WO2014002122A1 - Radial windings with rectangular conductors - Google Patents

Radial windings with rectangular conductors Download PDF

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Publication number
WO2014002122A1
WO2014002122A1 PCT/IT2012/000203 IT2012000203W WO2014002122A1 WO 2014002122 A1 WO2014002122 A1 WO 2014002122A1 IT 2012000203 W IT2012000203 W IT 2012000203W WO 2014002122 A1 WO2014002122 A1 WO 2014002122A1
Authority
WO
WIPO (PCT)
Prior art keywords
technique
windings
galette
winding
tab
Prior art date
Application number
PCT/IT2012/000203
Other languages
French (fr)
Inventor
Gianfranco Gonella
Original Assignee
Gianfranco Gonella
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Gianfranco Gonella filed Critical Gianfranco Gonella
Priority to PCT/IT2012/000203 priority Critical patent/WO2014002122A1/en
Publication of WO2014002122A1 publication Critical patent/WO2014002122A1/en

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Classifications

    • 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
    • H01F41/06Coil winding
    • H01F41/082Devices for guiding or positioning the winding material on the former
    • H01F41/084Devices for guiding or positioning the winding material on the former for forming pancake coils
    • 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
    • H01F41/06Coil winding
    • H01F41/061Winding flat conductive wires or sheets

Definitions

  • the subject of the patent is a new construction technique for rectangular conductor windings in electric transformers, simply referred to as the 'disc winding' method.
  • the new technique is characterized in that it modifies in a substantial manner the current method of execution, transforming it from a purely manual technique into a technique whereby the operations are almost entirely carried out by machinery.
  • This development makes it possible and economical to produce 'disc windings' also in high- voltage windings for dry-type or cast-resin transformers.
  • This technique can be adopted for windings in both oil-cooled and in the dry-type or cast-resin transformers.
  • the winding technique is principally manual and consists in winding a conductor (rectangular conductor) by means of a lathe or winding machine (Fig. 1, Table 1) equipped with spindle winder normally comprising an expander with 12 ⁇ 16 rays arranged so as to obtain, as far as possible, a geometrical shape that is circular.
  • the conductor is normally contained in windings of sufficient capacity located at distances of 3 - 6 metres from the 'M' winding axis of the lathe (Fig. 1, Table 1).
  • the conductor (rectangular: see item 4 in Table 1) is braked by means of felt pads (item 2, Table 1) and held in alignment by a pulley (item 3, Table 1).
  • the formation of the galette windings or 'discs' occurs as follows:
  • the operator executes out-feed of the rectangular conductor with the pincers (Fig. 1, Table 1) used for such purpose and produces the turns required for the first galette winding or disc.
  • the last turn of the galette winding is attached with a clamp or adhesives; the rectangular conductor is curved by hand as illustrated in Fig. 2 (Table 1) and a loose winding is performed, not restrained by felt pads.
  • the galette thus obtained must be then manually unwound so as to form, in reverse mode, a galette winding situated in a position adjacent to the first galette winding (Fig. 3, Table 1).
  • the first turn wound on the spindle (second galette winding, Fig. 2, Table 1) becomes the last turn at the top of the galette winding (Fig. 3, Table 1).
  • the operator manually creates the curvature for the beginning of the third galette winding (Fig. 3, Table 1) and proceeds with winding, superimposing the turns that will form the third galette winding (Fig. 4, Table 1).
  • Photo 1 shows a disc winding performed according to the aforementioned technique.
  • winding lathes with a vertical axis are used; this can facilitate the winding operations but the technique adopted is almost identical to that employed for lathes with a horizontal axis.
  • An example is provided in photo 2.
  • Tab. 3 shown the most popular used system to execute bobbins with rectangular conductor then introduced into specific molds where it is poured the resin.
  • the mandrel M set in rotation the copper or aluminium strip placed in a decoiler 2 Fig. 1.
  • the galette 1-2-3-nth Fig. 1 is made with subsequent turns and between turns are wrapped together 1 or 2 polyester tape film(item 3 and 4 on Tab. 3 Fig. 1) to create the functional insulation between turns.
  • the machine capable of implementing the new technique represents an evolution of the radial-layer winding machine, for which the undersigned inventor has already been granted an Italian Patent VI2007A124 and PCT/EP/2008/003235 referred to in Table 2, a brief overview of the functional principle of is provided herewith.
  • the rectangular conductor (item 1, Table 2) enters laterally, guided by one or more pulleys (item 2, Table 2).
  • the turn is formed by a mechanical expander (item 3, Fig.2, Tab.2) having a radial orientation, from XI to X2 and vice versa.
  • the expander and coil beneath it turn about the Y axis in the clockwise or counter-clockwise direction.
  • the formation of the turn is obtained with the aid of elastic belts (item 4, Fig.l, Tab.2) which rotate around a return pulley (item 5, Fig. l, Tab.2).
  • the turns thus obtained are then released and fall by effect of gravitational force through the Y axis.
  • the fall by the effect of gravity results in the formation of windings that are not perfectly arranged, and such a condition may be acceptable for wire conductors but not for rectangular conductor.
  • the irregular arrangement of the rectangular conductor does in fact cause a drastic reduction in the stacking of the winding, thereby jeopardizing its cost-effectiveness.
  • the new technique consists in stopping the turns during their fall at a point close to the expander, forcing them to be channelled in such a way as to form galette windings or discs as shown in Tables 5, 6 and 7.
  • the rods (d) and (e) are arranged in the form of a cage defining the area occupied by the galette winding which is being formed, as represented in Figure 2. There are 6 rods in the figure, however there may be 9 of them or even more than 9.
  • the internal rods can also be replaced by a cylinder.
  • the turn (b) is made to pass inside the forming rods (d), (c).
  • the expander forms turns of variable diameter which are arranged with a helical, centripetally from X2 to XI (Fig. 3) and arranged as shown in the section in Fig. 3.
  • the expander (a) starts to expand centrifugally from xl to x2.
  • the turns that are being formed are channelled as described for the first turn and proceed to form the second galette in an orderly manner as illustrated in the section in Figure 3.
  • the mechanical system (c) lowers the 2 formed galettes through a distance 'h ⁇ equal to the height of the rectangular conductor.
  • the expander (a) starts to form concentric turns centripetally, from x2 to xl, as described for the first galette winding.
  • the mechanical system (c) lowers the set of galette windings through a distance equal to the value 'h'.
  • the fourth and fifth galette windings and so on are thus formed in a regular manner as shown in Figures 1 and 2.

