KR900000434B1 - Method for producing moulded coil - Google Patents

Abstract

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Description

Manufacturing method of molding winding

1 and 2 are front and side views, respectively, of a winding barrel in which windings are made in accordance with the method of the present invention.

3 is a side view of the universal winding, used in the embodiment shown in FIGS. 1 and 2;

4 and 5 are partial side and partial front views of a winding formed in accordance with another embodiment of the method of the present invention.

6 is a partial side cross-sectional view of a winding formed according to the embodiment shown in FIGS. 4 and 5;

7 and 8 are cross-sectional views of another winding made by the method according to the invention.

FIG. 9 is a perspective view of a conductor used for winding as shown in FIG.

* Explanation of symbols for main parts of the drawings

1: universal winding 2: thin plate

5, 6: support member 7: forming plate

8: tie rod 9: thermosetting resin

10: central axis 11: threaded portion

12: copper segment 13: handle

14: slider 15, 16, 17: link

21, 31, 41, 51: internal insulation layers 22, 30, 40, 50: windings (conductors)

32, 42, 52: conductor layer 33, 35, 43, 45, 53, 54, 56: insulator

34, 44, 55: outer insulation layer

The present invention relates to a method for manufacturing a molded winding used in electrostatic induction devices such as transformers, reactors and the like.

Until now, a method of forming a molding winding with resin is known, in which a conductive wire such as an aluminum wire or a copper wire and an insulator are alternately wound on a barrel serving as a winding core to form a winding assembly, and a thermosetting resin is injected. To form a winding assembly.

The winding assembly is heated to solidify the resin to form a winding molded of the resin. This conventional method uses a cylindrical mold assembly as the above winding barrel. The mold assembly consists of a mold segment, which is made of a certain size and a certain length of the winding to be obtained according to the inner diameter and assembled together with the sealing member. A pair of dies is inserted into the hole in the mold assembly. Since the outer circumferential surface of the die is inclined, the die is easily separated from the mold assembly. The mold assembly is connected to the drive shaft of the winding machine by this die so as to move.

However, in this conventional method, a problem arises in that different sizes of dies and mold assemblies are required when manufacturing windings of different sizes. This requires other tasks, such as the storage and maintenance of many molds and dies, as well as rising die and die production costs of different sizes. Moreover, as the size of the winding to be produced is changed every time, the assembly of the mold and the die requires a lot of effort and time. Therefore, a lot of preparation time is required before the winding operation is actually started.

In the method proposed in Japanese Patent Publication No. 70-5848, the outer insulator of the winding is used as a mold for injecting resin in order to reduce the number of molds required for the production of the molding winding. However, this conventional method does not consider reducing the number of molds constituting the winding copper.

Accordingly, it is an object of the present invention to reduce the effort and time required for the manufacture of windings and the preparation of winding copper, and to provide a method for manufacturing molding windings that can produce molding windings of high efficiency.

In the manufacturing method of the molding winding according to the present invention, the conductor and the at least one insulator are alternately wound in the initially set number of layers in the cylindrical winding copper, and the thermosetting resin is injected into the layers of the conductor and the insulator and solidified by heat by heating to form a rigid molding winding. A method of installing a universal winding, comprising: installing a universal winding with a plurality of barrel segments arranged to provide a variety of circumferential sizes of winding copper; Securing the thin plate with a winding copper so as to be wound around the universal winding and separating, and separating the outer surface of the thin plate wound around the universal winding, and in the layer above the outer circumference of the thin plate Characterized in the method of forming a molding winding by consisting of steps of winding the insulator and the conductor alternately There.

According to the method of the present invention, the circumferential size of the winding copper can be freely adjusted and attached to the winding copper in a state where the thin plate can be separated, so that the winding core is easily formed into a continuous outer circumferential surface required for molding. In addition, the separation of the winding and the thin plate as well as the separation of the winding together with the thin plate from the winding can be made without difficulty.

The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the accompanying drawings.

