MXPA01001735A - Transformer coil support structure - Google Patents

Abstract

The present invention relates to a winding structure for a transformer. The winding structure has a first support having a central axis, and a second support also having a central axis. The second support is positioned having its central axis generally in-line with the central axis of the first support. The winding structure also has a winding which is wrapped around at least a portion of the first and second supports. The supports are provided for at least supporting the winding. The present invention also relates to a method of making a transformer comprising the steps of providing a mounting apparatus, and mounting a first support having a central on the mounting apparatus. The method also includes mounting a second support having a central axis on the mounting apparatus, wherein the second support is mounted on the mounting apparatus with its central axis mounted generally in-line with the central axis of the first support. In addition, the method includes winding a conductor around at least a portion of the first and second supports to form a winding.

Description

SUPPORT STRUCTURE FOR TRANSFORMER COIL Description * Technical Field The present invention relates generally to transformers and winding structures of transformers. More particularly, the present invention relates to a support arrangement used within the winding structures of transformers during and after transformer manufacturing to, at least, maintain the integrity of the windings and winding structures during and after the manufacturing process. BACKGROUND OF THE INVENTION In the past, transformer winding structures have included a coil or rigid winding base, or support, which provides significant stiffness to the spool or winding during the manufacturing process. Without any support, the conductor winding can cause the overall winding structure to collapse towards the inner portion or hollow core region (leg) of the transformer winding structure. The support helps to maintain the integrity of the windings during and after the manufacturing process, facilitates the assembly of the transformers and winding (s), and provides additional resistance to short circuits during fault conditions in view of the support and additional resistance of the transformer windings. In the past, the rigid support base has been an elongated, simple tube-like structure that extended from the upper interior portion of the transformer winding structures to the lower portion of the interior portion of the structures transformer winding. These elongated supports are typically expensive. For example, using three elongated supports for a three-phase transformer (each of the three winding structures of a three-phase transformer (three-legged) would use an elongated support) can increase the cost of such a transformer by more than $ 1,000.00 US dollars. The present invention is provided to solve these and other problems. SUMMARY OF THE INVENTION The present invention relates to a winding structure for a transformer. The winding structure has a first support having a central axis, and a second support also having a central axis. The second support is placed having its central axis generally in line with the central axis of the first support. The winding structure has a winding that is wrapped around at least a portion of the first and second supports. The supports are provided to at least hold the winding.

