RU2137279C1 - Method for forming multiple-row coil wound of insulated round wire - Google Patents

Abstract

FIELD: electrical engineering; windings for thyratron motor stators. SUBSTANCE: method mainly useful for non-oval shaped coils involves winding of main turns with main wire and extreme turns of each row, with backup wire. According to invention, turns wound with main and backup wire are arranged in staggered manner ; every two series rows of winding are formed by main wire and extreme turns are additionally wound with backup wire. Coil height is chosen to be multiple of wire diameter; starting and finishing leads of turns in each row are located on same side of coil former perimeter. Such arrangement provides for higher winding density and better heat transfer from inner layers of coil. EFFECT: facilitated procedure, reduced size of winding at desired turn number, improved reliability of coils. 13 dwg, 1 tbl

Description

 A method of directly forming a winding of a multi-row coil from a round insulated wire relates to the field of manufacturing frameless or frame coils of predominantly oval shape for electric apparatuses and machines, in particular, for stator valve motors.

 The main criteria that determine the design and technological parameters of the coils are the fill factor and the method of outputting the ends of the winding [1].

 A known method of producing frameless coils from a round insulated wire with the conclusion of the beginning of the winding on the outer surface of the coil [1], in which the output from the beginning of the winding is made of copper tape, which is soldered to the first turn of the winding and bring it to the outer surface at the end of the coil. Under the tape lay insulation from electric cardboard or varnish. The thickness of the tape is taken no more than 1 mm. With a large cross section of the wire, the copper tape must be chosen wide enough to provide the necessary current density.

 The conclusion of the beginning of the winding on the outer surface of the coil without using the soldering operation of the copper tape can be ensured by the special technique described in ([2], p. 76) for coils from an insulated rectangular wire, which is as follows.

 First, a wire with a length equal to the unfolded length of one vertical row of the coil is unwound from the coil of winding copper. The unwound backup wire is coiled and tied to the side of the winding template. Then they lead the wire into a winding template, fix it and begin to wind the coils with the main wire.

 In this case, the extreme turns during forward and reverse travel remain unfilled for one initial (for forward travel) and final (for reverse travel) turns. In the space that should be occupied by these turns during winding with the main wire, a distance gasket is placed.

 At the end of the main winding, the main wire is cut from the bay, the spiral of the backup wire is unwound, the remote strip is removed and the backup wire is laid in the place of the extreme turns from the first to the last row of the winding. Thus, the beginning of the winding is on the surface of the coil, and the operation of soldering copper tape is excluded.

 The indicated method of outputting the beginning of the winding is also applicable when using a round wire, but it is only possible for ordinary winding using spacers between the winding rows ([1], p. 48) and preliminary impregnation of the main winding (prototype).

 A denser checkerboard wire stitching is practically impossible due to the impossibility of even-row windings with a backup wire and instability of the main winding after removing the distance strip (see, for example, Fig. 4, a top view).

 It should be noted that in most cases, the laying of a round wire in a checkerboard type, which corresponds to the largest fill factor of the coil volume, in practice does not ensure the uniformity and straightness of the winding rows around the entire perimeter of the coil, and therefore theoretically high winding density due to sections of the "crosshair" turns when moving from row to row.

 These transition sections for the oval cross-section of the coil (circle, ellipse, oval) are located arbitrarily around the perimeter of the winding and are difficult to fix, especially with wire diameters of 0.5 mm and above.

 For the cross section of coils of an oval shape (square, rectangle, triangle), which mainly relates to the proposed method of winding, namely with a perimeter having bending points of the winding, the above “cross-sections” of the winding can be fixed in a certain part of the perimeter, namely between two adjacent corners of the bend of the winding, that is, on one of the faces of the coil, which we conventionally called the "non-working" side. Thus, to form on the remaining faces, which we conventionally called "working" parties, an ordered chess laying of the wire.

One of these coils, namely the coil in the shape of an acute-angled triangle, is used, in particular, as excitation coils in disk-type electric DC machines [3],
In FIG. 1 shows two options for the general appearance and location of the mentioned coils (1 and 2) on a fixed stator (3 and 4) of an electric machine, as well as the relative position of the stator and rotor (5 and 6) with the shaft (7).

