WO2022148124A1 - 一种浇注干式变压器及其制造方法 - Google Patents

一种浇注干式变压器及其制造方法 Download PDF

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Publication number
WO2022148124A1
WO2022148124A1 PCT/CN2021/129880 CN2021129880W WO2022148124A1 WO 2022148124 A1 WO2022148124 A1 WO 2022148124A1 CN 2021129880 W CN2021129880 W CN 2021129880W WO 2022148124 A1 WO2022148124 A1 WO 2022148124A1
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Prior art keywords
coil
casting
mold
cast
casting mold
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PCT/CN2021/129880
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English (en)
French (fr)
Inventor
许凯旋
梁庆宁
宋丹菊
周登灵
梁毅雄
戚宇祥
李飞
方文杰
梁雅仲
谭敬育
李万欢
李楚泳
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海鸿电气有限公司
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Priority to JP2022518394A priority Critical patent/JP2023520272A/ja
Priority to DE112021000119.1T priority patent/DE112021000119T5/de
Priority to US17/764,376 priority patent/US20230343511A1/en
Publication of WO2022148124A1 publication Critical patent/WO2022148124A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F30/00—Fixed transformers not covered by group H01F19/00
    • H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
    • H01F30/12—Two-phase, three-phase or polyphase transformers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/02—Casings
    • H01F27/022—Encapsulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/02—Casings
    • H01F27/025—Constructional details relating to cooling
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/25—Magnetic cores made from strips or ribbons
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2866—Combination of wires and sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H01F27/325—Coil bobbins
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/327—Encapsulating or impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus 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
    • H01F41/005—Impregnating or encapsulating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus 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
    • H01F41/02—Apparatus 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
    • H01F41/04—Apparatus 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus 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
    • H01F41/02—Apparatus 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
    • H01F41/04—Apparatus 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
    • H01F41/12—Insulating of windings
    • H01F41/127—Encapsulating or impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/327—Encapsulating or impregnating
    • H01F2027/328—Dry-type transformer with encapsulated foil winding, e.g. windings coaxially arranged on core legs with spacers for cooling and with three phases

Definitions

  • the invention relates to a three-dimensional wound iron core transformer, in particular to a cast dry-type transformer and a manufacturing method thereof.
  • Type transformers use casting material to cast the coil into a solid body, and the casting material is usually a flammable substance, which may catch fire and burn in the event of a failure, producing toxic gas. It is easy to crack, which leads to failure.
  • maintenance is required, because each phase coil is encapsulated into an entity by casting material, it can only be repaired by dismantling the entire coil and then rewinding it. Maintenance is very difficult.
  • the production process of traditional cast dry-type transformers is also complicated.
  • the main difficulty lies in the casting process.
  • the casting mold needs to be installed before casting, and then the casting material is poured into the mold to form.
  • the structure of the casting mold is often complicated. , the installation is time-consuming, and the pouring channel of the mold is narrow. During the pouring process, there are often leakage of the pouring material and some parts are not poured completely.
  • the coil needs to be repaired. After the pouring is completed, the mold and When assembling the transformer, it is easy to damage the casted coil, and the phenomenon of rework occurs from time to time, and the production efficiency is not high.
  • the present application aims to solve one of the technical problems in the related art at least to a certain extent. Therefore, the present application proposes a cast dry-type transformer and a manufacturing method thereof.
  • the novel cast dry-type transformer reduces combustible substances, solves the problems of cracking of the casting material and the difficulty of maintenance of the transformer, and creatively proposes a new process.
  • the implementation method by using an insulating mold and a special casting method, solves the problem of time-consuming installation of the casting mold, the air tightness of the casting mold, and the permeability of the casting material, which greatly improves the production efficiency of the transformer. Lower cost, lighter weight, higher overload capacity and easier maintenance.
  • an embodiment of the present invention provides a cast dry-type transformer, which is characterized by comprising: a plurality of coils, an iron core, a clip and a lead wire, the lead wire is drawn out from the coil, and the coil is arranged on the iron core Above, the coil and the iron core are fixed together by the clips on both sides, the coil is provided with a casting mold for casting the coil, the casting mold is provided with evenly distributed channels, the coil is cast There is a casting material made of insulating material, wherein the casting mold is made of insulating material, and it does not need to be disassembled and combined with the coil to form an integrated structure after the casting is completed.
  • the above cast dry-type transformer has at least the following beneficial effects: the casting mold of the present invention is provided with evenly distributed channels, the coil is cast with insulating material, the excess casting material can be discharged from the casting mold, and the casting thickness is reduced, While improving the moisture-proof and anti-corrosion performance of the coil, it saves materials and reduces the cost, so that the weight of the combustible material of the transformer is much less than that of the traditional cast transformer, which improves the safety and reliability of the transformer.