1 and 2 show a winding formed in a winding cavity according to the method of practicing the present invention. In the above-described step of the winding manufacturing process, the inner insulation layer 21 is already formed on the circumference of the universal winding 1, and the winding 22 is wound spirally on the inner insulation layer 21. As can be seen from the following description, the universal winding (1) is configured to adjust the size of the circumference of the copper, and the thin plate (2) is wound around the winding copper (1) to form a continuous outer circumferential surface.

The universal winding 1 has a central shaft 10 connected to a drive shaft (not shown) of the winding machine and a plurality of copper segments 12 arranged radially and axially around the central shaft 10. The number of copper segments 12 is appropriately selected according to the range of winding diameters to be manufactured, and these segments are arranged to define the outer circumference of the winding copper 1. As can be seen from the third view showing the winding copper in detail, since the central shaft 10 has the threaded portion 11 over a certain length along the axis, the slider 14 slides and moves by the threaded portion 11. As the handle 13 connected to the thread 11 rotates, the handle 13 moves along the axis of the central axis 10. The slider 14 is connected to the handle 13 so as to slide back and forth of the central axis 10 in accordance with the rotation of the handle 13. Each copper segment 12 is connected to the central axis 10 via links 15, 16, and 17. The links 15, 16, and 17 are pivotable by connecting one end of the link to a support member at both ends of the slider 14 and a support member fixed to the central shaft 10, respectively. The other end of the link is connected to both ends of the copper segment 12 so that it can turn. As the handle 13 rotates, the slider 14 is moved relative to the central axis 10 so that the copper segment 12 is moved radially by the links 15, 16, 17. The circumference of the winding copper 1 also consists of an array of links. The structure of the universal winding and the winding machine may be the same as that of the unmolded winding as described in the specification of US Pat. No. 4,061,289 assigned to the applicant of the present invention. Therefore, detailed description of the winding copper and the winding machine will be omitted for simplicity.

As described above, the outer circumference of the universal winding 1 is limited to a plurality of copper segments 12 arranged in the circumferential direction. Thus, some circumferential gap is formed between adjacent copper segments 12 except when the segment is installed with the minimum copper diameter. As a result, the resin melted by heating in the molding operation undesirably flows into the winding copper through the gap. Therefore, it is practically impossible to mold directly to universal winding. Furthermore, in the case where a prepreg material made by pre-containing an insulating material such as glass fiber together with a thermosetting resin is used, winding the conductor and the prepreg insulator directly to the universal winding is a winding of polygonal cross section. In addition, a preslag slack occurs in the gap between the copper segments, resulting in poor insulation. Therefore, according to the present invention, a thin plate having appropriate stiffness is wound around the universal winding and secured by the universal winding as well as being separable, thus forming a core with a continuous outer circumferential surface.

In this embodiment, the thin plate 2 is formed to be large enough to cover the winding copper 1. The thin plate 2 is wound around the winding copper 1, and the diameter of the winding copper is set according to the diameter of the winding to be manufactured. The thin plate 2 is then secured by allowing the end 3 of the fixed plate to be separated by suitable means such as heat resistant adhesive tape (see FIG. 1). Therefore, appropriate separation treatment, such as application of the separator, is required for the outer circumferential surface of the thin plate 2 and the winding of the separator. If the strength is too high, the strength of the thin plate 2 should be adequate because the end 3 of the plate will spring up and damage the smooth side of the cylindrical core, while too small the strength will not give the mold core the necessary force. . Therefore, the thin plate is preferably made of a stainless steel plate having a thickness in the range of 0.2 to 1.0 mm, or a template of polymer insulation made of a film of ethylene tetrafluoride. From an economic point of view, it is preferable to use heat resistant press boards, and other materials may equally be used, as will be apparent to those skilled in the art.

The process of forming the winding in the winding core installed as described above will be described in detail below.

In the first step, the prepreg formed of glass fiber or glass tape containing epoxy resin is wound around the thin plate 2 while the winding copper 1 is rotated by the force of the winding machine (not shown). An inner insulating layer 21 of an initial thickness is formed. The coil is then formed by winding the conductor 22 to a predetermined number of layers over the region of the initially set axis.

