EP3365902B1 - Winding arrangement - Google Patents

Description

The invention relates to a winding arrangement with a number of axially spaced apart and electrically connected to one another forming a series circuit, each having a conductor that is wound from an inner end to an outer end of the respective winding portion and thereby the winding portion enlarged in the radial direction, at least one winding section being electrically connected at its outer end to the inner end of the winding section following in the axial direction.

The invention also relates to a transformer and a coil or choke with such a winding arrangement.

The above-mentioned winding arrangement is for example from EP 2 251 877 B1 known. The winding arrangement shown there consists of a series connection of so-called disc windings, which are arranged at a distance from one another. The outer end of each disc winding is connected to the inner end of the disc winding arranged adjacent in the axial direction. In this way, during the production of the overall winding, the conductor can always be wound onto a shaping winding from the inside to the outside for each disc winding. This simplifies the manufacture of the winding arrangement with a consequent cost saving. However, it is disadvantageous that the intermediate section of the conductor, which extends between the disk windings, not only has to bridge the axial distance between the adjacent disk windings but also the radial expansion of the winding. The adjacent disc windings must therefore be arranged at a large distance from one another in order to create space for said intermediate section.

In addition, so-called lintel windings are known from practice. In the case of camber windings, the outer end of a disc winding is connected to the outer end of the disc winding following in the axial direction, but this is wound from the outside inwards. However, changing the winding direction during manufacture is complex and leads to additional costs.

From the EP 0 605 412 A1 a winding arrangement is known in the manufacture of which a pre-assembled conductor is used. The conductor used consists of conductor pieces which are arranged in pairs and have free conductor ends. The pre-assembled conductor is formed into a winding arrangement with the help of a lintel winding.

The EP 2 052 393 A2 shows a winding arrangement consisting of disc windings arranged in different winding layers. The winding layers are spaced apart from one another in the radial direction by cooling channels. Within the winding layers, the disc windings form what is known as a lintel winding, a first disc winding being wound from the inside outwards and the disc winding following in the axial direction from the outside inwards.

Further winding arrangements are from EP 2 747 096 A1 as well as from the US 2015/145631 A1 known.

The object of the invention is to provide a winding arrangement of the type mentioned at the beginning, which can be produced cost-effectively and whose winding sections are arranged at a comparatively small distance from one another.

The invention solves this problem in that at least one subsequent winding section in the axial direction forms a step area in which its inner end in the radial direction is level with the outer end of the winding section is arranged, with which this is electrically connected.

According to the invention, a winding arrangement is provided in which the connection of the one winding section to the respectively adjacent winding section is achieved by simply crimping the conductor without the conductor having to be guided over long distances between adjacent winding sections. All winding sections have the same winding direction. The winding direction does not change within the scope of the invention. The entire winding arrangement preferably consists of a single wound conductor. This continuous conductor is wound in such a way that winding sections are formed which are arranged one after the other in the axial direction. The spiral winding of the conductor at certain intervals creates winding sections. In the winding sections, the conductor tracks isolated from one another lie against one another and, with increasing number of turns, enlarge the winding section in a direction which is referred to here as the radial direction. By wrapping are extensive

formed closed winding sections which delimit a section interior. The section interiors of the winding sections are at least partially aligned in the axial direction, so that the stack of winding sections defines an inner contour, which is referred to below as the winding interior.

In order to make the conductor or conductor section connecting the winding sections as short and compact as possible, with the exception of the first winding section of the series connection, each winding section forms an eccentric step area in which its inner winding layer is at a greater distance from an imaginary central axis of the winding interior than outside the step area. This greater distance than the other sections corresponds to the distance between the inner and the outer end of the adjacent winding section, in other words corresponds to the thickness of the winding. The outer conductor therefore only has to be guided laterally, that is to say in the axial direction, from the outer winding layer of the respective winding section to the inner winding layer of the adjacent winding section. The conductor cranked in this way in said step area then serves as the inner winding layer of said adjacent winding section. By raising the inner winding layer to the level of the outer winding layer in the step area, the conductor section or the conductor between the winding sections can be made short, so that the distance between the winding sections can also be reduced.

With the exception of the first winding section of the series connection, each winding section advantageously forms a step area. According to this variant of the invention, the first winding section forms the so-called beginning of the winding arrangement, via which the winding arrangement is connected, for example, to the phase connection of a transformer or a choke. However, the outer end of the first winding section is then in the step area with the inner one Connected to the end of the subsequent winding section in the axial direction, so that this is then the first winding section which has a step area. This applies accordingly to the winding sections that follow in the axial direction.