  • the pouring channel is also the heat dissipation air channel of the coil, and the heat dissipation area is large, so it also improves the heat dissipation capacity and overload capacity of the transformer, so that the insulating material will not be cracked due to sudden temperature changes, shorten the curing time of the insulating material, and improve the production efficiency.
  • the casting mold can be disassembled. When there is a problem with the coil and needs to be dealt with, it is only necessary to open the casting mold, wrap and repair the coil, and then install the casting mold and pour it again, making the transformer easier to maintain.
  • the iron core adopts a three-dimensional wound iron core structure, and the iron core includes three single frames, each two of the single frames are joined together at an included angle of 60°, and a core column is formed at the joint of each two of the single frames.
  • the coil further includes an inner coil and an outer coil, the inner coil is wound between the stem and the outer coil, and the lead wire includes an inner coil lead wire and an outer coil lead wire.
  • the pouring mold includes an inner pouring mold and an outer pouring mold, the inner pouring mold is arranged inside the outer coil, and the outer pouring mold is arranged outside the outer coil.
  • the inner pouring mold and the outer pouring mold are both made of insulating materials, the inner pouring mold is a cylindrical structure, and the outer pouring mold is a combined structure of a cylinder and an end ring.
  • the outer coil includes a comb-shaped stay and a wire, the comb-shaped stay is arranged on the inner casting mold, and the wire is wound on the comb-shaped stay.
  • the comb-shaped stay includes a plurality of elongated bars with uniform intervals, and the wires are wound between the elongated bars.
  • the lead wire includes a first lead wire and a second lead wire, the first lead wire is drawn from the inner coil and the second lead wire is drawn from the outer coil.
  • a method for manufacturing a cast dry-type transformer includes a plurality of coils, an iron core, a clip and a lead wire, the lead wire is drawn out from the coil, and the coil is arranged on the iron core , the coil and the iron core are fixed together by the clips on both sides, the coil is provided with a casting mold for casting the coil, the casting mold is provided with evenly distributed channels, and the coil is cast with Casting material, wherein the casting mold is made of insulating material, and it does not need to be disassembled and combined with the coil to form an integrated structure after the casting is completed.
  • the coil also includes an inner coil and an outer coil, the inner coil is wound between the stem and the outer coil, the pouring mold includes a pouring inner mold and a pouring outer mold, and the pouring inner mold is set On the inner side of the outer coil, the casting outer mold is arranged on the outer side of the outer coil, and the outer coil includes a comb-shaped stay and a wire, and the comb-shaped stay is arranged on the inner casting mold, so
  • the comb-shaped stay includes a plurality of evenly spaced long bars, the wires are wound between the long bars, and the method includes the steps:
  • the steps include:
  • the casting outer mold can also be installed on the outer side of the outer coil after the casting material is cured.
  • the above-mentioned manufacturing method of a cast dry-type transformer has at least the following beneficial effects: the present patent does not need to consider the air tightness of the casting mold due to the different casting methods, the mold is simple and easy to install, and after the casting is completed, the casting mold can be directly used as a transformer
  • the insulating parts do not need to be removed, which improves the production efficiency of the product; the excess casting material is discharged from the casting mold, reducing the casting thickness, improving the moisture-proof and anti-corrosion performance of the coil, saving materials and reducing costs.
  • the weight of the combustibles of the transformer is much lower than that of the traditional casting transformer, which improves the safety and reliability of the transformer.
  • the casting channel is also the heat dissipation air channel of the coil, and the heat dissipation area is large.
  • the heat dissipation capacity and overload capacity of the transformer prevent the insulating material from cracking due to sudden temperature changes, shorten the curing time of the insulating material, and improve the production efficiency; in addition, when pouring, pour the degassed casting material into the casting In the tank, vacuum and pressure are used to inject the casting material into the coil through the channel reserved by the casting mold. Therefore, the casting material can easily penetrate into the coil, which solves the problem of incomplete casting of the coil, and the outer casting mold is removable. When there is a problem with the coil and needs to be dealt with, it is only necessary to open the casting mold, wrap and repair the coil, and then install the casting mold and pour it again, making the transformer easier to maintain.
  • FIG. 1 is a schematic diagram of a cast dry-type transformer according to an embodiment of the present invention.
  • Fig. 2 is the schematic diagram of the iron core of the embodiment of the present invention.
  • FIG. 3 is a schematic diagram of a coil of an embodiment of the present invention.
  • FIG. 4 is a cross-sectional view of a coil of an embodiment of the present invention.
  • Fig. 5 is the schematic diagram of the comb-shaped stay of the embodiment of the present invention.
  • FIG. 6 is a flowchart of a method for manufacturing a cast dry-type transformer according to an embodiment of the present invention.