At least one insulator between layers, such as insulating paper, is inserted between the layers of adjacent conductors 22 to conduct the voltage caused between adjacent conductor layers. An outer insulating layer is then formed on the outer surface of the coil in the same manner as the inner insulating layer 21.

Therefore, the molding winding is moved to the drying furnace together with the winding copper 1, and is heated according to a suitable process. After heating, the insulators between the layers are dried and the partially solidified thermosetting resin constituting the inner and outer layers is already solidified and the inner and outer circumferences of the winding are fixed. A hardened inner and outer insulating layer is used as a mold for pouring the resin, and the thermosetting resin in the form of putty is filled at both ends of the winding in the axial direction. The whole winding is heated again in the drying furnace, so that the resin at both ends of the winding in the axial direction is bonded not only to the insulators between the layers but also to the inner and outer insulating layers, so that secondary solidification is performed to form the molding winding in one complete body. After the second coagulation, the universal winding 1 is contracted in the radial direction and separated from the cylinder formed by the thin plate 2. Next, the end 3 of the thin plate 2 is released, and the thin plate 2 is contracted in the radial direction to be separated from the molding winding. Separation treatment on the surface of the thin plate 2 can facilitate the separation operation.

In this embodiment, primary and secondary solidification of the resin is achieved while the winding is held in the winding copper 1. However, this is not the only one, and after the winding has been separated from the winding copper, secondary solidification may occur. In this case, after fixing the inner and outer circumferences of the windings by initial solidification, ie primary solidification, the windings are separated from the winding copper 1 and the thin plate 2 in the manner described above. Next, the thermosetting resin in the form of putty is filled at both ends in the axial direction of the separated winding, and the winding is heated to solidify the thermosetting resin. This modified method makes it easier to fill the thermosetting putty at both ends of the winding as compared to the above embodiment.

In this embodiment, the inner and outer insulating layers are formed of prepregs. However, this is not the only one, and the present invention can be applied to the case of filling the thermosetting resin after the formation of the winding. In this case, as shown in FIG. 4, the winding 30 is formed in the winding copper as in the case of the above embodiment, and the winding includes an internal insulating layer 31, a conductor layer 32 and an insulator 33 between the layers, and There is an external insulating layer 34. Reference numeral 35 in the drawing denotes an insulator used to give satisfactory insulation between the conductor layers at both ends of the conductor. Thus, each terminating insulator 35 fills the gap between adjacent ends of the insulator 33 between the layers slightly projecting past the axial end of the conductor layer 32. After the winding 30 is formed, the winding copper contracts in the radial direction and is separated from the cylindrical hole formed by the thin plate 2 which is in contact with the winding elastically.

The supporting members 5, 6 are then inserted into the holes to support the holes of the thin plate 2. Subsequently, the end forming plates 7 and 7 are positioned to contact both ends of the winding 30 in the axial direction as shown in FIG. 6, and are fixed with tie rods 8. The thermosetting resin 9 is then filled with the winding 30 between the end plates 7, 7. In the meantime, the thin plate 2 acts as a mold core. Resin 9 solidifies with heat by heating. Therefore, the method of the present invention may be applied to the manufacture of the molding winding in a process in which the thermosetting resin is filled in the winding after the formation of the winding 30.

Even if a satisfactory connection with the resin can be obtained without using the termination plates 7 and 7, if the winding size is small, in the above embodiment using prepreg as the material of the inner and outer insulating layers, It is also preferable to use the termination plates 7 and 7.

7 and 8 show the structure of the molding winding produced according to the method of the present invention. The shaping winding 40 shown in FIG. 7 is essentially the same structure as that of the winding 30 described in FIG. That is, the structure consists of the internal insulation layer 41, the conductor layer 42, the insulator 43 between layers, the external insulation layer 44, and the termination insulator 45. However, the winding 40 is different from the winding 30 because the winding 40 has a conductor having a flat cross section to form the conductor layer 42.

