziffer 44 erhalten hat. Der axial verlaufende Schenkel 43, wird mit der ersten Isolierschichtlage 16 in den Spulenkörper eingewickelt. Für den gesamten Spulenkörper benötigt man so viele Winkelstücke (die in der Fig. 3 dargestellt sind), dass die Winkelstücke nach Fig. 3 den gesamten Umfang des Spulenrohres überdecken. Nach dem Aushärten des isolierenden Materials können die Winkelstücke herausgenommen werden. Die sich dabei ergebenden Öffnungen können frei bleiben oder mit Isoliermaterial verschlossen werden.In the second embodiment, the end wall portions are formed by angle pieces, which in the Fig. 3 are shown in perspective. At one end of the coil tube 11 adapted elbow 35 slots 36,37 are introduced. The tabs 40, 41 and 42 formed between the peripheral ends 38, 39 and the slots 36, 37 are bent radially outward so that the slots 36, 37 become V-shaped. The elbow 35 forms the leg 43 of the elbow, which in the Fig. 4 a total of the reference number 44 has received. The axially extending leg 43 is wrapped with the first insulating layer 16 in the bobbin. For the entire bobbin one needs so many contra angles (which in the Fig. 3 are shown) that the elbows after Fig. 3 cover the entire circumference of the coil tube. After curing of the insulating material, the elbows can be removed. Which thereby resulting openings can remain free or sealed with insulating material.

In der Ausführung nach der Fig. 2 sind Winkelstücke vorgesehen, deren radial ausgerichtete Schenkel die gesamten Stirnflächen des Spulenkörpers überdecken. Es besteht selbstverständlich auch die Möglichkeit, an den Stirnflächen oder -enden des Spulenkörpers mehrere Winkelstücke radial übereinander zu setzen, wobei die Bogenstücke 35 dem weiter außen liegenden Radius z.B. im Bereich der dritten Wicklungsabschnitte angepasst sind. Die Lappen besitzen eine radiale Länge, die der Einbaustelle am Spulenkörper angepasst ist, wobei die Lappen aller Winkelstücke in je einer radialen Eben liegen, die hier den Stirnebenen des Spulenkörpers entsprechen. Die Schenkel 43 der äußeren Winkelstücke werden dann von den entsprechenden Isolierschichten umhüllt.In the execution after the Fig. 2 Angle pieces are provided, cover the radially oriented legs of the entire end faces of the bobbin. Of course, it is also possible to place a plurality of angle pieces radially one above the other at the end faces or ends of the bobbin, wherein the arcuate pieces 35 are adapted to the outer radius, for example in the region of the third winding sections. The lobes have a radial length which is adapted to the installation point on the bobbin, wherein the lobes of all the angle pieces are each in a radial plane, which here correspond to the Stirnebenen the bobbin. The legs 43 of the outer angle pieces are then enveloped by the corresponding insulating layers.

Zur Vervollständigung eines Transformators sind gestrichelt dargestellt Kerne 50 vorgesehen, die mit einem Schenkel 51 in den Bereich innerhalb der Sekundärwicklung 31 eingreifen. Dies hat aber mit der hier beschriebenen Erfindung nichts zu tun, sondern dient lediglich dem besseren Verständnis.To complete a transformer cores 50 are shown in dashed lines, which engage with a leg 51 in the region within the secondary winding 31. However, this has nothing to do with the invention described here, but merely serves for better understanding.

Bezugszeichenliste:LIST OF REFERENCE NUMBERS

1010
Spulenkörperbobbins
1111
Spulenrohrcoil tube
12, 1312, 13
Endwandabschnitteend wall
1414
erste Isolierschichtfirst insulating layer
1515
erste Wicklungsdrahtlagefirst winding wire layer
1616
zweite Isolierschichtsecond insulating layer
17,1817.18
WicklungslagenabschnitteWinding layer sections
19, 2019, 20
gegenüberliegende Endenopposite ends
21, 2221, 22
Verbindungselementefasteners
2323
dritte Isolierschichtthird insulating layer
24, 2524, 25
dritte Wicklungsabschnittethird winding sections
26, 2726, 27
vierte Wicklungslagenabschnittefourth winding layer sections
3030
Abstandhalterspacer
3131
Sekundärwicklungsecondary winding
3535
Bogenstückelbow
36, 3736, 37
Schlitzeslots
38, 3938, 39
periphere Endenperipheral ends
40, 41, 4240, 41, 42
sich bildende Lappenforming lobes
4343
Schenkel des WinkelstücksThighs of the elbow
4444
Winkelstückelbow
5050
Kerncore
5151
Schenkel des KernsThighs of the core

Claims (9)