Landscapes

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

Abstract

Said a new construction technique for rectangular conductor windings in electric transformers. The new technique is characterized in that it modifies in a substantial manner the current method of execution, transforming it from a purely manual technique into a technique whereby the operations are almost entirely carried out by machinery. This development makes it possible and economical to produce 'disc windings' also in high-voltage windings for dry-type transformers. This technique can be adopted for windings in both oil-cooled and in the dry-type or cast-resin transformers.

Description

Radial windings with rectangular conductors
1. Subject matter of the patent
2. Description of the current technique of the disc windings
3. Description of the current technique of the rectangular conductor windings
4. Description of both the new technique and the machine
5. Advantages of the new technique
6. Claims
1. Subject matter of the patent
The subject of the patent is a new construction technique for rectangular conductor windings in electric transformers, simply referred to as the 'disc winding' method.
The new technique is characterized in that it modifies in a substantial manner the current method of execution, transforming it from a purely manual technique into a technique whereby the operations are almost entirely carried out by machinery. This development makes it possible and economical to produce 'disc windings' also in high- voltage windings for dry-type or cast-resin transformers. This technique can be adopted for windings in both oil-cooled and in the dry-type or cast-resin transformers.
2. Description of the current technique of the disc windings
As previously stated, the winding technique is principally manual and consists in winding a conductor (rectangular conductor) by means of a lathe or winding machine (Fig. 1, Table 1) equipped with spindle winder normally comprising an expander with 12 ÷ 16 rays arranged so as to obtain, as far as possible, a geometrical shape that is circular. The conductor is normally contained in windings of sufficient capacity located at distances of 3 - 6 metres from the 'M' winding axis of the lathe (Fig. 1, Table 1). The conductor (rectangular: see item 4 in Table 1) is braked by means of felt pads (item 2, Table 1) and held in alignment by a pulley (item 3, Table 1). The formation of the galette windings or 'discs' occurs as follows:
The operator executes out-feed of the rectangular conductor with the pincers (Fig. 1, Table 1) used for such purpose and produces the turns required for the first galette winding or disc. The last turn of the galette winding is attached with a clamp or adhesives; the rectangular conductor is curved by hand as illustrated in Fig. 2 (Table 1) and a loose winding is performed, not restrained by felt pads.
The galette thus obtained must be then manually unwound so as to form, in reverse mode, a galette winding situated in a position adjacent to the first galette winding (Fig. 3, Table 1). The first turn wound on the spindle (second galette winding, Fig. 2, Table 1) becomes the last turn at the top of the galette winding (Fig. 3, Table 1).
The operator manually creates the curvature for the beginning of the third galette winding (Fig. 3, Table 1) and proceeds with winding, superimposing the turns that will form the third galette winding (Fig. 4, Table 1).
At this point, the situation described for the first galette (Fig. 1, Table 1) is achieved and a new cycle is started.
The technique briefly described may vary slightly from one manufacturer to another but will essentially present the principles of execution referred to.
Photo 1 shows a disc winding performed according to the aforementioned technique.
For large oil-type transformers, winding lathes with a vertical axis are used; this can facilitate the winding operations but the technique adopted is almost identical to that employed for lathes with a horizontal axis. An example is provided in photo 2.
3. Description of the current technique of the rectangular conductor windings
Tab. 3 shown the most popular used system to execute bobbins with rectangular conductor then introduced into specific molds where it is poured the resin.
The mandrel M set in rotation the copper or aluminium strip placed in a decoiler 2 Fig. 1.
The galette 1-2-3-nth Fig. 1 is made with subsequent turns and between turns are wrapped together 1 or 2 polyester tape film(item 3 and 4 on Tab. 3 Fig. 1) to create the functional insulation between turns.
4. Description of both the new technique and the machine
The machine capable of implementing the new technique represents an evolution of the radial-layer winding machine, for which the undersigned inventor has already been granted an Italian Patent VI2007A124 and PCT/EP/2008/003235 referred to in Table 2, a brief overview of the functional principle of is provided herewith. The rectangular conductor (item 1, Table 2) enters laterally, guided by one or more pulleys (item 2, Table 2). The turn is formed by a mechanical expander (item 3, Fig.2, Tab.2) having a radial orientation, from XI to X2 and vice versa. The expander and coil beneath it turn about the Y axis in the clockwise or counter-clockwise direction.