On the other hand, the conductor 50 shown in FIG. 8 has a structure composed of an inner insulating layer 51, a conductor layer 52, insulators 53 and 54 between layers, and an outer insulating layer 55. As shown in FIG. The conductor layer 52 is also formed of a conductor having a flat cross section in this case. However, the structure of this winding 50 differs from the winding 40 shown in FIG. 7 in terms of the arrangement for the insulators 53, 54 and the terminating insulator 56 between the layers. That is, in this winding 50, each terminal insulator consists of an insulating adhesive tape of one side, and this insulating adhesive tape is continuously folded and attached to one side of the conductor layer 52. As shown in FIG. The insulating adhesive tape is formed by applying an appropriate adhesive on one side of the insulating paper. The insulators 53 and 54 between the layers of insulating paper are large enough to cover one part of the conductor layer 52 between the terminal insulators 56 and 56 and the same width as one part of the conductor layer, respectively. It is. Since the winding 5 has such a structure, the terminal insulation can be easily formed in the conductor layer, and the step of manufacturing the winding can be reduced. Furthermore, since high adhesion strength between the resin and the terminal insulator can be obtained, great stability and rigidity are given to the molding winding.

As can be seen in the above description, according to the method of the present invention, the molding winding is formed using a thin plate that can be separated and replaced with a winding core made of a universal winding which can change the circumference size. Therefore, this method has the following advantages.

(1) The barrel diameter is adjusted according to the inner diameter of the winding to be obtained, and the molded winding can be manufactured in various sizes by using a single winding copper so that a thin plate suitable for the size of the winding copper is wound on the copper. Moreover, the equipment cost for manufacturing the molded winding is reduced.

(2) Even if windings of various sizes are manufactured, the installation time before starting the windings is shortened. Furthermore, the separation of the windings from the windings is made easy without difficulty, thus reducing the steps in the process of manufacturing the windings.

(3) Since the diameter of the winding core can be freely adjusted, the molding winding can be designed more freely.

(4) Since the thin plate is in close contact with the inner surface of the winding in order to act as a mold core, a compact and high strength winding can be obtained even by forming after separating the winding from the winding copper.

While the invention has been described with reference to specific embodiments, various modifications and changes may be made without departing from the scope of the invention.

Claims (8)

In the manufacturing method of the molding winding in which the conductor and the at least one insulator are wound around the cylindrical winding copper by the number of initially set layers, the thermosetting resin is injected into the layers of the conductor and the insulator, and the resin is solidified by heat by heating to form a solid molding winding. And installing a universal winding inclined with a plurality of copper segments arranged to have various circumferential sizes of the winding copper, and fixing the universal winding to an initially set circumferential size, and winding elastic thin plates around the universal winding. And separating and securing the thin plate in the winding copper, separating the outer surface of the thin plate wound on two of the universal winding, and separating the insulator from the outer circumference of the thin plate. Manufacturing method of the molding winding, characterized in that to form a molding winding by winding the conductor alternately . 2. The method of claim 1, further comprising: winding an insulator containing a thermosetting resin to form an inner insulating layer and an outer insulating layer, and heating the windings of the windings after winding to first solidify the inner and outer insulating layers. Method for producing a molding winding, characterized in that consisting of. 3. The molding winding of claim 2, further comprising filling a winding between the inner and outer insulating layers after the primary solidification and thermosetting resin in the winding between the inner and outer insulating layers, and heating the entire winding to secondary solidify the winding. Manufacturing method. 3. The method of claim 2, further comprising: radially contracting the universal winding after the first solidification, separating the windings from the universal winding and then separating the windings from the thin plates, the internal and external insulation. And filling the windings between the layers with a thermosetting resin, and heating the entire winding to secondary solidify the windings. The method of claim 1, further comprising the steps of: radially shrinking the universal winding after winding, separating the windings from the universal winding with the thin plate, filling the winding with a thermosetting resin, and winding the entire winding. Manufacturing method of the molding winding, characterized in that it comprises the step of forming a solid molding winding by heating the resin solidified. The method according to claim 1, wherein the thin plate is a stainless steel plate having a thickness range of 0.2 mm to 1.0 mm. The method of manufacturing a molding winding according to claim 1, wherein the thin plate is a template of a polymer insulating material comprising a film of ethylene tetrafluoride. The method of manufacturing a molding winding according to claim 1, wherein the thin plate is a heat resistant press board.

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