  • FIG. 7 is a flowchart of a method for manufacturing a cast dry-type transformer according to an embodiment of the present invention.
  • the azimuth description such as the azimuth or position relationship indicated by up, down, front, rear, left, right, etc.
  • the azimuth description is based on the azimuth or position relationship shown in the drawings, only In order to facilitate the description of the present invention and simplify the description, it is not indicated or implied that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore should not be construed as limiting the present invention.
  • an embodiment of the present invention provides a cast dry-type transformer, which is characterized in that it includes: a plurality of coils 100 , an iron core 110 , a clip 120 and a lead 130 .
  • the coil 100 is provided with a casting mold for casting the coil 100, the casting mold is provided with evenly distributed channels 101, the coil 100 is cast with a casting material made of insulating material, wherein the casting mold is made of insulating material, After the casting is completed, it does not need to be disassembled and combined with the coil 100 to form an integrated structure.
  • the casting mold of the present invention is provided with evenly distributed channels 101, and the coil 100 is cast with insulating materials, which can discharge excess casting materials from the casting mold, reduce the casting thickness, and improve the performance of the casting. While improving the moisture-proof and anti-corrosion performance of the coil 100, it saves materials and reduces the cost, so that the weight of the combustible material of the transformer is much lower than that of the traditional casting transformer, which improves the safety and reliability of the transformer.
  • casting The channel 101 is also the heat dissipation air channel of the coil 100, and the heat dissipation area is large, so the heat dissipation capacity and overload capacity of the transformer are also improved, so that the insulating material will not be cracked due to sudden temperature changes, shorten the curing time of the insulating material, and improve the production efficiency.
  • the casting mold is detachable. When there is a problem with the coil 100 and needs to be dealt with, it is only necessary to open the casting mold, wrap and repair the coil 100, and then install the casting mold and pour it again, making the transformer easier to maintain.
  • the iron core 110 adopts a three-dimensional wound iron core structure, and the iron core 110 includes three single frames 111 .
  • a core 112 is formed at the splicing point, and each single frame 111 is wound from several silicon steel sheets or amorphous alloy strips.
  • the three-dimensional wound core transformer is an energy-saving power transformer. It creatively reforms the laminated magnetic circuit structure and three-phase layout of traditional power transformers, so as to optimize the product performance.
  • the three-phase magnetic circuit is completely symmetrical, and the oil-immersed type
  • the three-dimensional wound core transformer has significant power saving effect, greatly reduced noise, stronger heat dissipation and overload capacity, compact structure and small volume.
  • the coil 100 further includes an inner coil 102 and an outer coil 103 , and the inner coil 102 is wound between the stem 112 and the outer coil 103 .
  • the casting mold includes an inner casting mold 141 and an outer casting mold 142 , the inner casting mold 141 is arranged on the inner side of the outer coil 103 , and the outer casting mold 142 is arranged on the outer side of the outer coil 103 , and the casting material is injected into The casting material is poured into the mold so that the casting material penetrates into the coil 100 .
  • the pouring inner mold 141 and the pouring outer mold 142 are both made of insulating materials, the pouring inner mold 141 is a cylindrical structure, and the pouring outer mold 142 is a combined structure of a cylinder and an end ring. It can be directly used as a transformer insulation part without dismantling, which improves the production efficiency.
  • the outer coil 103 includes a comb-shaped stay 104 and a wire 105 , the comb-shaped stay 104 is arranged on the casting inner mold 141 , and the wire 105 is wound on the comb-shaped stay 104 superior.
  • the comb-shaped stay 104 includes a plurality of strips 1041 evenly spaced apart, and the wires 105 are wound in the gaps between the strips 1041 to form a gap between the coils 100 to improve the The heat dissipation properties of the coil 100 and the ease of injection and discharge of the casting material into and out of the coil 100 .
  • the lead 130 includes an inner coil lead and an outer coil lead, the inner coil lead is drawn from the inner coil 102 , and the outer coil lead is drawn from the outer coil 103 .
  • a method for manufacturing a cast dry-type transformer includes: a plurality of coils 100 , an iron core 110 , a clip 120 and a lead wire 130 , the lead wire 130 is led out from the coil 100 , the coil 100 is arranged on the iron core 110 , and the coil 100 is provided with a
  • the casting mold for casting the coil 100 is provided with evenly distributed channels 101.
  • the coil 100 is poured with a casting material made of insulating material, wherein the casting mold is made of insulating material and does not need to be disassembled and combined with the coil 100 after the casting is completed.
  • the iron core 110 includes three single frames 111 , each two single frames 111 are spliced together at an included angle of 60°, and a core 112 is formed at the splicing point of each two single frames 111 , and the coil 100 also includes an inner coil 102 and the outer coil 103, the inner coil 102 is wound between the stem 112 and the outer coil 103, the casting mold includes a casting inner mold 141 and a casting outer mold 142, the casting inner mold 141 is set on the inner side of the outer coil 103, and the casting outer mold 142 is set On the outside of the outer coil 103, the outer coil 103 includes a comb-shaped stay 104 and a wire 105.
