The winding machine is made of wire wound. There are copper wire and aluminum wire, each layer of wire between the cover of different types of insulation layer, that is, the wire directly and all kinds of insulation layer combined into a whole, the role of these insulation layer is to form the winding between turns of insulation. The coil we usually use is a single paper wrapped flat aluminum wire with a wire gauge of 2.2*2.5mm, which is continuously wound to form a single cake coil. The shape size, compactness, flatness and other aspects of the traction transformer cake coil need to meet the technical requirements. When the coil is wound, the wire gauge and the gap between turns determine the size of the coil. The premise of controlling the size of the coil is to find out the elements that affect the turn gap of the coil, which is also the necessary condition for controlling the size of the coil.
1, coil size problem
Recently, when vertical winding machine was used to wind single cake coil, the current value of magnetic powder clutch controlling the tension of winding machine was set at 0.45A. After the completion of winding, the size of B-end of the coil was too large, exceeding the required range of the process.
2. Analysis of the cause of the coil size problem
When winding machine tension related to current value setting of 0.45 A, found in the process of winding, due to the tension is too small to cause line plate conductor stress is not the average of online disk rotation at present due to the inertia line PanKong phenomenon, wire out more, from on-line plate and wire clamping device between the state of the extent of the conductor is not ideal, but drop curve, Therefore, the force of the wire is not even in the winding process, and the compactness of the finished wire cake is not enough, so the size of the coil B is larger than the technical request value.
3. Analysis of the relationship between winding machine tension and coil size
(1) appropriately increase the influence of winding machine tension on the coil. In the coil winding process, the tension is gradually increased, the tension related current value of the vertical winding machine is adjusted to 0.46A, and the coil is relaxed. The oversize has been improved, but it still doesn't fit the requirements. Continue to increase the tension related current value of the vertical winding machine and adjust it to 0.47A. The coil size meets the request, and the coil is tight. There is no obvious gap at the A and B ends, and there is no tension or upwarping at the four corners.
(2) the influence of excessive winding machine tension on the coil. Continue to increase the vertical winding machine tension related current value to 0.51A, the coil in the process of winding, 4 corners of the force is too heavy, there is warping phenomenon, after the completion of winding, there is no obvious gap in the wire, wire gauge did not decrease sharply, but the 4 corners of the warping phenomenon, do not meet the technical requirements.
As can be seen from the above, when the tension value of the vertical winding machine is too small, the coil will be small and tight, the wire will have gaps, and the size of the B-end will be larger than the technical request value after the winding is completed. Properly increasing the tension of the vertical winding machine can reduce the size of the B-end of the wire cake, and have a small impact on the wire gauge, so as to improve the problem of the larger size of the B-end. But when the vertical winding machine tension is too large, it will lead to small coil fit technical requirements. It can be seen that the tension is closely related to the size of the coil. When the coil is wound, the tension of the winding machine should be adjusted to the corresponding matching value.