The formation of the turn is obtained with the aid of elastic belts (item 4, Fig.l, Tab.2) which rotate around a return pulley (item 5, Fig. l, Tab.2). The turns thus obtained are then released and fall by effect of gravitational force through the Y axis. The fall by the effect of gravity results in the formation of windings that are not perfectly arranged, and such a condition may be acceptable for wire conductors but not for rectangular conductor. The irregular arrangement of the rectangular conductor does in fact cause a drastic reduction in the stacking of the winding, thereby jeopardizing its cost-effectiveness.
A. Technical evolution
The new technique consists in stopping the turns during their fall at a point close to the expander, forcing them to be channelled in such a way as to form galette windings or discs as shown in Tables 5, 6 and 7.
B. Table 5 (formation of the first galette winding)
The expander (a) and entire set of supports (c), (d), (e) and (f), which may be referred to as a 'carousel', revolve about the Y axis. The rods (d) and (e) are arranged in the form of a cage defining the area occupied by the galette winding which is being formed, as represented in Figure 2. There are 6 rods in the figure, however there may be 9 of them or even more than 9. The internal rods can also be replaced by a cylinder. By means of technical devices (rollers, separator discs), the turn (b) is made to pass inside the forming rods (d), (c).
The expander forms turns of variable diameter which are arranged with a helical, centripetally from X2 to XI (Fig. 3) and arranged as shown in the section in Fig. 3. Once the formation of the first galette winding has been completed, the mechanical system (c) lowers the galette of a distance 'h\ equal to the height of the rectangular conductor.
C. Table 6 (formation of the second galette winding)
The expander (a) starts to expand centrifugally from xl to x2. The turns that are being formed are channelled as described for the first turn and proceed to form the second galette in an orderly manner as illustrated in the section in Figure 3. Once the second galette has been completed, the mechanical system (c) lowers the 2 formed galettes through a distance 'h\ equal to the height of the rectangular conductor.
D. Table 7 (Formation of the third and nth galette winding)
The expander (a) starts to form concentric turns centripetally, from x2 to xl, as described for the first galette winding.
Once the third galette has also been completed, the mechanical system (c) lowers the set of galette windings through a distance equal to the value 'h'.
The fourth and fifth galette windings and so on are thus formed in a regular manner as shown in Figures 1 and 2.
The difference between the current technique and the new technique is clarified by the content of Tables 5, 6 and 7. In the new technique it is always the machine which forms the galette windings or discs, whether these latter are produced with centrifugal or centripetal turns.
5. Advantages of the new technique
The advantages obtained with the new technique has to be distinguished depending of the type of the winding: disk windings for oil cooled transformers or cast resin dry transformers.
For both oil transformers and dry transformers the advantages is the windings time reduction.
For the high voltage cast resin bobbin tranformers, the new technique is an alternative to the current one as shown in Tab. 3 and offers a range.of benefits listed below:
A. Increase staking from 60-66% up to more than 80%. That means an improvement of the electrical properties and the possibilty to optimize the transformers in terms of performances and the cost of materials used.
B. Excellent behavior against the partial discharges that are a
fundamental element of electrical safety of transformes. The main reason is the drastic reduction of the tension between gallette and gallette as syntetically shown in Tab. 4 Fig. 4 that compare the current technique with the new one. The voltage ratio between gallette or disks in the new technique is very low: 180-240 volt against 1800-2000 volt of the current system(see Fig.5, Tab.4). As known the partial discharges start to appear from 1500 volt of electrical field.
C. Excellent behavior under the aspect of the dielectric strength of the winding towards the low voltage winding and towards ground. That aspect is summarized in Tab. 8 which compare the electrical strengh carried out in the edges of a strip conductor in the current technique, with a rectangular conductor with rounded edges in the new tecnique. The electrical strength difference can be 3 time higher in the strip windings(Ref.F Fig.1,2 Tab.8). With this we can safely say that other conditions being equal, the rectangular conductor windings with new technique are electrically far more strength and safely