  • the comb-shaped stay 104 is arranged on the casting inner mold 141, and the wire 105 is wound on the comb-shaped stay 104.
  • the comb-shaped stay 104 includes A plurality of strips 1041 are evenly spaced, and the wires 105 are wound in the gaps between the strips 1041.
  • the method includes the steps:
  • the coil winding and the assembly of the body are completed, and the body is dried, and the steps include:
  • the casting outer mold can also be installed on the outer side of the outer coil after the casting material is cured.
  • the above-mentioned manufacturing method of a cast dry-type transformer has at least the following beneficial effects: the present patent does not need to consider the air tightness of the casting mold due to the different casting methods, the mold is simple and easy to install, and after the casting is completed, the casting mold can be directly used as a transformer
  • the insulating parts do not need to be removed, which improves the production efficiency of the product; the excess casting material is discharged from the casting mold, which reduces the casting thickness, improves the moisture-proof and anti-corrosion performance of the coil 100, saves materials, and reduces the cost of Cost
  • the weight of combustibles of the transformer is much lower than that of the traditional cast transformer, which improves the safety and reliability of the transformer.
  • the casting channel 101 is also the heat dissipation air channel of the coil 100, and the heat dissipation area is large, so It also improves the heat dissipation capacity and overload capacity of the transformer, so that the insulating material will not be cracked due to sudden temperature changes, shorten the curing time of the insulating material, and improve the production efficiency;
  • the pouring material can easily penetrate into the coil 100 through the reserved channel, which solves the problem of incomplete pouring of the coil 100, and the pouring outer mold can be disassembled. The coil is wrapped and repaired, and then the pouring mold is installed and poured again, which makes the transformer easier to repair.