According to a preferred embodiment of the invention, each winding section is a disk winding configured in the form of a disk. In the case of a disc winding, the individual winding layers are wound exactly one above the other, so that they extend in the form of a disc, as it were, in a common layer or "plane". According to this advantageous further development, the winding arrangement is made even more compact.

Each disc winding is advantageously designed to be circumferentially closed and delimits a section interior. The section interiors of the disc windings overlap in the stack that results from the stringing together of the disc windings in the axial direction, so that space is provided for a leg of a transformer or reactor core.

In a variant of this, each disc winding forms a circular ring section outside the step area. This makes it possible to use a circular cylindrical shaped body in the production of the winding arrangement according to the invention, on which the winding sections can be wound. This reduces the manufacturing cost.

According to a preferred embodiment of the invention, the disc windings arranged next to one another in the axial direction delimit a circular cylindrical interior which has a central axis, the first winding layer of each disc windings being at a greater distance from the central axis in the step area than in the ring area. The circular cylindrical interior of a winding allows the inclusion of the usual Leg of a yoke, so that it does not have to be laboriously adjusted.

The center of the step area of each disc winding expediently spans an angle α with the center of the step area of the directly adjacent disc winding with respect to the center axis. This rotation of the step areas around the center axis is necessary in order to bring the outer winding layer of the disc windings to the radial level or the radial height of the first winding layer of the respective subsequent disc winding.

According to a further development in this regard, each disc winding is arranged in alignment with the next but one disc winding. According to this variant, the entire winding arrangement forms eccentric bulges only at two points. This also simplifies the adjustment of the winding arrangement and its subsequent handling.

The angle α is advantageously 180 degrees. According to this variant, the bulges lie opposite one another on different sides of the winding arrangement. Deviating from this, the angle α is in the range from 10 to 30 degrees. According to this variant of the invention, both bulges are arranged on the same side of the winding arrangement, for example at the front. In this way, it is possible to limit a conductor space that is used to accommodate inlet and outlet lines.

In principle, any type of conductor can be used within the scope of the invention. For example, the conductor is a drawn wire conductor or a flat foil conductor.

The conductor is advantageously a strip conductor configured in the form of a strip. Copper or preferably aluminum, for example, come into consideration as the strip conductor material, the conductor or, here, the strip-shaped strip conductor being surrounded at least in sections by an insulating layer. In the The insulating layer can be, for example, an insulating lacquer layer or an insulating film. During winding, the insulating film is placed between successive winding layers.

According to an expedient embodiment in this regard, the strip conductor is bent over twice in the step area. As a result of the double bending over, the strip conductor can be guided particularly easily in the axial direction from the one winding section in each case to the subsequent winding section.

The winding arrangement is advantageously part of a transformer or a coil or choke.

Figur 1

eine Wicklungsanordnung gemäß dem Stand der Technik,

Figur 2

ein Ausführungsbeispiel der erfindungsgemäßen Wicklungsanordnung,

Figur 3

eine perspektivische Ansicht eines Ausführungsbeispiels der erfindungsgemäßen Wicklungsanordnung,

Figur 4

die Wicklungsanordnung gemäß Figur 3 beim Herstellungsprozess,

Figur 5

ein weiteres Ausführungsbeispiel einer erfindungsgemäßen Wicklungsanordnung in einer Teilansicht,

Figur 6

die Wicklungsanordnung gemäß Figur 5 während des Herstellungsprozesses,

Figur 7

die Wicklungsanordnung gemäß Figur 3 in einer schematischen Draufsicht und

Figur 8

ein weiteres Ausführungsbeispiel einer erfindungsgemäßen Wicklungsanordnung in schematischer Darstellung zeigen.

Further useful refinements and advantages of the invention are the subject matter of the following description of exemplary embodiments of the invention with reference to the figures of the drawing, the same reference symbols referring to components that have the same effect and where

Figure 1

a winding arrangement according to the prior art,

Figure 2

an embodiment of the winding arrangement according to the invention,

Figure 3

a perspective view of an embodiment of the winding arrangement according to the invention,

Figure 4

the winding arrangement according to Figure 3 in the manufacturing process,

Figure 5

a further embodiment of a winding arrangement according to the invention in a partial view,

Figure 6

the winding arrangement according to Figure 5 during the manufacturing process,

Figure 7

the winding arrangement according to Figure 3 in a schematic plan view and

Figure 8

show a further embodiment of a winding arrangement according to the invention in a schematic representation.