Claims

Claims
1.-the new technique production of rectangular conductor windings in radial pattern by means of a variable expander as shown on Tab. 2.
2. -the new technique production of galette or disks windings using the properties of the machine with at variable expander that allows the formation of disks with centripetal and centrifugal pattern as shown on Tab. 5 and Tab. 6 without the need of manual operations as current technique.
3. -the technique aimed to the formation of a required and well defined space whereby the rectangular conductor must drop, after being formed in the expander.
Space formed by various mechanical arrangements as shown on Tab. 5 and Tab. 6
PCT/IT2012/000203 2012-06-28 2012-06-28 Radial windings with rectangular conductors WO2014002122A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/IT2012/000203 WO2014002122A1 (en) 2012-06-28 2012-06-28 Radial windings with rectangular conductors

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IT2012/000203 WO2014002122A1 (en) 2012-06-28 2012-06-28 Radial windings with rectangular conductors

Publications (1)

Publication Number Publication Date
WO2014002122A1 true WO2014002122A1 (en) 2014-01-03

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2160276A1 (en) * 1971-11-17 1973-06-29 Zaporozh Transformator
DE2759253A1 (en) * 1977-12-31 1979-07-12 Bbc Brown Boveri & Cie Transformer coil winding machine - has winding head with various jaws and winding plate, movable axially relative to each other
US5507322A (en) * 1993-12-14 1996-04-16 Abb Power T&D Company Inc. Device and method for forming planar disk transformer windings
WO2008131889A1 (en) * 2007-04-27 2008-11-06 Siltech S.R.L. Vertical-stratification winding machine for electric transformers

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2160276A1 (en) * 1971-11-17 1973-06-29 Zaporozh Transformator
DE2759253A1 (en) * 1977-12-31 1979-07-12 Bbc Brown Boveri & Cie Transformer coil winding machine - has winding head with various jaws and winding plate, movable axially relative to each other
US5507322A (en) * 1993-12-14 1996-04-16 Abb Power T&D Company Inc. Device and method for forming planar disk transformer windings
WO2008131889A1 (en) * 2007-04-27 2008-11-06 Siltech S.R.L. Vertical-stratification winding machine for electric transformers

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