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  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulating Of Coils (AREA)

Abstract

本发明公开了一种浇注干式变压器及其制造方法，包括若干个线圈、铁心、夹件和引线，引线由线圈引出，线圈设置于铁心上，线圈以及铁心通过两边的夹件固定在一起，线圈设置有浇注模具，浇注模具设置有均匀分布的通道，将器身放入浇注罐中对变压器进行浇注，浇注材料通过预留通道很容易地渗透到线圈内部。该种新型浇注干式变压器减少可燃物质，通过使用绝缘浇注模具以及特殊浇注工艺，解决了浇注模具安装耗时问题、浇注模具气密性问题、浇注材料渗透性的问题，极大的提高了变压器的生产效率，且本专利变压器生产成本更低、重量更轻、过载能力更强、更加易于维修。

Description

一种浇注干式变压器及其制造方法 技术领域
本发明涉及立体卷铁心变压器，尤其是一种浇注干式变压器及其制造方法。
背景技术
随着变压器行业的发展，竞争越来越大，各生产企业也越来越注重提高产品的生产效率，以降低生产成本，同时也在不断的改进产品，提升变压器产品的各方面性能，以提高产品的市场竞争力。
浇注干式变压器作为一种传统的干式变压器，因其易于维护、电气性能优越等优点，已被广泛的应用在各种室内建筑之中，但也暴露了不少问题，首先，传统浇注干式变压器用浇注材料将线圈浇注成一个实体，且浇注材料通常是可燃物质，在故障时可能会起火燃烧，产生有毒气体，其次，由于浇注材料较厚，在寒冷地区使用及温度骤变的情况下，容易开裂，从而导致故障发生，当需要维修时，由于每一相线圈都被浇注材料包封成了一个实体，只能通过拆除整个线圈再重新绕制的方式维修，维修非常困难。
传统的浇注干式变压器的生产过程也是复杂的，其主要难点就在于浇注工序，按照传统工艺，浇注前需要先安装浇注模具，然后将浇注材料浇注进入模具中成型，但浇注模具往往结构比较复杂，安装耗时，且模具的浇注通道较窄，在浇注过程中时常会出现浇注材料泄漏以及一些部位没有被浇注完整的情况，需要对线圈进行修补，并且，浇注完成后，还要拆除模具以及进行变压器装配，容易损坏浇注好的线圈，返工现象时有发生，生产效率不高。
发明内容
本申请旨在至少在一定程度上解决相关技术中的技术问题之一。为此，本申请提出一种浇注干式变压器及其制造方法，该种新型浇注干式变压器减少可燃物质，解决了浇注材料开裂以及变压器难以维修的问题，并且创造性的提出来一种新型的工艺实施方法，通过使用绝缘模具以及特殊浇注方式，解决了浇注模具安装耗时问题、浇注模具气密性问题、浇注材料渗透性的问题，极大的提高了变压器的生产效率，且本专利变压器生产成本更低、重量更轻、过载能力更强、更加易于维修。
本发明解决其问题所采用的技术方案是：
一方面，本发明实施例提供了一种浇注干式变压器，其特征在于，包括：若干个线圈、铁心、夹件和引线，所述引线由所述线圈引出，所述线圈设置于所述铁心上，所述线圈以及所述铁心通过两边的所述夹件固定在一起，所述线圈设置有用于浇注所述线圈的浇注模具，所述浇注模具内设置有均匀分布的通道，所述线圈浇注有由绝缘材料制成浇注材料，其中浇注模具由绝缘材料制成，在浇注完成后无需拆卸与所述线圈结合成为一体化结构。
上述浇注干式变压器至少具有以下有益效果：本发明所述浇注模具设置有均匀分布的通道，所述线圈浇注有绝缘材料，能够将多余的浇注材料从浇注模具中排出，减小了浇注厚度，在提高了线圈防潮、防腐性能的同时，节约了材料，降低了成本，使变压器的可燃物重量比传统浇注变压器减少许多，提高了变压器的安全性和可靠性，同时又由于浇注材料较薄，浇注通道也是是线圈的散热气道，散热面积大，因此还提高了变压器的散热能力和过载能力，使绝缘材料不会因温度骤变而开裂，缩短了绝缘材料固化时间，提高了生产效率。另外，浇注模具可拆卸，当线圈出现问题需要处理时，只需要打开浇注模具，对线圈进行包扎修补，再装好浇注模具重新进行浇注即可，使得变压器更容易维修。
进一步，所述铁心采用立体卷铁心结构，所述铁心包括三个单框，每两个所述单框呈60°夹角拼合在一起，每两个所述单框拼接处形成一个心柱。
根据权利要求2所述的一种浇注干式变压器，每个所述单框由若干条硅钢片或非晶合金带材绕制而成。
进一步，所述线圈还包括内线圈和外线圈，所述内线圈绕设于所述心柱和所述外线圈之间，所述引线包括内线圈引线和外线圈引线。
进一步，所述浇注模具包括浇注内模和浇注外模，所述浇注内模设置在所述外线圈的内侧，所述浇注外模设置在所述外线圈的外侧。
进一步，所述浇注内模和浇注外模均由绝缘材料制成，所述浇注内模为圆筒结构，所述浇注外模为圆筒和端圈的组合结构。