The present invention also relates to a method of making a transformer, comprising the steps of providing a mounting apparatus, and mounting a first support having a central axis in the mounting apparatus. The method also includes mounting a second support having a central axis in the mounting apparatus, where the second support is mounted on the mounting apparatus with its central axis mounted generally in line with the central axis of the first support. In addition, the method includes winding a conductor around at least a portion of the first and second supports to form a winding. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of an emptied coil transformer (winding structure) of the present invention. Figure 2 is a perspective view of a dry type, coiled disc transformer, medium voltage, ventilated by openings, of the present invention. Figure 3 is a three-phase transformer of the present invention. Fig. 4 is an exploded perspective view of the transformer of Fig. 1. Fig. 5 is a cut-away perspective view of a winding structure of a high-voltage transformer (HV) version of the transformer of Fig. 4. Figure 6 is a perspective view cut away from a 8aa • MtUÉB.Mfí winding structure of a low voltage transformer (LV) version of the transformer of figure 4. Figure 7 is a top perspective view of a cylindrical winding structure without any support, of a transformer . Figure 8 is a top perspective view of a cylindrical winding structure with supports, of a transformer of the present invention. Figure 9 is a top perspective view of an oval winding structure without any support, of a transformer. Figure 10 is a top perspective view of an oval winding structure with supports, of a transformer of the present invention. Figure 11 is a cross-sectional diagram of an embodiment of a winding structure of a transformer of the present invention. Figure 12 is a cross-sectional diagram of another embodiment of a winding structure of a transformer of the present invention. Figure 13 is a side view of a mounting apparatus and supports for the manufacture of an embodiment of a winding structure of a transformer of the present invention. Figure 14 is a side view of a mounting apparatus and supports for the manufacture of another embodiment of a winding structure of a transformer of the present invention. Detailed Description Although this invention is susceptible of being embodied in many different forms, it is shown in the drawings and will be described in detail in the present preferred embodiments of the invention, with the understanding that the present disclosure should be considered as an exemplification of the principles of the invention and it is not intended to limit the broad aspects of the invention to the illustrated embodiments. With reference to figures 1, 4, 5 and 6, these figures show various views of an empty coil transformer 2. This transformer 2 has three winding structures 4, and each winding structure 4 has a primary winding (coil or conductor ) 6, and at least one secondary winding (coil or conductor) 8. The winding structures 4 can have an isolated wire length (winding conductor) formed in a plurality of adjacent turns that define a layer. As is well known, many layers of adjacent turns separated by insulation typically form the coils (winding). Other conductors may be used, such as a sheet or strip of metal for the windings 6, 8. As used herein, the term "conductor" may be defined as comprising a wire conductor, a metal-like conductor strip or strip, or such another conductor that can be used to create a winding for a transformer. In addition to conventional terminology, a winding structure may include common elements such as a winding, insulators, separators for the winding conductor, and other elements. With a particular approach to FIG. 4, an upper core staple 10 is provided to hold firmly in position the upper core assembly, including the upper coil yoke 12, and to increase the structural integrity. The upper core yoke 12 completes a core assembly and maintains the position of the cores within the coils. The upper core staple 10 includes lifting holes 14 to allow connection to a crane or other lifting devices and to move the overall transformer 2. Upper support blocks 16 are provided to axially support the coils of the winding structures 4. High voltage spike links 18 are also provided to dispose tips in the coils, above and below normal, as would be understood by a technician in the field. The low voltage (LV) terminals 20 are extended from the LV (indoor) coils 22 for connection to the LV bus bar. High voltage (HV) connections 26 are provided to connect the three phases of the primary transformer 2, and can be made from cables ^^ ¡^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^ isolated by plastic tubes. Lower support blocks 28 are also provided to axially support the coils 24, 26 of the winding structures 4 and maintain the spacing between the coils LV and HV 24, 26, as shown in a molded epoxy design. A lower core staple 30 is also provided to firmly hold the lower core assembly in place and to increase structural integrity. Mounting feet 32 are provided to support the overall transformer structure and allow a variety of standard or optional housings (not shown). A cruciform core 34 assembled from core laminations and positioned as shown, as would be understood by a person skilled in the art. The laminations are made of grain oriented silicon steel, high grade. Core belts 36 firmly hold core laminations to ensure structural and magnetic integrity. Referring to Figures 5 and 6, the primary conductors 6 are wound from aluminum, copper or other conductors, and are vacuum impregnated and completely encapsulated in a solid dielectric. Air ducts 38 are provided to allow free flow of air between the coil windings. Spacers 40 are used to create the air ducts 38. Secondary conductors 8 are wound from sheets of aluminum, copper or other conductors, and are laminated with pre-impregnated epoxy material. The coils are vacuum impregnated, baked, and then sealed. Figures 2 and 3 show additional types of transformers. In particular, Figure 2 shows a dry-type, coiled-disc, medium-voltage transformer, ventilated by openings, and Figure 3 shows a three-phase transformer of the present invention. The present invention can be applied to the above and other types of transformers. Figures 7 and 9 sketch cylindrical (circular center) and oval (square center) winding structures 44, 10 46, respectively. These winding structures 44, 46 were manufactured without any support (rigid coil / winding base) adjacent to the inner portion or hollow core region (leg) 48, 50 of these winding structures 44, 46. As can be seen in these drawings, without any support, the conductive winding 52, 54 and other stresses have caused these winding structures 44, 46 and in particular the inner insulator 56, 58 to collapse towards the inner portion 48, 50 or warp out of shape . Figures 8 and 10 sketch the same type of transformer winding structures 44 ', 46' of Figures 7 and 9, respectively, except that several supports 60 have been used in the manufacturing process of each winding structure. 