JPS5931969B2 - Manufacturing method of multi-wound coil - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing multi-wound coils used in transformers, reactors, etc.

Conventionally, among the coils of transformers, multi-wound coils are made by winding a coil conductor 2 in multiple layers on an inner circumference insulator 1 as shown in Fig. 1, inserting an interlayer insulator 3 in each winding layer, and winding the coil conductor 2 in multiple layers. A coil end filler 4 is also inserted at the end of the layer to prevent displacement of the coil conductor 2 and improve coil strength.

In such a multi-wound coil, after the coil conductor 2 is wound in one layer, the interlayer insulator 3 is wound and inserted, and then the end filler 4 is inserted. The coil winding operation is a series of steps including winding the coil conductor 2 and inserting the insulators 3 and 4. However, such work involves a combination of different tasks, and the coil winding work becomes a discontinuous work process when inserting the interlayer insulator 3 or the end filler 4, which lengthens the work time and makes it difficult to further advance automation. This was a major obstacle. On the other hand, from a material standpoint, multi-wound coils have different coil widths depending on various specifications such as model capacity, and therefore require interlayer insulators 3 according to each specification. Therefore, various interlayer insulators 3 are required to be manufactured, prepared and stored, and storage locations are required, making the work even more complicated. Also, in terms of insulation, the conventional interlayer insulator 3 is made of one or several sheets of thin sheet insulator with a wide width corresponding to the coil width including the end filler 4, cut to match the coil circumference of each winding layer. Roll it over and over,
It is fixed with cotton tape or polyester adhesive tape, etc., and the coil conductor 2 is wound on top of it, so the interlayer heather 3)
Moreover, the coil tends to have creases and curling bulges on the circumferential surface of the coil, and therefore has disadvantages such as a decrease in insulation properties, variations in finished dimensions, and weakening against vibration and electromagnetic mechanical force.

Also, on the work surface, since the coil circumferences of both the interlayer insulator 3 and the end filler 4 are different for each winding layer, the required number of sheets are cut to match the coil circumference for each winding layer and wound. , which required a different kind of work to fix with the aforementioned tapes.

The present invention has been made to eliminate the above-mentioned drawbacks.
The objectives are to standardize the types of insulating materials, improve production management, rationalize insulation, and be resistant to electromagnetic mechanical forces.In addition, it is possible to form end fillings and interlayer insulation regardless of the number of coil winding layers. It is an object of the present invention to provide a method for manufacturing a multi-wound coil, which can be performed in the same way as winding a coil conductor, thereby shortening the working time and facilitating automation.

An embodiment of the present invention will be described below with reference to FIG.

First, the winding start portion 12a of the coil conductor 12 and the winding start portion 13 of the tape-shaped insulator 13 are placed at a predetermined position on the inner peripheral insulator 11.
Fix a.

The coil conductor 12 is wound so as to proceed in the direction of arrow A, which is one direction in the axial direction, and the tape-shaped insulator 1
3 are simultaneously wound in a stacked manner in place to form the end stuffing 14a. After n% winding, coil conductor 1
2 advances to the (12・n customer) position, and the tape-shaped insulator 1
3 completes the formation of the end filling 14a. Thereafter, the coil conductor 12 is wound nn times until reaching the position (12·n), completing the formation of the first winding layer. On the other hand, the tape-shaped insulator 13 has an end filling 14a to form an interlayer insulator 15a.
Following the formation of N-
After winding NV times, the coil conductor (12・n) is (13・n)
The formation of the interlayer insulator is completed upon reaching the position n). still,
The number of turns of the tape-shaped insulator 13 to form the end stuffing 14a and the interlayer insulating material 15a is n times, which is the same as the number of turns of the coil conductor 12. It is the thickness of the layer.

The number of windings for forming the end stuffing 14a is smaller than the number of windings for end stuffings 14b to 14d having a thickness of approximately two layers, which will be described later. Therefore, in order to absorb this extra number of turns, when forming the first interlayer insulator 15a, the tape-shaped insulator 13 is wound extra so as to increase the wrap length and slow down its progress. Next, the coil conductor 12 is (12
・Start of winding of second layer from position n) (12・n+1)
The tape-shaped insulator 13 moves to the position of the end filling 1.
The winding is continued by moving to the forming position (13·n+1) of 4b.