进一步，所述外线圈包括梳形撑条、导线，所述梳形撑条设置在所述浇注内模上，所述导线绕制于所述梳形撑条上。
进一步，所述梳形撑条包括若干个间隔均匀的长条，所述导线绕制于长条之间。
进一步，所述引线包括第一引线和第二引线，所述第一引线由所述内线圈引出和所述第二引线由所述外线圈引出。
另一方面，一种浇注干式变压器的制造方法，所述浇注干式变压器包括若干个线圈、铁心、夹件和引线，所述引线由所述线圈引出，所述线圈设置于所述铁心上，所述线圈以及所述铁心通过两边的所述夹件固定在一起，所述线圈设置有用于浇注所述线圈的浇注模具，所述浇注模具内设置有均匀分布的通道，所述线圈浇注有浇注材料，其中浇注模具由绝缘材料制成，在浇注完成后无需拆卸与所述线圈结合成为一体化结构，所述铁心包括三个单框，每两个所述单框拼接处形成一个心柱，所述线圈还包括内线圈和外线圈，所述内线圈绕设于所述心柱和所述外线圈之间，所述浇注模具包括浇注内模和浇注外模，所述浇注内模设置在所述外线圈的内侧，所述浇注外模设置在所述外线圈的外侧，所述外线圈包括梳形撑条、导线，所述梳形撑条设置在所述浇注内模上，所述梳形撑条包括若干个间隔均匀的长条，所述导线绕制于长条之间，所述方法包括步骤：
⑴完成所述线圈绕制以及器身的装配，并对器身进行干燥；
⑵将器身放入浇注罐中，并对器身进行抽真空处理，然后将已经进行脱气处理的浇注材料注入所述浇注罐内，使浇注材料的液面高度高于所述线圈，浇注材料从所述浇注模具的通道注入并填满整个所述线圈；
⑶解除所述浇注罐的真空状态并对其进行加压，使所述浇注材料注入所述线圈内部的缝隙；
⑷完成浇注后，从所述通道排出所述浇注模具中多余的所述浇注材料；
⑸将器身放入干燥炉中，对所述浇注材料进行固化。
进一步，完成所述线圈绕制以及器身的装配，并对器身进行干燥，步骤包括：
⑴将内线圈绕制在所述铁心的心柱上；
⑵将浇注内模卷绕在所述外线圈的内侧，并固定好；
⑶将梳形撑条固定在所述浇注内模表面，固定好后，将所述线圈的导线缠绕在长条之间；
⑷将所述浇注外模卷绕在所述外线圈的外侧，所述浇注内模与所述浇注外模之间预留通道，以便浇注材料注入或排出。
在另一实施例中，也可以在浇注材料固化后再将浇注外模安装在外线圈的外侧。
上述浇注干式变压器的制造方法至少具有以下有益效果：本专利由于浇注方式不同，不需要考虑浇注模具的气密性问题，模具简单，易于安装，且浇注完成后，浇注模具可直接用作变压器的绝缘部件，不需要拆除，提高了产品的生产效 率；将多余的浇注材料从浇注模具中排出，减小了浇注厚度，在提高了线圈防潮、防腐性能的同时，节约了材料，降低了成本，使变压器的可燃物重量比传统浇注变压器减少许多，提高了变压器的安全性和可靠性，同时又由于浇注材料较薄，浇注通道也是是线圈的散热气道，散热面积大，因此还提高了变压器的散热能力和过载能力，使绝缘材料不会因温度骤变而开裂，缩短了绝缘材料固化时间，提高了生产效率；另外，浇注时，将已经进行脱气处理的浇注材料注入所述浇注罐内，再利用真空和压力使浇注材料通过浇注模具预留的通道注入线圈之中，因此，浇注材料容易渗透到线圈内部，解决了线圈浇注不完整的问题，并且浇注外模可拆卸，当线圈出现问题需要处理时，只需要打开浇注模具，对线圈进行包扎修补，再装好浇注模具重新进行浇注即可，使得变压器更容易维修。
本发明的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本发明的实践了解到。
附图说明
下面结合附图给出本发明较佳实施例，以详细说明本发明的实施方案。
图1是本发明实施例的浇注干式变压器的示意图；
图2是本发明实施例的铁心的示意图；
图3是本发明实施例的线圈的示意图；
图4是本发明实施例的线圈的剖视图；
图5是本发明实施例的梳形撑条的示意图；
图6是本发明实施例的浇注干式变压器的制造方法的流程图；
图7是本发明实施例的浇注干式变压器的制造方法的流程图。
具体实施方式
本部分将详细描述本发明的具体实施例，本发明之较佳实施例在附图中示出，附图的作用在于用图形补充说明书文字部分的描述，使人能够直观地、形象地理解本发明的每个技术特征和整体技术方案，但其不能理解为对本发明保护范围的限制。
在本发明的描述中，需要理解的是，涉及到方位描述，例如上、下、前、后、左、右等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。
本发明的描述中，除非另有明确的限定，设置、安装、连接等词语应做广义 理解，所属技术领域技术人员可以结合技术方案的具体内容合理确定上述词语在本发明中的具体含义。
下面结合附图，对本发明实施例作在本发明实施例中阐述。
参照图1和图4，本发明实施例提供了一种浇注干式变压器，其特征在于，包括：若干个线圈100、铁心110、夹件120和引线130，引线130由线圈100引出，线圈100设置于铁心110上，线圈100设置有用于浇注线圈100的浇注模具，浇注模具内设置有均匀分布的通道101，线圈100浇注有由绝缘材料制成浇注材料，其中浇注模具由绝缘材料制成，在浇注完成后无需拆卸与线圈100结合成为一体化结构。