Figure 1 shows a winding arrangement 1 according to the prior art. The winding arrangement 1 shows a winding of a conductor 2 which is electrically insulated from the next layer, for example by interposing an insulating film or by an insulating varnish. Said conductor 2 is wound so that the layers of the conductor 2 lie one above the other in a spiral shape. These conductor tracks lying spirally one above the other are referred to here as winding layers. The first winding layer therefore delimits an interior of the winding, which is referred to here as the section interior 11. The winding layers lying on top of each other lie on top of each other in a layer. In other words, the winding layers form disc-shaped disc windings 3a, 3b, 3c ... 3n as a winding section. The winding sections are arranged one behind the other in the axial direction 4. The disc windings 3a, 3b, 3c ... 3n are all arranged at a distance D from one another, wherein the distance D can be different. The distance between the disc windings 3a and 3b is, for example, smaller than the distance between the disc windings 3b and 3c. Each of said disc windings 3a, 3b, 3c ... 3n has an inner end 5a, 5b, 5c or 5n and an outer end 6a, 6b, 6c or 6n. Furthermore, each disc winding 3a, 3b, 3c ... 3n is wound from the inside out, as indicated for each disc winding 3a, 3b, 3c ... 3n by an arrow 12 in the radial direction. Said winding direction is also indicated by an arcuate arrow 7. It can be seen that all disc windings 3a, 3b, 3c ... 3n have the same winding direction 7. For the electrical connection, for example, of the disc winding 3a with the disc winding 3b, the outer end 6a of the disc winding 3a is connected to the inner end 5b of the disc winding 3b. In order to create space for the conductor section 2 extending between the disc windings 3a and 3b, these must be arranged at a distance D from one another. This applies accordingly to all other disc windings 3b, 3c and 3n.

Figure 2 shows an exemplary embodiment of the winding arrangement 8 according to the invention, which forms an electrical series connection of winding sections, here disk windings 3a, 3b, 3c ... 3n, corresponding to the winding arrangement 1 according to FIG. As in Figure 1 all disc windings 3a, 3b, 3c ... 3n have the same winding direction 7, i.e. are from the inner end 5a, 5b, 5c ... 5n to the respective outer end 6a, 6b, 6c ... 6n of each disc winding 3a , 3b, 3c ... 3n wound. As in Figure 1 the outer end 6a, 6b, 6c ... 6n-1 of the disc windings 3a, 3b, 3c ... 3n-1 is connected to the inner end of a further disc winding 3b, 3c, 3d which follows directly or immediately in the axial direction, with the exception of the last partial winding 3n of the series connection. In the exemplary embodiment shown, this is connected with its outer end 6n to a high-voltage connection, not shown in the figures, of the said transformer. The inner end 5a of the first disc winding 3a is connected to a further high-voltage connection of the said transformer.

As in Figure 2 is shown schematically, the disc winding 3b is raised so far with respect to the disc winding 3a in the radial direction 9 in the area of the connection from 6a to 5b that its inner end 5b is at the same "radial" height as the outer end 6a of the disc winding 3a . The conductor 2 therefore only has to be bent or cranked out of the "layer" of the disc winding 3a in the axial direction 4 in order to form the layer of the adjacent disc winding 3b to be transferred. There this forms the first winding layer. The further winding layers can be wound in the same direction by simply winding them further. A long conductor connection between the winding sections 3a, 3b, 3c ... 3n as in Figure 1 is therefore avoided within the scope of the invention. At the same time, in contrast to the so-called overturned winding, the winding direction 7 is the same for all disc windings 3a, 3b, 3c ... 3n. Thus, the disc windings 3a, 3b, 3c ... 3n can be arranged with a small distance D from one another, the manufacture of the winding arrangement 8 remaining inexpensive.

Figure 3 shows the winding arrangement 8 according to FIG Figure 2 in a perspective view. It can be seen that the disc windings 3a, 3b, 3c are arranged one behind the other in the axial direction 4 at a small distance from one another. In the in Figure 3 In the illustration shown, the disc winding 3a faces the viewer. It can be seen that each disc winding 3a, 3b, 3c ... 3n is designed to be circumferentially closed and a section interior 13 is thus delimited. The entire stack of disc windings 3a, 3b, 3c... 3n, that is to say the winding arrangement 8, delimits an inner cavity, which is referred to here as the interior space. The interior space 14 contains, as it were, the section interior spaces 13 that are aligned with one another.