  1. Method for winding a coil for a transformer, with the coil winding being introduced into a cylindrical, tubular insulating body,
    characterized by the following steps:
    - winding an inner first insulating layer onto a cylindrical inner tube (11) of insulating material, at the ends of which radially outwardly projecting end wall sections (12, 13) are provided, with the inner insulating layer (14) being wound as far as the end wall sections (12, 13), winding on a first winding wire layer (15) in such a way that the end windings thereof lie at a distance from the end wall sections (12, 13),
    - winding a further insulating layer (16) onto the first winding wire layer (15) as far as the end wall sections (12, 13),
    - winding on a second winding wire layer, which has one or more winding layer sections (17, 18), the opposite end windings of the second winding wire layer lying in the radial plane in which the end windings of the first winding wire layer (15) are located,
    - connecting the adjacent end windings by means of radially extending connecting elements (21, 22),
    - winding on a third insulating layer (23) as far as the end wall sections (12, 13),
    - winding on a third winding wire layer, which has one or more winding layer sections (24, 25) and the end windings of which lie in the radial plane of the end windings of the second winding wire layer,
    - connecting the free end windings of the second to the third winding wire layers by means of a radially extending connecting element (21, 22),
    - winding on a fourth insulating layer as far as the end wall sections (12, 13),
    - and so on.
  2. Method according to Claim 1, characterized in that the end wall sections (12, 13) are removed after curing of the insulating material.
  3. Method according to Claim 2, characterized in that the openings formed by the removal of the end wall sections (12, 13) are closed with insulating material.
  4. Coil for a transformer produced by the method according to one or more of the preceding claims, characterized in that in the coil former (10) wire winding sections are provided, the winding ends of which that are connected to one another each lying in a radial plane, so that all the winding sections lie between two radial planes in which at the same time the winding ends belonging to one another and connected to one another also lie, and in that radially extending connecting pieces (21, 22) are provided.
  5. Coil according to Claim 4, characterized in that the end wall sections (12, 13) are connected to an insulating tube surrounded by the coil former (10).
  6. Coil according to Claim 4, characterized in that, for the formation of the end wall sections (12, 13), L-shaped angle elements are provided, the legs of which extend perpendicularly to one another, and in that one of the legs is securely held parallel to the winding sections by the insulating layers, whereas the other leg serves for the formation of the end wall sections.
  7. Coil according to Claim 6, characterized in that angle elements are embedded for each insulating layer (14, 16, 23), so that dedicated end wall sections (12, 13) are provided for at least one insulating layer.
  8. Coil according to one of Claims 4 to 7, characterized in that arcuate angle elements (35) are provided for the formation of the end wall sections (12, 13), one of the legs forming an arcuate shape and the other legs being bent out perpendicularly thereto as lugs (40, 41, 42).
  9. Coil according to Claim 8, characterized in that a piece of bent tubing is provided for the formation of the lugs (40, 41, 42), at the one end of which tubing axial slits (36, 37) are provided, and in that the lugs (40, 41, 42) located between the slits (36, 37) are bent out perpendicularly.
EP07856455.6A 2006-12-19 2007-12-07 Method for producing a transformer coil, and a transformer coil produced using this method Not-in-force EP2102876B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL07856455T PL2102876T3 (en) 2006-12-19 2007-12-07 Method for producing a transformer coil, and a transformer coil produced using this method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102006060567A DE102006060567A1 (en) 2006-12-19 2006-12-19 Method for producing a transformer coil and a transformer coil produced by this method
PCT/EP2007/010650 WO2008074409A1 (en) 2006-12-19 2007-12-07 Method for producing a transformer coil, and a transformer coil produced using this method

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EP2102876A1 EP2102876A1 (en) 2009-09-23
EP2102876B1 true EP2102876B1 (en) 2013-04-17

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EP (1) EP2102876B1 (en)
KR (1) KR101398029B1 (en)
CN (1) CN101689422B (en)
BR (1) BRPI0720381A2 (en)
DE (1) DE102006060567A1 (en)
EG (1) EG25706A (en)
ES (1) ES2406069T3 (en)
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WO (1) WO2008074409A1 (en)

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Publication number Priority date Publication date Assignee Title
EP2474986A1 (en) * 2011-01-05 2012-07-11 ABB Technology AG Transformer coil
CN103247435A (en) * 2012-02-13 2013-08-14 新华都特种电气股份有限公司 Wound coil structure and processing method
CN112117125B (en) * 2020-08-27 2022-04-08 江门市蓬江区恒驰新材料有限公司 Automatic change coil and twine sticky tape equipment
CN112331467B (en) * 2020-11-23 2022-08-16 广东电网有限责任公司广州供电局 Method and device for reactor seismic design

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4518941A (en) * 1983-11-16 1985-05-21 Nihon Kohden Corporation Pulse transformer for switching power supplies
US5374810A (en) * 1992-06-05 1994-12-20 Gantt; Jackie L. Induction heating transformer and method of winding same
US5404123A (en) * 1993-03-01 1995-04-04 At&T Corp. Modular transformer structure providing enhanced leakage inductance and winding isolation
US5861791A (en) 1995-06-21 1999-01-19 Brunswick Corporation Ignition coil with non-filtering/non-segregating secondary winding separators
JPH1032127A (en) 1996-07-15 1998-02-03 Yamaha Corp Transformer and its assembling method
US6404316B1 (en) * 2000-05-09 2002-06-11 Lucent Technologies Inc. Magnetic device and method of manufacture therefor
US6549431B2 (en) * 2001-03-08 2003-04-15 Power Integrations, Inc. Method and apparatus for substantially reducing electrical earth displacement current flow generated by wound components
JP3578163B2 (en) 2002-05-31 2004-10-20 ソニー株式会社 Step-up transformer
US20040003492A1 (en) 2002-07-02 2004-01-08 Chi-Chih Wu Method for winding transformers
US7830233B2 (en) 2004-12-27 2010-11-09 Abb Technology Ag Electrical induction device for high-voltage applications

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PL2102876T3 (en) 2013-08-30
WO2008074409A1 (en) 2008-06-26
ES2406069T3 (en) 2013-06-05
KR20090101180A (en) 2009-09-24
US7847665B2 (en) 2010-12-07
BRPI0720381A2 (en) 2013-12-31
US20090309685A1 (en) 2009-12-17
CN101689422B (en) 2012-06-20
KR101398029B1 (en) 2014-05-27
CN101689422A (en) 2010-03-31
EG25706A (en) 2012-05-27
DE102006060567A1 (en) 2008-06-26
EP2102876A1 (en) 2009-09-23

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