44 ', 46'. As can be seen in these figures 8 and 10, the supports 60 are placed adjacent to the inner portion 25 ', 50' of the winding structure 44 ', 46'. In ^ ^ ^ ^ - * > As such, contrary to the winding structures 44, 46 in Figures 7 and 9, the supports 60 that exist within these winding structures 44 ', 46' have maintained the integrity of the windings 52 ', 54', and the winding structures 44 ', 46' during and after the manufacturing process, have facilitated the assembly of the windings 52 ', 54' and the winding structures 44 ', 46 ', and will provide additional resistance to short circuits during fault conditions in view of the additional support and resistance of the windings 52', 54 'and the winding structures 44', 46 'of the transformer. With reference to Figure 11, a cross-section of a winding structure 70 for use in a transformer is shown (see Figures 1 to 6). The winding structure 70 comprises a first support 72 having a central axis 74. The winding structure 70 also has a second support 76 also having a central axis 74, where the second support 76 is placed having its central axis 74 generally in line with the central axis 74 of the first support 0 72. The winding structure also has a winding 78 wrapped around at least a portion of the first and second supports 72, 76. The supports 72, 76 are provided to support the winding 78. As mentioned above, the winding 78 (see figures 4, 5 and 6) can be made of a 5 coil having a length of wire. As can be seen from the Figures 4-8, the first and second supports 72, 76 may each have a cylindrical shape. Alternatively, as can be seen from Figures 9 and 10, the first and second supports 72, 76 may each have a rectangular shape. The winding structure also has an insulator 80 positioned between the first support 72 and the winding 78, and between the second support 76 and the winding 78. The winding structure 70 can also have a third support 82 with a central axis 74. The third support 82 is also placed having its central axis 74 generally in line with the central axis 74 of first and second supports 72, 76. Winding 78 is also wound around at least a portion of third support 82. Additional supports, such as as the fourth support 84, they can be used within the winding structure 70. The preferred material for the supports is polyester glass. However, other insulating materials or combinations of laminated materials may be used. In the winding structure 70 shown in Figure 11, the first support 72 is separated from the second support 76 by a distance D. Similarly, the third support 82 is separated from the fourth support 84 by a distance d. However, the distance D between the supports may vary. In this way, the distance between two supports can be different from the distance between two other supports. In addition, the distance between two supports may be different from one of the two supports and another support. In the winding structure 70 shown in Figure 12, the first support 72 is positioned adjacent the second support 76. Similarly, the second support 76 is positioned adjacent the third support 82. Similarly, the third support 82 is placed adjacent the fourth support 84. Similarly, the fourth support 84 is positioned adjacent to a fifth support 86. With reference to Figures 11 and 12, in an alternative embodiment, the present invention is a transformer (see Figures 1-10) that has at least one winding structure 70. The winding structure 70 has a plurality of supports 72, 76, 82, 84, 86, each having a central axis 74. The supports 72, 76, 82, 84, 86 are generally aligned along its central axis 74. The winding structure also has a winding 78 wrapped around at least a portion of each of the supports 72, 76, 82, 84, 86. As in the pre-embodiments vias, the supports 72, 76, 82, 84, 86 are provided to support the winding 78. Other features of the previous embodiments also apply to the present embodiment. The winding structures shown in Figures 11 and 12 also have an air or vent duct 88 (cylindrical in shape) that is open at the top and the ^^^ ^ ^^^^ "gsgjg ^ iSMM? G ^^^^^^^ JÉ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ 88 is adjacent to the winding 78. A second winding 90 can be wrapped around the first winding 78, separated by spacers (not shown) to create ventilation 88. An outer housing 92 surrounds the second winding 90, and can be applied in accordance with the transformer principles described in relation to figures 1, 4, 5 and 6. With further reference to figures 13 and 14, the The transformer winding structure of the present invention is constructed as follows. A mounting apparatus 94 is provided for mounting the brackets 72, 76, 82, 84 thereon. The mounting apparatus 94 has a base 96 and an expandable cylinder 98 for receiving the brackets for mounting thereto. Figure 13 sketches the cylinder 98 in the unexpanded position, and Figure 14 sketches the cylinder 98 in the expanded position. The supports 72, 76, 82, 84 are mounted on the cylinder 98 when the cylinder 98 is in the unexpanded position. The cylinder 98 is then expanded to hold the supports 72 in place. 76, 82, 84 and to generally align the central axes 74 of the supports 72, 76, 82, 84. When mounting the supports 72, 76, 82, 84 on the cylinder 98, the supports 72, 76, 82, 84 they can be mounted at a distance D between the supports 72, 76, 82, 84, at a variable distance between them, or with the supports 72, 76, 82, 84 adjacent to each other. Other arrangements may exist, depending on the winding structure 70 that is being manufactured. An insulating form 80 can also be mounted on the supports 72, 76, 82, 84. A conductor 5 is then wound around the supports 72, 76, 82, 84, if the insulator 80 is not used, or around the insulator 80. if this is used, to form a winding 78. The mounting apparatus of Figures 13 and 14 uses a cylinder 98 for the supports 72, 76, 82, 84 having a cylindrical shape. Other types of mounting apparatus can be used for the supports 72, 76, 82, 84 having a rectangular shape. Other standard manufacturing steps are then carried out, as would be understood and understood by a technician in the field. Although specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, the scope of the protection being limited only by the scope of the appended claims.