The interior 14 is used to accommodate a magnetizable material which is set up to guide a magnetic field with low magnetic resistance. The individual disc windings 3a, 3b, 3c ... 3n are not circular in a plan view and therefore do not individually delimit a circular section interior 13. Rather, each disc winding 3a, 3b, 3c ... 3n has an eccentric step area 10a, 10b, 10c. ..10n, which has a greater distance from an imaginary central axis of the circular cylindrical interior 14 of the winding arrangement 8 than the remaining section of each disc winding 3a, 3b, 3c ... 3n, which follows a circular shape in a plan view. It can also be seen that the step area 10a is not arranged in alignment with the step area 10b of the disc winding 3b, which immediately follows the first disc winding 3a in the axial direction. Rather, the step area 10b is circumferentially offset with respect to the step area 10a, so that the two center points of the step areas 10a and 10b split an angle α with one another with respect to the imaginary center axis of the interior 14 of the winding arrangement 8. It can also be seen that the step area 10c of the next but one disc winding 3c is arranged in alignment with the step area 10a of the first disc winding 3a. This applies accordingly to the level ranges 10b and 10d. Each disc winding 3a, 3b, 3c ... 3n is therefore arranged with its step area 10a, 10b, 10c ... 10n in alignment with the next but one disc winding 3a, 3b, 3c ... 3n, the step areas 10a, 10b, 10c. ..10n of disc windings 3a, 3b, 3c ... 3n, which follow one another directly, are twisted against one another. Therefore, a total of two eccentric bulges 15, 16 can be seen in the winding arrangement 8, which are formed by the step areas 10a, 10c, 10e ... 10n-1 or the step areas 10b, 10d, 10f ... 10n. If the disc windings 3a, 3b, 3c ... 3n are numbered with whole numbers beginning with 1, one bulge 15 is separated from the disc windings 3a, 3c, 3e ... 3n-1 with an even number and the other bulge 16 from the disc windings 3b , 3d, 3f ... 3n formed with odd numbers.

In Figure 3 It can also be seen that the conductor 2 in the outer winding layer in the step region 10b is axially offset out of the plane of the disc winding 10a, that is, it is cranked and thus forms the inner end 5b of the second disc winding 3b. The inner end 5a is provided to terminate the discharge of a transformer, which is at high voltage during operation. The conductor 2 of the outer winding layer of the disc winding 3b, on the other hand, is cranked axially in the step area 10c in the direction of the disc winding 3c so that it is the inner end of the disc winding there 3c trains. However, this is in the Figure 3 covered by the disc winding 3a.

Figure 4 shows in a perspective representation during the manufacturing process how the conductor 2 of the disc winding 3b is cranked in the step area 10b of the subsequent disc winding 3c that is still to be wound. The step area 3a of the first disc winding can also be seen, with which this is connected to the transformer housing on the side facing away from the viewer.

Figure 5 shows in a partial view a further embodiment of the winding arrangement according to the invention in a perspective illustration. The strip conductor 2 wound to form the disk windings 3a, 3b, 3c ... 3n is in comparison to FIG Figure 3 The strip conductor 2 shown is made somewhat wider and thinner, the strip conductor 2 made of aluminum being covered by an insulating film. In particular, the step areas 10a, 10b, 10c ... 10n can be seen, with the disc windings 3a, 3c, 3e or 3b, 3d, 3f lying opposite each other in alignment. The step areas 10a and 10b of adjacent disc windings 3a and 3b are twisted against each other and span an angle α with one another with respect to the center axis of the hollow cylindrical interior 14 of the winding arrangement 8, so that by crimping the strip conductor 2 in the axial direction, it becomes the layer of the disc winding following in the axial direction can be transferred.

Figure 6 shows the winding arrangement according to FIG Figure 5 in the manufacturing process. It can be seen here how the strip conductor 2 is bent over during manufacture. The one in the Figures 5 and 6th The illustrated conductor 2 is designed to be flexible so that it can be bent twice in the step area 10. At a first bending point 17, it is bent backwards against the winding direction 7. At a second bending point 18, the strip conductor 2 is bent over again so that it extends again in the desired winding direction 7. With this one When bent twice, the conductor 2 is offset in the axial direction so that it can form the first winding layer of the subsequent disc winding.