 It can be seen that with the same number of coils on the stator, the thickness of the winding on the "working" sides of the coils (LI and L3) is a determining parameter for the dimensions of the radius of the rotor of the machine (respectively RI and R2).

 At the same time, the type of laying the wire on the "non-working" side (L2 and L4), namely at the base of the triangle, and hence the thickness of the winding on it, does not significantly affect the size of the machine.

 It is also seen that the output of the beginning (8) and end (9) of the winding to the outer surface of the winding, namely to the "non-working" side of the coil (the base of the triangle triangle), allows for a minimum clearance (δ) (between the stator and rotor, which is necessary to obtain maximum power of the car.

 Both of these conditions, namely, the most dense staggered stowage of the wire on the "working" sides of the coil and the output of the ends of the winding to the outer surface of the "non-working" side of the coil, provide our winding method. A general view of the coil (2) according to our winding method is shown in FIG. 2 to 4.

 In FIG. Figure 2 shows an isometric view of the coil with the image of the winding cross-sections on the top (10), the sides (11, 12) and the base (13) of the triangle contour. It can be seen that on the “working” sides of the coil, the wire laying is close to the most dense checkerboard arrangement (10, 11, 12), and sections with an unordered winding (13) are brought to the “non-working” side of the coil (the base of the triangle). Both ends of the winding are brought out there - the beginning (8) and the end (9), which ensures the minimum mounting height of the coil equal to the height of the winding (N).

 In FIG. Figure 3 shows the orthogonal projections of the aforementioned coils, indicating the main dimensions that correspond to the example we give for the proposed winding method.

 Laying the wire in the resulting coil (see Fig. 3, projection D-E-Zh), which corresponds to the cross-section (13) on the "non-working" side, as well as the cross-sections (10, 11, 12) on the "working" sides of the winding, are shown on fig / 4.

 Here, the white circles indicate the cross section of the main wire (14), and the shaded circles indicate the backup wire (15). Indices (1, 2, 3 ... m) refer to the number of turns of wire in one row of the winder, the length of which corresponds to the height of the coil (H), and indices (1, 2, 3 .... n) refer to the number of rows of winding and accordingly to the thickness of the winding (L3 and L4). The diameters of the main and backup wires are the same and equal (d).

Such a winding according to our proposed method is possible under two additional conditions, namely: 1) the height of the coil (length of the winding row) H must be a multiple of the diameter of the wire d:
H ≈ m • d + (0.03 -0.1) mm;
2) the beginning and end of the winding of the coil with the main and backup wires should be carried out at adjacent corners of a certain "non-working" face of the frame template; 3) the diameter of the wire should be 0.5 mm or more.

 The purpose of the invention is to increase the reliability of the coil and save winding wire by increasing the density of the winding.

 This goal is achieved in that every two consecutive rows of windings are formed by the main wire with the winding of their extreme turns by the backup wire. In this case, the laying of the turns with the main and backup wires is carried out in a checkerboard style with the beginning and end of the extreme turns of each row on the same edge of the frame perimeter, and the coil height is selected as a multiple of the diameter of the wire.

 The proposed method of forming a coil of a coil using the example of winding onto a template of two first rows is shown in FIG. 5.

 On the left side of FIG. 5 shows two positions of the template (16) with the "working" sides (17,18) and the "non-working" side (19), which correspond to the "working" sides (10, 11, 12) and the "non-working" side (13 for the resulting coil) ) The places of fixation on the template of the main (OP) wire (20) and the backup (RP) wire (21) at the beginning of winding, the direction of rotation of the template and the movement of the wires during winding are also indicated there.

 Here, as before, white circles indicate the cross section of the main wire, and shaded circles indicate the cross section of the backup wire. The “point” inside the circle shows the movement of the wire “toward you”, and the “cross” shows the movement of the wire “away from you”.

 Arrows with a white circle refer to the direction of movement and the sequence of winding the row of the main wire. Similarly, arrows with a shaded circle indicate the movement of the backup wire.

 To the right of the template are shown four consecutive stages of the formation of the first two rows of windings.