上述浇注干式变压器至少具有以下有益效果：本发明浇注模具设置有均匀分布的通道101，线圈100浇注有绝缘材料，能够将多余的浇注材料从浇注模具中排出，减小了浇注厚度，在提高了线圈100防潮、防腐性能的同时，节约了材料，降低了成本，使变压器的可燃物重量比传统浇注变压器减少许多，提高了变压器的安全性和可靠性，同时又由于浇注材料较薄，浇注通道101也是是线圈100的散热气道，散热面积大，因此还提高了变压器的散热能力和过载能力，使绝缘材料不会因温度骤变而开裂，缩短了绝缘材料固化时间，提高了生产效率。另外，浇注模具可拆卸，当线圈100出现问题需要处理时，只需要打开浇注模具，对线圈100进行包扎修补，再装好浇注模具重新进行浇注即可，使得变压器更容易维修。
再参照图2，在本发明实施例中，铁心110采用立体卷铁心结构，铁心110包括三个单框111，每两个单框111呈60°夹角拼合在一起，每两个单框111拼接处形成一个心柱112，每个单框111由若干条硅钢片或非晶合金带材绕制而成。立体卷铁心变压器是一种节能型电力变压器，它创造性地改革了传统电力变压器的叠片式磁路结构和三相布局，使产品性能更为优化，如三相磁路完全对称、油浸式立体卷铁心变压器节电效果显著、噪音大大降低、散热及过载能力更强、结构紧凑体积小等。
在本发明实施例中，参照图3，线圈100还包括内线圈102和外线圈103，内线圈102绕设于心柱112和外线圈103之间。
在本发明实施例中，参照图4，浇注模具包括浇注内模141和浇注外模142，浇注内模141设置在外线圈103的内侧，浇注外模142设置在外线圈103的外侧，将浇注材料注入浇注模具中，使得浇注材料渗透到线圈100内部。
在本发明实施例中，浇注内模141和浇注外模142均由绝缘材料制成，浇注 内模141为圆筒结构，浇注外模142为圆筒和端圈的组合结构，在浇注完成后可以直接用作变压器绝缘部件，免于拆除，提高了生产效率。
在本发明实施例中，参照图4和图5，外线圈103包括梳形撑条104、导线105，梳形撑条104设置在浇注内模141上，导线105绕制于梳形撑条104上。
在本发明实施例中，参照图5，梳形撑条104包括若干个间隔均匀分布的长条1041，导线105绕制于长条1041间的间隙内，使线圈100饼间形成间隙，以提高线圈100的散热性能以及使浇注材料易于注入和排出线圈100。
在本发明实施例中，引线130包括内线圈引线和外线圈引线，内线圈引线由内线圈102引出，外线圈引线由外线圈103引出。
参照图6，一种浇注干式变压器的制造方法，包括：若干个线圈100、铁心110、夹件120和引线130，引线130由线圈100引出，线圈100设置于铁心110上，线圈100设置有用于浇注线圈100的浇注模具，浇注模具内设置有均匀分布的通道101，线圈100浇注有由绝缘材料制成浇注材料，其中浇注模具由绝缘材料制成，在浇注完成后无需拆卸与线圈100结合成为一体化结构，铁心110包括三个单框111，每两个单框111呈60°夹角拼合在一起，每两个单框111拼接处形成一个心柱112，线圈100还包括内线圈102和外线圈103，内线圈102绕设于心柱112和外线圈103之间，浇注模具包括浇注内模141和浇注外模142，浇注内模141设置在外线圈103的内侧，浇注外模142设置在外线圈103的外侧，外线圈103包括梳形撑条104、导线105，梳形撑条104设置在浇注内模141上，导线105绕制于梳形撑条104上，梳形撑条104包括若干个间隔均匀分布的长条1041，导线105绕制于长条1041间的间隙内，方法包括步骤：
S100、完成线圈绕制以及器身的装配，并对器身进行干燥；
S200、将器身放入浇注罐中，并对器身进行抽真空处理，然后将已经进行脱气处理的浇注材料注入浇注罐内，使浇注材料的液面高度高于线圈，浇注材料从浇注模具的通道注入并填满整个线圈；
S300、解除浇注罐的真空状态并对其进行加压，使浇注材料注入线圈内部的缝隙；
S400、完成浇注后，从通道排出浇注模具中多余的浇注材料；
S500、将器身放入干燥炉中，对浇注材料进行固化。
在本实施例中，参照图7，完成线圈绕制以及器身的装配，并对器身进行干燥，步骤包括：
S101、将内线圈绕制在铁心的心柱上；
S102、将浇注内模卷绕在外线圈的内侧，并固定好；
S103、将梳形撑条固定在浇注内模表面，固定好后，将线圈的导线缠绕在长条之间；
S104、将浇注外模卷绕在外线圈的外侧，浇注内模与浇注外模之间预留通道，以便浇注材料注入或排出。
在另一实施例中，也可以在浇注材料固化后再将浇注外模安装在外线圈的外侧。