After winding n1 times, the coil conductor 12 is wound in the direction of arrow B and advances to the position (12·2n1), and the tape-shaped insulator 13 is an end filler having a thickness of approximately two layers. 1
Complete the formation of 4b. After that, the coil conductor 12 is n-n
It is wound once to reach the position (12·2n), completing the formation of the second wound layer. On the other hand, in order to form an interlayer insulator 15b, the tape-shaped insulator 13 advances in the direction of arrow B with an appropriate wrap over the second layer of wound coil conductor 12, following the formation of the end filler 14b. It is wound like this, n
-n After one winding, (1
3.2n) is reached and the formation of the interlayer insulator is completed.
Next, the coil conductor 12 moves from the position (12·2n) to the winding start position (12·2n+1) of the third layer, and the tape-shaped insulator 13 moves from the position (13·2n) to the end. The process moves to the formation position (13·2n+1) of the filling 14c. The coil conductor 12 is then wound in the same manner as the second layer to form a third wound layer, and the tape-shaped insulator 13 has an end filling 14c and an interlayer insulator 15c having a thickness of approximately two layers. form. Thereafter, the required number of layers are wound in the same manner. And end filling 1 of the final winding layer (fourth layer in this example)
4d, interlayer insulator 15d, etc. are completed, the coil conductor 12 is fixed at the position (12・Z), and then the tape-shaped insulator 13 is wound to form the end filling 14e, completing the entire coil winding work. do. As described above, in the method of the present invention, when the coil conductor 12 is wound to form one wound layer and the tape-shaped insulator 13 is simultaneously wound to form the end filling 14 and the interlayer insulator 15, the coil conductor The end filling 14a formed by winding the tape-shaped insulating material 13 around the end of the first winding layer of No. 12 on the winding start side has a thickness of approximately one layer, and the thickness of the other approximately one layer. Since the interlayer insulator 15a is formed on the first layer with the remaining number of turns after adding the number of turns to form the interlayer insulator 15a, from the second layer onwards, one turn is made of the coil conductor 12. Tape-shaped insulator 1 for the process of forming a circuit layer
3, it is possible to construct a pattern in which the steps of forming the end filler 14 having a thickness of two layers and the interlayer insulating material 15 of one layer are performed simultaneously.

Therefore, regardless of the number of winding layers of the coil, the second and subsequent winding layers can be wound in the same pattern.
Automatic coil winding work becomes easier and the process can be significantly shortened. Furthermore, the multi-wound coil manufactured by the method of the present invention uses the narrow tape-shaped insulator 13 to form the interlayer insulator 1.
5, the coil conductor 12 regardless of whether it is a square wire or a round wire.
It conforms well to the circumferential surface of the wound layer and does not cause wrinkles or bulges, resulting in no deterioration in insulation properties or variations in finished dimensions. Furthermore, since there are fewer dissimilar components and no wide insulating material is used, uniform tension can be applied to the coil conductor 12 and the insulating material used, making it possible to obtain a multi-wound coil that is resistant to electromagnetic mechanical force. In addition, in terms of production management, the conventional interlayer insulation of one size per model is no longer necessary, and tape-shaped insulation common to several models can be used. Furthermore, there is no need to create special end fillings, and the material can be changed. The number of species can be significantly reduced. Furthermore, this can simplify administrative procedures, reduce inventory, and shorten delivery times for obtaining materials. It also has many advantages such as the yield of materials used is nearly 100%.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of a conventional multi-turn coil, and FIG. 2 is a cross-sectional view of a multi-turn coil according to an embodiment of the multi-turn coil manufactured according to the present invention. 11... Inner peripheral insulator, 12... Coil conductor, 13... Tape-shaped insulator, 14...
...End filling, 15...Interlayer insulator.

Claims (1)

[Claims] 1. A coil conductor is wound n times to form a wound layer that advances in one direction in the axial direction, and at the same time, a tape-shaped insulator is wound n times to provide an end filler at the end of the wound layer on the winding start side. and then a first step of forming an interlayer insulator on the wound layer, and then transfer the coil conductor onto the interlayer insulator and wind it n times to form an inner wound layer. At the same time, the tape-shaped insulator is wound n times to form a winding layer that advances in the opposite direction to the end of the inner winding layer and the winding start end of the inner winding layer. A multi-wound coil obtained by forming a part filler and subsequently performing a second step of forming an interlayer insulator on the wound layer, and repeating this second step to form a predetermined number of wound layers. manufacturing method.