Figure 7 shows a further exemplary embodiment of the winding arrangement 8 according to the invention. In this view, it can be seen particularly well that the disk windings are arranged in alignment with one another. In the in Figure 7 it can be seen that the step regions 10n and 10n-1 of the disc windings 3n and 3n-1 with one another define an angle α with one another to the center of the circular cylindrical interior space 14. The circular cylindrical interior space 14 is indicated schematically by a dashed circular line. It can be seen that the interior space 14 is not configured completely in the shape of a circular cylinder. Rather, due to the angle α between 20 degrees here, an additional line routing space 19 is formed which can serve to accommodate conductors, cables, connections and the like if, for example, an underwinding and a leg of a core extend in the circular cylindrical interior.

Figure 8 shows a further embodiment of the winding arrangement 8 according to the invention, which differs from that in Figure 7 The exemplary embodiment shown differs in that the angle α that the step regions 10n and 10n-1 make with one another with respect to the center axis of the circular cylindrical interior space 14 is 180 °. It can be seen that in this embodiment the inner contour of the disc windings jointly delimit the circular cylindrical interior space, so that a more compact winding arrangement without additional space, as in FIG Figure 7 , for cable routing.

Claims (13)

1. Winding arrangement (8) comprising a number of winding sections (3a, 3b, 3c ... 3n) arranged at a distance from one another in the axial direction and electrically connected to one another so as to form a series circuit, which winding sections each have a conductor (2), which is wound from an inner end (5a, 5b, 5c ... 5n) to an outer end (6a, 6b, 6c ... 6n) of the respective winding section (3a, 3b, 3c ... 3n) and in the process enlarges the winding section (3a, 3b, 3c ... 3n) in the radial direction, wherein at least one winding section (3a, 3b, 3c ... 3n) is electrically connected at its outer end (6a, 6b, 6c ... 6n) to the inner end (5a, 5b, 5c ... 5n) of the winding section (3a, 3b, 3c ... 3n) that follows in the axial direction, characterized in that at least one winding section (3a, 3b, 3c ... 3n) that follows in the axial direction forms a stepped region (10a, 10b, 10c ... 10n), in which the inner end (5a, 5b, 5c ... 5n) of said winding section is arranged in the radial direction at the height of the outer end (6a, 6b, 6c ... 6n) of the winding section (3a, 3b, 3c ... 3n), to which outer end said winding section is electrically connected.
2. Winding arrangement (8) according to Claim 1, characterized in that, with the exception of the first winding section (3a) of the series circuit, each winding section (3a, 3b, 3c ... 3n) forms a stepped region (10a, 10b, 10c ... 10n).
3. Winding arrangement (8) according to Claim 2, characterized in that each winding section is a disk winding (3a, 3b, 3c ... 3n) designed in a disk-shaped manner.
4. Winding arrangement (8) according to Claim 3, characterized in that each disk winding (3a, 3b, 3c ... 3n) is formed in a circumferentially closed manner and delimits a section interior (13).
5. Winding arrangement (8) according to Claim 4, characterized in that each disk winding (3a, 3b, 3c ... 3n) forms a circular annular section outside of the stepped region (10a ... 10n).
6. Winding arrangement (8) according to Claim 5, characterized in that the disk windings (3a, 3b, 3c ... 3n) stacked in the axial direction delimit a circular-cylindrical interior (14), which has a central axis, wherein the first winding layer of each disk winding (3a, 3b, 3c ... 3n) is at a greater distance from the central axis in the stepped region (10a, 10b, 10c ... 10n) than in the annular section.
7. Winding arrangement (8) according to Claim 6, characterized in that the center of the stepped region (10a, 10b, 10c ... 10n) of each disk winding (3a, 3b, 3c ... 3n) and the center of the stepped region (10a, 10b, 10c ... 10n) of the directly adjacent disk winding (3a, 3b, 3c ... 3n) span an angle α with one another with respect to the central axis.
8. Winding arrangement (8) according to Claim 7, characterized in that each disk winding (3a, 3b, 3c ... 3n) is arranged in alignment with the respective next but one disk winding (3a, 3b, 3c ... 3n).
9. Winding arrangement (8) according to Claim 8, characterized in that the angle α is between 10 degrees and 30 degrees or is 180 degrees.
10. Winding arrangement (8) according to one of the preceding claims, characterized in that the conductor is a strip conductor (2) formed in a strip shape.
11. Winding arrangement (8) according to Claim 10, characterized in that the strip conductor (2) is bent over twice in each stepped region (10a, 10b, 10c ... 10n).
12. Transformer comprising a winding arrangement (8) according to one of the preceding claims.
13. Coil comprising a winding arrangement (8) according to one of Claims 1 to 3.

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