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Claims (24)

1. CLAIMS 1. A support structure for a transformer, comprising: a first support having a central axis; 5 a second support that also has a central axis, where the second support is placed having its central axis generally in line with the central axis of the first support; and a winding wrapped around at least a portion of the first and second supports, where the supports are provided to support the winding.
2. 2. The winding structure of claim 1, wherein the winding comprises a coil having a length of wire.
3. 3. The winding structure of claim 15, wherein the first and second supports each have a cylindrical shape.
4. 4. The winding structure of claim 1, wherein the first and second supports each have a rectangular shape.
5. 5. The winding structure of claim 1, further comprising: an insulator placed between the first support and the winding, and between the second support and the winding.
6. 6. The winding structure of claim 25 1, further comprising: a ||| There is a third support having a central axis, where the third support is placed having its central axis generally in line with the central axis of the first and second supports, and where the winding is wound around at least one portion of the third support, where the supports are provided to support the winding.
7. 7. The winding structure of claim 1, wherein the first support is made of polyester glass.
8. 8. The winding structure of claim 10, wherein the first support is spaced apart from the second support by a distance D.
9. The winding structure of claim 1, wherein the first support is positioned adjacent to the second support.
10. 10. A transformer having at least one winding structure, comprising: a plurality of supports, each having a central axis, the supports being generally aligned along their central axis; and a winding wrapped around at least a portion of each of the supports, the support being provided to support the winding.
11. The transformer of claim 10, wherein the supports each have a rectangular shape.
12. 12. The transformer of claim 10, wherein ¡G | g | LISLA. ^ j? gg ^^^ gi ^ the supports each have a rectangular shape.
13. The transformer of claim 10, further comprising: an insulating shape positioned between the supports and the winding.
14. The transformer of claim 10, wherein the supports are each made of polyester glass.
15. The transformer of claim 10, wherein each support is separated from each other support at a distance D.
16. The transformer of claim 10, wherein each support is placed adjacent to another support.
17. 17. A method of making a winding structure for a transformer, comprising the steps of: providing a mounting apparatus; mounting a first support having a central axis in the mounting apparatus; mounting a second support having a central axis in the mounting apparatus, wherein the second support is mounted in the mounting apparatus with its central axis mounted generally in line with the central axis of the first support; and winding a conductor around at least a portion of the first and second supports to form a winding, where the supports are provided to hold the coil.
18. 18. The method of claim 17, wherein the ^^^^^^^^^^^^^^^^^^^^ J ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^^^^^^^^^^^^^^^^^^ First and second supports have, each, a cylindrical shape.
19. 19. The method of claim 17, wherein the first and second supports have, each, a rectangu lar form.
20. The method of claim 17, further comprising the step of: placing an insulating shape on at least a portion of the first support and the second support, wherein the step of winding the conductor also includes winding the conductor around the insulating form.
21. The transformer of claim 17, further comprising the step of: mounting a third bracket having a central axis on the mounting apparatus, wherein the third bracket is mounted on the mounting apparatus with its central axis generally mounted in line with the central axis of the first support, and wherein the step of winding the conductor around at least a portion of the first and second supports also includes winding the conductor around at least a portion of the third support to form the winding, where the supports are provided to hold the winding.
22. 22. The method of claim 17, wherein the first support is made of polyester glass.
23. The method of claim 17, wherein the first support is mounted spaced apart from the second support a distance D.
24. 24. The method of claim 17, wherein the first support is mounted positioned adjacent the second support. The present invention relates to a winding structure for a transformer. The winding structure has a first support having a central axis, and a second support also having a central axis. The second support is placed having its central axis generally in line with the central axis of the first support. The winding structure also has a winding that is wrapped around at least a portion of the first and second supports. The supports are provided to at least hold the winding. The present invention also relates to a method of making a transformer, comprising the steps of providing a mounting apparatus, and mounting a first support having a central axis in the mounting apparatus. The method also includes mounting a second support having a central axis in the mounting apparatus, where the second support is mounted on the mounting apparatus with its central axis generally mounted in line with the central axis of the first support. In addition, the method includes winding a conductor around at least a portion of the first and second supports to form a winding.