 At the top (view along arrow A), for four consecutive steps (Figs. 5 a – d), the order of formation of an orderly staggered stowage of the wire on the “working” side face (17.18) of the template (16) is shown.

 At the bottom (view along arrow B), for four consecutive stages (Fig. 5 d-h), the order of formation of an unordered winding, namely, sections of the “crosshairs” of the winding during transition from row to row, drawn to the “non-working” face (19) of the template, is shown, respectively (16).

 The order of formation of an ordered chess winding on the "working" edges of the coil with the conclusion of the zone of disordered laying of the wire containing the places of the "cross" of the rows on the "non-working" edge of the perimeter, that is, on the base of the triangle, is as follows (Fig. 5.).

 After unwinding the backup wire (RP) and fixing it and the main wire on the “non-working” side (19) of the template (16), the latter is rotated by the main wire (OP) of the first row (Fig. 5 a, e), and then the second row without the last turn of the main winding (Fig. 5 b, f) in compliance with a checkerboard pattern on the edges (17, 18) and securing its end. Next, by reversing the movement of, for example, the template, the backup wire is laid in place of the extreme (last) turn of the second winding row (Fig. 5 c, g) and the formation of the extreme (first) turn of the third row (Fig. 5 g, h) while maintaining a checkerboard pattern wires between the second and third row on the working (17.18) edges of the template.

 The backup wire is fixed on the "non-working" edge of the template. Thus, the cycle of formation of the odd (first) row and the even (second) rows of winding is considered completed. Then, similarly, the main wire (20) (not shown in Fig. 5) forms the third and fourth (without end turn) rows of the main winding. Then, with the backup wire (21), the extreme turns of the fourth (first turn) and fifth (last turn) winding row.

 According to the proposed method, it is also possible to make winding according to the scheme: the first row with the main wire - the first turn of the second row with the backup wire - the second row with the main wire, etc., i.e. Complete the stacking cycle after each row. However, this method is less technologically advanced due to the difficulty of laying the wire at the junction of the first and second turns of each row.

 As can be seen from figure 5, the proposed method provides the conclusion of the zone of the crosshairs of turns when switching from row to row on the "idle" side (19) of the template (coil) and obtaining a tight checkerboard wire laying on the "working" edges (17, 18) of the template ( coils).

 At the same time, the beginning of the winding is also displayed on the outer surface of the “idle" face of the coil.

 At the end of the set of the required number of rows of windings, the shape of the winding is fixed, for example, by impregnation with a known compound such as KP 103 and subsequent removal of the coil from the template.

 By the proposed method, coils for the stator of a disk-type electric machine were manufactured (see FIG. 1, AB, FIG. 4), which provide a 10% reduction in the overall dimensions of the working sides of the coil (compare FIG. 1, B-D), and therefore a decrease in the total length of the winding wire with an equal number of turns (see table). In this case, the beginning of the winding is also displayed on the outer surface of the “idle" face of the coil.

 The proposed method of winding coils with an insulated round wire has the following advantages: allows you to get a coil with the conclusion of both ends of the winding on the outer surface; provides minimum winding sizes for a given number of turns; increases the manufacturability of the manufacture of coils by eliminating the operation of soldering the output plate and its isolation; improves heat transfer from the inner layers of the coil due to the larger contact area of adjacent turns.

Literature
1. N.V. Vinogradov. The wrapper of electrical machines. Ed. 8th, rev. and add. - M .: Higher school, 1973 - (prototype).

 2. F.A. Stupel. Electromechanical relays. Fundamentals of the theory of design and calculation. Tutorial. Ed. 2nd. - Kharkov: Publishing House of Kharkov State University, 1956

 3. USSR patent N 1494877 A3.

Claims (1)

 A method for directly forming a winding of a multi-row coil from an insulated round wire by laying winding coils with a main wire and extreme turns in rows with a backup wire, characterized in that every two consecutive rows of windings are formed with a main wire with winding of their extreme turns with a backup wire, while laying the turns of the main and backup wires are produced in a checkerboard style with the beginning and end of the extreme turns of each row on the same edge of the frame perimeter, and the coil height is selected multiple ametru wire.

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