上述浇注干式变压器的制造方法至少具有以下有益效果：本专利由于浇注方式不同，不需要考虑浇注模具的气密性问题，模具简单，易于安装，且浇注完成后，浇注模具可直接用作变压器的绝缘部件，不需要拆除，提高了产品的生产效率；将多余的浇注材料从浇注模具中排出，减小了浇注厚度，在提高了线圈100防潮、防腐性能的同时，节约了材料，降低了成本，使变压器的可燃物重量比传统浇注变压器减少许多，提高了变压器的安全性和可靠性，同时又由于浇注材料较薄，浇注通道101也是是线圈100的散热气道，散热面积大，因此还提高了变压器的散热能力和过载能力，使绝缘材料不会因温度骤变而开裂，缩短了绝缘材料固化时间，提高了生产效率；另外，浇注时，将已经进行脱气处理的浇注材料注入浇注罐内，浇注材料通过预留通道很容易地渗透到线圈100内部，解决了线圈100浇注不完整的问题，并且浇注外模可拆卸，当线圈出现问题需要处理时，只需要打开浇注模具，对线圈进行包扎修补，再装好浇注模具重新进行浇注即可，使得变压器更容易维修。
以上内容对本发明的较佳实施例和基本原理作了详细论述，但本发明并不局限于上述实施方式，熟悉本领域的技术人员应该了解在不违背本发明精神的前提下还会有各种等同变形和替换，这些等同变形和替换都落入要求保护的本发明范围内。

Claims (10)

  1. 一种浇注干式变压器，其特征在于，包括：若干个线圈、铁心、夹件和引线，所述引线由所述线圈引出，所述线圈设置于所述铁心上，所述线圈以及所述铁心通过两边的所述夹件固定在一起，所述线圈设置有用于浇注所述线圈的浇注模具，所述浇注模具内设置有均匀分布的通道，所述线圈浇注有浇注材料，其中浇注模具由绝缘材料制成，在浇注完成后无需拆卸与所述线圈结合成为一体化结构。
  2. 根据权利要求1所述的一种浇注干式变压器，其特征在于：所述铁心采用立体卷铁心结构，所述铁心包括三个单框，每两个所述单框呈60°夹角拼合在一起，每两个所述单框拼接处形成一个心柱。
  3. 根据权利要求2所述的一种浇注干式变压器，其特征在于：所述线圈还包括内线圈和外线圈，所述内线圈绕设于所述心柱和所述外线圈之间，所述浇注模具包括浇注内模和浇注外模，所述浇注内模设置在所述外线圈的内侧，所述浇注外模设置在所述外线圈的外侧，所述引线包括内线圈引线和外线圈引线。
  4. 根据权利要求3所述的一种浇注干式变压器，其特征在于：所述浇注内模和浇注外模均由绝缘材料制成，所述浇注内模为圆筒结构，所述浇注外模为圆筒和端圈的组合结构。
  5. 根据权利要求3所述的一种浇注干式变压器，其特征在于：所述外线圈包括梳形撑条、导线，所述梳形撑条设置在所述浇注内模上，所述导线绕制于所述梳形撑条上。
  6. 根据权利要求5所述的一种浇注干式变压器，其特征在于：所述梳形撑条包括若干个间隔均匀的长条，所述导线绕制于长条之间。
  7. 根据权利要求2所述的一种浇注干式变压器，其特征在于：每个所述单框由若干条硅钢片或非晶合金带材绕制而成。
  8. 一种浇注干式变压器的制造方法，其特征在于：所述浇注干式变压器包括若干个线圈、铁心、夹件和引线，所述引线由所述线圈引出，所述线圈设置于所述铁心上，所述线圈以及所述铁心通过两边的所述夹件固定在一起，所述线圈设置有用于浇注所述线圈的浇注模具，所述浇注模具内设置有均匀分布的通道，所述线圈浇注有浇注材料，其中浇注模具由绝缘材料制成，在浇注完成后无需拆卸与所述线圈结合成为一体化结构，所述铁心包括三个单框，每两个所述单框拼接处形成一个心柱，所述线圈还包括内线圈和外线圈，所述内线圈绕设于所述心柱和所述外线圈之间，所述浇注模具包括浇注内模和浇注外模，所述浇注内模设置在所述外线圈的内侧，所述浇注外模设置在所述外线圈的外侧，所述外线圈包括梳形撑条、导线，所述梳形撑条设置在所述浇注内模上，所述梳形撑条包括若干个间隔均匀的长条，所述导线绕制于长条之间，所述方法包括步骤：
    ①完成所述线圈绕制以及器身的装配，并对器身进行干燥；
    ②将器身放入浇注罐中，并对器身进行抽真空处理，然后将已经进行脱气处理的浇注材料注入所述浇注罐内，使浇注材料的液面高度高于所述线圈，浇注材料从所述浇注模具的通道注入并填满整个所述线圈；
    ③解除所述浇注罐的真空状态并对其进行加压，使所述浇注材料注入所述线圈内部的缝隙；
    ④完成浇注后，从所述通道排出所述浇注模具中多余的所述浇注材料；
    ⑤将器身放入干燥炉中，对所述浇注材料进行固化。
  9. 根据权利要求8所述的一种浇注干式变压器的制造方法，其特征在于：完成所述线圈绕制以及器身的装配，并对器身进行干燥，步骤包括：
    ①将所述内线圈绕制在所述铁心的心柱上；
    ②将浇注内模卷绕在所述外线圈的内侧，并固定好；
    ③将所述梳形撑条固定在所述浇注内模表面，固定好后，将所述线圈的导线缠绕在长条之间；
    ④将所述浇注外模卷绕在所述外线圈的外侧，所述浇注内模与所述浇注外模之间预留通道，以便浇注材料注入或排出。
  10. 根据权利要求8所述的一种浇注干式变压器的制造方法，其特征：浇注材料固化后在所述外线圈的外侧安装所述浇注外模。
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